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INSTRUCTIONS

1. 5 SPINDLE 5 E SHIFT BEARINGS See Fig 4 2 LD 1 WAY BARS 4 SPINDLE LUBRICATOR CARRIAGE See Fig 4 3 1 a HYDRAULIC LING FAN SS 2 HYDRAULIC RESERVOIR See Fig 4 5 FIGURE 4 1 Lubrication Points TABLE 4 1 Lubrication Points LUB LUB ITEM DESCRIPTION PROCEDURE CODE INTERVAL Machine Base Way bar Lub Reservoir Hyd System Hyd Reservoir Drive Unit Hyd Drive Motor Spindle Carriage Gearbox Spindle Shft Brgs Lub Code Commercial 1 Standard Oil Co Energol Blp 46 2 Standard Oil Co Sulkleer 102s 3 Mobil Shc629 Synthetic Oil 4 5 Shell Bearing Grease Cyprina 3 Standard Mk 1 Bearing Grade 1 SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions
2. HYDRAULIC SYS COOLING FAN HYDRAULIC SYS LEVEL amp FILL FIGURE 4 5 Hydraulics COOLANT RESERVOIR FIGURE 4 7 Drive Belt Tension FIGURE 4 8 Drive Belt Replacement FIGURE 4 9 Coolant Fan FIGURE 4 10 Wipers 19 DRIVE BELT TENSION Check drive belt tension on a regular basis to be sure Belts are not loose Belts should have no more than 1 8 in 3 18 mm deflection measured halfway between pulleys see Figure 4 7 Adjust as required CAUTION Keep Belts properly tightened and adjusted for correct operation of machines 1 Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure 2 Remove spindle carriage top cover and lower belt cover 3 Adjust Belt Tensioning Screw as required to get a belt deflection of 3 5 mm per 100 mm of span when a 60 N load is applied 035 in per inch of span when a 13 5 Ib load is applied 5 Replace all covers to ensure safe operation DRIVE BELT REPLACEMENT Check drive belt for wear see Figure 4 8 To replace belt proceed as follows 1 Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure 2 Remove spindle carriage top cover and l
3. HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO Ki K12 K14 K16 SS E Es SS RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON 62 Q3 ESC ACK 4 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 39 APPENDIX A 18 SCREENS F4 01 SETUPS SCREEN SOURCE 0 DEST 0 ACCEPT F7 CH CH SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL R
4. ove eed bet qo MU ets 6 anak Bids __ _ eR 6 PREPARING FOR OPERATION es 2 ERG 7 SC Le gt 7 1 __ d S ind ess een 7 eee utra e f roii 7 Sately VIO EE 10 Workholdine Fixt ure __ _ 10 POM 01 ne 11 LUPAND OPERATION eet aant La nde ie doct es 13 mos oce Gah utet ee 13 SE Ee a EE 13 a ees oe E uu tte ea eee eeu 13 Setup amp 232 20242822 buo T ante Bee 13 ROUTINE MAINTENANCE et eee EE SUE dade EDEN ES 17 en TUTTI PTT UMP E 17 Gun AMT 17 LADICA serae 17 lbid eeh avs ele a ee 18 Ge M __ _ _ is 18 D ve Belt Tension pir qu uie Pr 19 Dive Belt Replaccment ober oh thee ee hh ata
5. APPENDIX A 2 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 SCREENS START UP SCREEN SUNNEN PRODUCTS CO CYCLE STOP SPINDLE ROTATION HONING CYCLE TIME RUNOUT STROKE COUNT ENTER SPINDLE SPEED ENTER RECIPROCATION SPEED SUNNENSV3 SCREEN SPINDLE MACH F METRIC I m 7 li Lii wesch sel 29 ihi GE a m 7 1 HYD MAN JOG SPINDLE DWELL COOL WITH STOP AUTO DOWN JOG OFF MAN DRAW START MODE ON AUTO IS K10 K12 14 15 16 1 1 L RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON EXPAND 9 0 _ m 4 8 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 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 Calibrates Load Meter depending on spindle speed When F6 Calibrate Load Meter is pressed the following s
6. da 5 Lower Workpiece into place on Fixture 6 Align Workpiece with Fixtures Position Fixtures as required Workpiece should be clamped between 300 500 mm from its Ends for best Results 7 Adjust height of Top of Workholding Fixtureusing operator controls 8 Tighten Clamps HONING TOOL Assembly and install Honing Tool per instructions packaged with Tooling Rotary Tool 1 Assemble Honing Tool see Figure 2 4 2 Install drive adapter in spindle by sliding lock collar up and inserting spindle adapter shank see Figure 2 5 Take care to align square feed rod of spindle adapter with square socket of feed rod inside of spindle FIGURE 2 3 Fixture 10 HONE HEAD MODULAR DRIVE amp FEED EXTENSION ADAPTER INPUT YOKE ADAPTER FIGURE 2 6 Input Yoke Adapter MPS 11 3 Rotate spindle adapter to engage drive pins in bayonet slots and install reversing keys 4 Tighten lock nut MPS Tools 1 Assemble Honing Tool see Figure 2 4 2 Install drive adapter in spindle by sliding lock collar up and inserting spindle adapter shank see Figure 2 5 3 Install MPS Feed Unit see Figure 2 5 4 Align Input Yoke Adapter on Honing Tool with Drive Ring on Feed Unit and guide adapter onto Hex Shaft see Figure 2 6 5 Rotate input Yoke Adapter clockwise to engage and Lock into Drive Ring on Spindle Nose 6 If supplied
7. eek BRE ee 19 COON MOLON accidisse ee Nessie inen gi es 19 IV Pe se tt usu Ce LIA c inte ae be ME Su 19 separator OD coe sm Sud eh we A du ud dou dou dogs 20 TROUDBEEBSEHOOBDNOI dns det ood eod hat 21 a METUIT 2 Operational lroubleshooune ceu E RM aus 21 gt APPENDIXES CHC CS c quiste ated toto adr 23 bpced CHALE Lou ades ar bu 45 Coolant lows Dias aie onesie ups eru ri eue dioe d a e SEX ERE 46 1 325 feld dieu ood Lo eod eic oe eat iR ca Mi lin a 47 Purchased C ompole Dis god dt ______ __ 5 8 49 INTRODUCTION This Instruction Manual is provided to give the information required to install operate and maintain the SV3 Series Sunnen Vertical Honing Machines As there are numerous workpieces that can be honed on this machine all possible combinations cannot be discussed here The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop When ordering parts for or requesting information about your machine include the serial number of your machine READ THE FOLLOWING INSTRUCTION THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN SV3 VERTICAL HONING MAC
8. 5 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 CAUTION Remove machine from skid Do not lift directly on machine Lift with shipping brackets only 6 Remove machine from skid with a crane by attaching a clevis to each front mounting pad and a strap on 6 channel at top of upper shipping bracket CAUTION Use forklift to prevent kickback 7 The machine can be set up right by lifting on 6 channel of top shipping bracket Take care to use a forklift at bottom front edge of base to prevent a sudden dropping and kickback when machine tips upright 8 Install leveling screws in mounting pads see Figure 1 2 Machine does not need to be bolted to floor but should be set on 1 2 thick steel pads 9 Place a machinist level on machine table and level machine by adjusting Leveling Bolts on Support Feet using a 24 mm Open End Wrench 10 For permanent installation secure Machine s Support Feet to Floor with appropriate fasteners not supplied LEVELING SCHEW JAM NUT FIGURE 1 6 Doors 11 Remove top and bottom shipping brackets after machine is setting upright 12 After machine is up right and in position remove wrapping from operator s console and bracing bolted to side panels see Figure 1 3 13 If applicable While supporting console and arm with a crane remove
9. Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 33 APPENDIX A 12 SCREENS 01 DATA RECORD SCREEN 1 of 3 F1 F7 CH CH E 22 SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD E HELP Ki K7 CH CH ES Si CH HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG FF MAN DRAW START MODE ON AUTO RS K12 14 15 K16 C 11 1 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON amp 4 2 SHIFT IN
10. Retry M er Outy SolMolor PWM F lollfter RES Mode Alanin OP Enablowt EnableFR 0 1 2 Contmode Motor KW Mpole No Motor V Motor 1 AuloTune PU Long RT set Sto ply OL delay AM set PWM31 FM Tuns AM Tun ExtVbtuo Psivool Exilblas 0 0 ZOmA Exllgain RANGE to 14 17 10 0 17 to 20 23 24 0103 510 14 17 1 to 3 5 to 14 17 10 21 101 to 103 10510114 11T 11 a 121 0 to 400hr 0 to 50OA 0 to a to 5 secondr 0 1 2 10106 10 to 500A 99 0 to 20096 9999 10 to 2001111 9999 a to IONZ 909 0 to 5 0 to 40cht 01010 0 0 10 1511610 10 30 10 Note a Ojos 13tale 20 10 7 to 14 5K z 109 0 1 2 3 0 1 2 3 0 1 2 0 01087 0 4 to 55kW 9999 2 4 0 12 14 10 a to CGOV 5010 120 1 0 10 01031 100 99 25 seconds to 3 5 to 14 17 10 21 999 0 1 2 3 0 to OV 0 to 40hr 0 to OV It 40011X o to 20MA 0 to 60HZ 20mA eOHz 1 0 400 t SET SETTING VALUE 1 X 1 1 SOME 4 9999 1 0 second 0 0 99 9 99 99 0 GONZ a 9999 99 9991 20076 60 0 1 101 0 1 locondle OV Ohl ectir 20 4mA 0 It NOTES o4 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment 55 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART 2 I 2 I 2 I MILLIMETER ERACTION DECIMAL MILLIMETER FRACTION DECIMAL ___
11. VOLTS 460 AMP 45 PH 3 CYCLE 60 SPINDLE CARRIAGE RPM 300 BALDOR MOTOR CAT NO IDM3774T FRAME 215TC RPM 1760 F L A 25 4 12 7 3 CLASS H 53 8 NEMA NOM EFF 91 7 BLOWER BALDOR SPEC EF5000 SER 89803 VOLTS 230 460 PH 3 BREVINI GEAR BOX TYPE EM 1010 MN2 SER NO V13156 HYDRAULIC POWER UNIT SER NO F498 VOLTS 230 460 RPM MAX 6000 SER F 1 00 RATING 40C AMB CONT 2 AMPS 8 4 HZ 60 RATIO 7 1 DATE 12 99 THERMAL TRANSFER PRODUCTS INC MODEL AOVH 10 TEMP 350 DEG F CAT M3460 5 VOLTS 220 380 460 F L AMPS 2 1 2 1 CODE J NEMA NOM EFF 68 SER C 124316 SPEC NO O7H658W747GI H P 10 TE MAG CURR 11 5 5 HZ 60 TE RPM 3100 CLASS 1369 OPERATING PRESSURE 300 PSI COOLING FAN MOTOR BALDOR SEHR W0999 PH 3 HZ 60 FRAME 48 S F A 2 6 2 4 1 2 P F 63 HYDRAULIC PUMP MOTOR BALDOR CM3774T FRAME 215TC 3 VOLTS CLASS F NEMA NOM EFF 89 3 SPEC 07C152W693 SER F1099 HZ 60 208 230 460 DES 73 RATING 49 SPEC 34A51 232 HPM 3450 SER FAC 1 25 DES B CLASS RATING 40C AMB CONT H P 10 TE RPM 1760 S F 1 15 F L AMPS 28 5 28 4 14 2 CODE J 40C AMB CONT RECIPROCATION PUMP VICKERS 2348662 08 K 99 0 PVQ40 B2RA9
12. F8 in this Screen 31 APPENDIX A 10 SCREENS 01 SETUPS F3 SCREEN F7 ES Si CH e CH SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL 2 REV HELP 1 K7 E CH Si d HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO K10 K12 K14 K16 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON Gei EXPAND D 9 0 n gt 2 12 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 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 11 SCREENS 01 SETUPS SCREEN 01 DATA RECORD 02 STORED DATA RECORDS LISTED HERE SI m 7 zr IEE 22 e m zu lt z DI e mz T K7 GC CH GC JOG JOG SPINDLE DWELL COOL WITH a STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO Ei K10 K12 K13 14 15 K16 1 i Ll 1 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON EXPAND Q3 9 0 A gt 2 SHIFT INS HELP ENTER DEL
13. Honing Tool will continue to feed stones out to maintain 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 the honing timer and the stroke counter have both reached zero the honing tool will stop at the up go down reversal point or exit the part depending on the withdraw default selected on the Maintenance Screen Again a second pressing of will cause the tool to exit the second withdraw position if the MANUALLY withdraw default is selected 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 3 Press K2 Manual Auto Mode Button until LED is OFF 32 Retract stones slightly by pressing K9 Feed Retract Button 33 Swing Tool Support into Load Position 34 Press K12 Carriage Release Down Button and slide spindle carriage to the left 35 Slide Honing Tool out of Bore 36 Repeat the previous process to start a new honing cycle 15 3 HYDRAULIC DRIVE MOTOR See Fig 4 5
14. Hydraulic system filters are monitored electrically and will provide a warning on operators display screen when maintenance is required NOTE Change Filter a minimum of every Six Months or sooner as indicated on screen 3 Grease hydraulic system electric drive motor lube code 4 4 Check hydraulic system cooling fan and radiator for debris Clean as required Hydraulic system can overheat if it is overly dirty NOTE Clean a minimum of Twice A Year Blow Air Into Coils To Clean Hydraulic system can overheat if it is overly dirty 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 Plug X5 and X6 from Connecting Panel 7 Remove Drain Tube and disconnect oil fitting then slide Reservoir out from 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 Plugs X5 and X6 HYDRAULIC DRIVE MOTOR
15. Vii 1778 mm 63 75 in TOP VIEW 77 5 in 2082 8 mm 82 in SIDE VIEW FRONT VIEW FLOOR LAYOUT Sunnen SV3 Vertical Honing Machine viii N co st 160 875 in SECTION 1 INSTALLATION PURPOSE This Section is designed to aid user in unpacking inspecting and installing Sunnen Vertical Honing Machine SV3 Series Hereafter referred to as the Machine see Figure 1 1 LEFT RIGHT FRONT FIGURE 1 1 Vertical Honing Machine 1 TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing machine Wire Cutters Strippers Knife Screw Driver Std nose Hammer Slip Joint Pliers Crow Bar Cleaning Solvent Tin Strips Open End Wrench 17 19 amp 24 mm 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 the operator as one looks at Machine or assembly being described 1 Remove top and front of shipping crate 2 Cut remove and discard shipping bands NOTE Machine is shipped lying on its back with shipping brackets mounted to top and bottom of base CAUTION Weight is approx 3000 Ib 3 Move machine to desire location using a forklift Slide forks minimum 6 long under skid side only 4 Remove any loose hardware package with machine
16. _____ 003937 0400 9 2 7 1438 21 32 22 007874 02000 19 64 7 5406 one 08000 ang 7 9375 4364 0 3969 8 0000 11 16 22 015748 0400 2 64 8 3344 45 64 019685 05000 1132 87848 2 029622 06000 90000 23 32 22 027559 07000 23 64 9 1281 47 64 07988 38 9 5250 031496 0 8000 25 64 95919 a 22 035433 0 9000 100000 4964 039370 10000 13 2 103188 25 32 1 1906 27 64 00756 15875 11 0000 5 64 19844 7 6 1 1125 13 6 22 078799 20000 2964 11 5094 23813 1532 11 9063 53 64 27781 120000 27 32 __ ____ 3000 123097 55 64 31750 1 2 12 7000 35719 130000 78 3 9688 33 64 180969 87 64 22 187480 40000 17 2 349558 4 3656 55 54 138906 29 2 47625 14 0000 59 54 2 496850 5000 ang 142875 1516 5594 37 64 4684 5556 50000 61 64 5 9531 19 32 15 0813 am 236220 6 0000 3964 15 4781 68500 58 158750 63 64 67469 60000 275591 70000 og 162719 ine FORMULAS MULTIPLY BY TO GET MULTIPLY MILLIMETERS mm MILLIMETERS mm METERS m METERS m 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 4 2 GENERAL HONE CORP A Sunnen Company 4 Sube 471 US 250 East Ashland OH 44805 U S A revise spe
17. 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 FIGURE 4 3 Gearbox 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 see Figure 4 1 amp Table 4 1 NOTE The intervals between lubrication will vary with amount of use your Machine receives Lubricate all components at least once every six months CAUTION Be careful not to get oil on drive belts pulleys or brake strap Remove spindle carriage top cover and lower belt cover 2 Lubricate lower spindle bearing at grease fitting behind pulley see Figure 4 2 lube code 5 3 Lubricate upper spindle bearing lube code 5 4 Lubricate spindle motor bearings lube code 5 5 Spindle Motor Gearbox see Figure 4 3 When Spindle Drive is not running check lubricant level in Sight Glass on fill tube Fill as required Fill tube is accessible from inside machine column l
18. BOX ELECTRICAL ENCLOSURE CONTROL STATION WORKPIECE FIXTURE COOLANT RESERVOIR A BUCKET MAGNETIC DISCHARGE SEPARATOR CHUTE FIGURE 2 1 Major Components 6 SECTION 2 PREPARING FOR OPERATION GENERAL Consult this section when preparing Machine for operation MAJOR COMPONENTS EMERGENCY SWITCHES For location of major all electrical Emergency Switches on machine refer to Figure 2 1 CONTROLS For location of major components on machine see For location of controls see Figure 2 3 and refer to Figure 2 1 SUNNEN Table 2 1 thru 2 2 for function of controls FIGURE 2 2 Controls TABLE 2 1 Operator Controls Buttons amp Switches EMERGENCY STOP Red Pushbutton Shuts OFF all power to the machine functions Button must release before Power ON button can be pushed POWER ON Green Pushbutton POWER OFF Red Pushbutton CYCLE READY START Green Pushbutton Turns ON control power to the machine After E Stop Button is pushed Power ON button must be pushed once to reset E Stop Relay and again to turn ON Control Power Shuts OFF control power to the machine Fla
19. SETUP SCREEN LINE 4 Displays to access the PRINT SETUP SCREEN 36 If KEE LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 15 SCREENS 01 DATA RECORD SCREEN NO 1 NAME Data Record SAVE DATA RECORD Y HOME MACH ENG S METRIC FWD SEL R m 7 Lii TE 5 m m z 020 Sege JJ gt I 8 L3 HYD MAN JOG SPINDLE DWELL COOL STOP AUTO DOWN JOG OFF MAN START MODE ON AUTO K10 K12 14 15 K16 C RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON ESC ACK 4 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSIT
20. Slide Universal Cover over Input Yoke Adapter NOTES SECTION 3 SETUP amp OPERATION GENERAL This section describes a step by step operating proce dure for Machine Prior to starting Machine Operator shall ensure All prerequisites described in sections 1 and 2 are complete All 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 machine while lifting devices installed Ensure workpiece is securely fixtured and located before operating Ensure all guards are in place before operating Ensure area is clear of other personnel before oper ating 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 CE Push E STOP Button and turn OFF electrical power at Disconnect Switch on Electrical Enclosure when preforming service not requiring power 9 Turn OFF electrical power at Main Power Source when preforming maintenan
21. automatic K8 WITHDRAW Touch Button F6 ENG METRIC Touch Button F7 SPINDLE FWD REV Touch Button F8 DWELL SEL Touch Button K1 HYD STOP START Touch Button Press to interrupt honing cycle and stroke counter Ends honing cycle Resets all timers and counters Depressing again will cause tool to move to withdraw position Press to reset cycle timer and stroke counter to their default RESET Ar settings Touch Button NOTE function button LED indicators are on for a function operating or for the second function of a dual function key 8 TABLE 2 2 Operator Interface Cont d SYMBOL DESCRIPTION FUNCTION K10 WITHDRAW EXIT Touch Button Press to withdraw honing tool to mouth of bore Tool will jog up to second withdraw position with spindle rotating at jog speed Ends honing cycle Resets all timers and counters K12 PULSE FEED OFF ON Touch Button K13 JOG EXPAND Touch Button Press to turn pulse feed option ON or OFF depending on current status as indicated by LED ON Honing tool will expand for time set on tool feed screen and will then go into a blocked condition for amount of time set on tool feed screen Process will continue until cycle times out and run out stroke counter starts Press to expand honing tool Will not function if an auto expand cycle is activated K14 TOOL AUTO EXPAND Touch Button Press to automatic feed honing tool upon cycle start Otherwise tool
22. bolts mounting it to offset shipping pad where it attaches to machine column Remove shipping pad from column and remount assembly without pad to four holes on machine column Discard shipping pad Some machines may not have this pad 14 Adjust upper shaft collar with pins on operators console swing arm so swing arm can not move under spindle carriage assembly or hit column at each extreme of its movement see Figure 1 4 15 Remove shaft collars from way bars securing carriage from movement during shipping see Figure 1 5 16 Remove strap from encoder bracket mounted at tile bottom of way bar assembly 17 Remove doors if supplied from shipping skid and install on machine see Figure 1 6 Verify alignment of door interlock switch plungers on CE machines 18 Clean rust preservative from way bars and any other bright metal surfaces 19 Fill way lube system with a good grade of way lube oil see Figure 1 7 20 Remove 8 32 socket head cap screw from gearbox riser pipe cap see Figure 1 8 Located on spindle carriage and accessed from inside column 2 Position coolant system on left side of base with filter under trough extending from base 22 A small chute is provided to extend trough Attach chute to the trough with two 1 4 20 button head cap screws see Figure 1 9 FIGURE 1 9 Discharge Chute 23 Connect coolant hose to hose barb on base and clamp in place 24 Connect two plugs one
23. 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 amp 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 21 PROBLEM PROBABLE CAUSE SOLUTIONS SEC 1 Mandrel not trued 2 Improper stone length Barrel Taper
24. entered the bore 11 Enter this position in ENTER WITHDRAW POSITION field using RECIPROCATION POSITION display as a reference Cursor down to ENTER WITHDRAW POSITION and enter position using numeric keypad If a decimal point is needed it must be entered from keypad 28 5 12 Jog tool down until approximately 1 3 of Stone length is visible out top of Workpiece to allow for overstroke Enter UP GO DOWN POSITION 13 Continue to jog tool down until approximately 1 3 of Stone length is visible out bottom of Workpiece Enter DOWN GO UP POSITION 13 If required Enter DWELL TIME 14 Press F2 Screen Dir Cursor down to 03 SPINDLE and press Enter 15 Enter desired SPINDLE ROTATION DIRECTION by toggling F7 16 Press F2 Screen Dir Cursor down to 04 TOOL FEED and press Enter 17 Enter desired PULSE FEED ON OFF TIMES 18 Press F2 Screen Dir Cursor down to 05 TIMER COUNTER and press Enter 19 Enter desired amount of time for HONING CYCLE and desired amount of counts for RUNOUT CYCLE 20 Press F1 Main Menu Next 2 Jog tool up and out of bore until the TOOL IN WITHDRAW message appears 22 Enter desired SPINDLE SPEED and RECIPROCATION SPEED See Appendix X Spindle Speed Chart 23 Select any options needed such as K6 Dwell or K12 Pulse Feed using Keypad CAUTION Ensure honing tool is collapsed 24 Press K16 Tool Col to fully collapse tool 25 Press K4 Jog Down to inch tool down i
25. has sounded See ACK Button NUMERIC ALPHA KEYPAD NOTE K function button LED indicators are on for a function operating or for the second function of a dual function key CURSOR Arrows Used in conjunction with other keys buttons KEYS Used to move cursor on display screen 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 enter TABLE 2 3 Safety Symbols SYMBOL DESCRIPTION FUNCTION A 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 symbols used on this machine refer to Table 2 3 WORKHOLDING FIXTURE Position the Workholding Fixture as follows 1 Loosen Clamps see Figure 2 3 2 Position Fixture so Workpiece will be clamped close to its Ends approx 400 mm 3 Measure distance of workpiece to be honed gt 4 Lift Workpiece into Machine using a hoist as Ww 1 wm required
26. ENDIX A 9 SCREENS 07 SETUPS SCREEN SCREEN SPINDLE DWELL MACH METRIC FWD SEL EV m 7 1 Fi DIR Ki K7 C CH E HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG MAN DRAW START MODE ON AUTO 85 K10 K12 Ki3 14 8 5 K16 L 1 1 1 1 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON Q3 ESC ACK 4 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake
27. ER FAC 1 35 CODE M P F 57 1 9 1 8 9 GEAR REDUCER WINSMITH DATE 05 98 INPUT RPM 1800 INPUT H P 19 OUTPUT TORQUE 621 FOR TEMP 51 110 DEG F 51 Setting Record for FR A200E UL series Part 1 SET FUNCTION PART DISPLAY RANGE SETTING VALUE 0 rorous ooost manuan Tro Soft 01030 1 Maximum frequency Man F1 0 to 12077 12CIMi 2 Minimum frequency Min Fit 0 to 120Hz OHR 3 flags frequency WbsodiFl 0 to 4007 6011a 4 Multi speed selling high speed presetri 0 to 40072 5 Mulli liveed Boiling Middle speadl PfQs W2 0 to 400til 6 Multi ilileed selling low speed pfesswil 0 to 40011Z 101 7 Acceleration time 0 to 35M seconded 2 7 Acceleration time 0 to 300 seconds 8 c fallon time Dec 0 to 36M secondell 2 8 0 to 300 seconds 9 Electronic thermai OIL relay 5 4 THM 0 to 500A 13 10 DC Infection brake operation frequency DC BrF 0 to 120 2 9999 3112 10 11 DC injection broke operrallon time Dc ar T to 10 80 108 0 5 Second a 12 C C injection broke voltage OC ar V 0 to 3096 13 Starting frequairmy store F to 4011 057 14 Applied land selection Load VF 0 1 2 3 4 5 a 15 Jog frequency JOG F 0 to 400111 912 16 Jog secoloralionilloceiefallion time JOG T 0 to 3600 soconow 0 3 seconds 16 0 to 300 ascends 17 External thermal Orl relay input JOWO 0 1 2 3 0 18 high speed maximum frequency Max FZ 120 to 4007 120 it 19 8810 frequency voltage V Fbass V 5 to mov asaa 9999 20 Accaterstio
28. EV a K7 E CH CH E HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO K10 K12 K14 K16 B E E RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON Q3 9 0 A E 4 gt 8 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 40 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 19 SCREENS 01 SETUPS SCREEN 01 DATA RECORD 02 DELETE RECORDS Fi F7 _ GC 1 CH CH SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL REV C HELP K7 GC 1 Si Si s HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO 9 K10 K12 Ki3 14 Kis K16 1 C RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON D D A _ 4 2 SHIFT INS HELP ENTER DEL Operator entry current Reciprocation Position of spindle carriage in relation to HOME POSITION Operator entry of desired BACK GO FORWARD Reciprocation Reversal Set Point Operator e
29. HINE GENERAL INFORMATION amp SPECIFICATIONS Sunnen Vertical Honing Machine SV3 Series Diameter Range OD Workpiece Weight Workpiece Length Work Area Envelope Table Stroke Length Range Reciprocation Speed Stroke Hydraulic Stroke Motor Thrust Spindle Speeds Spindle Motor Feed Rotary Feed Push Feed Coolant Pump Pump Motor Coolant Capacity Pump Rate Coolant Requirements Floor Space Floor Weight Dry Floor Load Pneumatic Requirements Electrical Requirements Color Noise Emission 12 7 305 mm 50 12 in 1360 kg 3000 Ibs 1 m 39 38 in 762 x 1270 mm 30 x 50 in Up to 1219 mm 48 in 3 04 27 4 mpm 10 90 fpm 7 5 kW 10 hp 1134 kg 2500 Ibs maximum 10 to 300 rpm Opt 10 to 500 rpm 3 7 kW 5 hp 7 5 kW 10 hp Up to 14 8 m kg 20 ft Ib maximum torque Up to 952 kg 2100 16 force Centrifugal pump 0 187 kW 1 4 hp 189 L 50 US gal 38 LPM 10 GPM Sunnen Industrial Honing Fluids 2159 W x 2083 D x 3937 H mm 85 x 82 x 155 in 2268 kg 5000 165 739 kg sq meter 151 Ibs sq ft 30 LPM 5 4 Bar 1 CFM 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 Diameter range length range and workpiece weight are contingent on workpiece and application
30. I SV 301A il SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN VERTICAL HONING MACHINE SV3 Series READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN SV3 VERTICAL HONING MACHINE 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 Emergency breakdown support is available on a 24 hour 7 day basis Review all literature provided with your Sunnen equipm
31. IDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F 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
32. ION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 37 APPENDIX A 16 SCREENS 01 DATA RECORD SCREEN No New Data Record Number Displayed Name New Data Name Displayed Data Record Saved F1 F7 u E E eu DIR MACH METRIC FWD SEL REV A 1 HELP Ki K7 u e E HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO Ki En Ki6 gt ES ES ES RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON EXPAND Q3 4 2 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 38 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 17 SCREENS 07 SETUPS F4 SCREEN 01 SETUPS Fi F7 E e SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL REV L1 HELP K7 E CH CH
33. LIC SYSTEM Fill hydraulic system 50 gal at filler cap on tank see Figure 1 13 Fill pump case 2 qt by temporarily removing hose and filling through fitting with medium weight hydraulic oil BP Energol HLP 46 or equivalent pre filtered to 10 micron Reinstall the hose COOLANT RESERVOIR Fill coolant reservoir see Figure 1 14 Maximum capacity of reservoir is 189 Liters 50 gal subsequent to running Coolant pump Minimum capacity of Coolant Reservoir for proper pump operation is 110 Liters 29 gal MAGNETIC SEPARATOR Optional Consult installation Instructions packaged with Magnetic Separator refer to Figure 1 14 OPERATIONAL CHECK 2 Operate Machine and check rotation of optional Read Sections 1 and 2 thoroughly and carefully equipment according to Installation Instruction before performing the Operational Check package with optional equipment NOTE Power up and start machine to check for 3 Set up and test all machine functions refer to proper operation per machine Manual Honing Cycle Section 3 1 Operate Machine and check rotation of Spindle 4 After unpacking and installing Machine clean and Shaft Rotation of Shaft should be counterclockwise lubricate refer to Section 4 Routine Maintenance 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 SPINDLE w GEAR
34. N LINE 3 Displays to access the TRANSFER SETUP SCREEN LINE 4 Displays to access the PRINT SETUP SCREEN 28 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 7 SCREENS 05 TIMER COUNTER SCREEN ENTER HONING CYCLE TIME ENTER RUNOUT STROKE COUNT Fi F7 us S C CH CH CH SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL A REV HELP Ki K7 CH CH 1 Si HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO K10 K12 Ki3 K14 K15 K16 C KE L KE 1 WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON 62 ESC ACK 4 gt Y Wes SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This
35. NTER 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 26 222 ejeje LINE LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 5 SCREENS 03 SPINDLE SCREEN SPINDLE DIRECTION F7 FORWARD SPINDLE JOG SPEED 10 300 PASSWORD WARNING DO NOT USE SPINDLE REVERSE WITH ANY HONING TOOL WITH A THREADED CONNECTION HOME REEN DIR MACH E SPINDLE DWELL METRIC FWD SEL REV m rm 72 3 ca ssa ol 3 Le 7 e 16 MAN JOG SPINDLE DWELL COOL WITH STOP AUTO DOWN JOG OFF MAN DRAW START MODE ON AUTO m K10 K12 K13 14 K15 K16 L C E RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON 62 Q3 ESC ACK T gt SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes to be completed during HONING CYCLE Operator entry of desired Number of Reciprocatio
36. S 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 34 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 13 SCREENS 01 DATA RECORD SCREEN 2 of 3 05 DOWN GO UP 0 00 IN MM 06 DWELL 0 00 SEC 07 CYCLE TIME 08 CYCLE TIME Fi F7 E SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL REV L1 HELP K7 CH CH Si S CH JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE N AUTO K10 Kit K12 K15 K16 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON ESC ACK 4 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes to be completed during HONING CYCLE Operator entry o
37. SETUP SCREEN LINE 3 Displays to access the TRANSFER SETUP SCREEN LINE 4 Displays to access the PRINT SETUP SCREEN 42 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 21 SCREENS 01 SETUPS SCREEN NO 1 NAME OVERWRITE 2 Y F7 u 5 SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL REV 1 HELP Ki K7 H e HYD JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO K10 Ki4 K15 K16 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON 62 D ESC ACK 4 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursor
38. SS3F 20 C21 12 TOOL FEED PUMP VICKERS V10 1525 11020 382065 3 K 98 0 RECIPROCATION VALVE BOSCH 811 404 001 COMPENSATING VALVE BOSCH 811 401 223 SUBPLATE DAMAN ADO5SHSPS12S 0899 TOOL FEED VALVE BOSCH 810 231 006 4600 PSI 81WVO6PIV1004WS 115 60 D51 CHECK VALVE BOSCH FB1 PD HM 101 C 50 9 810 161 087 4500 PSI 9 810 161 171 NEW NUMBER REDUCING VALVE SUN PBDB LDN EBQ 9HM7 RELIEF VALVE SUN RPEC LDN FBP 9DP6 2 STATION MANIFOLD DAMAN ADO3PO22S 0598 3 WAY VALVE WATERMAN 12 315 15 14 PILOT CHECK VALVE KEPNER 2712112 LUBRICATION PUMP LUBE USA SERIAL NO JET 11035 CODE NO 010961 50 GUSHER PUMPS INC MODEL 6P3 LONG IMP 6081 A SPEC 34G226 231 SER W0100 VOLTS 208 230 460 RPM 3450 SER F 1 35 CLASS B CODE L P F 7396 RATING 40C AMB CONT MODEL HPS 10 COOLANT SYSTEM SER 1224 833 ELECTRIC MOTOR BALDOR FRAME 48YZ H P 25 TE AMPS HZ 60 3 DES NEMA NOM EFF 5416 S F A 1 3 1 2 6 MAGNETIC SEPARATOR FLOWCON SERIAL 5816 10 MAGNETIC SEPARATOR MOTOR BALDOR CAT NO VM3534 FRAME 56C 33 TE AMPS 1 8 1 6 8 HZ 60 CLASS B DES B NEMA NOM EFF 68 RATING 40C AMB CONT MODEL 2MCVD PART B 327 74XOP5 SER FACT 1 RATIO 750 AGMA LUBE AGMA 8 SPEC 34A63 884 SER W398 VOLTS 208 230 460 RPM 1725 PH 3 S
39. This Warranty does not apply to the following Normal maintenance items subject to 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 Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops Incorrect air supply volume and or pressure and or contaminated air supply 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 Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration 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 INC
40. 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 25 APPENDIX A 4 SCREENS 02 RECIPROCATION SCREEN RECIPROCATION POSITION ENTER WITHDRAW POSITION ENTER UP GO DOWN POSITION ENTER DOWN GO UP POSITION UWELE 1 00 SEC DWELL POSITION F8 JOG UP SPEED PASSWORD 4 30 JOG DOWN SPEED PASSWORD 4 30 1 CH CH SCREEN HOME ENG SPINDLE DWELL DIR MACH METRIC FWD SEL n HELP K7 1 S HYD MAN JOG JOG SPINDLE DWELL COOL WITH STOP AUTO UP DOWN JOG OFF MAN DRAW START MODE ON AUTO K10 K12 K14 K15 Si 3 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON 62 amp ESC ACK ejeje GNE 4 SHIFT INS HELP ENTER DEL LINE 1 Displays to access the PRI
41. ce is clean and clear of unnecessary materials particularly common plastics D Anti static bubble wrap has been included for use at the machine when 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
42. ce on or cleaning of Electrical Control Enclosure Clear area of excessive lubricant or lubricant spills DO NOT adjust stroke length while Spindle Retractor Carriage is not in locked position KEEP hands clear of all moving parts Stay clear of all moving parts 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 13 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 SV3 All operational information must be read and under stood before operating equipment Observe all caution labelsltags on machine Make no adjustments to hydraulic or electrical sys tems of machine while machine is powered unless you are a fully qualified repair technician When electrical panel s 15 are opened all power must be disconnected and locked out prior to initiat ing any modifications or repairs Never leave machine unattended while it is running e Stay clear from any areas of machine that are paint ed SAFETY yellow OPERATING HINTS There are several features on the STH Machines for correcting problems i
43. cifications 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 Hemel Hempstead Herts HP2 7EF 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 TO GET INCHES in FEET ft INCHES in x 25 4 FEET ft X 0 3048 Phone 44 1442 39 3939 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 41 71 648 34 34 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 Fax 86 21 5 813 2299 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 3834171 Fax 39 02 383 417 50 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 veri
44. condal 5 Cando 44 Second acceleration decoldration time 610861 0 to 360 seconds 45 Second deceleration time Doc r2 0 to 3000 secondW 45 Second deceleration time Doc r2 0 to 350 seconds 46 Second torque tippet Tro 0912 0 to 30 9999 9999 47 Second VIF base frequency VFbaoeF2 10 to 40077 9999 SO 48 Second staff Prevention operation current 5181121 1010 200 150 49 Second visit prevention operation frequency 9lal12 0 to 400 z 0 50 Second output frequency daieciton SetFU 2 10 to 400hr 3012 Note 16 7 5K or down 3 11K or up 2 5 seconds 7 5K or down 15 seconds 111K or up 3 Rated inverter output current A Provided that 0 4K 2 6A 0 75K 4 3A 200V series 0 4K 1 3A 0 75K 2 2A 400V series 52 FUNCTION PART 51 52 53 53 54 54 54 55 56 57 58 59 60 611 62 63 64 65 66 67 68 69 70 70 71 72 73 74 75 76 77 78 79 80 81 81 83 84 96 145 155 15 157 158 158 159 900 901 902 903 904 905 905 Inverter LEO display data selection PU main dmolay data selection PU level display date selection PU level display date selection FM terminal function selection FM terminal function selection FM terminal function selection Frequency monitoring reference Current monitoring reference Restart coasting time Restart cushion time Remote setting function selection Intelligent mode selection Reference for intelligent mode Rot of intelligent mode accoll Rot for Intelligen
45. creen 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 24 LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APPENDIX A 3 SCREENS SCREEN DIR SCREEN 02 RECIPROCATION 03 SPINDLE 04 TOOL RESET 05 TIMER COUNTER 06 MAINTENANCE 07 SETUPS NDLE DWELL D HYD MAN JOG JOG SPINDLE DWELL COOL STOP AUTO UP DOWN JOG OFF MAN S F R I m 9 Lii wech 72 29 m m a cm ma 2 e Ja m 9 mz m 08 T D T DRAW p START MODE ON AUTO K10 Ki4 K16 RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT ON EXPAND 9 0 A n 4 2 12 SHIFT INS HELP ENTER DEL Operator entry 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 Number of Reciprocation Strokes to
46. e Do not attempt to connect machine if supply voltage is not within 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 If supply voltage does not match voltage stated on W ma T Electrical Specification Plate but is within acceptable 2 RW limits electrical connection can proceed but Machine Conversion below will be necessary 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 12 FIGURE 1 12 Electrical FIGURE 1 13 Hydraulic MAGN TIC SEPARATOR FIGURE 1 16 Coolant Reservoir 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 is
47. ent This literature provides valuable information for proper installation 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
48. equipped with Key Lock Safety Latches WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to discharge 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 4 Insert Electrical Supply Cord through Oil Tight Fitting and route to Electrical Disconnect Block Allow for approximately 305 mm of cable from where it enters Enclosure then cut off excess 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 PE Terminal on Electrical Disconnect Block Earth Ground 8 If applicable Connect Blue Wire to E Zero Point as noted on Block 9 Connect other three wires to Disconnect Block as noted on Block 1 1 L2 L3 10 Route and secure Cord inside of Enclosure 11 Tighten Oil Tight Fitting 12 Close and secure lock Door s to Enclosure 13 Route and connect Electrical Supply Cord to power source PLUG Machine s Electrical Supply Cord into a properly polarized grounding type wall receptacle 14 Turn ON Master ON OFF Switch HYDRAU
49. essure A Use softer stone A Decrease cutting pressure A True stone amp shoes to exact hole dia A Use finer stone A Check coolant A Use bronze mandrel or bronze shoes A Decrease cutting pressure A Use finer stone B Use softer stone A If using hard steel mandrel change to soft steel mandrel If using soft steel mandrel change to bronze mandrel 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 22 APPENDIX A 1 SCREENS OPERATOR CONTROLS STATION SUNNEN SUNNEN PRODUCTS CO CYCLE STOP SUNNENGV3 PULSE 06 TOOL FEED AUTO OFF ON ep EXPAND lt SPINDLE LOAD EMERGENCY NJ STOP POWER ON POWER OFF CYCLE READY CYCLE STOP START 23
50. f desired Number of Reciprocation Strokes to be completed during RUNOUT CYCLE Operator entry of desired Reciprocation DWELL TIME Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 35 APPENDIX A 14 SCREENS 01 DATA RECORD SCREEN 3 of 3 08 CYCLE TIME 09 RUNOUT COUNT 10 PULSE FEED ON TIME 11 PULSE FEED OFF TIME ENG METRIC I m un 2 c o e u r m 2 T DWELL COOL WITH OFF MAN DRAW ON AUTO z z o 215 51 50 5 lt 508 m 8211 lt 02 Imi gg T m 29 o z mel m m 1 RESET WITH ULSE TOOL AUTO ON EXPAND A _ 4 2 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
51. fy discrepancy with Sunnen before proceeding http Awww sunnen com e mail sunnen sunnen com PRINTED IN U S A 0410
52. if no filter is used to receptacles on small electrical box located on base 25 Connect drive adapter to spindle nose by aligning pins with bayonet slots push up while allowing spring loaded collar to move see Figure 1 10 Rotate pins into slots and allow collar to drop back down Tighten ring nut on drive adapter against spindle nose Rotate hex shaft to align drives feed rod hex socket inside spindle shaft Connect desired tooling to adapter PNEUMATIC CONNECTION Connect pneumatic line airline as follows see Figure 1 11 NOTE The Factory Air Supply Line is not supplied A minimum of 0 55 MPa 80 psi clean dry compressed air is 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 3 Airline Filter Regulator Valve This valve is preset at the factory to 0 55 MPa 80 psi ELECTRICAL REQUIREMENTS All wiring is to be performed by a competent Licensed Electrician 1n 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 CAUTION Note model electrical supply cord requirement printed on machine nameplate electrical specification plat
53. in Open Hole Taper in Blind Hole Out Of Round rmm 1 length to bridge waviness in bore A Use L BL or multi stone mandrel stone length should be 1 1 2 times bore length A Shorten overstroke A Use softer stone Rough Finish Scratches in Bore Random 3 Improper stone 1 Workpiece is not being reversed 2 Mandrel not trued 3 Improper stroke 4 Stroker Arm and Spindle not aligned 1 Improper stone length 2 Inadequate oil flow 3 Inadequate relief in blind end 1 Undersize honing tool 2 Mandrel not true 3 Workpiece flexing thinwall 4 Improper stone 1 Improper mandrel 2 Improper stroke 3 Improper stone 1 Improper feed 2 Mandrel not trued 3 Improper stone 4 Improper or diluted coolant 5 Soft or exotic materials 1 Improper feed 2 Improper stone 3 Improper mandrel 4 Improper or diluted coolant A True stone amp shoes A Use longer stone or shorten guide shoes on both ends B Use mandrel with longer stone amp shoes A Use finer stone A Reverse workpiece on mandrel A True stone amp shoes A Lengthen overstroke on tight end A Align Stroker Arm and Spindle A Shorten stone and shoes to 3 4 length of bore B True stone amp shoes frequently A Adjust Oil Nozzle A Provide sufficient relief B Short stroke tight end C Use hard tip stone A Change honing tool A True stone amp shoes A Decrease cutting pr
54. ing down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 43 NOTES 44 APPENDIX B SPEED CONVERSION CHART PERIPHERAL SFM TO RPM Bore Surface Speed in FPM Bore Dia 70 75 80 65 90 95 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 08 1067 1144 1220 1296 1372 1449 1525 1677 1830 1982 2135 2286 2440 2593 2745 2898 305013203 985 1035 1140 1245 1347 1452 1555 1658 1763 1868 1970 2075 2180 995 1070 1148 1224 1301 1377 1454 1530 1607 1040 11021 1163 1224 1285 969 1020 1071 45 APPENDIX C COOLANT FLOW DIAGRAM CENTRIFUGAL PUMP Mmm Kai FLOW CONTROL VALVE NOZZLE gt gt TRAY COOLANT RESERVOIR OPTIONAL MAGNETIC SEPARATOR 46 PNEUMATIC FLOW DIAGRAM Filter Pressure Regulator Lubricator Valve Valve Carriage Release Cylinder Air Pressure Switch Gage gt 47 gt APPENDIX D NOTES 48 PURCHASED COMPONENT DATA GHC DATA PLATE MODEL SV3 10 1 E RH M MFG DATE 11 00 HONING MACHINE VERTICAL STROKE 48 SIN
55. ly active while in spindle screen Press to alternate spindle direction display between forward and reverse Selects rotation of spindle head Can only be changed while machine is not in cycle This is a screen sensitive key and is only active while in reciprocation screen Press to display dwell position top bottom or both Used in conjunction with K6 Dwell Off On If dwell is turned on honing tool will dwell at selected position K2 MAN AUTO MODE Touch Button Press to turn hydraulic system either ON or OFF depending on its current status Press to select operating mode of machine MAN Used joystick to move spindle carriage AUTO Required to initiate Cycle Ready Start K3 JOG UP Touch Button Press to move spindle carriage in upward direction KA JOG DOWN Touch Button K5 SPINDLE JOG Touch Button Press to move spindle carriage in downward direction Press to initiate spindle for short intervals Cause spindle to rotate in the selected direction at a slow speed K6 DWELL OFF ON Touch Button Press to initiate dwell status Used in conjunction with dwell position selected on reciprocation screen LED associated with this function key indicates current status with LED on meaning that dwell function is on K7 COOL MAN AUTO Touch Button Press to select operation of coolant pump MAN Coolant flows continuously AUTO Coolant flows only during honing cycle Machine defaults to
56. n Strokes to be completed during RUNOUT CYCLE Operator entry of desired Reciprocation DWELL TIME Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 27 APPENDIX A 6 SCREENS 04 TOOL FEED SCREEN PULSE FEED ON TIME PULSE FEED OFF TIME TOOL AUTO COLLAPSE TIME TOOL FEED DIRECTION F3 PASSWORD AUTO MODE FEED DEFAULT F4 PASSWORD REEN DIR I m ed 71 c 35 zo wn o m m Lr zo gt zo RE 55 gt zr m 2112 EE ca 65 8 zr 25 8 m 3 D mno 82 lt 02 T Tm m PULSE FEED OFF ON TOOL AUTO EXPAND 2211 zm am m 25512 T mc 2518 cos 2 A Sal E oo 2 4 2 SHIFT INS HELP ENTER DEL LINE 1 Displays to access the PRINTER PARAMETER SCREEN LINE 2 Displays to access the EDIT SETUP SCREE
57. n 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 bore Opens up blind end then goes into regular cycle START UP 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 in Manual Mode when power is turned ON 5 Press ACK Button to acknowledge message Re Zero Machine Re Home Servo 6 Press K5 Home Machine on Control Panel 7 If required Press K2 Man Auto Mode Button until LED is OFF 8 Press Hyd Stop Start to START hydraulic unit 9 Press K16 Tool Col to fully collapse tool 10 Go to 02 RECIPROCATION screen CAUTION Remember that when jogging down spindle carriage will move at a slow speed for first three seconds and then will change to jog speed rate set on Reciprocation Screen 10 Inch down until honing tool is in desired full withdraw position but has not yet
58. ne or on any of the optional equipment If specially built automation components 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 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE OFCONTENTS 22 32 aom ich dui d wal us a ati aded utl s Roa 1 LIST OF APPENDIXES ii INTRODUCTION ee een ee Ser ii GENERAL INFORMATION A SPECIFICATIONS 111 FLOOR LAYOUT Configuration 1V INSTALLATION Po ee 1 ICTU 1 TOO dirae d ae 2 i wa b P US yet eeu ES 2 Pneumatie Connection 55121555 Veen 4 lenken 4 Electrical Requirements 2 oeste add qnt teg 4 en ue tero a eS ou 5 5 Coolant 22225 a ___ aeg 6 Maenetic Separdtor Opuonal oe Geis
59. nto workpiece bore 26 Press K13 Jog Expand 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 27 Close guard doors 28 Recheck all values entered in Control Panel 29 Press K2 Man Auto Mode until LED is ON This indicate machine is in automatic mode At this point the Cycle Ready Start Button will be illuminated indicating that all conditions have been met to start a honing cycle 30 Depress CYCLE START OPTO SWITCHES on sides on Operator Control Console simultaneously to initiate A honing Cycle CE Models Press Cycle Ready Start Button to initi ate A Honing Cycle NOTE At this point machine should start reciprocating between the reversal points spindle should be rotating tool should be expanding if selected and cycle timer should be counting down to At any time during cycle operator may hit cycle stop and cycle will interrupt Counters will hold their count unless cycle is terminated The operator may also press K10 Withdraw Exit and honing tool will exit bore and stop at withdraw position and cycle will end The operator may also press K8 WIthdraw and honing tool will stop just above up go down posi tion A second pressing of K8 will allow carriage to exit to withdraw position At any time during cycle spindle and reciprocation speeds may be changed Change will take place immediately
60. ntry of desired FORWARD GO BACK Reciprocation Reversal Set Point Operator entry of desired Number of Reciprocation Strokes 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 Only active when K4 Dwell Off On Keypad in turned ON Operator entry to select desired Reciprocation DWELL POSITION MORE This screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 41 APPENDIX A 20 SCREENS 01 SETUPS SCREEN 01 DATA RECORD 02 03 04 99 RK E a CH We SCREEN HOME ENG METRIC SEL CH 1 JOG WITH UP DRAW SPINDLE DWELL FWD REV A HELP K7 2 HYD MAN JOG SPINDLE DWELL COOL EH STOP AUTO o z z o zm gt PULSE FEED OFF ON 22 5 zm SE ay m 55 2 dE T mc 5 12 SEH gt Or eala oo 4 2 SHIFT INS HELP ENTER DEL LINE 1 Displays to access the PRINTER PARAMETER SCREEN LINE 2 Displays to access the EDIT
61. olant from the sludge there is normally an inch or more of coolant that collects in the bucket This coolant can be dipped out and returned to the reservoir FIGURE 4 11 Magnetic Separator 3 Periodically Drain Inlet Hopper wipe clean and adjust Gap Plate as required Proper Gap setting 1s 4 5 mm 1 mm 3 16 in 1 16 in 20 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 3 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 coolant Check
62. ower belt cover 3 Loosen two 2 Hex Head Capscrews in the Motor Mounting Block to release belt tension 4 Remove old Belt 5 Install new Belt 6 Pull up on Motor to adjust Belt Tension and tighten Hex Head Capscrew in Motor Mounting Block 7 Replace all covers to ensure safe operation 8 Turn ON power at Master ON OFF Switch COOLANT MOTOR Check cooling motor fan on top of spindle drive motor for proper operation see Figure 4 9 Clean as required WIPERS Check way bar wipers see Figure 4 10 Replace as required 1 Turn OFF power to Machine at Master ON OFF Switch on Electrical Enclosure 2 Remove spindle carriage top cover and lower belt cover MAGNETIC SEPARATOR Optional The magnetic separator should be checked cleaned and adjusted as follows see Figure 4 11 NOTE For complete maintenance instructions refer to instructions packaged with Magnetic Separator 1 Water Based Coolant Clean discharge chute daily When using water based coolant the sludge that builds up in the chute often hardens if the machine is turned off for 8 hours or more Therefore the sludge should be cleaned off the chute at the start of each shift When using honing MAGNETIC oil as a coolant the sludge rarely if ever hardens in SEPARATOR the chute and will not have to be checked as often NOTE A certain amount of coolant will be carried into the sludge bucket along with the sludge After gravity separates the co
63. r consequential or accidental damages and to the extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any 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 machi
64. receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates 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 users 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 fo
65. rildocaletabon reference freauency AcctOecF to 40 Mz SOft 70 21 Accolemisonidocelarabon time increments Imr T 0 1 0 22 Stop prevention overnown is i Btu PVI 0 to 20011A 9999 150 23 Stall prevention operation lovei correction coefficient 23 at double soe d 31U PV2 0 to 200 99 9 24 muiwope d setting speed 41 Presetirill 0 to 401211 9999 9999 25 Multi spoiad setting speed 5 pfuletF5 0 to 400tit 9999 9111199 26 MulWipsed setting speed 61 PresotFG 0 to 40tMa 9999 9 9 27 Mulwagood setting speddl 71 Prossitil T 0 to 400ttt 9999 91 119 28 Multil speed input como9nestion pre comp 0 1 0 29 Acceierattonfil9ceisration oaftern AcciDecP 0 1 2 1 0 30 Exteinni broke radiator selection er 61A 0 1 0 31 Free us ncy jump A FWmp IA 0 to 400ttz 9999 32 Frequency iumv 15 Flume 16 0 to 4001ft 9999 9999 33 Fisquency jump 2A Ffump 2A 0 to 400HI 9999 9999 34 Frequency lump 20 Flump 20 0 to 400 9 9999 91111111119 35 Frequency pump 3A Flumo 3A 0 to 400ttZ 9999 9999 36 Frequency jump 30 Flump 3a 0 to 40ONZ 9999 99 37 Speed display Disound 2 10 10 11 to 999111 4 38 Automatic torque boost A Tr4flot 010200 0 39 Automatic torque boost operation starting current HoLood 1 0 to 500A 0 40 output terminus assignment Selectoo 01091199 1234 41 1 19 to froovency sonvilivily SU Range Otol0096 1096 42 Output frequency detection 3stFU FW 0 to 400 a 43 Output frequency detection at favors a rotation 44 Second acceleration decoldration time 105 2 0 to 3800 se
66. screen has more text lines accessed by cursoring down Operator entry to select desired AUTO SHORT STROKE TIME Active in Main Screen with F8 Button Operator entry to select desired AUTO SHORT STROKE DISTANCE Active in Main Screen with F8 Button Engages and disengages Spindle Brake F8 in this Screen 29 APPENDIX A 8 SCREENS 06 MAINTENANCE SCREEN LANGUAGE CONTRAST SECOND WITHDRAW DEFAULT PASSWORD LOGOUT SPINDLE MAXIMUM SPEED 300 500 RPM PULLEY DEPENDENT PASSWORD REEN HOME DIR MACH EN SPINDLE D METRIC FWD SEL REV I m 71 SA g slk K7 e JOG SPINDLE DWELL COOL WITH STOP AUTO DOWN JOG OFF MAN DRAW START MODE ON AUTO RS K12 14 15 K16 E L 1 E RESET WITH PULSE JOG TOOL TOOL TOOL CNTRS DRAW FEED EXPAND AUTO BLOCK COL EXIT OFF ON amp ESC ACK ID 2202 4 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 30 ejeje LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINE 6 LINE 7 LINE 8 LINE 9 LINE 10 APP
67. shes when conditions have been met to start a honing cycle On CE models serves as the cycle start pushbutton light stays on while in cycle CYCLE STOP Red Pushbutton UP DOWN 3 Way Joystick Stops honing cycle All counters hold their count and cycle can be resumed at place where cycle was interrupted Used to move spindle carriage in either direction To short stroke tool at either end of bore or anywhere in workpiece used joystick to hold or reverse direction of travel CYCLE START OPTO SWITCHES U S Domestic Models Two optically isolated switches that must be operated simultaneously in order to start a honing cycle They are located on either side of the operator s console SPINDLE FEED Load Meter TABLE 2 2 Operator Interface SYMBOL DESCRIPTION FUNCTION F1 MAIN MENU Touch Button Press to access MAIN MENU NOTE Hitting the escape key will return to previous screen F2 SCREEN DIR Touch Button F3 Touch Button Press to access SCREEN DIRECTORY Operator can access any screen by cursing to desired screen and pressing ENTER Various functions Screen Dependent 24 Touch Button Various functions Screen Dependent F5 HOME MACHINE Touch Button Press to automatically move Spindle Carriage to Home In manual mode causes machine to re zero encoder to PLC This will convert units of measurement to English or Metric system This is a screen sensitive key and is on
68. t made decal Starting for elevator mode Retry selection Stall prevention operation reduction starting frequency Number of raffles at alarm OCCUU6111CS Retry wading time Retry count display erasure Special regenerative broke dilly Applied motor PWM frequency selection 0 to SV 0 to OV selection Reasons time for analog signal React sitiectionIPU disconnection dejection Alarm code output selection Parameter write disable selection Reverse rotshon prevention solection operation mode selection Motor capacity Number of motor poles Rated motor voltage Rated motor frequency Auto tuning sattinglittato Parameter unit language switching RT activated condition Stall prevent select at regeneration OL signal waiting time AM terminal function selection PVVM f decrease at low speed FM terminal calibration AM terminal calibration Frequency setting voltage bias Frequency loading voltage gain Frequency selling current blow Frequency setting current gain Note 4 Inverter output current A 5 The setting range depends on the Inverter capacity 0 41K to 1 5K 2 2K to 7 5 1 and up 5 The factory setting for the FR A240E UL 400V series is 400V 7 Pr 79 6 is set switch over function is selected SETTING RECORD FOR FR A200E UL SERIES Part 2 53 DISPLAY Set LED set Main Sol Lvl Sol Lvl Set FIM Set FIM Set FIM CalbFM F 4CalbFM 1 Rwshilrl ResUtT2 Rnd set In Mode Retry Still colf Retry No
69. the USA contact your local authorized Sunnen Distributor Additional information available at http 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 seda 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 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 surfa
70. ube code 3 6 Check way bars for lubrication film and wear see Figure 4 4 Wipe Bars with a clean soft cloth Fill way bar lubricator as required lube code 2 7 Replace all covers to ensure safe operation 6 3 a Ap T zm 124 E d N i NZ t n FIGURE 4 4 Way Bars HYDRAULICS CAUTION Any Hydraulic Oil used for filling Hydraulic Reservoir or Priming or Filling Pump and Motor Cases Must be filtered thru 10 Micron Filter 1 Check hydraulic oil system level at sight gauge on side of machine see Figure 4 5 Fill as required lube code 1 NOTE Change Hydraulic Oil In Reservoir Once Each Year 2
71. will start up in a blocked condition K15 TOOL BLOCK Touch Button K16 TOOL COL Touch Button Press for honing tool to stay in a blocked condition meaning tool will neither expand or collapse An automatic cycle will start up in this condition unless operator selects another option Press to collapse honing tool SHIFT Touch Button 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 INS DEL Touch Button HELP Touch Button 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 ENTER Touch Button ACK Touch Button 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 ESC Touch Button Escape Press to return to previous screen or step FEED IN PROGRESS LED SHIFT LED Indicates tool is feeding Also see K9 and K10 Buttons Indicates that Shift Button has been pressed See Shift Button HELP LED Indicates that help screen is available for present screen See Help Button CAUTION LED Indicates that an alarm

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