New Machine Inspection and Installation PROCEDURE for
Contents
1. 637083 OUTLET HOSE PLAIN END INTAKE HOSE W STRAINER FIGURE 2 PF 165 Installation Kit INTAKE I OUTLET 7 7 a KNOCKOUT HOLES COLLAR INTAKE INTAKE HOSE Li S W STRAINER i ELBOWS amp COLLAR OUTLET OUTLET HOSE FROM PF 150 INTAKE HOSE SUCTION OUTLET HOSE FIGURE 5 Filtration Unit T HANDLE FILTER 4 ELEMENT 6 nj AIR VENT Dfa be EM CLAMP HALVES NOTE TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET THEN TIGHTEN T HANDLE FIGURE 6 Filter Element INSTALLATION ML Application To install Unit on one of Sunnen ML Series Power Stroked Honing Machines proceed as follows NOTE Receiving Bucket IS NOT used when PF 150 is used with ML Series Honing Machines 1 Drain coolant from machine reservoir as instructed in machine operating instruction book 2 Turn OFF all power to machine Unplug electrical power supply cord or disconnect at main power source 3 Remove reservoir from machine and clean as instructed in machine operating manual 4 Install Knockout Plugs in two holes in base of interior wall of reservoir see Figure 3 5 Elbows and pipe nipple supplied with Kit will be installed in Holes in left side panel of Reservoir 6 Outlet Apply Permatex No 2 Sealant or equivalent to 3 8in Nipple and assemble 3 81n Elbows with Collars to machine base as shown see Figure 4 Tighten securely to prevent leaks Apply Permatex No 2 Sealan2. White Wire L2 to Fuse 4 5FU2 Black Wire L3 to Fuse 4 5FU3 Green Wire to Ground Lug PE 4 Install fuses supply with kit as shown OPERATIONAL CHECK CAUTION DO NOT run pump without priming 1 Fill machine reservoir with Sunnen Industrial Coolant Pull out movable tray to its fully extended position and pour coolant into tray CAUTION Make Filtration Unit installation checkout with honing machine turned off 2 Manually prime filter pump as follows see Figure 27 Disconnect Intake Hose on unit cabinet at location as shown Fill Hose with honing oil Reconnect Hose and tighten securely i A a FIGURE 29 Air Vent 5 Open Air Vent in Filter Cover and start filter pump indicator light on Unit will indicate that power is on see Figure 29 As coolant fills filter container air will escape through Air Vent 6 When coolant appears at Air Vent usually one to two minutes close vent 7 After air vent 1s closed filtered coolant will be flowing back to honing machine reservoir If Receiving Bucket is used Filtered coolant will be flowing into Receiving Bucket see Figure 30 To get coolant to work piece start honing machine motor and adjust flow control valves on flow control manifold in usual manner Unit pumps more filtered oil into Receiving Bucket than honing machine uses This excess filtered coolant is returned to reservoir through Overflow Holes If Pump Bypas
3. sion or limitation of liability for 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 machine tool may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine DO NOT remove or defeat any safety device Always wear eye protection when operating this machine DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Service Representative for repairs not covered in this book 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 INTRODUCTION Sunnen PF 150 Filtration Unit is designed to filter grit and metal particles from coolant supply on Sunnen Precision Honing Machines and other manufacture machines Unit is a 100 filter in that it filters all of coolant that passes through it none is bypassed unless you intentionally bypass it In operation unit s pump sucks dirty coolant from machine
4. 3670 Customers outside the USA contact your local authorized Sunnen Distributor Additional information available at htip www sunnen com or e mail sunnen Q9 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 changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 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
5. Limitations and Exclusions 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 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 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 gt Improper machine setup or operation causing a crash to occur gt Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse 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 NO
6. part of the price evidenced by your 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 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
7. 57 gt SUNNEN New Machine Inspection and installation PROCEDURE THESE INSTRUCTIONS COVERS THE PF 150 BEGINNING WITH SERIAL No 3485 1pH 10382 3pH for SUNNEN FILTRATION UNIT Model PF 150 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNENG PF 150 FILTRATION UNIT SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Emergency breakdown support is available on a 24 hour 7 day basis Review all literature p
8. C Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics 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
9. ERS mm METERS m INCHES in FEET ft UK SUNNEN PRopucrs LTD Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel 6 sunnen co uk SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change or aient qup AUN AN revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch CHINA SHANGHAI SUNNEN MECHANICAL Co LTD Phone 86 21 5 813 3322 Fax 86 21 5 813 2299 www sunnensh com e mail sales sunnensh com gt SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Road St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 SUNNEN ITALIA S R L Phone 39 02 383 417 1 www sunnenitalia com Fax 39 02 383 417 50 e mail sunnen sunnenitalia com FRANCE SUNNEN SAS Phone 33 01 69 30 0000 Fax 33 01 69 30 1111 www sunnen fr e mail info sunnen fr Russia Sunnen RUS accessories previously sold Information contained herein is considered to be accurate based on available information at the ti
10. Hex Wrenches 1 8 amp 5 32 in Open End Wrench 7 16 amp 9 16 in UNPACKING Unpack Unit as follows see Figure 1 Cut Bands on shipping carton 2 Cut around base of outer shipping carton and lift carton off 3 Cut down side of inner shipping carton and remove 4 Open Unit and remove any contents packaged inside unit 5 Open Accessory Pack and inventory contents see Figure 2 6 Remove any Packaging from inside Unit 7 Inspect Unit and Accessories for signs of damage resulting from improper handling by carrier If damage is evident immediately file a claim with carrier and notify Sunnen Customer Service CLAMPS 1 2 NIPPLE amp ELBOW INTAKE HOSE NOT USED IN ALL APPLICATIONS ELBOW 8 COLLAR SUCTION LINE RECEIVING BUCKET NOT USEDsINeALL APPLICATIONS KNOCKOUT PLUG GENERAL This section is designed to aid in installation of Sunnen PF 150 FILTRATION Unit Unit may be used in either of two ways First Unit can be installed to supply clean coolant to machine pump without additional adapters or fittings Belt driven pumps will then supply clean coolant to machine s flow control manifold See Installation Second Unit may also be installed using optional MBB 1620 Pump Bypass Kit not supplied must be ordered separately When unit is installed in this manner machine pump is bypassed and clean FIGURE 1 Unpacking 3 8 NIPPLE ELBOW amp COLLAR OUTLET HOSE
11. T BE LIABLE FOR DIRECT INDIRECT INCIDENTAL 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
12. be installed in these Holes see Figure 9 On some early model Sunnen honing machines and other manufacturers machines holes were not provided in side panel of machine base With these machines locate and drill one 7 in 22 mm diame ter Hole and one 3 4in 19 mm diameter Hole If sheet metal drills or hole saws are not available use a piece of wood to back up area being drilled On Sunnen honing machines manufactured prior to 1979 both Holes in machine base were 3 4in 19 mm diameter Enlarge Hole nearest back of machine base to 7 81n 22 mm diameter 10 Apply Permatex No 2 Sealant or equal to 3 8in Nipples and assemble 3 8in Elbows with Collars to machine base see Figure 10 Tighten securely 11 Connect Intake Hose with strainer to rear 12 in Elbow Use sealant on threaded connection and tighten securely 5 in 127mm COLLAR INSIDE UNIT 7 8in 22mm RECEIVING BUCKET FIGURE 10 Coolant Lines INSTALLATION Standard Application To install Unit on one of Sunnen Precision Honing Machines proceed as follows 1 Drain coolant from machine reservoir as instructed in machine operating instruction book 2 Turn OFF all power to machine Unplug electrical power supply cord or disconnect at main power source 3 Remove Left Rear Cover of machine base and remove Oil Pump Belt see Figure 7 4 Locate coolant line tube and spring assembly inside machine base that connects oil pum
13. carton Remove all loose components Check components against list Inspect Unit and components Move unit to desired location Oo oOo A W n Oo c1 A co n LDLDDLDLDL LDLDDLDLDL FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART 2 X O T 2 0 MILLIMETER DECIMAL MILLIMETER FRACTION DECIMAL 003087 01000 9 32 7 1438 21 32 007874 02000 19 64 7 5406 one 08000 sne 7 9375 6 0 3969 8 0000 6 018748 0400 2164 8 3344 45 64 019685 05000 1 32 8 7313 023622 0 6000 9 0000 23 32 027559 0 7000 4 9 1281 4 0708 8 9 5250 031406 0 000 4 99209 sa 035433 0 9000 10 0000 49 64 039370 10000 2 10 188 2 11906 4 107156 15875 11 0000 4 19844 6 11 1125 6 0787460 20000 4 11 5094 2088 2 11 9063 53 64 2778 120000 27 32 e 11870 3000 4 120081 55 64 31750 12 12 7000 3 5719 180000 7 8 3 9688 33 64 18 0969 4 157480 40000 2 184988 48656 35 64 13 8906 2 47625 14 0000 196850 50000 916 142875 6 5594 37 64 146844 5 5563 15 0000 61 64 59531 2 15 0813 2 286220 60000 4 15 4781 1 4 6 3500 5 8 15 8750 63 64 6 7469 16 0000 FORMULAS MULTIPLY INCHES in FEET ft TO GET MULTIPLY MILLIMETERS mm METERS m TO GET MILLIMET
14. ck Valve into manifold from inside machine base see Figure 19 15 Screw Hose Barb supplied into Low Pressure Relief Valve use sealant on pipe threads see Figure 20 NIPPLE BACK CHECK VALVE FIGURE 19 Back Check Valve FRONT OF UNIT 3 8 ELBOW 3 8 TEE OUTSIDE OF UNIT FIGURE 15 Fittings LEFT REAR lt lt SLASH GUARD a a FLOW CONTROL MANIFOLD FLOW CONTROL MANIFOLD FIGURE 18 Manifold LOW PRESSURE RELIEF VALVE WN CENTER OPENING A OF TEE FITTING OUTLET HOSE TO BACK CHECK 4 P 9 LOW PRESSURE RELIEF VALVE INTAKE HOSE F RESERVOIR FIGURE 20 Low Pressure Relief Valve OUTLET HOSE INTAKE FIGURE 22 Coolant Line 16 Screw threaded end of Outlet Hose into Center Opening of Tee Fitting as shown refer fo Figure 20 Use sealant on pipe threads Connect plain end of this hose to Hose Barb on Back Check Fasten with hose clamp 17 Reinstall reservoir in honing machine 18 Slide Tube and Spring Assembly removed in step 4 over hose barb on Low Pressure Relief Valve and secure it with a Hose Clamp see Figure 21 NOTE Make sure free end of Tube and Spring Assembly is in reservoir Otherwise coolant will be pumped onto floor 19 Place Unit at left side or in back of machine 20 Connect Intake and Outlet Hoses between Unit and machine see Figure 22 Use sealant on all threaded connections and tighten securely to prevent
15. connection should be made by a qualified electrician Unit wiring should comply with all local state and federal codes and ordinances 115V UNIT Outlet for 115 volt unit should look like the following m ADAPTER CA GROUNDING SCREW 1 PROPER OUTLET GROUNDING PI Electrical supply cord is equipped with a grounding pin A temporary adapter may be used to connect this plug to a 2 pole receptacle if a properly grounded outlet is not available Temporary adapter should ONLY be used until a properly grounded outlet can be installed by a qualified electrician Green colored rigid ear lug etc extending from adapter MUST be connected to a permanent ground such as a properly grounded outlet box Unit wiring should comply with all local state and federal codes and ordinances FIGURE 24 Electrical Requirements ELECTRICAL CONNECTION Wiring is complete on all Filtration Units Wiring diagrams are furnished with every unit Also each Unit is shipped with a tag attached that specifies operating voltage NOTE The electrical data plate attached to Unit provides helpful data including maximum current requirements Wiring diagram number for unit 5 stamped on this plate Should additional copies be needed specify DIAGRAM NUMBER with your request 115 230 V 60 Hz Single Phase Units These Units are supplied with an electrical cord and plug that is rated 250 volts 15 amps Cord and plug are generally consid
16. d in these Holes see Figure 14 On some early model MBB 1650 honing machines holes were not provided in side panel of machine base With these machines locate and drill one 7 81n 22 mm diameter Hole and one 3 4in 19 mm diameter Hole If sheet metal drills or hole saws are not available use a piece of wood to back up area being drilled On honing machines manufactured prior to 1979 both Holes in machine base were 3 4in 19 mm diameter Enlarge Hole nearest back of machine base to 7 8in 22 mm diameter 7 Apply Permatex No 2 Sealant or equal to 1 2in Nipple and 3 8in Elbows see Figure 5 Install Nipple Elbows and Collar in 7 81n 22 mm diameter Hole as shown Collar 1s installed on inside of machine base Tighten securely to prevent leaks 9 Apply sealant to all threaded connections and install following items thru 3 4in 19 mm diameter Hole as shown refer fo Figure 15 3 8 Elbow PF 165 Installation Kit 3 8 Close Nipple PF 165 Collar PF 165 3 8 Tee MBB 1620 Pump Bypass Kit Low Pressure Relief Valve MBB 1620 10 Tighten all pipe connections to prevent leaks 11 Remove Left Rear Splash Guard from machine see Figure 16 12 Loosen Screw and remove Flow Control Manifold see Figure I7 13 Unscrew Pipe from Manifold then reinstall Manifold and left rear splash guard on machine see Figure I6 14 Apply sealant to threads on Nipple then thread Nipple with Back Che
17. ered as acceptable disconnecting means If required by local code disconnect switch fuses or circuit breakers must be provided by user see Figure 24 230 460 V 60 Hz 3pH amp 380 440 V 50 Hz 3pH Manual Start Units Open switch enclosure cover and with hardware provided mount starter switch on Unit cabinet Assemble cable connector to switch enclosure as shown see Figure 25 Wire cable conductors to switch as follows Red conductor to Terminal TI White conductor to Terminal T2 Black conductor to Terminal T3 Green conductor to Ground Lug CONNECTION IN BOTTOM FIGURE 25 Switch Enclosure CAUTION Note model electrical supply cord requirement printed on machine nameplate or electrical specification plate 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 Electrical Specification Plate but is within acceptable limits electrical connection can proceed but Machine Conversion below will be necessary 3 phase supply not furnished must be brought into switch enclosure through one of knockouts provided Locally approved line disconnect switch and over current protection if required are to be pr
18. it cabinet 16 Open top to Unit and remove clamp and cover 17 Insert Filter Element into container rotate element slightly while inserting to make it slide down center post more easily see Figure 12 18 Replace cover center carefully on rubber gasket to assure no leakage Then replace Clamp and tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle 19 Hookup is now complete Check for proper oil line routing 20 Proceed to Electrical Connection NOTE Coolant will be replaced in honing machine and left rear cover of honing machine base will be reinstalled during Operational Check INSTALLATION Pump Bypass Kit Filtration Unit may also be installed using Optional MBB 1620 Pump Bypass Kit To install using optional Kit proceed as follows 1 Drain coolant from machine reservoir as instructed in machine operating instruction book 2 Turn OFF all power to machine Unplug electrical power supply cord or disconnect at main power source 3 Remove Left Rear Cover of machine base and remove Oil Pump Belt see Figure 13 4 Locate oil line tube and spring assembly inside machine base that connects pump to Flow control manifold and Do not discard 5 Clean machine reservoir Remove reservoir from machine and clean as instructed in machine operating manual 6 If so Equipped Remove two knockouts from left side panel of machine base Elbows and pipe nipples supplied with Kit will be installe
19. l on honing machine base OVERFLOW HOLES ADJUSTING SCREW FIGURE 31 High Pressure Relief Valve 3 Turn Total Volume Control Valve on honing machine clockwise to off position see Figure 28 4 Check pump for correct rotation by momentarily switching on unit and observing shaft between pump and motor Facing pump end shaft should be turning counterclockwise NOTE For Units which operate on 3 phase power if filter pump 15 rotating backwards remove power from power cord supplying Unit and reverse any two of line connections at terminals L1 L2 or L3 on switch For Units for use on single phase power are connected for correct rotation when manufactured If reversal of pump rotation 1s ever necessary follow directions on pump motor terminal box cover NOTES NEW MACHINE INSPECTION amp INSTALLATION PROCEDURE CHECKLIST FOR SUNNEN PF150 FILTRATION UNIT MECHANICAL GENERAL Connect coolant system supply hose Connect coolant system return hose Fill coolant system reservoir Perform operational check 5 ELECTRICAL Open doors to unit Route cables and connect to enclosure Attach power cord Route and connect cord to power source Visual check cable connectors Close doors Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment 11 Move unit to staging area Remove shipping
20. leaks NOTE These oil hoses are attached to Unit cabinet for shipment Connect hoses to machine first then to swivel adapter on Unit cabinet 21 Open top to Unit and remove cover clamp and cover 22 Insert filter element into container rotate element slightly while inserting to make it slide down center post more easily see Figure 23 23 Replace cover center carefully on rubber gasket to assure no leakage Then replace cover clamp 24 Hookup is now complete Check for proper oil line routing 26 Proceed to Electrical Connection NOTE Coolant will be replaced in honing machine and left rear cover of honing machine base will be reinstalled during Operational Check 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 230 UNIT Outlet for 230 volt unit should look like the following 5 0 GROUNDING PIN Electrical supply cord is equipped with a grounding type plug Make sure unit is connected to an outlet having the same configuration as the plug No adapter is available or should be used with this unit If the unit MUST be reconnected for use on a different type of electrical circuit the re
21. me of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding Phone 7 495 258 43 43 Fax 7 495 258 91 75 www sunnen ru e mail sunnen sunnen russia ru CZECH REPUBLIC SUNNEN S R O Phone 420 383 376 317 Fax 420 383 376 316 www sunnen cz e mail sunnen sunnen cz POLAND SUNNEN POLSKA Sp Z 0 0 Phone 48 22 814 34 29 Fax 48 22 814 34 28 www sunnen pl Email sunnen sunnen pl http www sunnen com e mail sunnen sunnen com PRINTED IN U S A 0909 COPYRIGHT SUNNEN PRODUCTS COMPANY 2009 ALL RIGHTS RESERVED
22. ovided by user When wiring is complete reinstall DEN TETELA switch enclosure cover 9 17 Ide ELECTRICAL ML Application i BU LIU p p WARNING All wiring must be performed by a competent Licensed Electrician in accordance with all local i AT state and federal codes and regulations along with NT Se NI NOTE INSTALL OPT any special information provided on the machine nameplate or electrical specification plate PF 150 FILTER UNIT Verify supply voltage is the same as voltage on i ay Machine nameplate or Electrical Specification Plate Please note some models are sold with an 4 external transformer that steps down the voltage Fl to the machine s nameplate voltage PF 150 nameplate voltage MUST BE THE SAME as ML 2000 nameplate voltage GND PE TERMINAL Option Installation Kit is required to connect the PF 150 to the ML 2000 PF 167C for 230V 60Hz machine or PF 168C for 400V 50Hz machine Kit include fuseholder and fuses The PF 150 is supplied with a cable that 1s to be installed into ML 2000 main electrical enclosure Refer to wiring diagram shipped with PF 167C or PF 168C kits for electrical connection 1 Open door to ML 2000 electrical enclosure 2 Install Fuseholders supply with kit as shown see Figure 26 TOTAL VOLUME i T CONTROL VALVE 3 Route cable supply with kit into ML 2000 d Electrical enclosure and attach wires as shown z Red Wire L1 to Fuse 4 5FU1
23. p to Flow control manifold and disconnect Do not discard 5 Clean machine reservoir Remove reservoir from machine and clean as instructed in machine operating manual 6 Attach Receiving Bucket to pump support see Figure amp Pump Support must engage notches in front and rear walls of Bucket Knockout Plug should face left side of reservoir as seen when facing front of machine DO NOT remove Knockout Plug 7 Place reservoir back in machine and reconnect oil line to Flow control manifold PUMP 87 55 SCREW 4 v lon LEFT REAR COVER amp 6 RECEIVING BUCKET KNOCKOUT PLUG FIGURE 8 Receiving Bucket FILTER ELEMENT NOTE TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET THEN TIGHTEN T HANDLE 77 HOLE 7 8in 22mm KNOCKOUT HOLE 3 4 in 19mm FIGURE 14 Knockouts 12 Connect Outlet Hose plain end to forward 3 81n Elbow Use sealant on threaded connection and tighten securely 13 Loosen clamps on Receiving Bucket Install Intake under clamp on outside of Bucket and install Outlet Hose under clamp on inside of bucket Then tighten clamps 14 Place Unit at left side or in back of machine 15 Connect Intake and Outlet Hoses between Unit and machine see Figure Use sealant on all threaded connections and tighten securely to prevent leaks NOTE These oil hoses are attached to Unit cabinet for shipment Connect hoses to machine first then to swivel adapter on Un
24. reservoir and pushes this dirty coolant through a 5 micron paper filter element Clean filtered coolant is then returned to machine Unit pumps an oversupply of filtered coolant to machine This oversupply of coolant is bled off to machine reservoir by overflowing receiving bucket or by action of optional low pressure relief valve MBB 1620 Pump Bypass Kit depending upon which method of installation is employed As filter canister fills with sludge being removed from coolant an ample supply of filtered coolant continues to be supplied to machine Over 75 cubic inches 1 2 liters of sludge can accumulate in canister without interfering with filtering operation When filter element clogs coolant supply to machine is shut off 5 micron filter element can be changed easily in a few minutes restoring flow filtered coolant Important information to assist you with the unpacking and installation of your Sunnen Vertical Honing System NEW MACHINE INSPECTION amp INSTALLATION PROCEDURE FOR SUNNEN PF150 FILTRATION UNIT coolant is supplied directly from Unit to machine s flow control manifold advantages of this installa tion is a stronger more constant flow of coolant to workpiece and a slight increase in power at machine s spindle since spindle motor is no longer operating machine s pump See Optional Installation SUGGESTED TOOLING The following tools are required for installation Knife Screw Driver std
25. rovided with your Sunnen equipment 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 e Have Model Number and Serial Number printed on your equipment Specification Nameplate e Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required 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
26. s Kit 1s used Check for proper flow of filtered coolant to reservoir by slowly raising free end of Tube and Spring Assembly see Figure 31 Since Flow control manifold has been turned off full flow of filtered coolant from Unit is being returned to reservoir through Tube and Spring Assembly To get coolant to work piece adjust flow control valves on Flow control manifold in usual manner It is not necessary to operate honing machine motor to apply coolant to workpiece when Pump Bypass Kit is used Check for proper Low Pressure Relief Valve adjustment Adjust flow control valves on Flow control manifold as appropriate You should be able to overshoot workpiece with 3 coolant streams with all oil jets operating at same time Low Pressure Relief Valve may be adjusted for more or less coolant pressure by turning Adjusting Screw on end of Low Pressure Relief Valve First loosen Locking Nut then tighten Adjusting Screw to increase oil pressure or loosen Adjusting Screw to decrease oil pressure Retighten Locking Nut when adjustment is satisfactory CAUTION Unit also has a High Pressure Relief Valve on the pressure side of pump to prevent crushing of filter elements This High Pressure Relief Valve is located adjacent to filter pump see Figure 32 Valve is a factory sealed adjustment DO NOT ATTEMPT TO READJUST 7 Examine all hose and pipe fittings for any oil leaks Retighten if necessary 8 Reinstall left rear pane
27. t or equivalent to Fitting on end of Outlet Hose Then connect Hose to inside Elbow and tighten securely 7 Intake Apply Permatex No 2 Sealant or equivalent to Fitting on end of Intake Hose and assemble 1 2in Elbows with Collars to machine base as shown refer to Figure 4 Tighten securely to prevent leaks Then attach Strainer to end of Intake Hose with Clamp provided 8 Slide Reservoir back into machine 9 Connect Intake Hose Dirty Oil and Outlet Hose Filtered Oil between Filtration Unit and machine see Figure 5 Use sealant on all threaded connections and tighten securely to prevent leaks NOTE These oil hoses are attached to Unit cabinet for shipment Connect hoses to machine first then to swivel adapter on Unit cabinet 10 Open top to Unit and remove cover clamp and cover Insert filter element into container rotate element slightly while inserting to make it slide down center post more easily see Figure 6 Replace cover center carefully on rubber gasket to assure no leakage Then replace Clamp and tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle 11 Hookup is now complete Check for proper oil line routing 12 Make Electrical Connection 8 Replace oil pump belt and adjust tension as instructed in machine operating instruction book 9 If so Equipped Remove two knockouts from left side panel of machine base Elbows and pipe nipples supplied with Kit will
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