INSTRUCTIONS
Contents
1. Od NIG D CYCLE READY CYCLE STOP INCH START REVERSE FORWARD SHORT STROKE C SINNEN FIGURE 2 9 Spindle Retractor Carriage 3 Swing Tool Support Bar into load position and tighten Adjustment Handle Adjust height by loosening Collar Clamp and raising or lowering as required see Figure 2 7 4 Rest Honing Tool on Tool Support Bar 5 Align Input Yoke Adapter on Honing Tool with Drive Ring and guide adapter onto Hex Shaft see Figure 2 8 6 Rotate input Yoke Adapter clockwise to engage and Lock into Drive Ring on Spindle Nose 7 If supplied Slide Universal Cover over Input Yoke Adapter 8 Guide Honing Tool into bore by sliding Spindle Carriage to right Press K11 Carriage Release Up Button to lock spindle carriage into normal operating position 9 Loosen Adjustment Handle and swing Tool Support Bar into operating position Tighten Adjustment Handle WARNING Do not operate Machine with Tool Support Bar in load position SPINDLE CARRIAGE Spindle Retractor Carriage allows Honing Tool to be withdrawn from Workpiece for gaging stone set replacement or installing a new Workpiece without removing tool or changing any of the settings NOTE The Spindle Retractor Carriage provides 380 mm of tool withdrawal motion 1 After honing2. APPENDIX G COOLANT FLOW DIAGRAM CENTRIFUGAL PUMP NOZZLE 4 e 4 FLOW CONTROL VALVE gt gt COOLANT RESERVOIR OPTIONAL MAGNETIC SEPARATOR 36 APPENDIX H SURFACE ROUGHNESS TABLE Ra CLA GUS Knocc 1 9 2 9 3 5 3 8 44 4 8 53 58 6 2 8 TI 7 9 8 6 8 8 9 6 11 0 12 0 13 2 14 4 15 4 16 8 17 6 19 2 19 8 21 6 22 0 0 28 6 2 39 6 2 48 4 8 57 0 62 0 66 0 72 0 79 0 86 0 110 120 154 168 198 216 220 240 264 288 308 336 352 384 37 0 5 0 7 0 8 1 0 1 2 1 4 1 6 1 7 1 9 2 3 27 3 0 1 7 3 4 1 9 3 8 2 3 4 2 2 1 2 3 7 0 4 5 2 5 2 5 6 0 10 0 7 1 12 5 9 6 16 5 13 0 22 0 17 0 28 0 18 0 30 0 22 0 35 0 25 0 40 0 28 0 45 0 APPENDIX I FIXTURE HEIGHT CHARTS L SERIES HOW TO USE FIXTURE HEIGHT CHART Find Workpiece O D by reading across the top and down the left side of the chart Where the column and line intersect is the approximate height at which the fixture should be set EXAMPLE OD of Workpiece is 165 mm Find column 150 mm on top of chart move down the column until it intersects line 15 For this example the Fixture should be set at 192 mm Standard Fixture Inverted Standard Fixture Norma
3. m e um Operator entry of desired Reciprocation Rate spindle carriage will travel at after initial three 3 seconds of INCH FORWARD Operator entry of desired Reciprocation Rate spindle carriage will travel at after initial three 3 seconds of INCH REVERSE Operator entry of desired Tool Retract Time at end of cycle Sets output torque from feed motor Also calibrates load meter range to match selected output torque Available on L Series ONLY Calibrates Load Meter depending on spindle speed Do this after any speed change When F6 Calibrate Load Meter 15 pressed the following screen will appear Spindle will start rotating upon calibration start Has all tooling been removed and brake engaged If so press F7 to begin calibration If not press F8 to return to system screen Operator entry to select ENGLISH or METRIC Units of Measurement Supervisor entry to reset PASSWORD Required Circuit Prevents various password protected parameters from being altered 30 APPENDIX C2 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 APPENDIX C3 SCREENS SETUP SCREEN RECIPROCATION POSITION 2 00 IN ENTER BACK GO FORWARD 2 00 IN ENTER FORWARD GO BACK ENTER HONING CYCLE TIME ENTER RUNOUT STROKE COUNT DWELL TIME FOR 2 00 SEC DWELL POSITION F7 MAIN SETUP SYSTEM STORE SETUP h ENABLE A
4. IMPORTANT Workpiece MUST maintain old position CONTINUING OPERATION WORK CYCLE SEQUENCE Load new workpiece into fixture in same position as previous workpiece Press K11 to lock spindle carriage in position Press K10 to expand stone in workpiece bore Retract stones slightly by pressing 9 Swing Tool Support Bar into operating position Press K2 until LED is ON Press Cycle Ready Start Button to start Honing Cycle Machine will stop when Run Out Stroke Counter reaches zero 0 and honing cycle ends Retract stones slightly by pressing K9 Swing Tool Support into Load Position Press 12 and slide spindle carriage to the left Slide Honing Tool out of Bore 27 l Guide Honing Tool into bore by sliding Spindle Carriage to right D A Q A WY NO L L1 E1 E1 E1 L1 E1 F1 E1 E1 F1 ET E NOTES 28 APPENDIX CI SCREENS MAIN SCREEN SUNNEN PRODUCTS COMPANY CYCLE STOP Fi F2 F3 F4 F5 F6 F7 F8 e e MAIN SETUP SYSTEM STORE SCREEN SCREEN SCREEN SELECT m SETUP Ki K3 K4 K5 K7 KB amp L E 5 SERVO MAN SPINDLE DWELL COOL B G F F G B WITH ENABLE AUTO JOG OFF ON MAN AUTO AUTO DRAW MODE AUTO ENTER ENTER K10 Kit Ki2 Kia K15 K16 ED CARRIAGE CARRIAGE AUTO HOME RESET ED fi FE ACT ADVANCE RELEASE RELEASE U DOWN SHORT SERVO COUNTS STROKE m lt 0 SHIFT I
5. SPINDLE DRIVE ADJUSTMENT d MOTOR E HANDWHEEL CONTROL STATION ELECTRICAL ENCLOSURE RESERVOIR SAFETY SWITCH ACTIVATOR MASTER ON OFF DISCONNECT SWITCH FIGURE 2 2 Emergency Switches 6 SECTION 2 PREPARING FOR OPERATION GENERAL EMERGENCY SWITCHES Consult this section when preparing Machine for For location of major all electrical Emergency operation Switches on machine see Figure 2 2 MAJOR COMPONENTS CONTROLS For location of major components on machine see For location of controls see Figure 2 3 and refer to Figure 2 1 Table 2 1 thru 2 2 for function of controls STOP POWER OFF CYCLE STOP lt _INCH 6 0 0 0 0 9 2272 E OKE MUNNEN FIGURE 2 3 Control Station TABLE 2 1 Operator Controls Buttons amp Switches EMERGENCY STOP Shuts OFF all power to the machine functions Button must Red release before Power ON button can be pushed Pushbutton POWER ON Turns ON control power to the machine After E Stop Green Button is pushed Power ON button must be pushed once Pushbutton to reset E Stop Relay and again to turn ON Control Power POWER OFF Shuts OFF control power to the machine Red Pushbutton CYCLE READY START Starts honing
6. Touch Button NO SYMBOL ud K1 Press to enable Stroke Reciprocation Drive Servo Control SYMBOL SERVO ENABLE Touch Button K2 Press to select Operating Mode NO MAN AUTO MODE Manual Use inch joystick to move spindle carriage SYMBOL Required to initiate home servo Touch Button Auto Required to initiate cycle start NO K3 Press to initiate spindle for short intervals SYMBOL SPINDLE JOG Touch Button NO K4 Press to initiate dwell status of Stroke Reciprocation Used SYMBOL DWELL OFF ON in conjunction with Dwell Time and Dwell Position Touch Button programming on Setup Screen K5 Press to select operation of coolant pump COOL MAN AUTO Manual Coolant flows continuously Touch Button Auto Coolant flows only during honing cycle NO SYMBOL NO K6 Press to automatically enter the current Stroke Reciprocation SYMBOL B G F AUTO ENTER Position as the Back Go Forward reversal set point Touch Button K7 Press to automatically enter the current Stroke Reciprocation mod F G B AUTO ENTER Position as the Forward Go Back reversal set point Touch Button NS K8 Press to interrupt honing cycle and stroke counter SYMBOL WITHDRAW Ends honing cycle Resets all timers and counters Touch Button K9 Press to manually feed stones IN retract collapse FEED RETRACT Touch Button TABLE 2 2 Operator Controls Buttons 8 Switches SYMBOL DESCRIPTION FUNCTION Press to manually feed stones OUT expand Press t
7. 29 32 47625 140000 59 64 19680 5000 we 142875 6 5594 6 14 6844 5 5563 150000 4 5 9531 10 32 150813 31 82 236220 60000 4 154781 1 4 6 3500 5 8 15 8750 63 64 6 7469 16 0000 FORMULAS TO GET MULTIPLY MILLIMETERS mm METERS m BY TO GET x 25 4 MILLIMETERS mm x 0 3048 METERS m MULTIPLY INCHES in FEET ft INCHES in FEET ft SUNNEN THE SUNNEN LOGO GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change or j j 4 4 GENERAL CORP A company n y Lo 471 US 250 East Ashland OH 44805 U S A revise specifications and product design Phone 419 289 3000 Fax 419 281 0700 in connection with any feature of our U S A Toll Free Sales and Service 1 800 837 1999 products contained herein Such changes SUNNEN PRODUCTS LIMITED do not entitle the buyer to corresponding SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service No 1 Centro Maxted Road 5 Hemel Hempstead 2 75 ENGLAND changes improvements additions or replacements for equipment supplies or Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen
8. D Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the following Normal maintenance items subject t
9. Switzerland Phone 41 71 649 33 33 Fax 41 71 649 34 34 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 1 Fax 39 02 383 417 50 0407 OCOPYRIGHT SUNNEN PRODUCTS COMPANY 2004 ALL RIGHTS RESERVED 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 Fax 86 21 5 813 2299 http Awww sunnen com e mail sunnen sunnen com PRINTED IN U S A
10. wo Prism Plate 470 600mm 18 5 23 6in MILLIMETERS PLATES 19 7 20 5 21 7 22 5 23 6 NOTE Refers to Outside Diameter of Workpiece 38 APPENDIX FIXTURE HEIGHT CHARTS H SERIES HOW TO USE FIXTURE HEIGHT CHART Find Workpiece O D by reading across the top and down the left side of the chart Where the column and line intersect is the approximate height at which the fixture should be set EXAMPLE OD of Workpiece is 165 mm Find column 150 mm on top of chart move down the column until it intersects line 15 For this example the Fixture should be set at 206 mm Fixture Inverted Fixture Normal 30 300mm 1 2 11 8in 180 405mm 7 1 15 9in mm 60 90 120 150 180 210 240 270 300 330 6 8 129 113 98 82 66 JAEL 128 112 97 81 65 12 215 127 11 79 63 15 229 212 126 10 94 78 175 156 139 124 108 92 76 173 154 138 122 106 90 74 4 224 20 12 2 6 190 171 153 136 120 104 88 72 27 223 204 189 169 151 135 119 103 87 71 INCHES 12 2 3 35 47 9 in 2 4 7 9 al pedos e TT TT zr 0 1 6 89 8 73 5 ACIS ETE oa oa aaa a 1 1 719 14 88 80 74 67 59 53 47 41 34 2
11. Machine 8 Take out Magnetic Filter from Reservoir 9 To remove Coolant that was not pumped out by Pump remove Drain Plug on front of Reservoir 10 Drain and clean Reservoir 11 Slide Reservoir under Machine 12 Connect oil fitting then install Drain Tube and connect Coolant Reservoir Plug 21 FIGURE 4 6 Coolant Reservoir NOTES 22 SECTION 5 TROUBLESHOOTING GENERAL OPERATIONAL TROUBLESHOOTING This section contains Troubleshooting information For suggestions on correcting problems with bore in table form which should be used when problems conditions or with honing operation consult Table 5 1 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 PROBLEM PROBABLE CAUSE SOLUTIONS Stone not cutting 1 Stone Glazing Dress stone Increase cutting pressure Increase stroking speed Use softer stone Check coolant 4 Dress stone Increase stroking speed Use softer stone Use coarser stone Check coolant 4 Calibrate Load Meter 5 Increase spindle speed Increase cutting pressure Use softer stone Use coarser stone Stone Loading Load Meter needs calibration Slow stock removal Improper spindle speed Inadequate stone feed up Improper stone Improper or diluted co
12. REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F 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 with
13. Screen Button 40 Set Stroke Rate Using Keypad enter desired Stroke Rate Reciprocation Speed m min or ft min and press ENTER Key 41 Hold JOYSTICK 1n the Inch Reverse direction until Honing Tool is even with workpiece left end end nearest Operator Control Panel 42 Set Feed Rate Adjust Feed Knob to lowest setting that gives good cutting action with respect to NOTES SECTION 4 ROUTINE MAINTENANCE CAUTION Be careful not to get oil on drive belts pulleys or brake strap SPINDLE CARRIAGE WAYS Wipe Spindle Carriage Ways with a clean soft cloth and lubricate with MOBIL WAY OIL 300 or its equivalent see Figure 4 1 EVERY THREE MONTHS SPINDLE CARRIAGE LINEAR BUSHINGS Linear Bushing Assemblies subject to normal loads may be lubricated with a lithium base grease of a consistency class NLGI to DIN51818 The grease supply should be enough to allow the balls to recirculate smoothly but without undue viscous resistance refer to Figure 4 1 3 5 CCM ONCE PER YEAR GEARBOXS When Spindle Drive is not running Check lubricant level in Sight Glass on the Spindle Drive Gearbox and fill as required refer to Figure 4 1 69 H Series ONLY Check lubricant level of optional Gearbox and fill as required see Figure 4 2 Add oil as required according to label on Gearbox s Mobilgear SHC 629 Change lubricant in Gearbox s every 5000 hour of operation and fill with fresh lubricant according t
14. bore Opens up blind end then goes into regular cycle SETUP amp OPERATION 1 Assemble and install Honing Tool refer to Section 2 2 Turn ON power at Main Power Disconnect Switch on Electrical Enclosure 3 Release all Emergency STOP Buttons Also insure Carriage is in locked position 4 Press Power ON Button If Main Power has been cycled press Power ON Button twice NOTE Machine automatically comes up 1n Manual Mode when power 15 turned ON 5 Press ACK Button to acknowledge message Re Zero Machine Re Home Servo 6 Press K1 Servo Enable Button on Control Panel 7 If required Press K2 Manual Auto Mode Button until LED is OFF 8 Press K15 Home Servo Button 9 If not connected Hold JOYSTICK in Inch Forward direction to move carriage far enough to the right so Honing Tool can be connected 10 Press K10 Feed Advance Button to expand stone in workpiece bore hold until all stones contact bore wall Shaking Honing Tool keeps hone from binding in bore while stones are being fed out 15 GENERAL This section describes a step by step operating pro cedure for Machine Prior to starting Machine Operator shall ensure prerequisites described in sections 1 and 2 are complete personnel are clear of machine SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel while working on or around Machine DO NOT operate machin
15. cycle Flashes when conditions have been Green met to start a honing cycle Pushbutton CYCLE STOP Stops honing cycle All counters hold their count and cycle Red can be resumed at place where cycle was interrupted Pushbutton INCH Man Mode Used to move spindle carriage in either direction Movement begins at pre set Inch Creep Speed after 3 sec 3 Way Joystick increases to pre set Inch Reverse Forward Speed REVERSE FORWARD Auto Mode Used to reverse direction of spindle carriage SHORT STROKE To Short Stroke tool at either end of bore or anywhere in 3 Way Joystick workpiece used joystick to hold or reverse direction of travel FEED Selector Switch TABLE 2 2 Operator Controls Buttons 8 Switches SYMBOL DESCRIPTION FUNCTION NO F1 Press to access MAIN SCREEN SYMBOL MAIN SCREEN Touch Button NO F2 Press to access SETUP SCREEN SYMBOL SETUP SCREEN Touch Button NO F3 Press to access SYSTEM SCREEN SYMBOL SYSTEM SCREEN Touch Button NO F4 Press to access STORE SELECT SETUP SCREEN SYMBOL STORE SELECT SETUP Touch Button NO F5 Various functions Screen Dependent SYMBOL Touch Button NO F6 Various functions Screen Dependent SYMBOL Touch Button F7 Various functions Screen Dependent Touch Button NO SYMBOL F8 Various functions Screen Dependent
16. cycle is completed retract stones slightly by pressing K9 Feed Retract Button see Figure 2 9 2 Swing Tool Support Bar into load position and tighten Adjustment Handle Adjust height by loosening Collar Clamp and rising or lowering as required 3 Press K12 Carriage Release Down Button and slide Spindle Carriage to the left 4 Perform required operation Guide Hone Head Module into bore by sliding Spindle Carriage to right and press K11 Carriage Release Up Button to lock in place WARNING Do not hone with Tool Support Bar in load position Honing Tool may catch on Bar and cause personal injury and or Machine damage 5 Loosen Adjustment Handle and swing Tool Support Bar back from load position Tighten Adjustment Handle 2 Swing Tool Support Bar into load position and tighten Adjustment Handle Adjust height by loosening Collar Clamp and rising or lowering as required 3 Press UNLOCK CARRIAGE Button and slide carriage to the left 4 Perform required operation Guide Hone Head Module into the bore by sliding Spindle Retractor Carriage to the right until Carriage Release Locks in place WARNING Do not hone with Tool Support Bar in load position Honing Tool may catch on Bar and cause personal injury and or Machine damage 5 Loosen Adjustme
17. exotic materials A Use bronze mandrel or bronze shoes Scratches in Bore 1 Improper feed A Decrease cutting pressure Random 2 Improper stone A Use finer stone B Use softer stone 3 Improper mandrel A If using hard steel mandrel change to soft steel mandrel If using soft steel mandrel change to bronze mandrel 4 Improper or diluted coolant A Check coolant 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 24 APPENDIX A CHECKLIST SETUP amp OPERATION SEQUENCE SETUP WORKHOLDING FIXTURE Section 2 Install and position the Workholding Fixture SETUP HONING TOOL Section 2 Assemble Honing Tool Rest Honing Tool on Tool Support Bar Install Honing Tool Guide Honing Tool into bore by sliding Spindle Carriage to right Press K11 to lock spindle carriage in position Press K10 to expand stone in workpiece bore Retract stones slightly by pressing K9 Swing Tool Support Bar into operating position l Press K12 and slide Spindle Carriage to the left Swing Tool Support Bar into load position G O nA LS L1 L1 EI L1 LI L1 EI E11 LI OPERATION S
18. kawakami ra aue Be ee 6 PREPARING FOR OPERATION gt lt ceeded dE nS 7 COB gt gt 7 Maor Components 22 dide bars 7 0 Ww uoce dox dade vas Pd bee merui cu 7 CONTOS er 7 es a gt 10 AVorkholding FXE db xac Re Oh __ dure 10 Honno Tobias acts E ae 1 I ibm Kuu da ER due co 12 Spidle Catriace Opona 13 SIUDPANDOPERATIONE 15 RE D DS ou de wat 15 Sosis LO BS e dus dui a di AR doo furto emt de 15 IE HERES oe qon e pad Peu ert dd fd tiM LL ML E 15 zs Ex INT Ih ue ai 15 ROUTINE MAINTENANCE addc EE REA ES cune meee ee EINE EG AES mec 19 da RG Su kiem ug ee tad A E ee 19 Canino Rd Ce danser Den oe 19 bi C O sare esti tk hed oats ue 19 AR ob Mi ane 20 CODE eer 20 TROUPES Rent ae p UE SLE Torn ha agus addu 8 23 EDITT Ae a eke oe ees Ca ea
19. 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 5 STH 4000L STH 6000L 30 370 mm 350 600 mm with special fixturing 1 2 14 5 in 13 8 24 in with special fixturing 1815 kg 4000 165 Up to 2 m 78 in Up to 4 157 in Up to 6 236 in Up to 8 m 315 in Up to 40 mpm 130 fpm 3 3 kW 4 4 hp 4 2 kW 5 6 hp 68 to 340 rpm Opt 47 234 38 188 30 148 3 kW 4 hp 5 5 kW 7 4 hp Centrifugal pump 0 187 kW 1 4 hp 0 56 kW 3 4 hp 235 L 62 gal 500 L 132 gal 38 LPM 10 GPM 113 6 LPM 30 GPM Sunnen Industrial Honing Fluids 14755 mm 580 9 in 1289 mm 50 7 in 1505 mm 59 3 in 4200 kg 9261 Ibs 739 kg sq meter 151 Ibs sq ft 30 LPM 6 5 4 Bar 1 6 80 PSI 230 460V 60Hz 3Ph 380 400V 50Hz 3Ph Pearl Gray Pewter Gray Burgundy Trim Less than 76 dB A continuous Less than 78 dB A peak Load max noise condition in a typical factory environment 6255 mm 246 1 in 10255 mm 456 7 in 1289 mm 50 7 in 1289 mm 50 7 in 1505 mm 59 3 in 1505 mm 59 3 in 2200 kg 4851 lbs 3000 kg 6615 Ibs Model Diameter Range OD Workpiece Weight Stroke Length Range Stroke Rate Stroke Motor Stroke Motor Optional Spindle Speeds Spindle Motor Spindle Motor Optional Coolant Pump Pu
20. ww 16 vas 1 81 222 20 ms ws wm we wer 95 76 bs ex a mae 299 aes tr te wi vj no oa 76 Fe es dex 20 228 20 eo 78 te vo 12a Tod 76 esame ere 202 228 208 ser vr 154 m 248 290 ers on zd 20 2 7 247 229 214 200 223 204 189 1691 151 135 119 103 87 71 INVERTED POSITION INCHES NORMAL POSITION i 12 2 31 45 4 7 59 24 35 47 59 711 8 3 95 106 11 8 130 2 00 10 3 96 90 84 8 7 80 74 66 59 52 46 40 33 8 01 102 9 6 89 8 3 87 79 73 65 58 52 45 39 33 7 02 10 29 5 89 8 3 86 7 8 72 64 57 51 44 39 32 6 0 4 10 1 9 4 8 8 8 2 85 78 7 1 63 57 50 44 38 32 6 05 10 0 9 4 87 8 1 85 7 7 70 63 56 50 44 37 3 1 5 0 6 10 09 3 8 7 81 90 83 76 70 62 56 50 43 37 3 1 07 99192 861 8 0 9 0 8 3 76 69 61 55 49 43 36 0 0 8 9 8 9 1 85 8 0 89 82 75 68 61 54 48 42 35 29 0 9 9 8 9 1 85 7 9 8 8 8 1 7 5 67 60 54 47 41 35 2 8 11 97 90 8 4 7 9 88 801 7 4 67 59 53 47 41 34 8 NOTE Out Side Diameter is in MILLIMETERS INCHES OOL SUPPORT BAR Setup Position ADJUSTMENT HANDLE FIGURE 2 7 Tool Support REMOTE FEED UNIT INPUT YOKE ADAPTER
21. 3 1 Spindle Speed Standard SPINDLE SPEED IN RPM 6 in mm RPM 6 in mm under 40 45 50 55 60 65 70 75 80 85 90 The optimum cutting Speed is about 55m min 17500 9 RPM Bore Diameter in millimeters Calculate Optimum Spindle Speed TABLE 3 2 Spindle Speed Optional SPINDLE SPEED IN RPM in mm No o in o in mm No mm No N 1 N IN IN NI N N NIN N NISN NI N NI N CALCULATION Spindle Speed 12 58 70 466 668 373 332 1 Spindle Speed 58 176 RPM x 22 95 466 668 373 332 2 Spindle Speed 176 420 RPM x 10 466 668 373 332 3 The optimum cutting Speed is about 55m min 17500 Bore Diameter in millimeters Calculate Optimum Spindle Speed RPM TABLE 3 3 Feed Rate SPINDLE FEED DIAMETER SPEED mm in RPM FINISH FOR FASTER STOCK REMOVAL INCREASE FEED IF STONES WEAR RAPIDLY Reduce Feed Rate Use Harder Stones 1 Always use this setting during the first few roughing strokes For finishing use Feed Setting of 1596 to 2096 380 16 WARNING Do not operate Machine with Tool Support Bar in load position 11 Loosen Adjustment Handle and swing Tool Support Bar into operating position Tighten Adjustment Handle 12 Retract stones slightly by pressing K9 Feed Retract Button Starting hone with stones pressed tightl
22. 8 NOTE Refers to Out Side Diameter of Workpiece NOTE Refers to Out Side Diameter of Workpiece Special Fixture w Prism Plate 350 530mm 13 8 20 9in MILLIMETERS NOTE Refers to Outside Diameter of Workpiece Special Fixture wo Prism Plate 500 700mm 19 7 27 5in MILLIMETERS PLATES NOTE Refers to Outside Diameter of Workpiece 39 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART 2 I 2 I 2 0 I MILLIMETER Traction DECIMAL MILLIMETER FRACTION DECIMAL 003087 01000 9 32 7 1438 21 82 007874 0 2000 19 64 7 5406 onsn 08000 she 7 9375 6 0 3969 8 0000 11 16 015748 0400 2164 8 3344 45 64 018685 0 5000 11732 8 7313 028622 06000 9 0000 23 32 027859 07000 2364 9 1281 47 64 0708 9 5250 031496 08000 2564 9929 3 4 035433 0 9000 10 0000 0393870 10000 13 32 103188 2 11906 27 64 107156 15875 11 0000 51 64 19844 6 n5 6 078760 20000 29 64 11 5094 2 3813 2 1 9068 4 27781 s 12 0000 27 32 11800 80000 123081 55 64 31750 12 12 7000 36719 180000 78 3 9688 33 64 13 0969 4 157480 40000 17 32 13 4938 48656 35 64 138906
23. 8 Connect other three wires 10 Disconnect Block as noted on Block L1 L2 L3 9 Route and secure Cord inside of Enclosure 10 Tighten Oil Tight Fitting 11 Close and secure lock Door s to Enclosure 12 Route and connect Electrical Supply Cord to power source PLUG Machine s Electrical Supply Cord into a properly polarized grounding type wall receptacle 13 Turn ON Master ON OFF Switch COOLANT RESERVOIR Maximum capacity of Coolant Reservoir is 235 Liters 62 gal subsequent to running Coolant pump see Figure 1 12 Minimum capacity of Coolant Reservoir for proper pump operation 15 110 Liters MAGNETIC SEPARATOR Consult installation Instructions packaged with Magnetic Separator see Figure 1 13 SPECIAL FIXTURE Optional Special fixturing 1s available for OD above 370 mm 13 8 in Refer to Appendix I OPERATIONAL CHECK Read Sections 1 and 2 thoroughly and carefully before performing the Operational Check 1 Operate Machine and check rotation of Spindle Shaft Rotation of Shaft should be counterclockwise as viewed from output end of Spindle Drive Motor If rotation is incorrect reverse any two wires red white or black of electrical supply cord where they connect to Disconnect Block DISCHARGE CHUTE FIGURE 1 13 Magnetic Separator CAUTION Note model electrical supply requirement printed on machine nameplate or electrical specification plate Do not attempt to connect machine i
24. ET EI E F1 ET ET F1 ET ET ET FT E ET ET ET E T ET APPENDIX A OPERATION Cont d Cursor down to Enter Auto Retract Time enter desired time and press ENTER Use Joystick to set tool to middle of Workpiece Set Spindle Speed Disconnect Honing Tool Install U Joint Stabilizer Press F6 Follow directions on screen and press F8 Connect Honing Tool Press Set Stroke Rate Reciprocation Speed and press ENTER Hold Joystick in Inch Reverse direction until tool is even with left end of workpiece Set Feed Rate Position Coolant Nozzle Open Flow Control Valve Install and position Splash Guards Swing Tool Support Bar into operating position Recheck all values entered in Control Panel Press K2 until LED is ON Press Cycle Ready Start Button to start Honing Cycle Machine will stop when Run Out Stroke Counter reaches zero 0 and honing cycle ends Press K2 until LED 15 OFF Retract stones slightly by pressing K9 Swing Tool Support into Load Position Press K12 and slide spindle carriage to the left Slide Honing Tool out of Bore 26 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 32 53 54 II I I D add DIEI E E E EI E El E ET EI E ET ET F1 ET APPENDIX 8 CHECKLIST WORK CYCLE SEQUENCE NOTE The following sequence 18 for when machine is set up and machine 15 ready to start next honing cycle with previously selected values
25. I STH 202C ENS SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN TUBE HONE STH Series 2 4 amp 6 meter machines READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN TUBE HONE SUNNEN THE SUNNEN LOGO GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS 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 installati
26. NE 12 APPENDIX C4 SCREENS STORE SELECT SETUP SCREEN GO TO PRINTER PARAMETER SCREEN EDIT SETUP TRANSFER SETUP PRINT SETUP DRAW ENTER ENTER ENABLE AUTO JOG OFF ON F2 F4 F6 F8 1 C C 1 EI MAIN SETUP SYSTEM STORE SCREEN SCREEN SCREEN SELECT A SETUP HELP Ki K2 K4 K5 K6 K7 K8 L ss 1 C SERVO MAN SPINDLE DWELL COOL B G F F G B WITH J MAN UTO N 1 N EN 12 co C m L L FEED FEED CARRIAGE CARRIAGE AUTO HOME RESET RETRACT ADVANCE RELEASE RELEASE SHORT SERVO COUNTS 60 U DOWN STROKE ESC ACK Y NO ele T SHIFT INS HELP ENTER DEL LINE 1 Displays to access the PRINTER PARAMETER SCREEN LINE 2 Displays to access the EDIT SETUP SCREEN LINE 3 Displays to access the TRANSFER SETUP SCREEN LINE 4 Displays to access the PRINT SETUP SCREEN 32 APPENDIX D CALCULATIONS FORMULAS STOCK REMOVAL in cm STOCK REMOVAL x Length n Removal qm EXAMPLE 100 mm x a 0 28 mm 52 8 cm HONING TIME in minutes 320 cm3 h HONING TIME Length x Removal min EXAMPLE 100 mm x 0 28 mm _ 10 min Stock Removal for SURFACE FINISH Required Stock Removal on Existing Finish Desired Finish _ mm 100 EXAMPLE 0 8 Ra N6 0 1 Ra NS L Ra NS 0 007 mm STONE CONSUMPTI
27. NS HELP ENTER DEL LINE 1 LEFT Displays current Honing Cycle CYCLE STOP or CYCLE RUN LINE 1 RIGHT Displays various messages TOOL IN WITHDRAW RECIPROCATION POSITIONS ENTERED INCORRECTLY LINE 2 Displays current Honing Time remaining in the HONING CYCLE LINE 3 Displays current number of Runout Strokes remaining in the RUNOUT CYCLE LINE 4 Operator entry of desired Reciprocation Rate for HONING CYCLE or RUNOUT CYCLE 29 SCREENS SYSTEM SCREEN INCH CREEP SPEED INCH REVERSE SPEED 1 30 INCH FORWARD SPEED 1 30 ENTER TOOL AUTO RETRACT TIME LOAD METER SENSITIVITY F5 CALIBRATE LOAD METER ENGLISH METRIC UNITS SELECTION PASSWORD LOGOUT Fi F2 F3 F4 F5 6 F8 Eh E E E MAIN SETUP SYSTEM STORE SCREEN SCREEN SCREEN SELECT SETUP A L Ki Ki K5 RG K7 K8 L L L 1 sss sss SERVO MAN SPINDLE DWELL COOL B G F F G B ENABLE AUTO JOG OFF ON MAN AUTO AUTO MODE AUTO ENTER ENTER Lud e R E A co D EN 14 15 K16 AUTO HOME SHORT SERVO COUNTS STROKE ESC lt gt SHIFT INS HELP ENTER DEL Operator entry of desired Reciprocation Rate spindle carriage will travel at during initial three 3 seconds of INCH FORWARD or INCH REVERSE Also Reciprocation Rate spindle carriage will travel at during HOME SERVO aml m m Z 2 O al om 25 6 al ITI
28. ON One Set of Stones consists of 4 Sticks 0 85 cm x 0 85 cm 10 2 cm long 29 48 in one set of H70 A45N Stones On the assumption of stone wear being at a ratio of 1 25 to Material Removed 29 48 25 737 cm3 material removed with one set of H70 Stones Parts per Set of Stone 79797 __ Parts Stock Removal EXAMPLE 137 14 Parts per Set of Stone 52 8 cm 33 APPENDIX E CROSSHATCH ANGLE 30 tg 15 0 2679 CROSSHATCH ANGLE tg 22 5 0 4142 60 tg 30 CALCULATING 609 2 309 EXAMPLE CALCULATE Bore Diameter 100 mm m UND SUA RPM 175 Crosshatch Angle 60 V m min MA RAN YAQA 3 5 MN A 0 0 M NNN NAM OA NN BRINN 0 XY M A MA x XXX x Q wy 0 AA X OAK M 0 To calculate the Crosshatch Angle consult following Formulas Stroke Speed V m min x 3 14 x RPM tg 30 m min 1000 EXAMPLE 100 x 3 14 x 175 x 0 5774 31 73 m min 1000 Spindle Speed RPM 1000 V m min RPM x 3 14 x tg 30 EXAMPLE 1000 x 0 165 5 RPM 100 mm x 3 14 x tg 0 5774 34 APPENDIX F PNEUMATIC FLOW DIAGRAM 1 Filter 2 Pressure Regulator 3 Valve 4 Valve 5 Carriage Release Cylinder 6 Air Pressure Switch 7 Gage SET AT 30 PSI 4 12 de pH gm Ea DES lt SS 14 SET AT 70 PSI ws 6 39
29. OSITION tin 1 2 2 3 13 5 4 7 5 9 241 35 47 59 711 8 3 9 5 6 0 010 4 9 8 9 1 84 7 8 81 7 4 68 60 53 4 7 44 0 1104 9 7 9 0 83 7 8 81 7 4 67 59 52 46 0 0 2 10 3 9 6 9 0 8 3 77 8 0 7 3 67 591 52 5 3 9 0 4 10 2 9 5 8 9 8 2 77 8 0 7 2 6 6 5 8 51 45 39 0 55102 9 5 8 8 8 2 7 6 7 9 7 1 6 5 57 50 44 38 0 6 10 1 9 41 87 8 1 7 6 85 7 8 70 64 57 50 44 38 0 7 10 0 9 3 8 7 8 0 75 8 4 7 7 7 0 63 56 49 43 37 0 8 10 0 9 3 8 6 80 74 831 7 6 7 0 63 55 4 9 43 6 0 9 9 9 92 8 5 7 9 74 83 7 6 69 62 55 48 4 2 5 1 1 9 8 9 2 8 5 7 9 7 3 82 7 5 69 6 1 54 48 41 5 NOTE Out Side Diameter is in MILLIMETERS INCHES HOW TO USE FIXTURE HEIGHT CHART Find Workpiece O D by reading across the top and down the left side of the chart Where the column and line intersect is the approximate height at which the fixture should be set EXAMPLE OD of Workpiece is 165 mm Find column 150 mm on top of chart move down the column until it intersects line 15 For this example the Fixture should be set at 192 mm INVERTED POSITION MILLIMETERS NORMAL POSITION mm 30 60 90 120 150 60 90 120 150 180 210 240 270 300 330 Fo aea mms 203 1 w wo ee tr tm asl 212 say we 7 ww n s es alan aol we ssa mmo 21 wr
30. UTO Q MANUAL SHORT STROKE FORWARD Ll MANUAL SHORT STROKE BACK RACT ADVANCE AUTO SHORT STROKE DISTANCE AUTO SHORT STROKE TIME SPINDLE BRAKE F8 D 516 4 zis v Displays current Reciprocation Position of spindle carriage in relation to HOME POSITION Operator entry of desired BACK GO FORWARD Reciprocation Reversal Set Point Operator entry of desired FORWARD GO BACK Reciprocation Reversal Set Point Operator entry of desired Cycle Time to be completed during HONING CYCLE Operator entry of desired Number of Reciprocation Strokes to be completed during RUNOUT CYCLE Operator entry of desired Reciprocation DWELL TIME Forward amp Back Positions Only active when K4 Dwell Off On Keypad 15 turned ON Operator entry to select desired Reciprocation DWELL POSITION Back Forward Both lt MORE gt This screen has more text lines accessed by cursoring down Operator entry to set Manul Short Stroke Forward Distance Operator entry to set Manul Short Stroke Back Distance Operator entry to select desired AUTO SHORT STROKE FORWARD Only active whenK 14 Auto Short Stroke Off On Keypad is turned ON Operator entry to select desired AUTO SHORT STROKE TIME Only active when K14 Auto Short Stroke Off On Keypad is turned ON Engages and disengages Spindle Brake F8 in this Screen 31 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 LINE 11 LI
31. arriage base plate and level machine by adjusting Leveling Bolts on Support Feet using a 24 mm Open End Wrench see Figure 1 3 NOTE Align Work Base to Machine Base Level work base using hex head leveling bolts supplied Leveling bolts and jam nuts were packaged with hardware in coolant reservoir 14 Align both Bases then install M16 Bolts between Tables see Figure 1 2 Bolts were packaged with hardware in coolant reservoir NOTE Two M16 Bolts for connecting Machine Bases are supplied CAUTION DO NOT move Machine once Bolts are installed Serious damage may be caused to Bases 1f Machine is lifted once Bolts are installed 15 Remove lifting bracket from front of machine and install drip pan STH 2545 using four screws M6x8 BHCS 16 Remove spindle carriage shipping bracket and replace two screws 16 12 BHCS Use same screws to mount electical conduit support 17 For permanent installation secure Machine s Support Feet to Floor with appropriate fasteners not supplied 18 Install machine base to work base drain hose to work base hose barb fitting 19 Install and align 2 yellow electronic Sensor Units Photo Eyes to sheet metal of work base at machine base work base joint see Figure 1 4 CAUTION Serious damage will be caused to the spindle carriage if spindle carriage is initialized or moved before lifting straps are removed 20 Attach Operators Control Console Attach Arm to unders
32. bols that may be used on this machine refer to Table 2 3 WORKHOLDING FIXTURE Position the Workholding Fixture as follows ME ROUGE 1 Loosen four Socket Head Capscrews in base of THIS Workholding Fixtures and Screw in Collar Clamps ia use 10 mm Hex Wrench see Figure 2 4 2 Position Fixture so Workpiece will be clamped close to its Ends approx 400 mm NOTE Column Base is shown in its Normal Position If OD of Workpiece is below 975 mm HAND y mount Column Base in upside down position 4 CRANK a EE Z Sa MEASURE THIS DISTANCE 3 Measure distance between Slot and Bottom line of Column Base THREADED 4 Adjust height of Workholding Fixture by turning COLUMN Adjusting Nut see Figure 2 4 amp Table 2 4 The Workholding Fixture should be adjusted so SPLIT CLAMP centerline of Workpiece is approximately in line INVERTED with Spindle Axis 5 Lay Securing Chain out of Fixture 6 Lift Workpiece into Machine using a hoist as required WORKPIECE 7 Align Workpiece with Fixtures Position Fixtures 5 1 CLAMP NEAR ENDS as required Workpiece should be clamped between kasa 300 500 mm from its Ends for best Results 8 Lower Workpiece into place on Fixture WORKHOLDING FIXTURE 9 Wrap Securing Chain around Workpiece and engage in Catch FIGURE 2 4 Fixture 10 10 Adjust tension on Securing Chain by turning Hand Cran
33. e ET 23 Operational TEouDIeSDOOLITIg ah aka dede bo eae CRUS 23 APPENDIXES A Check Lis Setup S Open 0 m 25 BD Check List Work CyCle Sequence aos 27 SCC ssc a ea uu ro miu d e uuo oe OMe ce RD Sm Re ane OO ae h 29 tuned re coin ina amp RR dod a ue 33 E Crosshateb NS mu n ee 34 I Pneuriatc Plow Dido atl es aos at ca RUE dude m dte ACD Rte eu eb dos TR ue 35 Coolant Flow nt seen io mibi er Mata a CU RS ee rar duo ON Ut nae as 36 I surface Roubhness Tables aue b cre the _ 37 Taxture Hergehte Mart aS d ver ad e teta Bae E pet see eas 38 T Fixture Herent Chart Ses acide ue RR CR e ROC Reed ae ca ucu LR NUR RC ees 39 INTRODUCTION This Instruction Manual is provided to give the information required to install operate and maintain the STH Series Sunnen Tube Hones models STH 2000 4000 amp 6000 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
34. e limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any 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 co
35. e while lifting devices are installed Ensure workpiece is securely fixtured and located before operating Ensure all guards are in place before operating Ensure area 15 clear of other personnel before operating machine Keep machine clear of tools or other foreign objects 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 Keep area around machine free of paper oil water and all other debris at all times When lifting part or tooling use proper lifting procedures DO NOT overreach keep proper footing and balance at all times Push E STOP Button and turn OFF electrical power at Disconnect Switch on Electrical Enclosure when preforming service not requiring power e 66 Turn OFF electrical power at Main Power Source when preforming maintenance on or cleaning of Electrical Control Enclosure Clear area of excessive lubricant or lubricant spills DO NOT adjust stroke length while Spindle Retractor Carriage 15 not in locked position KEEP hands clear of all moving parts Stay clear of all moving parts Remove keys and wrenches from machine before honing DO NOT operate machine with tool support bar in load position To avoid personal injury allow spindle and stroking arm to come to a complete stop before removing part TABLE
36. ection 3 1 Assemble Honing Tool 2 Turn ON Main Power 3 Release Emergency STOP Button 4 Press Power ON Button 5 Press ACK 6 Press 1 7 If required Press K2 8 Press K15 9 Connect Honing Tool Use Joystick to move Carriage 10 Press K10 to feed out stones 11 Swing Tool Support Bar into operating position 12 Press 9 to retract stones slightly 13 Use Joystick to set overstroke on left end of Workpiece 14 Press F2 15 Press K6 16 Set Left Safety Switch Activator 17 Use Joystick to set overstroke on right end of Workpiece 18 Press K7 19 Set Right Safety Switch Activator 20 Cursor down to Honing Cycle Time enter desired time and press ENTER 2 Cursor down to Run Out Stroke Count enter desired number of strokes and press ENTER 22 Cursor down to Dwell Time enter desired time and press ENTER 23 Press F7 to select desired Dwell Location 24 Cursor down to Manual Short Stroke Forward Distance enter desired distance and press ENTER 25 Cursor down to Manual Short Stroke Back Distance enter desired distance and press ENTER 26 Cursor down to Auto Short Stroke Distance enter distance and press ENTER 27 Cursor down to Auto Short Stroke Time enter desired time and press ENTER 28 If desired Press F8 to release Spindle Brake 29 Press F3 30 Press F5 Load Meter Sensitivity If Available cursor down to Jog in Auto Feed Rate and press ENTER CONTINUED 25 HII I I i EI EI E ET EI E1 El E
37. er K10 FEED ADVANCE Touch Button K11 CARRIAGE RELEASE UP Touch Button K12 CARRIAGE RELEASE DOWN Touch Button K13 Touch Button K14 AUTO SHORT STROKE Touch Button K15 HOME SERVO Touch Button K16 RESET TIME COUNT Touch Button SHIFT Touch Button INS DEL Touch Button HELP Touch Button ENTER Touch Button ACK Touch Button ESC Touch Button FEED IN PROGRESS LED CAUTION LED NO CURSOR Arrows Used in conjunction with other keys buttons SYMBOL KEYS Used to move cursor on display screen NO SYMBOL NUMERIC ALPHA KEYPAD NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL NO SYMBOL TABLE 2 3 Safety Symbols 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 Warning Strip Warns that a physical hazard exists and that proper precautions should be taken Designates this machine is CE compliance Warning Warns that a hazard from objects falling off work table exists and that proper Label precautions should be taken Warning Warns not to hold workpiece in hand without a torque Label resisting fixture SAFETY SYMBOLS For a description of safety sym
38. f 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 ELECTRICAL CONNECTION A pre drilled hole has been provided in Electrical Enclosure for Electrical Supply Cord not supplied Connect Cord as follows see Figure 1 11 NOTE For Cord dimensions refer to General Information amp Specification at front of this manual CAUTION Doors are equipped with lockable Safety Door Latches Doors should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Doors Latches should be Locked Out and Tagged during servicing to prevent machine from being powered up 1 If applicable Loosen Safety Latches on door s to enclosure using a screwdriver Or on CE models unlock doors to Electrical Control Enclosure using key supplied with machine Door s to enclosure 15 equipped with Key Lock Safety Latches 4 After unpacking and installing Machine clean and lubricate refer to Section 4 Routine Maintenance SPLASH a GUARDS 6 SPINDLE GEAR BOX 2 Operate Machine and check rotation of optional equipment according to Installation Instruction package with optional equipment 3 Set up and test all machine functions refer to Section 3
39. his parameter with repect to bore diamter honing application 1e stock removal pol ishing straightening and tooling arrangement Example A small dia polishing application will require a lower HP Limit Setting A large dia bore heavy stock removal application would require a higher HP setting Move cursor down to Auto Feed Rate The ranage here is 1 100 This is the rate at which feed motor expands during a honing cycle 10096 would be the fastest allowed expand rate Move cursor down to Jog in auto Feed Rate The range here is 1 100956 This is the rate at whcihc the feed motor will expand when you press the rapid expand button during a honing cycle 100 would be the Max allowed expand rate 3 Cursor down to highlight Enter Tool Auto Retract Time Using Keypad enter Time sec and press ENTER 32 Use JOYSTICK to move Honing Tool to middle of Workpiece 33 Set Spindle Speed Using Spindle Motor Speed Adjustment Handwheel select desired Spindle RPM see Table 3 1 or Table 3 2 34 Disconnect Driveshaft from Spindle and slide slightly forward 35 Install U Joint Stabilizer onto Feed Rod Output Shaft 36 Press F6 Calibrate Load Meter Button 37 Follow instructions on screen and press F8 when complete 38 Reconnect Driveshaft to Spindle refer to step 31 NOTE DO NOT leave this screen until calibration is complete If you do you must return to this screen to complete calibration 39 Press F1 Main
40. hoes 2 Improper stone length Use longer stone or shorten guide shoes on both ends B Use mandrel with longer stone amp shoes 3 Improper stone A Use finer stone Taper in Open Hole 1 Workpiece is not being reversed A Reverse workpiece on mandrel 2 Mandrel not trued A True stone amp shoes 3 Improper stroke A Lengthen overstroke on tight end 4 Stroker Arm and Spindle not aligned Align Stroker Arm and Spindle Taper in Blind Hole 1 Improper stone length A Shorten stone and shoes to 3 4 length of bore B True stone amp shoes frequently 2 Inadequate oil flow A Adjust Oil Nozzle 3 Inadequate relief in blind end A Provide sufficient relief B Short stroke tight end C Use hard tip stone Out Of Round 1 Undersize honing tool A Change honing tool 2 Mandrel not true A True stone amp shoes 3 Workpiece flexing thinwall A Decrease cutting pressure 4 Improper stone A Use softer stone Waviness 1 Improper mandrel or stone length A Use mandrel with sufficient stone length to bridge waviness in bore Rainbow 1 Improper mandrel A Use L BL or multi stone mandrel stone length should be 1 1 2 times bore length 2 Improper stroke A Shorten overstroke 3 Improper stone A Use softer stone Rough Finish 1 Improper feed A Decrease cutting pressure 2 Mandrel not trued A True stone amp shoes to exact hole dia 3 Improper stone A Use finer stone 4 Improper or diluted coolant A Check coolant 5 Soft or
41. ide of machine base and securing with supplied washer and hitch pin see Figure 1 5 Route and connect electrical plug to electrical enclosure through conduit clamp see Figure 1 6 21 Install coolant reservoir under machine and connect coolant hoses Clean coolant supply work base drains amp machine base to work base drain Route and connect electrical plug to electrical enclosure refer to Figure 1 6 22 If supplied Position container under discharge chute of magnetic filter 23 Remove four 4 MI2 lifting eyes from work holding fixtures see Figure 1 7 24 Check Coolant Nozzles refer to Figure 1 7 25 Position two Splash Guards on Machine see Figure 1 8 26 Inspect Safety Arch on work base Requires 10mm Hex Wrench see Figure 1 9 CONNECTION MIA NN ANOMAN FIGURE 1 10 Pneumatic f os 4 iii FIGURE 1 11 Electrical Control Enclosure 27 Clean Spindle Carriage Ways with solvent to remove anti rust and any foreign materials After this lightly lubricate with Oil PNEUMATIC CONNECTION Connect pneumatic line airline as follows see Figure 1 10 NOTE The Factory Air Supply Line 15 not supplied A minimum of 0 55 MPa 80 psi clean dry compressed air 1s required for proper operation 1 Install Quick Disconnect not supplied in airline port on Airline Filter Regulator 2 CONNECT 1 2 in 13 mm factory air supply line not supplied to Quick Disconnect no
42. k Hand tightens to approximately 40 50 Newton meters 11 Tighten four Capscrews in base of each Workholding Fixture and Collar Clamp Screws loosened in step 1 refer to Figure 2 4 HONING TOOL Assembly and install Honing Tool per instructions packaged with Tooling 1 Assemble Honing Tool see Figure 2 5 2 Press K12 Carriage Release Down Button and slide Spindle Carriage to the left see Figure 2 6 NOTE The Spindle Retractor Carriage provides 380 mm of tool withdrawal motion OUTPUT FLANGE ADAPTER UNIVERSAL COVER HONE HEAD MODULAR INPUT YOKE ADAPTER DRIVE 8 FEED EXTENSION DISASSEMBLY RING FIGURE 2 5 Honing Tool SPINDLE RETRACTOR CARRIAGE TABLE 2 4 Fixture Height Adjustment L SERIES INVERTED POSITION MILLIMETERS NORMAL POSITION 30 60 90 0 60 90 120 180 210 240 2701 300 0 265 248 231 4 207 9 153 135 119 103 87 71 263 246 229 212 206 7 151 133 117 101 86 0 261 244 228 211 204 5 149 1311 115 99 84 8 260 242 226 9 203 3 147 130 114 98 83 7 258 241 224 8 201 181 146 128 113 97 81 65 257 239 222 206 215 198 179 144 127 112 96 80 64 255 237 220 204 214 196 178 142 125 110 94 78 62 253 236 218 202 212 194 177 140 1241 108 92 76 60 252 234 216 201 210 192 176 139 1221 106 90 74 58 250 233 215 200 209 190 175 137 121 105 89 73 7 INVERTED POSITION INCHES NORMAL P
43. l 30 177mm 1 2 6 9in 75 375mm 3 0 14 7in MILLIMETERS MILLIMETERS 30 60 90 120 150 60 90 120 150 180 210 240 300 330 265 248 231 214 199 207 189 173 153 135 119 87 71 263 246 229 212 198 206 187 171 151 133 7 86 0 NORMAL 261 2441228 211 196 2041 185 169 149 131 115 84 68 260 242 226 209 195 2031 183 167 147 130 114 83 67 258 241 224 208 193 2011 181 165 146 128 113 81 65 257 239 222 206 192 198 179 163 144 127 2 80 64 255 237 220 204 190 196 178 161 142 125 78 62 NORMAL 253 236 218 202 188 194 177 159 140 124 76 60 252 234 216 201 187 EE 192 176 157 139 122 74 58 250 233 215 200 186 190 175 155 137 121 73 57 INCHES INCHES 5 9 in 2 3 4 7 1 8 3 3 5 2 81 74 60 53 47 51 28 22 7 7 7 PE 3 6 2 6 1 6 0 76 85178170 64 57 50144138 31125 NOBNAL 85 78 70 64 57 50 5 784 77 79 63 56 49 43 37 31 24 9 62 74 55 49 43 36 30 24 7 4 69 62 55 48 42 85 29 23 7 3 NOTE Refers to Outside Diameter of Workpiece Special Fixture w Prism Plate 350 510mm 13 8 20 1in min 350 370 max 370 0 1 860764 L padwsweswrpami NOTE Refers to Outside Diameter of Workpiece MILLIMETERS Special Fixture
44. located under drip pan with approx 45000 of Mobilgear 630 CLP ISO VG220 EVERY 10 000 HOURS see Figure 4 3 CHAIN Lubricate Spindle Carriage Chain with a Chain Spray same as Motor Cycle EVERY THREE MONTHS see Figure 4 4 CHAIN Check Chain tension of Spindle Carriage and adjust as follows see Figure 4 5 1 Bring the Spindle Carriage in the middle of stroke then move by hand forward and backward If you feel any clearance adjust the Chain tension of Spindle Carriage by the following operations 2 Press E S TOP 3 Loosen Screw in Top of Chain Adjuster approx Turn 4 Loosen both Nuts of Chain Adjuster 5 Pull back the Chain Adjuster by hand and tighten first nut by hand 6 Then tighten first Nut with a 46 mm Open End Wrench Turn and tighten second Nut STH 2000 1 Turn STH 4000 1 Turns SIH 6000 2 Turn STH 8000 274 Turns 7 Tighten the Serew in Top of Chain Adjuster COOLANT RESERVOIR Clean Coolant Reservoir and Replace Coolant as follows see Figure 4 6 1 Direct one or more Coolant Nozzles into an approved waste container 2 Open Coolant Control Valves 3 Press K5 Cool Man Auto Button turn pump ON and pump waste Coolant into waste container 4 As Coolant flow drops off press E Stop Button 5 Close Coolant Control Valves 6 Disconnect Coolant Reservoir Plug from Connecting Panel 7 Remove Drain Tube and disconnect oil fitting then slide Reservoir out from
45. mp Motor Coolant Capacity Pump Rate Coolant Requirements Floor Space Length Depth Height Floor Weight Dry Floor Load Pneumatic Requirements Electrical Requirements Color Noise Emission Diameter range length range and workpiece weight are contingent on workpiece and application Vii viii FLOOR PLAN Sunnen Tube Hones Ul 069 X 2 08 X 6 099 HGOGL X 0681 X 199 1 0009 HLS Ul 068 x Z 0S X 9cy HGOGL X 0681 X 199201 0007 15 Ul 669 X 2 09 X 9 2 H90S X 0682 X 19929 0002 15 5 5 191 ws 6y 62 uey sse MAIA LNOH 0009 15 MAIA LNOYS 0007 0002 15 M3IA Adis SECTION 1 INSTALLATION PURPOSE This Section is designed to aid user in unpacking inspecting and installing Sunnen Tube Hone models STH 2000 4000 amp 6000 Hereafter referred to as the Machine see Figure 1 1 LEFT RIGHT FIGURE 1 1 Tube Hone 1 TOOLS 8 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 and inspecting Machine All references to right and left in these instructions are unless otherwise noted as seen by
46. mponents 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 Indicates CE version ONLY 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 OFCONTENIS 7 ure osa Sa ose eas ui ii V LIST OE APPENDIXES Pa side ema EDAM E AES NE EE vi INTRODUCTION 262 5400426443 oho A ___ taies vi GENERAL INFORMATION SPECIFICATIONS vii FLOOR LAYOUT Configuration Vill NS RARES MONS So eee ee S usupa 1 1 DUS cu uu tt ass dic E ERA 2 re re aU cu E n ee De No ou SD aoe de 2 Pneumatic COMM CUO zo uas ee AE pin ted qoa RU Ghee A UD 3 saute acini nude Does 4 expo sm ba 4 blectrical quc zc ut den D ad s a aS en ___ 5 statem s ae Eee ote oe ee cae a I AE ee ana E 5 Niacnetic separator Punsyu sua Y Q puma kas SAO uqa hooey wee 5 0 h aQaa sss one 5 uqaqa es
47. n load set by Feed Knob until Honing Cycle Time reaches zero 0 At that point the stones stop feeding out and remain in a blocked position until Run Out Stroke Counter reaches zero 0 and Honing Cycle ends NOTE After Timer reaches or WITHDRAW Key 1s pressed Machine Stops honing at end of next completed stroke Timer automatically resets each time Cycle Stop Button keeps remaining time 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 POWER ON Button must be pressed twice before machine will operate Also K9 FEED RETRACT Button must be used so that stones will not be under pressure before machine can be restarted When honing cycle is interrupted Timer resets itself 50 Press K2 Manual Auto Mode Button until LED is OFF 5 Retract stones slightly by pressing K9 Feed Retract Button 52 Swing Tool Support into Load Position 53 Press K12 Carriage Release Down Button and slide spindle carriage to the left 54 Slide Honing Tool out of Bore 17 28 If desired Press F8 Button to release Spindle Brake 29 Press F3 System Screen Button 30 Press F5 Load Meter Sensitivity Available on L Series ONLY This 1s an adjustqable parameter This represents Max HP Limit at 10096 as displayed by Load Meter 100 Load of meter 15 determined from this parameter setting Range are 4 3 2 amp 1 HP Adjust t
48. nt Handle and swing Tool Support Bar back from load position Tighten Adjustment Handle 13 HANDWHEEL SPEED SELECTOR LEVER FIGURE 2 10 Spindle Drive Optional SPINDLE CARRIAGE Optional The Spindle Retractor Carriage allows the Honing Tool to be withdrawn from the Workpiece for gaging stone set replacement or installing a new Workpiece without removing tool or changing any of the settings Refer to Section 3 and Table 3 2 for setting Spindle Speed NOTE The Spindle Retractor Carriage provides 380mm of tool withdrawal motion 1 After honing cycle is completed retract stones by switching RAPID FEED RETRACT Switch NOTES SECTION 3 SETUP amp OPERATION 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 IT IS DANGEROUS to rotating parts such as drive shafts and honing tool during operation OPERATING HINTS There are several features on the STH Machines for correcting problems in the bore These features are as follows 1 During honing cycle the Short Stroke Joystick can be used at any time to reduce Tight Spots 2 Additionally the Short Stroke Joystick can be used to stop or oscillate the stroke at either end of the bore for correcting barrel or bellmouth conditions 3 Ability to dwell at either or both ends 4 Auto short stroke at blind end of
49. o ENGAGE Spindle Carriage Lock Press to DISENGAGE Spindle Carriage Lock NOT USED Press to initiate AUTO SHORT STROKE Used in conjunction with Auto Short Stroke Time amp Position progamming on setup screen Press to automatically move Spindle Carriage to Home Position and Recalibrate Servo Counter Press to reset Honing Cycle Time and Runout Stroke Counter Used in conjunction with Numeric Alpha Keypad to switch to enter letters Because of limited space if letter is not shown press last letter shown and use arrows to select letter Button will light when operator entry screen for which there is a help screen Pressing button will take operator to help screen Press ESC button to return to previous screen Pressing this button enters operations and entries that require this function If an alarm appears on screen then operator presses this button acknowledge alarm and return to operations screen Red light will remain lit until condition is cleared Escape Press to return to previous screen or step Indicates tool is feeding Also see K9 and K10 Buttons Indicates that Shift Button has been pressed See Shift Button Indicates that help screen is available for present screen See Help Button Indicates that an alarm has sounded See ACK Button Used to enter numbers Using Shaft Button allows operator to enter letters Press last letter and use up arrow to scroll to desired letter and press ent
50. o label on Gearbox Capacity of Spindle Drive Gearbox is 0 75 Liters Capacity of optional Gearbox is 7 5L NOTE New Spindle Drive Gearbox models without a Sight Glass and Fill Plug have Live Lubrication FILLER PLUG GEAR BOX FIGURE 4 2 Gearbox Optional 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 CLEANING Daily Wipe exterior of Machine with a clean dry cloth Monthly Wipe exterior of Machine with a clean dry cloth Wash exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water Wipe dry with a clean dry cloth LUBRICATION Hand lubricate various machine components called out in below NOTE The intervals between lubrication will vary with amount of use your Machine receives Lubricate all components at least once every six months FILLER PLUG SIGHT GLASS FIGURE 4 1 Spindle Carriage Ways FIGURE 4 4 Chain FIGURE 4 5 Chain 20 STROKING GEARBOX Lubricate Stroking Gearbox
51. o wear and tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI RFI Storm lightning flood or fire damage Failure to perform regular maintenance as outlined in SPC manuals Improper machine setup or operation causing a crash to occur 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 Non authorized customer installed electronics and or software Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE
52. olant Check coolant 4 Load Meter needs calibration Calibrate Load Meter 3 Poor stone life Excessive stone feed up Decrease cutting pressure 2 Inadequate spindle speed Increase spindle speed 2 Improper stone Use harder stone Use coarser stone Improper or dilute coolant Check coolant 4 Load Meter needs calibration Calibrate Load Meter 3 Bellmouth Bore Mandrel not trued True stone 4 shoes longer than 2 3 Short or unbalanced part Shorten stroke length 2 Use softer stone Shorten stone only slightly on each end stone length Improper stone Improper stone length A B C D E A B C D E A A A A B A A A A A B A A A A A A True stone amp shoes Shorten stroke length 2 Use softer stone Shorten stone amp shoes equally to 1 1 2 times bore length Bellmouth Bore Mandrel not trued shorter than 2 3 Short or unbalanced part stone length Improper stone Improper stone length gt gt gt gt 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 23 PROBLEM PROBABLE CAUSE SOLUTIONS SEC Barrel 1 Mandrel not trued True stone amp s
53. on operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available 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 Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required 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 inf
54. ormation available at http www sunnen com or e mail sunnen 6 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 aa to POTE Ponang 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 3 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 C Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics
55. out 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 abov
56. rs and press ENTER 26 Cursor down to highlight Auto Short Stroke Forward Distance Using Keypad enter distance inches millimeters and press ENTER 27 Cursor down to highlight Auto Short Stroke Time Using Keypad enter Stroke Time sec and press ENTER bore diameter condition of bore material and stones used see Table 3 3 NOTE The Feed Settings shown in Table are offered as a suggested starting point Experiences with your particular operation will dictate the most economic feed setting for your shop 43 Position Coolant Nozzle to direct oil into bore Ensure there 15 enough clearance for overstroke by Honing Tool Use ONLY one Coolant Nozzle so metal chips may be properly flushed from workpiece during honing 44 Open Flow Control Valve on Coolant Nozzle 45 Install and position Splash Guards WARNING Do not hone with Tool Support Bar in load position Honing Tool may catch on Bar and cause personal injury and or Machine damage 46 Loosen Adjustment Handle and swing Tool support Bar back from load position Tighten Adjustment Handle 47 Recheck all values entered 1n Control Panel 48 Press K2 Manual Auto Mode Button until LED is ON 49 Press CYCLE READY START Button to initiate A Honing Cycle Honing Tool will continue to feed stones out to maintai
57. t supplied 3 Airline Filter Regulator Valve This valve 15 preset at the factory to 0 55 MPa 80 psi ELECTRICAL REQUIREMENTS All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY BT eoi 7717 WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to discharge 2 Turn Master ON OFF Switch to OFF position and open Doors Doors WILL NOT open unless Master ON OFF Switch is in OFF position WARNING You must use hole provided Drilling any new holes in electrical enclosure may void machine warranty 3 Remove hole plug from entrance hole in enclosure and install an approved oil tight fitting not supplied 4 nsert 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 5 Strip 153 mm 6 in off cable s outer jacket 6 Strip 6 mm 1 4 in of insulation off each wire 7 Connect Green Wire GRN to Ground Terminal beside Electrical Disconnect Block Earth Ground
58. the operator as one looks at Machine or assembly being described 1 Cut remove and discard shipping bands 2 Remove top and front of shipping crate 3 Remove Components from crate and remove protective packing material from the components 4 Remove 2 Lift Off Type Coolant Splash Hoods from work base and set them aside FIGURE 1 2 Align Bases 5 Remove Operator Control Console Assembly and set it aside 6 Remove hardware from coolant reservoir 7 Remove eight bolts securing Tables Support Feet to bottom of crates using 3 4 in open end wrench 8 Install lifting straps chains not supplied around center support tube at rear of machine base and around lifting bracket at front of machine base 9 Remove machine base from skid and set it in place 10 Install lifting straps chains not supplied through four M12 lifting eyes supplied in Fixture Base Plates Verify Fixture Base Plates are secured to Work Base Ways before attempting to lift Work Base CAUTION NON OPERATORS Install 2 yellow Electrical Barrel type plugs Photo SIDE Eye Cables through grommetted holes in work base Ps sheet metal as bases come together 11 Remove work base from skid and set 1t 1n line with machine base 12 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 13 Place a machinist level on spindle c
59. y against bore wall produce unnecessary stone wear 13 Use JOYSTICK to move Honing Tool to left end of Workpiece then run Tool approximately 1 3 of Stone length out of Workpiece to allow for overstroke Back Go Forward Reciprocation Reversal Position 14 Press F2 Setup Screen Button 15 Press K6 B G F Auto Enter Button 16 Set Left SAFETY SWITCH ACTIVATOR 12 mm 1 2 1n from Limit Switch Arm 17 Use JOYSTICK to move Honing Tool to right end of Workpiece then run Tool approximately 1 3 of Stone length out of Workpiece to allow for overstroke Forward Go Back Reciprocation Reversal Position 18 Press K7 F G B Auto Enter Button 19 Set Right SAFETY SWITCH ACTIVATOR 12 mm 1 2 1n from Limit Switch Arm 20 Cursor down to highlight Enter Honing Cycle Time Enter desired time minutes amp seconds and press ENTER 2 Cursor down to highlight Enter Run Out Stroke Count Using Keypad enter desired number of Run Out Strokes to be completed during Run Out Cycle and press ENTER 22 Cursor down to highlight Dwell Time Using Keypad enter Dwell Time Forward amp Back sec and press ENTER 23 Press F7 to select desired Dwell Location Forward Back or Both 24 Cursor down to highlight Manual Short Stroke Forward Distance Using Keypad enter distance inches millimeters and press ENTER 25 Cursor down to highlight Manual Short Stroke Back Distance Using Keypad enter distance inches millimete
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