ISV502E:Layout 1.qxd
Contents
1. IV iris sen 2 44 a5 eae eek ee eek ee ae e di bo ss V General Information amp SpecificationS Vi SECTION 1 INSTALLATION or MT r rm I ool Fa rica A I Ic nh ee hake ne 26 Cd eee aoe oe needa Soke sk bee Se m Sa aS I luci e prorrata Be dd bed eee SS da a ee area aoe hes ok 2 Electrical Conneccion Sooke oh oe ma uushapa IE kosa k E ue PU D mp PE LPS 2 gucci AA E In es 3 iii cali Oy aap A 3 J ili C Cit AA 3 AU unde A ae eee abe SES koe eed oe re sees eee we Choe Bones 3 Coolant System COnNCCHON bene oe ou deed 4 Magnete o o luu yupin RES sa IEEE UIN eed sta ine a te wee ane eo Rumi Lines lasse 4 Sp Gi rdi nee ado ee ee ae cep ie web et oe boca oe ok ee obese eee seuss 4 Open ibid qe P 4 SECTION 2 PREPARING FOR OPERATION Gor MERC T 5 Major aos voce fem dor testers a pad EA Eb ER RUNE w S ahin h ante e 5 Operator Canirols cada ro ka aqa ba bai chu yr sb aa h b em dul dinh dr uit Ug ee hh ete 7 Si a o M MMT2. V m 1 Workholding Peru en sterne Pas EE ASE od deter chat 7 Monto FOOL ee ee ee a ee ee ne 7 SECTION 3 SETUP amp OPERATION Conor MMC 9 Date P a Lu aoa wb ON SES d aad aes REI EC 9 OG AGS OS es pares merida aa pal erario era a Es REN NEMUS Cones dp due es 9 A AA 9 Salio Indexe Table oe 9 Fiure asta gt puts ae ps st e Reade 10 oli TOOL cn rea EA ea eee I io aaa buo 10 SEINE Op Piki et o a Se s s E Eee oe RENI ie 10 Safe Shutdown Turning Machine Off 12 SECTION 4 ROUTINE MAINTENANCE Ss A nn 13 CICAD ro raros croatas ita adas 13 Libi c On E AAA AENA AB DE aa 13 Routine Maintenance Sehedule 42 42 6cac04 043050 08 os Pe W Peg ddr arabe 13 Filter Element Replacement ce quos Banane dorm RE Rd EC 14 Sum TI C anne dormancia aaa 14 li ji Ml academia Pu We P ERE dam ua eugait Rar da diee 14 lA 15 lv rp lie Res VO een w Eb Q ow E ansa Wie eee dU ENT C pues Bene ee ee 15 accensa qut wq E uon ERU ae ek cee ea Sardis aep ded EP DS 15 SECTION 5 TROUBLESHOOTING
3. ed eee R yw ceed p EI ee 17 Operational Troubleshooting Ren a EERE 17 Machine Troubleshooting 41 5 dco uim cea Rs aaa a LR a 17 APPENDIXES A Coolant System Flow Diagram 2 B Grease Lubricating System Flow Diagram 23 GENERAL INFORMATION amp SPECIFICATIONS Sunnen CNC Vertical Honing Machines SV 500 Series Diameter Range ID Workpiece Weight Maximum Workpiece Length Stroke Travel Z Axis Stroke Speed Z Axis Stroke Column Motor Thrust Spindle Speeds Spindle Motor Feed System Sump Pump Sump Pump Motor Coolant System Coolant Requirements 19 300 mm 75 12 in 900 kg 2000 lbs 710 mm 28 in 864mm 34in Up to 762 mm 30 in Floor Weight Dry 1 160 spm length dependent Floor Load 7 5 kW 10 hp DC Servo Electrical Requirements 1360 kg 3000 Ibs maximum Color 0 to 300 rpm 15 kW 20 hp 300rpm peak Linear Push Pull Centrifugal Pump 0 25 kWQ 114 LPM 33 hp 30 Optional Sunnen Industrial Honing Fluids Diameter range length range and workpiece weight are contingent on workpiece and application The SV 500 does NOT come with a Coolant System The Coolant System is an option and MUST be or
4. DECIMAL MILLIMETER EQUIVALENTS CHART 2 X 2 O T O T MILLIMETER DECIMAL MILLIMETER FRACTION DECIMAL 908997 0 1000 9 32 7 1438 21 32 007874 02000 19 64 7 5406 Orem 0800 sho 79975 43 64 03969 8 0000 1116 Ll 015748 0400 2164 8 3344 45 64 019685 0 5000 1182 8 7313 023622 0 6000 9 0000 23 32 027559 07000 23 64 9 1281 47 64 07998 9 5250 Ll 031496 0 000 2564 09219 035433 0 9000 10 0000 49 64 039370 10000 13 32 10 188 25 82 11906 27 64 10 7156 15875 11 0000 5164 1 9844 7 16 1 4125 13 16 078740 2000 29 64 11 5094 2383 15 32 11 9068 53 64 27781 120000 27 32 Ll 3000 12 3031 55 64 31750 12 12 7000 3 5719 18 0000 78 3 9688 3364 13 0969 57164 45740 4000 17 32 184988 4 3656 35 64 138906 29 32 4765 14 0000 59 64 196850 5000 ene 142875 15 16 5594 3764 14 6844 55563 15 0000 61 64 5 9531 19 32 150813 3182 286220 60000 39 64 15 4781 1 4 6 3500 5 8 15 8750 63 64 6 7469 16 0000 FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS m MULTIPLY MILLIMETERS mm METERS m TO GET INCHES in FEET ft INCHES in FEET ft SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS LIM
5. TABLE 2 1 Operator Controls SYMBOL DESCRIPTION FUNCTION E STOP Shuts OFF all power to the machine functions Button must release before Power ON button Pushbutton Red can be pushed STROKER TOOL Select either Tool Position or Tool Feed Mode on Operator Touch Screen POSITIONING Tool Position Mode Dial can be used to position Tool vertically in bore up or down Dial Tool Feed Mode Dial can be used to expand or retract stones in bore POWER ON Turns ON control power to the machine After E Stop Button is pushed Power ON button must be Pushbutton White pushed once to reset E Stop Relay and again to turn ON Control Power CYCLE STOP Stops honing cycle All counters hold their count and cycle can be resumed at place where Pushbutton Red cycle was interrupted DWELL Switch is used to make stroker dwell while machine is honing NOTE Under Run screen Run Selector Switch Settings Control Tab Column A Bore Profile there are 5 marks in middle of screen that represent five locations in bore Using up and down ARROW keys you can move this marker to place where you would like to dwell When you press dwell button stroker will dwell in location that you selected with arrow keys for 2 seconds For continuous dwell hold Dwell Button in for desired length of time F KEYS These keys are used for a variety of functions as indicated across the bottom of the display screen NN KEYPAD Numeric keypad is u
6. 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 part of the price evidenced by
7. additional information 15 needed at any time during set up refer to the related setup overview which follows SETUP amp OPERATION Consult the following procedure when setting up your machine for operation Machine s control software will walk you through the setup procedure step by step on the view screen Follow all instructions carefully 1 Release E stop by turning clockwise 2 Press Power ON button 3 The software will start In the last screen displayed prior to turning off the machine Go to setup Menu 4 Then press F2 New Setup 5 Follow direction on display screen for entering new setup Key in desired value using key pad Press OK to accept START DIAMETER Key in desired value using key pad Press OK to accept FINAL DIAMETER Key in desired value using key pad Press OK to accept BORE LENGTH Select Material Press OK to accept MATERIAL Select Hardness Press OK to accept HARDNESS 6 If an Index Table 15 installed you will neeed to set this up as well as identify the part status at each fixture 7 Press NEXT to continue to next screen 8 If airlines are part of the machine you will be able to setup the state of the airlines at different table locations 9 Press NEXT to continue to next screen 10 If fixture interlocks are installed you will be able to set their functions here 11 Press NEXT to continue to next screen 12 Press NEXT and cont
8. injectors are installed begin looking for grease to come out of the injectors As soon as grease can be seen coming out of an injector then connect a grease line to that injector 6 After all grease lines have been reconnected allow the system to finishing the 100 cycles If no faults occur in those 100 cycles then the air has been successfully bled out of the system 19 PROBLEM Routine inspection of lubrication system shows that grease is not coming out of one or more grease lines SOLUTIONS Remove the grease lines from the tops of the grease injectors Under the Diagnostics section of the software set the lube system to cycle 50 times 1 If grease is seen coming out of the injectors then the problem 15 with the grease line It is either clogged or has a leak In either case it should be replaced 2 If grease is not seen coming out of one or more injector then remove the injector s from the manifold Is grease coming out of the manifold port s as the system continues to cycle If not then proceed to step 5 3 If grease 15 coming out of the port s then reinstall the injector s Only reinstall an injector into a port where grease is present If air is trapped below the injector it will not work properly 4 If grease does not come out of the reinstalled injector then the injector is not working properly An injector may be disassembled and cleaned to get it to resume working if that does not work then
9. 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 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 Th
10. the injector is defective and should be replaced 5 If grease is not seen coming out of the port s when the injectors are removed then air must be bled from the grease pump Open the air bleed port just below the grease reservoir and continue cycling the system until grease can be seen coming out of the port If this does not happen then the pump 1s defective 6 After taking the necessary corrective action and reassembling but before reattaching the grease lines to the ball screw and ball spline cycle the lube system 50 times and verify that grease is coming out of the lines NOTES 20 A COOLANT SYSTEM FLOW DIAGRAM SUMP PUMP OPTIONAL COOLANT SYSTEM FLOW CONTROL ON OFF VALVE WORKPIECE MACHINE RESERVOIR PAPER FILTER FILTERED 1 COOLANT SYSTEM with PAPER FILTER MAGNETIC SEPARATOR OPTIONAL COOLANT SYSTEM with MAGNETIC SEPARATOR FIGURE A 1 Coolant System Flow Diagram 21 NOTES 22 GREASE LUBRICATING SYSTEM FLOW DIAGRAM Grease Lubricating System Grease Lubricating System en SPINDLE BEARING BALLSCREW y NUT C LOWER SPINDLE BEARING FIGURE B 1 Grease Lubricating System Flow Diagram 23 NOTES 24 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION
11. 1 5 502 SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN CNC VERTICAL HONING MACHINE Models SV 500 Series READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN SV 500 SERIES CNC VERTICAL 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 INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Emergency breakdown support is available on a 24 hour 7 day basis Review all literature provided with your Sunnen equipmen
12. ITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 www sunnensh com SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 O2 383 417 1 Fax 39 02 383 417 50 www sunnenitalia com e mail sunnen sunnenitalia com 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 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 accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before p
13. achine or on any of the optional equipment If specially built automation components are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co Indicates CE version ONLY 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 IMPORTANT NOTE The temperature requirements of the Sunnen SV 500 Series Vertical Honing Machine have been established as 35 degrees 95 degrees F Above this temperature an optional cooler will be available to handle temperatures from 35 to 46 C 95 to 115 F IT IS NOT recommended that the SV Machine be operated at temperatures above 46 C 115 F Sunnen Products Company warrants the SV Machine for operating environments up to 35 C 95 F For operating environments of 35 to 46 C 95 to 115 F the warranty only applies if the optional cooler is installed on the Machine No warranty coverage is offered for operating environments above 46 C 115 F INTRODUCTION This Instruction Manual provides information required to install operate and maintain Sunnen Vertical Honing Machine When ordering parts for or requesting information about your Machine include model and serial numbers located on Electrical Enclosure of your Machine In this book the lt symbol indicates steps o
14. ailable Placement and system requirements will vary with coolant system used Sunnen provides several optional coolant systems see Figure 1 8 Check with your local Sunnen Field Service Engineer or Sunnen Products Company Technical Services for available systems or before installing another manufacturer s system IMPORTANT Operating Instructions and Repair Parts Catalogs for the optional Coolant Systems are supplied by the systems manufacturer Fill Coolant Reservoir with either Sunnen Industrial Honing Oil or Sunnen Water Based Coolant Refer to Section 4 COOLANT SYSTEM CONNECTION The machine comes with a Sump Pump and a small Reservoir Intake and Outlet Hose Barbs are provided for connecting optional Coolant System see Figure 1 8 CAUTION Supply coolant pressure should not exceed 20 psi 0 14 MPa MAGNETIC SEPARATOR Optional Like the Coolant System the machine 15 not supplied with a magnetic separator see Figure 1 8 If your application produces large amounts of metal residue it is recommended that you employ either or both a magnetic separator and filter system Check with your local sunnen Field Service Engineer or Sunnen Products Company Technical Services for available options or before installing another manufacturer s system SPECIAL FIXTURE Optional Because of the numerous applications possibilities the machine 15 not supplied with any fixturing optional fixtures are available see Figure 1 9 Che
15. around Machine Do not wear cotton or heavy gloves while operating this equipment Keep area around Machine free of paper oil water and other debris at all times Keep Machine and area around machine cleaned of excessive lubricant and lubricant spills Keep tools and other foreign objects clear of Machine while in operation Keep tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life Inspect Tools before using Check for cracks burrs or bent parts that might effect operation DO NOT force tools when operating Tools will do a better and safer job when operated at the rate for which they were designed Turn OFF electrical power when performing service on your machine which does not require power Disconnect Machine from main power supply and allow drives to drain before any work 15 performed inside of Electrical Enclosure Ensure all Guards are in place and are in proper working order DO NOT override safety switches or lockouts Where interlocking systems rely on special actuators or keys DO NOT keep spare master actuators or keys on around or near machine Use proper lifting procedures when loading and unloading the Machine Keep all non essential persons clear of work area Visitors especially children should not be permitted near the work area DO NOT use machine for other than its intended use Using these Machi
16. 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 Machine or assembly being described refer to Figure 1 1 NOTE When ordering parts for or requesting information about your Machine include Model and Serial Numbers printed on Nameplate Mi iui Teu ic FIGURE 1 1 Vertical Honing Machine 1 Move Machine to staging unpacking area 2 Remove shipping carton and plastic wrap Cut remove and discard shipping bands 3 Remove steel bracket that holds column from moving during shipping 4 Remove all loose components 5 Check all components against packing list 6 Inspect Machine and components for dents scratches or damage resulting from improper handling by carrier If damage is evident immediately file a claim with carrier CAUTION Weight 15 approx 4309 kg 9500 Ib 7 Remove Bolts securing Machine to Skid 8 Using a forklift remove machine from skid and move to desired location and lower into place see Figure 1 2 NOTE Machine should be located on a leveled concrete floor away from heavy traffic Allow at least 1 m 381n around enclosure to any adjacent equipment and walls Refer to Figure 1 A Floor Plan Layout 9 Adjust Leveling Bolt in Four 4 feet as required Tighten Jam Nuts to lock bolt in place see Figure 1 3 Machine does not need to be bolted to floor but s
17. brication Other Service The linear runners blocks are prepacked for a standard linear displacement of 100 000 km The operator station will indicate if the limit 15 close to being reached The stroker carriage can be lubed with Sunnen 90123 Kluberplex BEM34 132 or its equivalent at this time FILTER ELEMENT REPLACEMENT Periodically check and clean Filter Element on the side of the Electrical Enclosure replaced as required To clean or replace the Filter Element proceed as follows see Figure 4 2 1 Turn OFF all power to Machine at Master ON OFF Switch 2 Remove Access Panel on rear of machine by removing six 6 button socket head capsrcews 3 Snap Filter Cover off Filter 4 Remove Filter Element 5 Clean Filter with warm water and a mild detergent or mild industrial solvent 6 Rinse thoroughly with clean hot water and allow to dry 7 Reinstall Filter Element available through the Sunnen or your local supplier 8 Snap Filter Cover into place over Filter Element 9 Reinstall Access Panel 10 Turn ON power to the machine SUMP TANK CLEANING Periodically check and clean Sump Tank Sump Tank should be cleaned when there 15 a noticeable drop in coolant pressure 1 Turn OFF all power at Master ON OFF Switch 2 Remove Drain Cover in right side of machine base by removing one 1 button socket head capsrcews 3 Attach hose to hose fitting on left inside of machine base and turn valve ON 4 T
18. ck with your local Sunnen Field Service Engineer or Sunnen Products Company Technical Services OPERATIONAL CHECK Read Sections 1 2 and 3 thoroughly and carefully before performing the Operational Check NOTE Power up and start machine to check for proper operation When machine is powered up it should open Sunnen software 1 Release E STOP and press POWER ON Button 2 Once machine 15 through initializing press Green Cycle Start Button 3 Then press Main Menu then press Fl Setup Menu 4 Then press F2 New Setup and follow directions on display screen 5 Once a setup 15 install at Main Menu press 2 Run Menu 6 In run settings you can toggle the coolants lines to check the rotation of the Sump Pump Motor CONNECTIONS HYDRAULIC SYSTEM EM edi Wa MAGNETIC WSEPARATOR Z B ze FIXTURE LA FIGURE 1 9 Universal Fixture Optional Rotation of Shaft should be as shown on Motor Cover 7 If rotation 15 incorrect turn OFF power to Machine and reverse any two wires red white or black of electrical supply cord where they connect to Disconnect Block 8 Operate Machine and check rotation of optional equipment according to Installation Instruction package with optional equipment 9 Set up and test all machine functions refer to Section 3 10 After unpacking and installing Machine clean and lubricate refer to Section 4 Routi
19. consuming fixture to spindle alignment process The rotary indexing table can be made to index only through simultaneously touching Palm Buttons on f the machine The control program will only allow this indexing motion at points in the Setup or in Diagnostics Modes where it 15 safe and pertinent to the instructions displayed on the operator control console screen CAUTION Never attempt to activate the Palm Buttons without first reading the display screen These buttons perform different functions at different stages of the setup At some points during the setup and operation the indexing table will only move one station at a time or two at a time 1f you are setup for double indexing At other points during setup the table may continue to move until the required position 15 reached SETUP FIXTURE INSTALLATION This procedure is provided as an overview to align fixture base with spindle For detailed instructions refer to instructions packaged with your fixture To initially align Spindle and Fixture proceed as follows 1 Install Fixture bases at each station on table Roughly align fixtures with hole in table and secure with mounting bolts Snug DO NOT tighten bolts at this time 2 On spindle column mount a dial indicator 3 Close all Guards 4 Turn ON power at Master ON OFF Switch located on Electrical Enclosure 5 Release Emergency STOP Button on Operator Control Console 6 Press POWER ON Button 7 Pres
20. cording to its particular requirements Read Sections 1 2 and 3 thoroughly and carefully before Operating this Machine WARNING ALWAYS have power OFF when doors are open or performing service not requiring power CLEANING Daily after use wipe exterior of the Machine with a clean dry cloth to remove any coolant dust and grime Empty Pail Magnetic Separator as required Monthly wipe with a clean dry cloth Then clean the exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse AIR BLEED PLUG 8mm FILTER d MACHINE FIGURE 4 2 Air Filter Element 13 thoroughly with clean hot water and wipe dry Lightly lubricate following lubrication instructions LUBRICATION Inspect Grease Lines and Fittings monthly for leaks or damaged parts Replace parts as required CAUTION ALWAYS fil grease canister using filling port Ensure no air 15 inside grease canister Grease Lubricating System Fill Grease Reservoir with Sunnen 90123 Kluberplex BEM34 132 or its equivalent see Figure 4 1 Fill grease reservoir through grease fitting with grease gun equipped with air relief valve It 15 important to the operation of the grease pump that no air 1s in the grease reservoir System is equipped with a Pressure Switch which flashes a warning on the operator display screen when the level pressure drops below minimum requirement To bleed system proceed as follows 1 Turn ON machine and
21. der separately Work Area includes Machine Floor Space plus clearance for operator to move around machine 2275 mm Control System Machine Floor Space Foot Print Noise Emission Optional Equipment Inductrial PC w Windows 2210 W x 2056 D x 2275 H mm 87x81x89 5in w o Opt Coolant Sys 4309 kg 9500 Ibs 512 kg sq meter 105 lbs sq ft 400V 460V 60Hz 3Ph CE approved Black Stainless Steel Less than 72 dB A continuous Less than 75 dB A peak Load max noise condition in a typical factory environment Coolant Tank w Magnetic Separator Paperbed Filtration Custom Guarding T Slot Table Rotary Index Table 2 32 position Linear Shuttle Table Air Gage Intergrated Hone Head amp Post Process Gaging w Feedback 2056 mm WORK AREA TOP VIEW DODODODO 71 in x SIDE VIEW 2210 mm VIEW A FRONT VIEW FIGURE 1 A Floor Plan Layout System Configuration Vi SECTION 1 INSTALLATION GENERAL Consult this section when unpacking inspecting and installing Sunnen CNC Vertical Honing Machine see Figure 1 1 Hereafter referred to as the machine TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing of your Machine Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips Screwdriver Std Slip Joint Pliers Forklift INSTALLATION Read the following instructions carefully and thoroughly
22. e USA contact your local authorized Sunnen Distributor Additional information available at hitp www sunnen com or e mail sunnen sunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 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 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
23. hort stroke tight end 3 Run Diagnostic C Replace tool 2 Setup 3 Inadequate oil flow A Adjust Oil Nozzle Out Of Round 1 Undersize honing tool A Replace tool 2 Setup 2 Workpiece flexing thinwall A Decrease feed rate 3 Run Diagnostic B Change method of fixturing 2 C Decrease spindle speed 3 Run Diagnostic D Reduce stock removal 3 Improper tool A Replace tool 2 Setup 4 Excessive float in tool s A Decrease tool float 2 Setup 5 Fixture not properly Aligned A Adjust Fixture 2 Setup Waviness 1 Improper tool length A Use tool with sufficient 2 Setup stone length to bridge waviness in bore Hainbow 1 Improper tool length A Replace tool 2 Setup tool length should be 1 1 2 times bore length 2 Improper overstroke A Shorten overstroke 3 Run Diagnostic 3 Improper tool A Replace tool 2 Setup Rough Finish 1 Improper feed rate A Decrease feed rate 3 Run Diagnostic 2 Improper tool A Replace tool 2 Setup 3 Material loading tool A Inspect amp clean 4 Improper or diluted coolant A Check coolant 4 Scratches in Bore 1 Improper feed rate A Decrease feed rate 3 Run Diagnostic Random 2 Improper tool A Replace tool 2 Setup Improper or diluted coolant A Check coolant 4 NOTE Many honing problems such as poor tool life and rough finish are caused by the following the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full s
24. hould be set on 1 2 thick steel pads Place a precision machinist level on Horizontal Column Guides on right side of machine Lower Frame Assembly and check for level left to right and front to back as shown Adjust Leveling Bolts on Adjustable Feet as required using a 24mm Open End Wrench refer to Figure 1 3 FIGURE 1 2 Fork Lift Repeat for left side of machine Check left to right and front to back and re adjust as required Tighten Jam Nuts to lock bolt in place Adjust center Leveling Bolts on left and right sides of table until they just touches the floor Tighten Jam Nuts on all the feet 10 ATTENTION The Cable Track has been disconnected from column for shipping purposes Reattach Cable Track to top of column using bolt and washer supplied see Figure 1 4 11 ATTENTION Remove Wooden Support added to Machine to restrict movement of Column during transit 12 Wipe all protective shipping oil and grease from Machine Clean rust preservative from way bars and any other bright metal surfaces ELECTRICAL All wiring 15 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 see Figure 1 5 CAUTION This machine was wired for 460VAC If it 1s to be run at 400VAC the taps on the control
25. ing out of ines then refer to Machine Operation Troubleshooting section for corrective action Inspect the ball screw grooves for pitting or wear Any sign of this 1f t occurs in a region where the machine strokes during the honing cycle indicates a failure is imminent and replacement should be planned for the near future Check the tension of the spindle belt Tension used belt until 140 N is applied midspin results in a 5mm deflection Tension New belt until 175 N is applied midspin results in a 5mm deflection CAUTION Belt can be tensioned with the aid of screw placed in the assembly This screw is only to assist in belt tensioning Care must be taken that belt is not over tightened by attempting to tighten this screw Every 10 000 km of Carriage Travel NOTE The control system records cumulative carriage travel If your application runs at recommended stroker speeds 10 000 km of travel will be reached after approximately 7000 hours of run time Re lubricate the carriage runner blocks using Mobil SHC 639 oil The ends of the runner block assemblies have a small set screw that can be removed for the insertion of oil The opening 15 small so a small hose or needle will be needed to squirt oil into the runner block hole Each runner block will need approximately 2 2 ml It will be normal for some of this oil to run out of the runner blocks shortly after re lubrication but much of it will be retained for long term lu
26. instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting Index PROBLEM PROBABLE CAUSE SOLUTIONS SEC Lower feed rate Replace tool Dress tool Increase tool s rpm Check coolant Dress tool Increase feed rate Increase stroking speed Replace tool use softer Tool generates high load Tool not cutting Slow stock removal 1 High feed rate Worn tool Tool Loading Metal particles on tool surface Glazing Improper spindle speed Inadequate tool feed rate Improper tool Inadequate tool s rpm Improper or diluted coolant OU gt O gt gt conditions or with honing operation consult Table 5 grit tool Check coolant Increase spindle speed Increase feed rate Replace tool Increase tool s rpm Check coolant SCREEN Run Diagnostic Setup Setup Run Diagnostic Run Diagnostic Setup Run Diagnostic Run Diagnostic Setup Run Diagnostic Poor stone life Excessive tool feed rate Inadequate tool s rpm Improper tool Improper or dilute coolant Excessive stock removal Excessive float in tool s Worn guide bushings Decrease feed rate Increase tool s rpm Heplace tool Check coolant Decrease stock removal Decrease tool float Replace bushings gt Co Run Diagnostic Run Diagnostic Setup Setup Bellmouth Barrel Short or u
27. inue to follow direction on display screen Select Adapter This will display your tool adapter options Select Tool Family This will display your tool selection options Select Tool 13 Press NEXT and continue to follow direction on display screen Under Honing Options click in the boxes to active Pre amp Post Hone Spindle Rotation This will active grayed out buttons to the left These Honing Parameter are calculated based on pre programmed information Do Not change these settings at this time NOTE To Change Click on parameter you wish to change key in value and press OK 14 Press NEXT and continue to follow direction on display screen Under Feed Options clicking in the box to activate Rapid Until Load will gray out Amount Before Start button to the left and activate Rapid Until Load Button 11 Under Feed Options clicking in the box to activate Auto Bore Detection will gray out Auto Bore Detection Force button to the left and activate Auto Bore Detection Button Click in Auto Bore Detection to activate These Pre Honing Feed Parameter are calculated based on pre programmed information Do Not change these settings at this time 15 Press NEXT and continue to follow direction on display screen Under Feed Options click in boxes for Sizing and Sparkout This will active the related buttons to the left and gray out Amount Before Start button Leave Crosshatch Optio
28. is Warranty does not apply to the following Normal maintenance items subject to wear and tear belts fuses filters etc e 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 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 gt Improper machine setup or operation causing a crash to occur gt 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
29. ixtures used on these machines are custom made for each job Follow installation and alignment procedures packaged with your fixture HONING TOOL All tooling used on these machines are custom made for each job Follow installation and alignment procedures packaged with your tooling DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists Designates this machine is CE compliance Warning Label Warning Strip Warns that no drilling is allowed Drilling any new holes may void warranty Warns that a physical hazard exits and that proper precautions should be taken Caution Label Moving Parts Warning Label Light Warning Label Safety Glasses Warns that a finger hazard exists Do not touch while stroker is operating Warns that power must be OFF when belt guard is opened to prevent injury Warns that safety glasses should be worn at all times when operating this machine Warning Label General Warning NOTES SECTION 3 SETUP amp OPERATION GENERAL This section gives step by step setup and operating procedures for Sunnen Vertical Honing Machine SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around your Machine Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required DO NOT wear loose fitting clothes or jewelry while working on or
30. liminary steps can be helpful nstall and align any fixturing SETUP INDEXING TABLE Some Machines are equipped with a Rotary Indexing Table On top of the table 15 a round Tooling Plate This plate 15 the mounting surface for the workpiece holding fixtures If your fixtures were purchased as part of a complete Honing System it 1s likely that the tooling plate was machined specially to mount the unique fixtures for your application If you are making your own fixtures you will probably have to machine the tooling plate to accept the fixtures you provide If your Sunnen fixtures arrive assembled to the tooling plate then they have also been accurately aligned to the spindles for best honing performance No other alignment should be necessary but be sure to read any special instructions that come with your unique fixtures If you are providing the fixtures or if they are taken off the tooling plate for any reason they must be aligned to the spindles when they are reinstalled The tooling plate 15 bolted and pinned to the rotary indexing table The roll pin provides precise repeatability of location if the tooling plate 15 ever removed If you will be running more than one application on the same machine and 1f those applications use different fixtures 1 15 recommended that each set of fixtures be assembled permanently to a tooling plate In that way the plate can be changed as the setup 1s changed and you can avoid the time
31. location to save file Name the File Then Press Save 29 Press Fl to return to Main Menu 30 Press F2 to access Run Menu 31 32 33 34 Dx 36 Install workpiece in fixture Press F2 Run Settings Click on Machine Tab Toggle ON Coolant Green Under Cycle Mode click Single Press APPLY and then press OK 37 Close all Guards 38 Press CYCLE START button and run a honing cycle 39 Open Guards 40 Remove and check gage workpiece s To edit Press F4 Edit Setup Then press F4 to edit Part Specifications or F5 to edit Column Setup Machine 4 Press OK when finished 42 Press F1 to return to Main Menu 43 Press F2 to return to Run Menu 44 Load parts 45 Continue Honing SAFE SHUTDOWN Turning Machine Off To turn OFF the Machine properly DO NOT just turn off the disconnect switch Please follow the following steps 1 Using the Mouse left click on the Ex that is located in the upper right corner of the screen 2 This will display the exit password dialog box Enter shutdown all lower case and then click on he OK button 3 After a few moments a dialog box will come up on the screen saying that 1t 1s safe to turn off the computer At this time you can turn off the disconnect switch SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures are given as guides only and are not to be construed as absolute or invariable Each machine must be maintained individually ac
32. nbalanced part Improper tool Improper stroke length Excessive float in tool s Worn guide bushings Improper stroke length 2 Improper tool gt Pou gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt m Shorten stroke length Replace tool Shorten stroke length Decrease tool float Replace bushings Shorten stroke length Increase stroke length Replace tool Replace tool N OQ O NONOR NO ANO N Run Diagnostic Setup Run Diagnostic Setup Run Diagnostic Run Diagnostic Setup Setup NOTE Many honing problems such as poor tool life and rough finish are caused by the following the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine 17 TABLE 5 1 Operational Troubleshooting Index cont d SOLUTIONS Taper in Open 1 Improper overstroke A Lengthen overstroke on 3 Run Diagnostic Hole tight end 2 Workpiece and Spindle A Align Workpiece and 3 Run Diagnostic not aligned Spindle 3 Part tool geometry A Readjust stroke position 3 Taper in Blind 1 Improper stroke length A Increase stroke length 3 Hole 2 Inadequate relief in blind end A Provide sufficient relief B S
33. ne Maintenance SECTION 2 PREPARING FOR OPERATION GENERAL MAJOR COMPONENTS Consult this section when preparing the Machine for Consult the following figure for location of major operation components on your machine see Figure 2 1 Read Sections 1 2 and 3 thoroughly and carefully la The Machine Base is equipped with before Operating this Machine Ib Leveling Bolts for stabilizing Machine and lc Stainless Steel Guards 14 Stainless Steel Access Doors Located on both sides of Machine NOTE Power up and start machine to check for proper operation When machine is powered up it should open the Sunnen software es LUBRICATOR 2 OR x COLUMN ENCLOSURE 2A ELECTRICAL ENCLOSURE AA a S SPINDLE ENEE V CARRIAGE MOTOR L BF eee BALL SCREW Fn uu ACCESS DOORS 4C IO DRIVE TUBE STAINLESS STEEL oan GUARD TURN TABLE EBen N E v TURN TABLE Ian LOCKS nn NA 6A TT SUMP PUMP MACHINE BASE BO OPT WORKHOLDING 1B LEVELING i dil BOLTS 8 OPT COOLANT SYSTEM FIGURE 2 1 SV 500 Vertical Honing Machine 5 _ CTRI F RJ RJ 4 P FJ PR FJ 2 soni F17 Fis 9 F20 UNMNEN Fit F12 F14 F s J Fis U Ww X Y PALM BUTTONS PALM BUTTONS FIGURE 2 2 Operator Control Panel
34. nes for other purposes could result in damage to machine and loss of warranty Be sure to work in a well lit area to avoid dangerous unseen conditions which may exist otherwise Use ONLY factory authorized or recommended parts or replacement accessories Using parts or accessories other than those approved by Sunnen could result in damage to machine and loss of warranty Electrostatic discharge can damage the circuitry of the electronic components used in this Machine Use proper electrostatic controls when working with or around electronic components Ground Machine and use wrist strap to reduce the chances of static discharge Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to drain SETUP INITIAL To set up your machine for operation select SETUP from main menu The machine s operating system software will walk you through the setup procedure step by step on the display screen Follow all instructions carefully Special Topics Controls See Section 2 Operator Controls Select amp install Tool See Section 2 Tool Runout See Section 2 Table Setup See separate instructions package with table Fixture Setup See separate instructions package with fixtures Tool amp Fixture Alignment See separate instructions package with fixtures In preparation for going through the setup sequence the following pre
35. ns alone at this time These Post Honing Feed Parameter are calculated based on pre programmed information Do Not change these settings at this time 16 Press NEXT and continue to follow direction on display screen 17 Install Indicator on Column A 18 Pressing NEXT will take you to Column A Station Alignment Screen Follow directions on display screen for aligning fixture Place a workpiece in station 1 Verify tool is out of the way of the indicator Use Palm Buttons to move workpiece to Column A 19 Press NEXT and select Install New Tool and adapter 20 Press NEXT and follow direction on display screen for installing tool NOTE Refer to instructions for Tool Installation 2 Once Tool 15 installed remove Indicator press NEXT and then press YES 22 Set tool SNUG diameter by moving tool around in bore while using handwheel expand tool CW or retract tool CCW until tool feels snug in bore 23 Press TEACH to set Snug Diameter Box to right will turn green and display the snug size 15 set 24 Press NEXT and continue the follow direction on display screen for setting stroke 25 Press NEXT when stroke 15 set and follow directions on display screen for setting load position 26 Press FINISH when stroke 15 set NOTE On multi spindle columns machines repeat steps 13 22 for the remaining columns following the directions on the screen 27 Press Yes to save setup 28 Select
36. operate Lubrication Pump 2 Loosen the air bleed plug by one turn in the counterclockwise direction using an 8mm wrench 3 Air and grease will now emerge from tip of plug 4 When discharge of grease becomes a continuous flow tighten plug and stop pump by turning clockwise 6 Start pump and confirm that there 15 no leakage of grease from the air bleed plug ROUTINE MAINTENANCE SCHEDULE The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements Daily f using Coolant System check coolant level Gage on front of Coolant System and add coolant as necessary CAUTION DO NOT overfill system f using Sunnen Coolant Concentrate check concentration and add water or concentrate as necessary Every 1000 Hours e Remove the lthe sheet metal covers that are attached to the carriage Verify the operation of the lubrication system as follows Remove raise way covers on top of carriage to get to points where grease lines enter ball screw and spindle Disconnect grease lines at these locations Under Diagnostics section of software set lube system to cycle 50 times Verify that grease 15 coming out of grease lines There may be some delay in grease coming out of lines This 15 normal If grease 1s not com
37. ould be closed and latched during operation to prevent accidental interruption of operation from doors being opened Door Latch should be Locked Out and Tagged during servicing to prevent machine from being powered up 2 Turn Master ON OFF Switch to OFF position and open Door Door WILL NOT open unless Master ON OFF Switch 15 in OFF position 3 Open Door to enclosure WARNING You must use the hole provided Drilling any new holes in the electrical enclosure may void the warranty MASTER ON OFF SWITCH NAMEPLATE EL L s m d A CU ELECTRICAL DISCONNECT BLOCK ELECTRICAL DISCONNECT BLOCK 1m HOLE ga 1 li 10 38 UN PRE DRILLED PNUEMATICS OPTIONAL FIGURE 1 6 Pneumatic Connections Optional 4 Remove hole plug located on top left side of the enclosure Then install an oil tight fitting 5 Insert Electrical Supply Cord through Oil Tight Fitting and route to Electrical Disconnect Block 6 Strip 254 mm 10 in off cable s outer jacket 7 Strip 6 mm 1 4 in of insulation off each wire 8 Connect Green Wire GRN to Terminal PE on Electrical Disconnect Switch Earth Ground 9 Connect other three wires to Disconnect Block 1DISC as noted on Block L1 L2 L3 10 Route and secure Cord inside of Enclosure 11 Tighten Oil Tight Fitting 12 Close and secure lock Door to Enclosure 13 Route and connect Electrical Supply Cord to factory main po
38. parts are available through the Unit manufacturer or your local supplier 8 Install Bowl Assembly with O Ring on Unit Rotate Bowl until Button on side of Bowl snaps into place locking Bowl into Unit 9 Connect In Coming Factory airline at Quick Disconnect 10 Turn Red Safety Valve ON 11 Close top access Cover to the Machine 12 Turn ON power to the Machine at Master ON OFF Switch on Electrical Enclosure FILTER HYDRAULIC Optional Change filter on main hydraulic drive unit every six months or sooner if required see Figure 4 4 HYDRAULIC RESERVOIR Optional Change hydraulic fluid in reservoir once each year refer to Figure 4 4 CAUTION Any hydraulic oil used for filing the hydraulic reservoir or priming or filling pump and motor cases must be filtered with a 10 micron filter HYDRAULIC FLUID COOLER Optional The hydraulic fluid heat exchanger located on top of power unit requires cleaning twice a year refer to Figure 4 12 CAUTION If this 1s not done overheating will result Blow air into the coils to clean NOTES GENERAL SECTION 5 TROUBLESHOOTING OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore This section contains Troubleshooting information in table form which should be used when problems occur with machine The table lists problems encountered possible causes and solutions for problems along with reference to section of manual where detailed
39. r information that are only for CE version of this machine The CE version is constructed to meet highest level of safety standards as required by the European Machinery Directive Required for European market this CE version 15 available for any customer The regular version of this machine is quite safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing risks of operator carelessness The SV 500 Series Vertical Honing Machine is to be used for finishing bores in small workpieces In finishing bores this machine can achieve any or all of following results fast stock removal consistent final size a high degree of cylindrically fine surface finish To achieve best results and ensure safe operation ONLY Sunnen Tools and Abrasives are to be used in the SV 500 Series Vertical Honing Machines TABLE OF CONTENTS Page General Information o EE Rae det ded adesse dated ad EP Pd P bea Sooo RSS ase puro 11 ESD Prevention Review ded is RE qa sr ubere Ra E Ed a d s Red apa rds bred s d ad 11 S nnen Limited Product WattadlY 40 0 ues 2 00 40 dlrs rea RESI GR kis ae Ru dad ace urs ee 111 Sunnen software License Abreem e nl L us 0 nn a wh Pe wd e aa eb T X 111 saad Aue TE soos iv INPOHANENOI d rrrTT iv Ji MCPCLc c
40. roceeding Fax 86 21 5 813 2299 e mail sales 9 sunnensh com http www sunnen com e mail sunnen sunnen com PRINTED IN U S A 0807 OCOPYRIGHT SUNNEN PRODUCTS COMPANY 2008 ALL RIGHTS RESERVED
41. s Palm Buttons to HOME the machine 8 Go to Main Menu System Settings and click on Indexing Settings Tab 9 Press Index Positions and select number of positions fixture and press OK 10 Go to Diagnostics Machine and click on Index Table Tab 11 Verify that tooling is out of way of fixtures 12 Press and hold Palm Buttons to position fixture 1 under spindle 13 Open Guards 14 Position indicator so it can sweep a hole or other cylindrical surface on your fixture 15 Turn the spindle by hand with Power OFF and read the indicator Adjust fixture location until precise alignment is achieved The allowable amount of misalignment depends on your application and the type of fixturing used 16 Then tighten mounting bolts NOTE An alternate method 15 to mount a special close fitting alignment bar in the spindle adjust its runout to nearly zero and then use this bar to locate fixture on tooling plate 17 When first fixture 15 aligned advance table to next fixture and align next fixture 18 Repeat with each fixture in turn until all fixture bases are aligned 19 Route and attach airlines to fixtures as needed 20 Attach and position coolant lines at column SETUP TOOL INSTALLATION To set up your machine for operation select SETUP from main menu The machine s control software will walk you through the setup procedure step by step on the display screen Follow all instructions carefully If
42. sed to enter information into the display screen 2a Electrical Enclosure Located on rear of Machine 2b Column Enclosure Located on rear of column 3a The Operator Station houses all electronic hardware and software for hone control It 1s also main operator interface with machine 4a The Spindle Carriage 15 mounted on 4b The Spindle Motor which by way of a belt drives 4c the Drive Tube which imparts stroking and rotational motion from spindle to honing tool Houses feed rod 4d A Ball Screw Stroker Assembly located inside of Column provides stroking power to Spindle Carriage 5a Turn Table opt Located in Base of Machine 5b Turn Table Lock Located on rear of Rotary Table 5c Workholding Fixture opt 6a The Sump Pump pumps coolant from the machine base reservoir 6b A Coolant Interface allows an optional coolant system to be attached to the machine 7 An automatic Lubricator provides grease to the major components of the machine 8 A Coolant System opt can be added to ensure debris 1s removed from coolant TABLE 2 2 Safety Symbols OPERATOR CONTROLS For the location and function of the operator controls refer to Figure 2 2 and Table 2 1 SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 2 WORKHOLDING FIXTURE Install and align Workholding Fixtures according to instructions packaged with fixtures supplied for your particular application NOTE F
43. t This literature provides valuable information for proper installation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it Have Model Number and Serial Number printed on your equipment Specification Nameplate Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding Use of any optional devices equipment between the Drive amp motor output chokes etc For fast service on your orders call Sunnen Automotive Customer Service toll free at 1 800 772 2878 Sunnen Industrial Customer Service toll free at 1 800 325 3670 Customers outside th
44. transformer 1T must be changed All wiring 1s to be performed by a competent licensed electrician in accordance with all local state and federal codes and regulations FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE MACHINE WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY CAUTION Do not attempt to connect machine 1f supply voltage 15 not within acceptable limits as noted on nameplate or electrical specification plate If supply voltage 1s not within these limits MACHINE WILL BE DAMAGED Verify supply voltage 15 same as voltage on Machine Nameplate or Electrical Specifications Plate ELECTRICAL CONNECTION A pre drilled hole has been provided in Electrical Enclosure for Electrical Supply Cord not supplied Connect Cord as follows refer to Figure 1 5 WARNING Residual Voltage exists for 2 3 minutes after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to discharge 1 Unlock Door to Electrical Control Enclosure Loosen Safety Latches on door s to enclosure using a screwdriver JAM NUT LEVELING BOLT m amd PRECISION L MACHINIST LEVEL B Y FIGURE 1 3 Leveling Bolts k TA TY FIGURE 1 4 Cable Track CAUTION Door 15 equipped with lockable Safety Door Latch Door sh
45. trength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine MACHINE OPERATION TROUBLESHOOTING Error Messages The SV Series Machines have built in error messages that will appear on display screen to alert operator when machine has stopped due to an error problem or incorrect setup Problems Solutions WARNING Some troubleshooting procedures require examining parts inside machine enclosure ALWAYS have power OFF when guards are open If problem cannot be diagnosed by Power Off inspection then consult a Sunnen Service Technician PROBLEM Control system gives a message indicating that the grease system 1s out of grease but grease can still be seen in the reservoir SOLUTIONS An air pocket in the grease system can cause this fault Use the following procedure to bleed the air from the system 1 Disconnect all grease lines from their grease injectors 2 Remove all the grease injectors from the manifold 3 In the Diagnostics section of the control software set the grease system to cycle 100 times 4 Watch the open ports in the manifold As soon as grease comes out an open port then install that injector in the open port NOTE If you cannot hear the grease pump cycling then either the pump 15 defective or there 15 a loose electrical connection 5 When all
46. urn ON power to the machine and operate Pump 5 While Pump is operating use hose to spray into open drain to stir up any slug in drain and reservoir NOTE If build up 15 light this will stir up the slug and allow the pump to carry it out of the reservoir 6 Turn OFF power 7 Turn OFF valve and disconnect hose 8 Replace Drain Cover PNEUMATIC LINES CHECK Inspect Pneumatic Lines and Fittings monthly for leaks or damaged parts Replace parts as required Filter Element Replacement The Filter Element in the Airline Regulator should be cleaned or replaced when there is a noticeable drop in air pressure To clean or replace the Filter Element proceed as follows see Figure 4 3 1 Turn OFF power to Machine at Master ON OFF Switch Electrical Enclosure mag tt FILTER ELEMENT BAFFLE EXCHANGER FILTERE FIGURE 4 5 Hydraulic Reservoir 2 Turn Red Safety Valve to OFF and disconnect In Coming Factory airline at Quick Disconnect 3 Bleed any trapped air from filter 4 Remove Bowl Assembly from Unit by holding down on release Button and rotating Bowl Lay Bowl aside for reinstallation CAUTION Use care in disassembling to prevent O Ring from being damaged 15 5 Unscrew Baffle and remove Baffle and Filter Element from Shaft 6 Wipe Bowl and internal parts clean 7 Install new Filter Element on Shaft While holding Filter in place screw Baffle into place NOTE Replacement Elements and
47. wer source 14 Turn ON Master ON OFF Switch PNEUMATICS Optional Connect pneumatic line airline as follows see Figure 1 6 NOTE The Factory Air Supply Line 15 not supplied A minimum of 0 55 MPa 80 psi clean dry compressed air 1s required for proper operation 1 Install Quick Disconnect not supplied in airline port on Airline Filter Regulator 2 CONNECT 1 2 in 13 mm factory air supply line not supplied to Quick Disconnect 3 Airline Filter Regulator Valve This valve 15 preset at the factory to 0 55 MPa 40 psi LUBRICATING SYSTEM The machine is equipped with an automatic grease lubricating system Grease Reservoir 1s filled at the factory with Sunnen 90123 Kluberplex BEM34 132 or its equivalent refer to Figure 1 6 System 15 equipped with a Pressure Switch which flashes a warning on the operator display screen when the level pressure drops below minimum requirement HYDRAULIC CONNECTION Optional Position Hydraulic Unit and connect hydraulic lines see Figure 1 7 and Hydraulic Diagram 1 Connect numbered lines as shown between numbered fittings on side of Machine Base and End of Unit 2 Unit comes filled with DTE25 hydraulic fluid filtered to 10 microns from factory COOLANT SYSTEM Optional The machine comes with a Sump Pump and a base Reservoir Because of the numerous application possibilities the machine 15 not supplied with a coolant system optional Coolant Systems are av
48. y 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 equipment may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing this equipment DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Hepresentative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this m
49. 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 sion or limitation of liabilit
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