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1. re ee eee ee eee eee ee 15 Sio suu 202 E et hoa 9 Ase ee ERTE TETEE EEEE T EET 15 Operatin MOGGS 22 5273 2 4 40 08 88 eR defen ot oh i a i 15 Manual Stroked Honing RES ee qaae eque xus 15 Power stoked ONIN eke no oe sda sews Hebe OEE eos GEE 17 ROUTINE SERVICE CPP 19 Clean 20 00200000 00 00200 BG bo eS See eee 19 225504262554 4n5s eee oe eee ou eee eae ee 19 Double Rail amp Stroke Assembly 19 Coolant Car 2 20 20 2 40 00 0 cate ees ESTIS 19 Routine AGJUSUHMGNE 2 46 ptr eed yad sere ae std dad 905 0 es te esewedeane 19 Column Rail Wear Adjustment 2244044443444 654 65209544066 SS SHOTS S ERE SESE SEE TERE ae ee 19 Honing Indicator Adjustment 0 0 0 0 eee eee 20 Podab dust 9 d terse 000 IRE Pega ee PR 20 Zero Shuto Adjustment ded RR Rd E EEG Eo Sad edd end 20 21 Motor V Belt Replacement 5 EUR eR eee oe dr HER ee eee 22 Spindle Drive Belt Replacement s cw 40 45 od cow 0 20 02 92 0 8 22 Light Curtain Function Check uuu 4044244 0 5 23 ight Cutan Cleanine renee eE eee ESSA EISE booed oe ee een ee ea aed 23 TROUBLESHOOTING
2. 2 Turn Potentiometer on the left for spindle until it displays desired spindle speed see Figure 2 20 TABLE 2 4 Cutting Pressure Setting inches millimeters INITIAL SETTING 1 5 2 5 060 100 0 12 0 0 495 0 25 0 0 1 000 5 92 0 0 3 625 0 2 1 2 NOTE The customer can only adjust spindle speed and stroke speed The other parameters are locked by Sunnen Company according to design So the customer cannot change them by himself otherwise the customer will assume all duties If the customer have special demands and need to change the parameters please contact to Sunnen company we will supply all support and help don t change them by yourself 9 0 12 0 3 Adjust light cutting pressure control according to bore size and adjust heavy cutting pressure control to 0 see Table 2 4 or your Sunnen SMOPS Guide ADJUSTING STROKE LENGTH SCREW 1 Measure length of bore to be honed and length of stone um a RIGHT RAIL If part is shorter than stone COVER stroke length 0 85 x stroke length COVER m If part is longer than stroke length 0 85 x part length The longer of two is maximum stroke length The minimum stroke length must be larger than difference between two For workpiece with blind holes maximum stroke length should be bore length including relief minus 2 3 stone length For workpiece with tandem holes using a solid line of stones stroke length should e
3. cleanliness of the coolant To clean Coolant Cart proceed as follows Replace Coolant using ONLY Sunnen Industrial Honing Oil Sunnen Water Based Coolant Coolant should be neither diluted or cut with other coolant Based on machine use it is recommended that every quarter you pull the coolant cart out from the back of machine and drain the coolant from the coolant cart see Figure 4 2 Clean out coolant cart and re fill with clean coolant to desired level Maintenance in this way can not only reduce the processing cost but can also ensure the product quality ROUTINE ADJUSTMENT Routine adjustment must be taken into consideration in following seven aspects COLUMN RAIL WEAR ADJUSTMENT If honing several short workpieces for large quantities and for years it may cause rail wearing clearly on one end At this time you can remove the column rail from the support base and reverse the rail to be installed then it can recover the running state of new rail It can also use the cycle method to avoid the wearing part Because the linear bearings that we used are cycled by six even spaced ways that is every 60 even spaces a row of linear ball bearing see Figure 4 3 Then you can rotate the column rail 20 relative to linear bearing and can run at the no wear column rail If years later it emerged wear again rotate the column rail 20 again can recover the good running state HONING INDICATOR ADJUSTMENT
4. 027559 07000 23 64 9 1281 47 64 0 7938 38 9 5250 08146 08000 25 64 9 9219 035433 0 9000 100000 49 64 039370 10000 13 32 10188 25 82 1 906 4 10 7156 15875 11 0000 51 64 1 984 6 111125 6 0787460 20000 29 64 11 5094 2 3813 15 32 119063 4 2778 12 0000 27 82 s 1780 3000 31 64 123081 4 31750 12 12 7000 3 5719 180000 78 39688 3364 13 0969 57 64 e 187480 40000 17 32 134938 4 3656 35 64 13 8906 29 82 47625 140000 4 196850 50000 9 6 142875 8 5594 4 146844 5 5563 150000 61 64 5 9531 19 32 150813 31 92 286220 60000 4 15 4781 68500 8 15 750 63 64 6 7469 16 0000 1276691 70000 4 64 168 2719 6 FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS m MULTIPLY BY MILLIMETERS mm x 0 03937 METERS m 3 281 TO GET INCHES in FEET ft INCHES in FEET ft BRAZIL SUNNEN DO BnasiL LTDA Phone 55 11 4177 3824 Fax 4 55 11 4362 3083 www sunnen com br e mail Sbrasil sunnen be BELGIUM SUNNEN BENELUX BVBA Phone 32 3 880 28 00 Fax 32 3 844 39 01 www sunnen be e mail info sunnen be CHINA SHANGHAI SUNNEN MECHANICAL Co LTD Phone 86 21 5813 3990 Fax 86 21 5813 2299 www sunnensh com e mail shsunnen sunnensh com CZECH REPUBLIC SUNNEN S R O Phone 420 383 376 317 Fax 420 383 376 316 www sunnen cz e mail sun
5. Indicates the rotation of spindle motor Warning Label Indicates the rotation of stroker motor Warning Label Safety Glasses this machine Warns that safety glasses should be worn at all times when operating Warning Strip be taken Warns that a physical hazard exists and that proper precautions should Caution Label Moving Parts Warns that a finger hazard exists Do not touch while stroker is operating Warning Label resisting fixture Warns not to hold workpiece in hand without a torque Foot Starts honing cycle and controls stone expansion Pedal SPINDLE SPEED STROKE RATE DISPLAY JOG DISPLAY BUTTON POTENTIOMETER POTENTIOMETER MODE SELECTOR C OA e Oo OO amp POWER OFF BUTTON EMERGENCY STOP SUMMEN RESET BUTTON FIGURE 2 7 Operator Control Station TABLE 2 2 Operator Controls SPINDLE SPEED Display the spindle speed Display STROKE RATE Display the stroke speed rate Display POTENTIOMETER The potentiometer on the left is to adjust the spindle speed Black Knobs The potentiometer on the right is to adjust the stroke speed POWER ON Turns ON electrical power and starts Coolant Pump White Motor Pushbutton Switch POWER OFF Shuts off electrical power and stops Coolant Pump Red Pushbutton Switch JOG BUTTON Jog the moving of stroke Black Pushbutton Switch RESET BUTTON STOPS honing cycle and resets cycl
6. first few roughing strokes 2096 20 20 70 75 75 For finishing use Feed Setting of 15 to 20 18 Repeat as necessary until desired hole size is reached 19 Repeat honing operation for remaining parts When honing several parts with each honing operation bore diameter will be undersize by amount of stone wear By noting Honing Dial reading as you start honing each part you can tell whether stock to be removed is uniform from part to part When parts have a uniform amount of stock to be removed you can accurately estimate how much stone feed up is needed before starting to hone Adjust Feed Dial accordingly and hone until Honing Dial reads 0 If you accurately estimated rate of stone wear when dial reads 0 part will be honed to size This allows part to be honed in one opera tion without having to gage and hone each part sev eral times until it is to size When parts vary widely in amount of stock to be removed you can NOT estimate how much stone feed up is needed Generally it is better to hone part until Honing Dial reads 0 gage hole advance Feed Dial accordingly to compensate for stone wear and then continue honing until hole size is reached 20 The cutting pressure should be just enough to produce good cutting action Heavier pressure may cause excessive stone wear lighter pressure may result in stone glazing instead of cutting Increase or decrease cutting pressure no
7. on honing unit If honing unit fits into spindle very loosely use a Spindle Sleeve see Figure 2 11 FIGURE 2 8 Cycle Lockout Zero Shutoff FIGURE 2 11 Spindle Sleeve LARGE SETSCREW 13 Remove Spindle Cover 14 Rotate Spindle so Large Set Screw points up Screw is in 12 o clock position 15 With setscrew indentation on honing unit at 9 o clock position insert Honing Unit into Spindle Nose as far as it will go rotate unit 1 4 turn clockwise to engage Wedge with Feed Rod then push Honing Unit all the way in until it bottoms see Figure 2 12 16 Test Wedge hookup by pulling Honing Unit straight out if Wedge comes out repeat steps 9 thru 16 If wedge is hooked up it will not allow unit to come out of spindle 17 Push unit back into Spindle Nose until it bottoms 18 Tighten Large Set Screw with T Wrench NOTE CR Series of Honing Units stones and shoes are self truing no truing sleeve is furnished or required TRUE IN MANDREL AND STONE TRUE IN MANDREL 1 Rotate Cycle Lockout Zero Shutoff fully clockwise refer to Figure 2 8 2 Turn Feed Dial counterclockwise until you feel resistance 3 Place a Truing Sleeve or a suitable undersized workpiece in a torque absorbing workholding fixture see Figure 2 13 4 Install Truing Sleeve in Workholding Fixture on mandrel 5 Set Light Cutting Pressure to 2 6 With motor off depress Pedal and turn Feed Dial clockw
8. 308 2 8 11 432 495 11 13 495 619 13 16 619 4 16 19 744 0 19 25 1 000 1 250 25 32 1 250 1 625 32 41 1 625 2 000 41 51 2 000 2 500 51 64 2 500 3 250 64 83 OVER 3 250 OVER 83 CAUTION Power MUST be OFF when Guard is open 14 Loosen Lettered Set Screw s in Spindle Nose on side with lowest reading and tighten Lettered Set Screws on opposite side 15 Repeat as required until conical runout has been reduced to 1 division 16 Move Pivot Lock Lever to lock position 17 Turn Knob A counterclockwise one full turn 18 Turn Knob B in either direction to set Runout Indicator Pointer to 0 approximate 19 Rotate Spindle by hand to locate highest reading on gage readjust Knob B as required so high point can be located 20 Loosen Numbered Set Screw s in Spindle Nose on side with highest reading and tighten Numbered Set Screws on opposite side 21 Repeat as required until parallel runout has been reduced to division 22 Release Pivot Lock Lever 23 Pull Spring Clip out slightly and slide Runout Indicator off Pivot Pin 24 Turn the E Stop button clockwise and release the locking mechanism 26 Press Reset pushbutton and remove Alignment Bushing 26 Turn cycle lock out fully clockwise 27 Press E STOP Button 28 Reinstall Spindle Cover SPINDLE SPEED 1 Look up spindle speed according to bore size see Figure 2 19 amp Table 2 3
9. D of bushing if necessary 2 Rotate Cycle Lockout Zero Shutoff fully clockwise refer to Figure 2 8 3 Turn Feed Dial counterclockwise until you feel resistance 4 Install Alignment Bushing on the mandrel see Figure 2 16 5 With Power OFF Depress Pedal and turn Feed Dial clockwise until Honing Dial Needle reads 5 6 Release the Pedal 7 Install Runout Indicator on Stroking Arm see Figure 2 17 Slide Indicator on Pivot Pin until Spring Clip engages slot in pin 8 Release Stroker Carriage Lock and center Gage Points over Alignment Bushing 9 Align Runout Indicator with Alignment Bushing LOADING RUNOUT INDICATOR amp A inde SPRING CLIP PIVOT PIN FIGURE 2 17 Runout Indicator LETTERED SET SCREW INDICATING GAGING POINT REFERENCE GAGING POINT ALIGNMENT BUSHING PIVOT LOCK LEVER KNOB A POINTER 2 RUNOUT A INDICATOR FIGURE 2 19 Spindle Speed 10 Adjust spacing of gaging points on Runout Indicator so points are as far apart as Alignment Bushing permits see Figure 2 18 11 Release Pivot Lock Lever 12 Turn Knob A in either direction to set Runout Indicator Pointer to 0 approximate 13 Rotate Spindle by hand to locate lowest reading on gage readjust Knob A as required so low point can be located 11 TABLE 2 3 Spindle Speed Selection WORK DIAMETER SPINDLE inches millimeters SPEED UNDER 308 UNDER 8
10. Diameter range length range and workpiece weight are contingent on workpiece and application vii 1350 mm 53 in 1243 mm 49 in Floor Weight TOP VIEW Approximately 720 kg 1587 Ibs including coolant 1358 mm 53 4 in 1243 mm 49 in SIDE VIEW FRONT VIEW viii SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen SSH 1680 Precision Honing Machine Hereafter referred to as the Machine see Figure 1 1 FIGURE 1 1 Precision Honing Machine 4 j DO NOT LAY ON SIDE _ i SUNNEN SUNNEN PRODUCTS COMPANY ST LOUIS MO FORK LIFT THIS SIDE FIGURE 1 2 Unpacking 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 Open End Wrenches Tin Strips Cleaning Solvent Hex Wrenches UNPACKING amp INSTALLATION Read the following instructions carefully and thoroughly before unpacking inspecting and installing your Machine All references to right and left in these instructions are unless otherwise noted as seen by operator as one looks at front of Machine or assembly being described refer to Figure 1 1 UNPACKING
11. Light indicates the protected machine is Receiver allowed to operate Machine Stop Light indicates the protected machine is not Receiver allowed to operate Interlock Light indicates the protected machine is not Receiver allowed to operate until the protected zone is cleared and the start button is pressed and released Status Indicator Indicates the light curtain is functional Transmitter FIGURE 1 7 Light Curtain TOP COVER LIGHT CUTTING FEED DIAL PRESSURE CONTROL DIAL RIGHT SPEED LEFT SIDE PANEL PANEL SCREEN ZERO SHUTOFF ASSEMBLY LEFT PANEL STROKER ASSEMBLY IGHT SIDE PANEL OPERATOR CONTROL STATION MAIN POWER SWITCH HONE HEAD ASSEMBLY BACK COVER LEFT RAIL COVER WORK TABLE MOVABLE PANEL DRIP TRAY MACHINE BASE 2 ASSEMBLY ELECTRICAL ENCLOSURE LITERATURE POCKET ou Located on inside of Door SHOCKPROOF FRONT DOOR RING FIGURE 2 1 Major Components 4 SECTION 2 PREPARING FOR OPERATION GENERAL This section should be consulted when preparing the Machine for operation MAJOR COMPONENTS For location of major components on the machine see Figure 2 1 1 MACHINE BASE The precision honing machine is equipped with the base of cast iron to support the hone head assembly and houses components 2 WORKTABLE It is the work area Dual rails are installed on both sides The stroke support is fixed on moveable linear bearings In ord
12. Stone may not retract it may need to be pushed back into Mandrel with your fingers WARNING To prevent personal injury and machine damage DO NOT hone without installing part in workholding fixture 5 Gage hole size using Sunnen Precision Hole Gage to determine amount of stock to be removed 6 Install part in Workholding Fixture 7 Slide part on Mandrel so part is centered over stone 8 Depress Pedal 9 Turn Feed Dial clockwise until Honing Dial readings is equal to amount of stock to be removed per step 5 For various honing units types refer to Table 3 1 or data plate located above Feed Dial on your machine for various mandrel types 10 Turn part several revolutions on Mandrel to seat part on stone 11 Release Pedal CAUTION Machine MUST be set at proper Spindle Speed and Pressure Control Setting 12 Release E STOP Button by rotating counterclockwise 13 Press POWER ON Button White Light ON and coolant pump starts 14 Adjust position and direction of coolant nozzle and coolant flow as required CAUTION If bore is rough or out of round DO NOT fully depress Pedal until bore has smoothed up as evidenced by diminishing vibrations 15 Slowly depress Pedal while stroking part Overstroke each end of Stone by 1 3 to 1 2 bore length or stone length whichever is shorter see Figure 3 2 Frequently stop machine and reverse part on Mandrel NOTE If Honing Dial Needle moves too slowly i
13. With Power OFF set light cutting pressure control dial to 2 and heavy cutting pressure control dial to 0 With zero point of honing indicator is at 6 o clock position needle should be at red line position Y 4 HEXAGON If needle is to left of red line honing is close to 0 SOCKET stone pressure will immediately decrease and SCREW rapidly slows down cutting WE If needle is just at red line it can hone to 0 point under full load condition Therefore it is necessary to adjust needle a bit to the red line 1 If needle is not at red line loosen hexagon socket screw and slide indicator up to maximum position and then move it down When needle moves one turn continue to move it until needle is at red line Tighten screw to lock this position see Figure 4 4 2 Advance feed dial when feed dial 1s released needle should return to red line position If needle does not return to red line position or moves very slowly Remove honing indicator from machine Clean indicator shaft and check that indicator is working properly Then reinstall indicator and repeat step 2 3 Clean and lubricate support assembly see Figure 4 5 PEDAL ADJUSTMENT When the machine stops check that the pedal can be adjusted in or out and up or down for standing or sitting When fully depressed pedal must be at least 20mm from floor and not higher than 135mm from floor To adjust proceed as follows 1 Loosen screw to adjust U b
14. a clean soft lint free cloth Painted light curtain surfaces may be cleaned with a mild de greasing cleaner or detergent NOTES 24 SECTION 5 TROUBLESHOOTING GENERAL OPERATIONAL TROUBLESHOOTING INDEX 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 the machine The table lists problems encountered possible causes and solutions for the problems along with reference to the section of the manual where detailed instructions may be found to correct the problems TABLE 5 1 OPERATIONAL TROUBLESHOOTING INDEX PROBLEM PROBABLE CAUSE SOLUTION SEC Dress stone Increase cutting pressure Increase stroking speed Use softer stone Check coolant Dress stone Increase stroking speed Use softer stone Use coarser stone Check coolant 1 Stone Glazing Stone not cutting Honing Dial Needle moves Stone Loading too slowly gt Improper spindle speed Inadequate stone feed up Pressure flow Improper stone Increase spindle speed Increase cutting pressure Adjust pressure Use Softer Stone Use coarser stone Check coolant Slow stock removal Honing Dial Needle moves too slowly Improper or diluted coolant Excessive stone feed up Poor stone life Inadequate spindle
15. and light XL2 is not lit Then the car riage could be at the front or back limit position and the limit switch SA4 or SA5 is open so the power is not on At this time only to move the car riage away from the two limit positions can elimi nate the trouble If the carriage is not at the front or back limit position but the power remains off then it is possibly caused by the pedal switch SA2 is not being reset and 1 3 ends of SA2 are open Only to press reset button SB1 can turn on the power normally The troubles mentioned above are caused by the effect of limit protection switch and back cover protection switch and this is not the electrical fault However setting protection switch is neces sary for protecting personnel and machine safety WARNING For safety when the inverter has a fault it should be checked and repaired by maintenance personnel The inverter parameters are locked by design so the customer cannot change them by himself otherwise damage to the machine can occur If the customer has special demands and needs to change the parameters please contact Sunnen Products Company we will supply all support don t change them by yourself TABLE A 1 Protection Functions INVERTER PROTECTION FUNCTION The inverter has several protection functions itself This can avoid certain loss of some operations or caused by misuse When the protection function is in effect it can automatically cut off the output of the
16. com or e mail sunnen sunnen com NOTE Sunnen reserves the un to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges C Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics D Anti static bubble wrap has been
17. cycle lockout fully counterclockwise 4 Press E Stop button and make sure power is off 5 Depress pedal and turn feed dial clockwise until honing dial reads 2 and then release pedal 6 Loosen stroker lock handle and move stroking arm so front stroking fingers are lined up with workpiece 7 Adjust rear stroking fingers Then tighten stroker lock handle 8 Slide gate close to workpiece allowing sufficient clearance between workpiece and gate fingers to prevent binding approximately 0 8mm 9 Tighten clamping blocks and lock screw 10 Loosen stroking fingers and move fingers in toward mandrel so they will contact workpiece face adjacent to bore Then tighten stroking fingers 11 Both front and rear fingers should clear part as it is manually rotated 12 Turn E Stop button clockwise to release the locking mechanism 13 Press Reset button and remove workpiece from mandrel 14 Rotate Cycle Lockout Zero Shutoff fully clockwise refer to Figure 2 8 15 Close coolant control valves 16 Press POWER ON pushbutton 17 Before adjusting stroke position unlock lock handle and push carriage toward rear Then relock handle This is to ensure carriage is back touching stroke stop 18 Press Stroke Jog pushbutton stroke carriage will move forward and back slowly Check to make sure stroke clears all obstacles and that both overstrokes are equal The position can be aligned with rule on worktable left
18. included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sensi tive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY SUNNEN Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the following Normal maintenance items subject to wear and tear belts fuses
19. inverter and displays the type of protection functions For the operators convenience the table below provides some possible causes according to the displayed information and eliminate the trouble The protection functions shown in Table A 1 are related to possible error from the honing process and this is not a fault of the inverter The operator can turn master power switch off and on to clear the fault however the operator must record the situation including the displayed information the condition of the process and then turn off the machine to analyze the cause and eliminate the fault Then turn the machine on to restart working WIRING DIAGRAM 1 Introduction of several components a Master power switch QS b E Stop switch 1 c Power ON button SB2 d Power OFF button SB3 Reset button 1 f Stroke jog button SB4 2 Electrical Diagrams Placed in the door files under the base PROTECTION TYPE DISPLAYED INFORMATION SOLUTIONS 1 Overcurrent Protection OC1 0C3 Decrease cutting pressure Check if the out power is lower 2 Overvoltage Protection 001 003 Decrease cutting pressure Decrease load 3 Overheat Protection OH Check around temperature 4 Too Much Disturb CPU Check if there is a disturb source 30 APPENDIX B COOLANT FLOW DIAGRAM MANIFOLD O gt tr a SETTLEMENT TRAY COOLANT CART DIRTY OIL FIGURE B 1 Coolant Flow Diagram 31 NOTES 32 NOTES 33 NOTE
20. or the coolant flow is little the coolant line may be clogged then you should check and clean the line or possibly the rotation of the pump motor is incorrect then exchange two wires of the power source to change the rotation of the pump motor FILTER SCREEN COOLANT PUMP COOLANT LEVEL GAGE LEFT WORK TRAY LOCKING SCREW FIGURE 1 5 Side Guards OPTIONAL LIGHT CURTAIN CE Machines Only CE machines come with optional Light Curtain and guarding installed Light Curtain alignment is preset at the factory Light Un EVER Curtain Set consists of a Transmitter and Receiver DISCONNECT Unit see Figure 1 7 1 Check for signs of external damage to the light curtain transmitter receiver or cables and wiring 2 Inspect electrical connections between guarded machine s control system and light curtain Verify they are properly connected ELECTRICAL ENCLOSURE 3 Turn on power to machine beam indicators located on the receiver will 6 Push STOP Button illuminate when alignment of a beam is not met 7 Turn OFF power at Main Power Disconnect refer to Figure 1 7 5 Close two Individual Coolant Valves on Flow Control Manifold LEFT SIDE RIGHT SIDE COVER COVER SENDER UNIT LIGHTS Floating Blanking Light indicates that one or more of the beams Reise Receiver has been deactivated This light should not T be illuminated If it is contact a Sunnen representative for repair Machine Run
21. 00 03 EINER ye eae d EU E REUS 25 Operational Troubleshooting Index 25 General Troublesh otme Index 2 022 0 cade ed eeektetd peewee HERAT 28 APPENDIXES A Machine Electrical Principles and Notes 29 B Coolant Elow py e dog a nse re 0 00 000 0 PP e beets 3l INTRODUCTION This Instruction Manual is provided to give the information required to install and operated the Sunnen Precision Honing Machine The SSH 1680 Precision Honing Machine is to be used for finishing bores in small workpieces In finishing bores this machine can achieve any or all of the following results fast stock removal consistent final size a high degree of cylindricity fine surface finish As there are numerous workpieces which can be honed on this machine all the 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 INSTRUCTIONS THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE PRECISION HONING MACHINE GENERAL INFORMATION Honing is a machining process for precision bore sizing and finishing Because the Stone s touches most of the part surface during honing the re
22. 1 Refer to instructions on side of shipping carton for lifting when unloading Machine As the center of gravity of the shipping pallet leans to one side the two fork arms of the forklift must fork under the shipping pallet on the side shown on the machine box see Figure 1 2 In this way you can lift the machine steadily and remove it from the truck 2 Remove the waterproof wrapping from box 3 Remove top and front of shipping carton by cutting along edges 4 Remove Components shipped inside carton Then unbolt and remove Machine from carton 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 INSTALLATION 6 Move Machine to desired location Using a forklift carefully move the machine to desired installation location and lower into place When using a crane you should be sure that the crane steel wire cannot push down on the machine cover and the aluminum alloy double rail work table otherwise the machine may be damaged 7 Remove and discard cardboard packing 8 Level Machine Installing the machine does require the concrete floor to be flat but does not require the use of foot screws to fix to the floor but the 4 feet of the machine must be firmly on the floor leveled side to side Lean the machine 1 to the front by adjusting two 2 screws M16 at the back of the machine This is to ensu
23. F CONTENGS 2212 2 25 5 2 35194 AERE d 20 eae tees ewe se 2 quads V LIST OF gt 1 V INTRODUCTION A en 9 9 99 4 055506 2 SE PSU B vi GENERAL INFORMATION SPECIFICATIONS eee vii FLOOR PEANLAYOUM ud 0 0 ed SHE dS Vill INSTALLATION PUIDOSe se rccooe ees 1 66 2 02 8 002 002 200 0 55 8 1 Unpacking 6 105 101101100 oe ane oe nee ee be dades dee duo de chan ede bees 1 060 44 2 0 0 Mies 0 0 0 Oe aaa od acad eidatubu p Geol d ido 2 gt 2 Optional Light 0 77 3 PREPARING FOR OPERATION Gaile l ee 43 000 0000 00 0 0 0 2 0 2200 5 Major Components 142 2 22 0 02 022 0 0 00 0059000005 50 mE 220 d ado d dad dct 5 Dewi 8 Gees 9 Mandrel Runout Adjustment 0 0 0 0 ce ne ee een ene ene teen eens 10 NJ IM ENS 24644462064 eda bee es 0 bbe ee ha 0 ses 1 0 2 0 200 202000 000 250 ieee 0 12 Torge SUPPO gt 2 2 2 0 2002000000 5000 een was soe be ad 2 0 12 29 9 59 0 452457546 e 00 Oe ee 12 STORE m D L 13 OPERATION
24. Feed Dial four 4 numbers Depress Pedal and continue honing until Honing Dial Needle reaches 0 then release Pedal CAUTION Always release Pedal before removing Truing Sleeve from mandrel 19 Reverse Truing Sleeve frequently After reversing Truing Sleeve several times stop and examine stone and shoes NOTE High spots on stones will be loaded see Figure 2 15 Use the LBN 700 Abrasive Stick to remove high spots on stone High spots on shoe will be bright and shiny A few light strokes with a file will remove these high spots use an abrasive stick like the LBN 700 to true hardened steel guide shoes 20 Repeat above operation until at least a line contact is achieved on each shoe and on stone NOTE The objective of truing the mandrel and stone is to make the shoes and stones parallel However when honing to very close tolerances or when honing holes with keyways the honing unit should also be trued to the finish bore diameter as closely as possible When truing Keyway Y type mandrels refer to instruction sheet packed with mandrel Keyway mandrels should be fully radiused to within 005 0 13 mm of workpiece finish bore size 21 When mandrel is trued in push STOP Button 22 Replace Spindle Cover MANDREL RUNOUT ADJUSTMENT Eliminate conical and parallel runout as follows NOTE Mandrel and Stones must be trued before adjusting conical and parallel runout 1 Select proper Sunnen Alignment Bushing Resize I
25. I SSH 160 SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN PRECISION HONING MACHINE Model SSH 1680 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN PRECISION HONING MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your SUNNEN equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information for proper installation operation and maintenance of your e
26. MACHINE ELECTRICAL PRINCIPLES AND NOTES WORKING ENVIRONMENT The installing environment for the inverter has direct influence on normal use of inverter function and inverter life Therefore the working environment must conform to the following conditions 1 Power requirements 380V 10 50Hz 230V 10 3PH Load capacity gt 40A XXA Grounding resistance lt 10 2 Temperature 10 40 C 3 Relative humidity less than 95 4 Keep coolant out of the electrical enclosure 5 To prevent dust cotton fiber metal dust and other wastes from getting into the electrical enclosure 6 Be far away from the caustic gas liquid radioactive substances and combustible mass 7 To prevent electromagnetic interference and to reduce vibration 8 To avoid rain drenching and direct sunshine ELECTRICAL CIRCUIT 1 Major loop The spindle loop is composed of QS 1KM INVI MI The stroke loop is composed of QS IKM INV2 M2 The coolant loop is composed of QS 3KM FR M3 2 Control loop It is composed of the circuit that is supplied by the secondary 8 9 end of the transformer 3 Auxiliary loop It is composed of the circuit that is supplied by the secondary 4 5 6 7 end of the transformer INSTALLING 1 Open the door of electrical enclosure and visually check whether the components are in good condition and whether the connected wires are loose 2 Open the covers to check whether the w
27. Nuts securing Feed Arms as follows Insert 3 16 in 5 mm rod in Cross Hole in Feed Rod to keep Feed Rod from turning refer to Figure 4 12 Using 5 16 in hex wrench remove Screw and washer from Thrust Assembly 6 Turn Feed Dial counterclockwise all the way until Adjusting Nut Assembly is clear of Feed Screw 22 DRIVE TENSION ROLLER FIGURE 4 11 Spindle Drive Belt SCREW me 2 A lt T I v gt E IN FIGURE 4 9 Light Curtain 7 Separate Arms and remove Pull Feed Arm Assembly with Thrust Assembly off Feed Rod 8 Remove old Spindle Drive Belt and install new Belt 9 Ensure projection on Adjusting Nut Assembly is pointed upward then install Feed Arms and secure with Nuts and Bolts removed in step 5 Reassemble Feed Arm Assembly to Feed Rod by engaging Adjusting Nut Assembly with Feed Screw and turning Feed Dial clockwise while inserting Feed Rod into Thrust Assembly Projection on Adjusting Nut Assembly must point upward Bearing retaining screws in Thrust Assembly must face back of machine head 23 10 Adjust belt tension using Tension Screw 11 Close and secure rear Door 12 Turn ON power LIGHT CURTAIN FUNCTION TEST CE Machines Only Check Light Curtain operation as follows see Figure 4 13 WARNING The test outlined below must be performed at installation according to employer s regular insp
28. S 34 Like any machinery this equipment may be dangerous if used improperly Be sure read and follow operation of equipment to MANUFACTURED UNDER ONE MORE DF THE FOLLOWING UNITED STATES PATENTS 4 478 160 3 4 809 220 4 866 855 4 993 189 9 02 2 196 2 185 969 9 209 615 2 222 525 2 234 295 2 243 792 5 178 543 5 755 476 3007 446 04 23 6026 77 5 663 886 6 074 232 6 927 620 6 790 084 7 371 149 Fao ade 2 727 051 instructions for 8 096 853 8 796 859 B 277 2BD 8 248 718 8 535 573 OTHER U S AND FOREIGN PATENTS PENDING SS ee ee ee ee ee ee ee ee Sian TUNNEN COMPANY LIIS eo LTA Se WARNING An Arc Flash Hazard Exists Follow safe work practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury DO NOT WEAR COTTON OR HEAVY GLOVES WHILE OPERATING THIS EQUIPMENT 1 1198 PNP520 35 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART ss 2 O 1 2 0 MILLIMETER bEcIMAL MILLIMETER FRACTION DECIMAL 008987 01000 2 7 1438 21 32 007874 02000 4 7 5406 011878 osoo 516 7 9375 4 03969 80000 1116 018748 04000 2164 8 3344 4 019685 08000 11 32 8 7313 023622 0 6000 9 0000 23 32
29. S NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to us
30. ar in or out to a convenient operating position 2 The crank arm should freely move to its lower position This position can be achieved when the crank bar is in a line see Figure 4 6 At this time pedal must be at least 20mm from floor If tall operators prefer it can adjust up to 135mm If inappropriate adjust pedal height by turning self locking nuts on end of pedal link see Figure 4 7 ZERO SHUTOFF ADJUSTMENT Operate machine and needle should be at 0 when honing cycle is complete 1 Needle stops more than 5 division from 0 adjust locking adjustment screws using 5 64 hex wretch as follows see Figure 4 8 a To move shutoff point counterclockwise on dial loosen upper screw and tighten lower screw b To move shutoff point clockwise on dial tighten upper screw and loosen lower screw FIGURE 4 6 Crane Arm 20 PEDAL ASSEMBLY LOCK SCREW ADJUSTING SCREW AUTO TRIP LEVER 1 TOGGLE 1 FIGURE 4 9 Automatic Cycle Stop Adjustment 21 2 Needle stops less than 5 divisions from 0 Loosen honing dial bezel clamp screw and rotate bezel until 0 agrees with shutoff point Then tighten clamp screw AUTOMATIC CYCLE STOP ADJUSTMENT If honing cycle stops before cycle 15 complete adjust as follows see Figure 4 9 1 Press E Stop pushbutton 2 Turn cycle lockout fully counterclockwise 3 Set heavy cutting pressure to 0 4 Set light cutting pressure to 2 5 Open cover of the machin
31. before operating machine 3 Keep machine clear of tools or other foreign objects 4 Wear proper safety items such as safety glasses non slip safety shoes and other personal safety equipment as necessary or required 5 Do not wear cotton or heavy gloves while operating this equipment If gloves must be worn wear only the tear away type 6 Do not wear loose clothing or jewelry while working on or around machine 7 Keep area around machine free of paper oil water and all other debris at all times 8 When lifting part or tooling use proper lifting procedures 9 Turn OFF electrical power at Disconnect Switch on Electrical Control Enclosure when preforming service not requiring power 10 Turn OFF electrical power at Main Power Source when performing maintenance on or cleaning of Electrical Control Enclosure 11 Clear area of excessive lubricant or lubricant spills Precision Honing Machine Operation 12 Do not adjust stroke length while honing 13 Stay clear of all moving parts 14 Remove keys and wrenches from machine before honing 15 Do not hand hold parts while honing 15 OPERATING MODES The SSH 1680 Precision Honing Machine has the following six modes of operation The last four modes can employ the Stone Saver 1 Manual Stroke Honing is used when honing only a few parts or special parts Parts too long too heavy or that don t fit in the fixture 2 Power Stroke Honing is used fo
32. due to improper machine setup or adjustment consult Table 5 2 TABLE 5 2 GENERAL TROUBLESHOOTING INDEX PROBLEM PROBABLE CAUSE SOLUTION SEC Cycle Lockout improperly set Turn Cycle Lockout fully counterclockwise AUTOMATIC Improperly set Selector Switch Adjust switch SIZE CONTROL Improperly set Sensing Tip Adjust Sensing Tip Hone shuts off Automatic Cycle Stop Adjust when Pedal improperly set is released Insufficient or improperly set Adjust Feed Contact local Sunnen Electrical problem Field Service Technician Hone does not shut off when part is to size Pedal does not 1 Pedal travel improperly set A Adjust Pedal travel move down Pedal moves too 1 Pedal travel improperly set A Adjust Pedal travel fast up or down Pedal moves 1 Pedal travel improperly set A Adjust Pedal travel slowly or does not complete travel Switch improperly set Adjust switch 4 4 4 Honing cycle Cycle Lockout improperly set Turn Cycle Lockout fully stops as Pedal counterclockwise moves back up Pedal travel improperly set Adjust Pedal travel Power will not Machine Door is not closed Make sure all doors are closed come on when POWER ON is pressed Work Area Cover or machine Make sure all covers and guards Door is not closed are in place Previous cycle was interrupted Work Area Cover must be lifted between each honing cycle to reset the machine Cycle won t start 28 APPENDIX A
33. e 6 Depress pedal and observe motion of cam screw as pedal pressure is released slightly Cam screw should move approximately 0 4mm past center towards the front of the machine adjust as follows Loosen locknut using 3 8 wrench rotate cam screw as required using 3 32 hex wrench then tighten locknut 7 Install a mandrel with stones into spindle nose and place truing sleeve or workpiece on mandrel 8 Fully depress pedal 9 Turn feed dial until honing dial needle moves to between 1 and 2 10 Release pedal Pedal should raise but crank arm should remain held by toggle link If crank arm does not stay down repeat step f 11 Adjust trigger adjustment screw so they are at equal depth in trigger using 5 64 hex wrench refer to Figure 4 8 12 Slowly rotate feed dial counterclockwise and observe honing dial needle and pedal motion 13 If automatic cycle stop trips before needles reaches 0 adjust as follows Loosen upper trigger adjustment screw and tighten lower trigger adjustment screw Then return to step g and repeat steps 14 If automatic cycle stop does not trip at all adjust as follows Loosen lower trigger adjusting screw and tighten upper trigger adjusting screw Then return to step g and repeat steps until the requirements are met 15 If automatic cycle stop trips before pedal is complete raise adjust as follows Loosen upper trigger adjusting screw and tighten lower trigger adjusting screw Th
34. e Blue Pushbutton Switch MODE SELECTOR MANUAL Selects manual stroke honing MANUAL NONE AUTO NONE Unlatched setting Machine is at idle state 3 Position AUTO Auto setting is for power honing Depressing the Selector foot pedal can start power honing immediately Switch Emergency Stop Controls electrical power to STOP ALL Machine functions Red Locking Before restarting the machine rotated E Stop Button Pushbutton Switch clockwise and release the locking mechanism 9 COVERS It consists of the left panel the right panel the left side panel the right side panel the backside panel the top cover and the back cover 10 ACCESSORIES a Manual Torque Support Bars Inch 9 64 3 16 b Hex Wrench Inch 1 4 5 32 1 8 3 32 5 64 c Hex Wrench Metric 3mm 5mm 6mm 8mm d MBC 400 Runout Indicator e Work Tray Splash Panels SETUP GENERAL 1 Press E STOP Button to ensure power is OFF and lock is engaged 2 Turn ON Main Power Disconnect at Main Electrical Control Enclosure power indicator on operator control panel is lit 3 Turn E Stop button clockwise and release locking mechanism 4 Set Mode Selector Switch to NONE position and push RESET pushbutton 5 Turn OFF Coolant supply by turning two Individual Control Valves Coolant Flow Control Manifold 6 Rotate Cycle Lockout Zero Shutoff fully clockwise see Figure 2 8 7 Select Honing Unit and Stone from Sunnen Bor
35. e Sizing and Finishing Supplies Catalog X SP 5500 Depending on your part configuration select a honing unit type and size most suitable Assemble honing unit by using instructions included with your new mandrel and or adapter 8 Select Stone from Sunnen Bore Sizing and Finishing Supplies Catalog X SP 5500 Determine amount of stock to be removed and number of operations required to getting workpiece to proper size and surface finish Many times a three stone operation is the most economical that is deburring fast stock removal and fine finishing If deburring is attempted with a stock removal stone excessive stone wear will result If stock removal is attempted with a deburring stone or finishing stone honing time will be excessive Use a harder stone to improve stone life Use a softer stone to promote freer cutting Use a coarse stone for fast stock removal and a fine stone for finishing Always use the coarsest stone that will produce an acceptable surface finish Short open bores blind bores and tandem bores may require minor alterations of standard stones 9 Assemble Honing Unit According to instructions packed with Honing Unit 10 Turn Feed Dial counterclockwise until you meet resistance then advance dial clockwise about five 5 turns see Figure 2 9 11 Pull Mandrel Wedge straight back as far as possible using hook on end of T Wrench see Figure 2 10 12 If required install Spindle Sleeve LN 570A
36. e the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subsequent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclu sion or limitation of liability for consequential or accidental damages and to the extent this is true the above limitations may not apply A
37. ection program and after any maintenance tooling change setup adjustment or modification to Light Curtain System or the guarded machine Where a guarded machine is used by multiple operators or shifts it is suggested that the test be performed at each shift or operation change Testing ensures that Light Curtain and machine control system work properly to stop the machine Failure to test properly could result in injury to personnel 1 Interrupt light curtain system with proper size test object Test object size 30 mm diameter When using the test object guide it through the detection zone as shown below At least one individual beam indicator must be lit while test object is anywhere in detection zone 2 Start machine While machine 1s in motion interrupt detection zone with test object Machine should stop immediately Never insert test object into dangerous parts of machine 3 With machine at rest interrupt detection zone with test object Verify that machine will not start with test object in detection zone 4 Verify that braking system is working properly Machine must come to a quick controlled stop when light curtain is interrupted Drive faults spindle coasting and stroker coasting are unacceptable LIGHT CURTAIN CLEANING Accumulation of oil dirt and grease on the front filter of the light curtain transmitter and receiver can affect the system operation Clean filters with a mild detergent or glass cleaner Use
38. en repeat steps until requirements are met MOTOR DRIVE BELT REPLACEMENT To inspect and replace Motor Drive Belt proceed as follows see Figure 4 10 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Open Door on front of Machine and swing Drain Pipe up so Coolant Cart can be removed 3 Remove four 4 Screws and remove cover from back of base 4 Pull out the coolant cart from the back of machine 5 Inspect Motor Drive Belt for signs of wear and or damage Replace as required 6 Loosen Belt Tension Roller 7 Remove Motor Drive Belts 8 Install New Motor Drive 9 Adjust Belt Tension Roller and tighten 10 Push Coolant Cart back under Machine base and reinstall cover using four 4 screws 11 At front of Machine and swing Drain Pipe down then close and lock Door 12 Turn ON power SPINDLE DRIVE BELT REPLACEMENT To inspect and replace Spindle Drive Belt proceed as follows see Figure 4 11 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Open top Door on rear of Machine 3 Inspect Spindle Drive Belts for signs of wear or damage Replace as required 4 Loosen Tension Screw on side of Motor Plate see Figure 4 12 5 Remove two Bolts and
39. er to protect the stroke support two limit switches are installed on the bottom of the right rail Honing fixture and coolant pipe can be attached to the stroke structure see Figure 2 2 SS RIGHT RAIL LEFT RAIL STROKE g LOCKOUT COVER SUMI e SLIGHT LOCK HANDLE ie pa FIGURE 2 2 Worktable TORQUE SUPPORT LIGHT CUTTING PRESSURE CONTROL DIAL FEED DIAL HONING INDICATOR SPINDLE ASSEMBLY HEAVY CUTTING PRESSURE CONTROL DIAL FIGURE 23 Hone Head Assembly 3 HONE HEAD ASSEMBLY It includes the following major parts see Figure 2 3 amp Table 2 1 Spindle It is located on the lower right of the assembly Honing tool is installed in the bore of spindle Four 4 screws on the two ends of the spindle are used to adjust tool conical and parallel runout Feed Dial It 18 located on the front center of the assembly and linked with the feed arms through a screw It is used to set the honing stone expansion Light Cutting Pressure Control Dial It is located on the top left of the assembly It is used to adjust the cutting pressure of the honing stone for small diameter bores soft materials rough bores or fine finishes Heavy Cutting Pressure Control Dial It is located on the lower left of the assembly It is used to adjust the cutting pressure of the honing stone where heavy stock removal is required The Spindle Drive Motor It is located on the back
40. filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI RFI Storm lightning flood or fire damage Failure to perform regular maintenance as outlined in SPC manuals Improper machine setup or operation causing a crash to occur Misapplication of the equipment Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse Non authorized customer installed electronics and or software Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUME
41. ilable information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding http www sunnen com e mail PRINTED IN U S A 1402
42. ires connected to the motor pump pedal safety switch limit switch and the inverter display panel are good 3 After the above surface check connect A B C three phases separately to terminal L1 L2 L3 of the XT3 power supply block 4 Connect electrical grounding cord to the PE ter minal of the XT3 block NOTE No connection to the center line 29 WORKING PRINCIPLES 1 Close the master power switch QS and light XL is lit to indicate that the electrical enclosure is connected to the power source At the same time the cooling fans F2 of the inverter motor begin rotating and the fan F3 on the side of the enclosure also rotates Use a piece of paper test to see if 1 and F2 are taken the air while F3 drains the air Through 6FU SAI SA6 make have electricity and add 3 phase power source to the terminal R S T of the inverter now the inverter 1s displayed 2 Press Reset button SB1 then 2KM has electricity YA electro magnet pulls in to make the pedal reset 3 Make the stroke carriage away from the front and back position to make sure that SA4 and SA5 are closed 4 Press Power ON button SB2 then 3KM has electricity and locked pump motor M3 is working Check the rotation of the motor if rotation is incorrect reverse any two wires of A B or C 5 Jog operation Press and hold Jog button SB4 then 6K has electricity and ends 4 9 are closed INV2 is working and make M2 have electricity
43. ise until Honing Dial Needle reads 3 7 Release Pedal 8 Rotate E STOP Button counterclockwise to release lock WARNING Power to the machine is ON Spindle will rotate when Foot Pedal is pressed 9 Push POWER ON Button 10 Slowly open two Individual Control Valves Generously apply coolant to honing stone guide shoes and bore of Truing Sleeve see Figure 2 14 Close Total Volume Control Valve 11 Set spindle speed to 250 rpm 12 Set Mode Selector switch to manual stroke 13 Center Truing Sleeve over stone and shoes CAUTION Make sure that the Truing Sleeve is held in a workholding fixture that transmits torque to the Manual Torque Support see Figure 2 13 14 Grasp Workholding Fixture and Truing Sleeve firmly and depress Pedal slowly 15 As mandrel begins its rotation stroke Truing Sleeve forward and back Use short strokes at first then gradually lengthen stroke until stroke length is about as long as stone or Truing Sleeve whichever is longer If Truing Sleeve is too hard to hold or Honing Dial Needle moves too rapidly reduce cutting pressure If Honing Dial Needle does not move or moves too slowly increase cutting pressure 16 The coolant on Truing Sleeve and stone create a lapping paste as you are honing as paste dries out add a small amount of Coolant Always hone workpiece most where you feel most pull or resistance 17 When Honing Dial Needle reaches 0 release Pedal 18 Advance
44. lative speed and pressure between the stones and work piece are less than those of grinding and the temperatures are lower Honing produces greater accuracy and a finer surface finish than grinding in mass production Honing will create no surface stress Honing is also a good means of high efficiency for the high precision bores thin long bores and blind bores With the development of high performance abrasives and high efficiency automatic honing machine tools the applications for honing as a machining process have been widely increased Vi GENERAL INFORMATION amp SPECIFICATIONS Sunnen Precision Honing Machine Model SSH 1680 Diameter Range ID Spindle Speeds Spindle Motor Stroke Motor Stroke Speeds Stroke Length Brake of Spindle and Stroke Coolant Pump Motor Coolant Capacity Coolant Requirements Floor Space Floor Weight Electrical Requirements Color Noise Emission 3 to 60 mm 118 2 36 in 250 2500 rpm Variable Speed Adjustment 1 5 kw 2 hp 0 200 Hz 0 75 kw 1 hp 10 200 Hz Motor 80 310 n m 0 160 mm Electro Type Brake 0 125 kw 0 17 hp 96 liters 25 gallons Sunnen Industrial Honing Fluids 1350 1243 W x 1358 H mm 53 x 49 x 53 4 in with work light 1570mm 720 kg 1587 Ibs 230V 60Hz 3pH 380V 50Hz 3pH 380V 6072 3pH Pearl Gray Pewter Gray Black Trim Less than 70 dB A continuous Load max noise condition in a typical factory environment
45. left of the assembly and installed on the base It supplies power for the honing operation 4 PEDAL ASSEMBLY It is located on the front and inside of the machine base and linked with start operation and zero shutoff mechanisms through a pull rod when the pedal assembly is depressed it starts the machine and expand the stone while manual honing or starts the spindle motor and stroker motor at the same time while Semi Automatic 5 STROKE ASSEMBLY It is located on the back of the machine It is composed of stroke motor stroke drive structure Rod Screw Support stroke connection rod stroke slide rod and other major components It is connected to stroke support with fine adjustment locking mechanism see Figure 2 4 STROKER MOTOR STROKE SLIDE ROD TENSION WHEEL RELEASE HANDLE ELECTROMAGNET Hl Pee STROKE lt gt SELT PULLEY CONNECT ROD 4 ROD SCREW SUPPORT MOTOR FIGURE 2 4 Stroke Assembly 6 COOLANT ASSEMBLY The coolant pump is a centrifugal unit It is located on top of coolant cart ting the individual coolant nozzle control valves The return honing oil flows into the filter basket and flows back to coolant cart through outlet oil pipe see Figure 2 5 Coolant flows through oil pipe flow control manifold and coolant nozzles see Figure2 6 The flow control manifold includes two individual coolant nozzle control valves 7 SAFETY SYMBOLS For a description of safety symbols
46. more than 1 2 division at a time until most efficient pressure is established Changing cutting pressure will cause a slight change in reading of Honing Dial Increasing pressure results in a smaller reading and decreasing it could cause bore to go oversize For additional troubleshooting information see Section 5 Troubleshooting POWER STROKED HONING 1 Press E STOP Button 2 Turn Mode Selector Switch to AUTO 3 Turn Cycle Lockout fully counterclockwise 4 Back off Feed Dial by turning counterclockwise to allow part slide onto Mandrel NOTE On smaller Mandrels Stone may not retract it may need to be pushed back into Mandrel with your fingers 17 WARNING To prevent personal injury and machine damage DO NOT hone without installing part in workholding fixture 5 Gage hole size using Sunnen Precision Hole Gage to determine amount of stock to be removed 6 Install part in Workholding Fixture 7 Open Stroking Arm Gate 8 Slide part on Mandrel so it is centered over stone 9 Depress Pedal 10 Turn part several revolutions on Mandrel to seat part on stone 11 Release Pedal 12 Turn Feed Dial clockwise until Honing Dial readings is equal to amount of stock to be removed per step 5 For various honing unit types Mandrel types refer to Table 3 1 or data plate located above Feed Dial on your machine CAUTION Machine MUST be set at proper Spindle Speed Pressure Control Setting Stroke Length and S
47. ncrease Cutting Pressure If Needle moves too rapidly decrease Cutting Pressure 16 When Honing Dial reads 0 release Pedal DO NOT hone beyond 0 on Honing Dial Honing beyond 0 results in loss of reference point and ability to repeat size on succeeding parts possible stone glazing and unpredictable finish unnecessarily prolonged honing operation loss of accuracy because of stone becoming loose in bore 16 TABLE 3 1 Stone Expansion STONE EXPANSION PER HONING DIAL AND FEED DIAL NO HONING UNIT TYPE 002 in 0 050 mm AK AN 600 JK JAK K KR R28 Y YY 001 in 0 025 mm AL BAL BL BLR L LR P20 P28 0003 in 0 008 mm D2 208 FIGURE 3 1 Cycle Lockout WORKPIECE at one end of stroke WORKPIECE at other end of stroke r 71 LLLI _ STROKE gt OVE OVER 2 lt HONING UNIT TYPICAL FIGURE 3 2 Overstroke TABLE 3 1 Spindle Speed SPINDLE SPEED IN RPM o in RPM o in mm under 40 45 50 17 Remove workpiece from the mandrel and gage bore size using Sunnen Precision Hole Gage TABLE 3 2 Feed Rate SPINDLE FEED SETTING SPEED RPM ROUGH FINISH 350 0 DIAMETER mm in FOR FASTER STOCK REMOVAL INCREASE FEED IF STONES WEAR RAPIDLY Reduce Feed Rate Use Harder Stones 850 10 1 Always use this setting during the
48. nen sunnen cz FRANCE SUNNEN SA Phone 33 0 1 69 30 00 00 Fax 33 0 1 69 30 11 11 www sunnen fr e mail info sunnen fr ITALY SUNNEN ITALIA S R L SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Road St Louis MO 63143 U S A Phone 1 314 781 2100 Fax 1 314 781 2268 R L U S A Toll Free Sales and Service 1 800 325 3670 poor cians ME E International Division Fax 314 781 6128 POLAND SUNNEN PoLskA SP 2 Phone 48 22 814 34 29 Fax 48 22 814 34 28 www sunnen pl e mail sunnen sunnen pl RussiA SUNNEN RUS Phone 7 495 258 43 43 Fax 7 495 258 91 75 www sunnen ru e mail sunnen sunnen russia ru SWITZERLAND SUNNEN AG Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch UK SUNNEN PRODUCTS LTD Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk COPYRIGHT SUNNEN PRODUCTS COMPANY 2014 ALL RIGHTS RESERVED accessories previously sold Information contained herein is considered to be accurate based on ava
49. ning fluids away from Machine 26 TABLE 5 1 OPERATIONAL TROUBLESHOOTING INDEX Cont d PROBLEM PROBABLE CAUSE SOLUTION SEC 1 Improper mandrel A Use L BL or multi stone mandrel stone length should be Rainbow 1 1 2 times bore length Short or unbalanced part Shorten overstroke Improper stone Use softer stone Improper feed Decrease cutting pressure 2 Mandrel not trued True stone amp shoes to exact hole diameter Rough Finish Stone loading Use softer stone Scratches in Bore Random Improper stone Improper or diluted coolant Soft or exotic materials Improper feed Stone loading Improper stone Improper mandrel Use finer stone Check coolant 4 Use bronze mandrel or bronze shoes Decrease cutting pressure 2 Use softer stone Use finer stone Use softer stone If using hard steel mandrel change to soft steel mandrel if using soft steel mandrel change to bronze mandrel Improper or diluted coolant A Check coolant 4 NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from Machine 27 GENERAL TROUBLESHOOTING INDEX For suggestions on correcting problems
50. not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements CLEANING Monthly wipe the exterior of the Machine with a clean dry cloth Then clean the exterior of Machine with warm water and a mild detergent or mild industrial solvent rinse thoroughly with clean hot water and wipe dry LUBRICATION Hand lubricate the various machine components called out in Figure 4 1 according to the suggested intervals called out in Table 4 1 NOTE The intervals between lubrication will vary with the amount of use your Machine receives Lubricate all components at least once every six months OUTLET PIPE FILTER BASKET COOLANT PUMP FIGURE 4 3 Column Rail 19 DOUBLE RAIL amp STROKE ASSEMBLY Four linear bearings on the two sides of the double rail stroke carriage and one on the stroke leading rod are JBD30UU It is recommended to clean it about every three years according to local use conditions and re filled with Grease Pin bearings in stroke connecting rods of stroke assembly should be cleaned about every three years according to local use conditions and re filled with Grease Ball bearings in bearing base of stroke assembly can extend its time to clean and replace Grease because these bearings are sealed in the bearing base CLEANING COOLANT CART The quality of the bore honing 15 related to
51. ny 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 WARNING Do not wear cotton or heavy gloves while operating this equipment If gloves must be worn wear only the tear away type 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 safet
52. one until Honing Dial reads 0 If you accurately estimated rate of stone wear when dial reads O part will be honed to size This allows part to be honed in one operation without having to gage and hone each part several times until it is to size When parts vary widely in amount of stock to be removed you can NOT estimate how much stone feed up is needed Generally it is better to hone part until Honing Dial reads 0 gage hole advance Feed Dial accordingly to compensate for stone wear and then continue honing until hole size is reached 26 The cutting pressure should be just enough to produce good cutting action Heavier pressure may cause excessive stone wear lighter pressure may result in stone glazing instead of cutting Increase or decrease cutting pressure no more than 1 2 division at a time until most efficient pressure is established Changing cutting pressure will cause a slight change in reading of Honing Dial Increasing pressure results in a smaller reading and decreasing it could cause bore to go oversize For additional troubleshoot ing information see Section 5 Troubleshooting TABLE 4 1 Lubrication Chart ITEM DESCRIPTION LUBRICANT PROCEDURE INTERVALS Grease 3 1 Pump Pull Rod Linkage 1 6 Piston 1 Linkage 1 FIGURE 4 1 Lubrication Points SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are
53. qual total stone length minus tandem distance For workpiece with tandem holes using separated tandem stone the maximum stroke length should equal tandem land length or individual stone length whichever is longer 2 Open back cover of Machine RULE NOTE There is a safety switch between back cover CARRIAGE and right side panel and power will be shut off automatically when cover is opened to ensure operator safety 3 Loosen Lock Screw on Stroke Drive see Figure 2 21 4 Adjust length of stroke by rotating Adjusting Knob according to Stroke Rule ADJUSTING WHEEL FIGURE 2 23 Stroking Arm FIGURE 2 24 Stroke Speed FIGURE 2 26 Potentiometer 5 Then tighten Lock Screw 6 Close Back Cover Safety switch has been pressed TORQUE SUPPORT 1 Reinstall workpiece on mandrel 2 Lower stroker gate and stroker arm 3 Loosen capscrew in torque support and roller assembly Center assembly under workholding fixture and tighten capscrew 4 Check clearance between torque support and roller assembly and adjust as required 5 Tighten capscrew in torque support and roller assembly STROKE POSITION CAUTION In order to avoid injury and damage to machine first place workpiece in holding fixture then install it on the mandrel 1 Loosen clamping blocks on gate and lock screw and slide gate open enough so gate will clear workpiece 13 2 Install workpiece in holding fixture on mandrel 3 Turn
54. quipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available e Have ALL MANUALS hand The Customer Services Representative or Technician will refer to it Have Model Number and Serial Number printed on your equipment Specification Nameplate e Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required 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 For fast service on your orders call Sunnen Automotive Customer Service toll free at 1 800 772 2878 Sunnen Industrial Customer Service toll free at 1 800 325 3670 Customers outside the USA contact your local authorized Sunnen Distributor Additional information available at htip www sunnen
55. r a mass production of the same workpiece or the large stock removal workpieces although the quantities are not many 3 E Stop When machine is in automatic mode if you press down E Stop machine will stop immediately To resume work release E Stop press Reset button and power ON button 4 Machine rear cover Power ON State When machine 15 in power state and press E Stop Button wait 2 seconds then open rear cover If rear cover is opened with power ON power to machine will shut OFF 5 WARNING Machine will start when pedal is depressed Guidelines It is impossible to set down exact rules for when you should use each operating mode but following Guidelines should be of some help Manual Stroke Honing is generally used when part s bore is larger then 95 mm 3 750 in part is too long or too heavy to economically fixture for power stroking honing only a few parts Power Stroke Honing is preferred when there are many identical parts to be produced stock removal requirement is large even on only a few parts Since no stroking effort 1s required of operator in Power Stroke Honing production rates tend to be much higher MANUAL STROKED HONING Press E STOP Button 2 Turn Mode Selector Switch to MANUAL 3 Rotate Cycle Lockout Zero Shutoff fully clockwise see Figure 3 1 4 Back off Feed Dial by turning counterclockwise to allow part to slide onto Mandrel NOTE On smaller Mandrels
56. rail cover see Figure 2 22 If stroke s position needs to be adjusted Loosen lock Nut rotate adjusting wheel until the value on left rule 15 at correct position see Figure 2 243 Then relock Nut STROKE SPEED 1 Look up stroke speed according to the table of stroke length see Figure 2 24 For example 150spm 2 Turn the Potentiometer on the right for stroke until it displays 150 see Figure 2 25 3 Power ON button to start honing parts NOTE The customer can only adjust spindle speed and stroke speed The other parameters are locked by Sunnen Company according to design So the customer cannot change them by himself otherwise the customer will assume all duties If the customer have special demands and need to change the parameters please contact to Sunnen company we will supply all support and help don t change them by yourself 4 Setup is complete proceed to Section 3 Operation SECTION 3 OPERATION GENERAL This section describes a step by step operating procedure for the SSH 1680 Prior to starting Machine Operator shall ensure 1 All prerequisites described in sections 1 and 2 are complete 2 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 Precision Honing Machine 1 Ensure all guards are in place before operating 2 Ensure area 15 clear of other personnel
57. re coolant doesn t flow into the spindle while running and to keep the machine s base stable 9 Remove four 4 Screws and remove cover from back of base Pull Coolant Cart out from behind the base see Figure 1 3 10 Clean inside of Coolant Cart then pour approximately 90 liters 23 gallons of Sunnen industrial honing or HM 18 honing oil into cart 11 Push Coolant Cart back under Machine base and reinstall cover using four 4 screws 12 Install oil pipe and connect pump motor power plug NOTE The pedal assembly movement up and down should not interfere with Coolant Cart and trundle 13 Install Work Tray and place tray pads in tray see Figure 1 4 14 Install Side Guards see Figure 1 5 15 Install work light ELECTRICAL CONNECTION 1 Connect Machine to the power source 3ph 380V 50Hz or 3ph 230V 60Hz depending on unit ordered see Figure 1 6 2 Connect the ground cord to earth ground terminal OPERATIONAL CHECK Read 5ection 2 and 3 thoroughly and carefully before performing Operational Check 1 Turn ON power at Main Power Disconnect 2 Direct Coolant Nozzles downward toward anti splash pad 3 Push Power ON Button to start Coolant Pump Motor Wait a few seconds for coolant pressure to build up 4 With Coolant Nozzles directed downward turn two individual coolant nozzle control valves on coolant manifold on coolant can be seen coming out of the nozzle If coolant cannot be seen
58. speed Honing Dial Needle Excessive Pressure moves too fast Improper stone Decrease cutting pressure Increase spindle speed Adjust pressure Use harder stone Use coarser stone Check coolant A A A A B A A A A A B A Improper or diluted 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 25 TABLE 5 1 OPERATIONAL TROUBLESHOOTING INDEX Cont d PROBLEM Bellmouth Bore longer than 2 3 stone length Bellmouth Bore shorter than 2 3 stone length Barrel Taper in Open Hole Taper in Blind Hole Out Of Round PROBABLE CAUSE 1 Mandrel not trued 2 Short or unbalanced part 3 Improper stone 4 Improper stone length 1 Mandrel not trued 2 Short or unbalanced part 3 Improper stone 4 Improper stone length 1 Mandrel not trued 2 Improper stone length 3 Improper stone 1 Workpiece is not being reversed 2 Overstroke uneven 3 Mandrel not trued 4 Improper stroke 5 Stroker arm amp spindle not 1 Improper stone length 2 Inadequate oil flow 3 Inadequate relief in blind hole 1 Undersize honing tool 2 Mandrel no
59. t true 3 Workpiece flexing thinwall 4 Improper stone Improper mandrel or stone length SOLUTION A True stone amp shoes A Shorten stroke length A Use softer stone A Shorten stone only slightly on each end A True stone amp shoes A Shorten stroke length A Use softer stone A Shorten stone amp shoes equally to 1 1 2 times bore length 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 more often A Readjust overstroke A True stone amp shoes A Lengthen overstroke on tight end A Align sroker arm amp spindle A Shorten stone amp 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 pressure B Use fixture which will not distort the workpiece A Use softer stone A mandrel with sufficient stone to bridge waviness bore 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 clea
60. then the stroke carriage slides back and forth at the set jog speed Release the jog button to stop sliding 6 Manual stroke operation Turn SA3 to Manual Depress pedal SA2 and 1 3 ends of SA2 are closed 4K has electricity and to make 2 9 ends of INV1 closed INV1 is working and make M1 have electricity then spindle rotates 7 Power stroke operation Turn SA3 to Auto Depress pedal SA2 and 1 3 ends of SA2 are closed 5K has electricity and to make 2 9 ends of INV2 closed INV2 is working and make M2 have electricity then the stroke carriage slides back and forth at the set jog speed This type of cycle running completes the honing operation 8 When honing is completed the zero shutoff mechanism works to make 1 3 ends of SA2 open and 4K or 5K lose electricity INVI INV2 stops running and the spindle and stroke are both stopped 9 When temporarily not running press Power OFF button SB3 then 3KM loses electricity pump motor M3 stops and light XL2 is black out Now jog operation manual stroke operation and power stroke operation have no effect 10 When stopping honing for a short time you can also turn SA3 to Blank APPENDIX A NOTES 1 When the master power switch QS is closed but the inverter has no display then it is possible that the back cover is not closed and the safety switch SA6 is open 2 When press Power ON button SB2 there is no control power
61. troke Speed 13 Close Stroking Arm Gate 14 Release E STOP Button by rotating clockwise 15 Press POWER ON Button coolant pump starts 16 Adjust Coolant Nozzles as required 17 Press RESET Button one time 18 Slowly depress pedal to floor and then release The honing operation will automatically continue until honing cycle is completed 19 The honing cycle automatically STOPS when Honing Dial Needle reaches 0 NOTE If Honing Dial Needle moves too slowly increase Cutting Pressure If Needle moves too rapidly decrease Cutting Pressure WARNING To avoid personal injury allow spindle and stroking arm to come to a complete stop before removing part 20 Open Gate and remove part 21 Gage bore size using Sunnen Precision Hole Gage 22 Place workpiece on mandrel and advance Feed Dial for amount of stock to be removed 23 Depress pedal and continue to hone to 0 and gage 24 Repeat as necessary until desired hole size is reached 25 Repeat honing operation for remaining parts When honing several parts with each honing opera tion bore diameter will be undersize by amount of stone wear But by noting Honing Dial reading as you start honing each part you can tell whether stock to be removed is uniform from part to part When parts have a uniform amount of stock to be removed you can accurately estimate how much stone feed up is needed before starting to hone Reset Feed Dial accordingly and h
62. used on this machine refer to Table 2 1 8 ELECTRICAL COMPONENTS It consists of Electrical Enclosure Operator Control Station Limit Switch Safety Switch and so on Electrical Enclosure Enclosure is located on the right of the machine In the electrical enclosure there are inverters transformers contactors and overload protection control fittings The power source 1s 380V 50Hz 3PH or 230V 60Hz 3ph depending on machine to connect the factory power The inverter connects to the digital displays and can display and set the spindle speed and stroke speed Operator Control Station Station is located on the front right of the machine and is connected to the electrical enclosure see Figure 2 7 amp see Table 2 2 Stroke Limit Switch Switch is located on bottom of the right rail to control the stroke range of the carriage and it is used for protecting the machine Safety Switch A Safety Switch 15 located inside the back cover on the side of the machine refer to Figure 2 4 When the back cover is open the machine 15 inoperative The back cover must be closed and turn on the power before the machine can be operated TABLE 2 1 Safety Symbols DESCRIPTION COOLANT E FILTER ART COOLANT BASKET PUMP COOLANT E NOZZLE INDIVIDUAL VOLUME CONTROL VALVES FIGURE 2 6 Coolant Assembly FUNCTION Warning Label Warns that an electrical hazard exists Warning Label
63. y device on this machine 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 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 after power has been turned off IMPORTANT NOTE The temperature requirements of Sunnen Precision Honing Machines equipped with electronic components have been established as 35 degrees C 95 degrees F Above this temperature an optional cooler will be available to handle temperatures from 35 to 46 C 95 to 115 IT IS NOT recommended that Machine equipped with electronic components be operated at temperatures above 46 C 115 F Sunnen Products Company warrants Machine equipped with electronic components for operating environments up to 35 C 95 F For operating environments of 35 to 46 C 95 to 115 P the warranty only applies if the optional cooler is installed on Machine equipped with electronic components No warranty coverage is offered for operating environments above 46 C 115 F SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Copyright 2014 by Sunnen Products Company Printed in U S A IV TABLE OF CONTENTS Page TABLE O

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