INSTRUCTIONS
Contents
1. 14 SECTIONS TROUBLESHOOTING 17 O O O O M 17 OPERATIONAL TROUBLESHOOTING a 17 MACHINE OPERATION TROUBLESHOOTING 18 APPENDIX A TYPICAL COOLANT SYSTEM FLOW DIAGRANMNI 19 APPENDIX B DECLARATION OF CONFORMITY CE 20 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 The Sunnen 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 machines Vi GENERAL INFORMATION amp SPECIFICATIONS SUNNEN SV 2015 2LB SERIES 2 COLUMN VERTICAL HONING MACHINES Diameter Range ID Wo2. JAI 1 TOOLS 1 MAJOR COMPONEN Pose 1 3 P lI I STK u uuu 4 LLIPI S o TE M aas 4 1 97 1 T 4 e NIS ROTE TL ETE 5 COOLANTS S TEE 5 Coolant System RB UIS MAL ds 5 MAGNETIC SEPARATOR OPTIONAL 6 FIXTURE OPTIONAL PET 6 OPERA HONAC EID A LOT 6 SECTION 2 PREPARING FOR OPERATION i 7 T 7 OPERATOR CONTROL PANEL Q u u uu u au tgo vU 7 SECTIONS SE BUP amp OPERA TION 9 C III AP m 9 SAFETY PRECAUTIONS uuu 9
3. 65 05000 768 80000 _ 0262 2568 9000 0228 0700 190000 031496 0800 569 3870 10000 039370 1006 7670 _ 69 1 06 0799 20000 826772 0009 180000 _ HO 90000 19 220000 _ sien 130000 _ 400 9 230000 sne 14060 1980 000 449 240000 _ 6908 15000 _ 522 6006 90252 250000 699 16000 _ 99 70000 FORMULAS MULTIPLY BY TO GET MULTIPLY BY TO GET INCHES in x 254 MILLIMETERS mm MILLIMETERS mm x 0 03937 INCHES in FEET ft x 0 3048 METERS m METERS m x 3 281 FEET ft SUNNENG AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Brazil Sunnen do Brasil LTDA Sunnen reserves the right to change or Phone 55 11 4177 3824 55 11 4362 3083 T www sunnen com br e mail Sbrasil sunnen be revise specifications and product design in 5 Belgium Sunnen Benelux BVBA Phone 32 3 880 28 00 Fax 32 3 844 39 01 connection with any feature of our products wwwsunnenbe email info sunnen be I I China Shanghai Sunnen Mechanical Ltd contained herein Such changes do not NNER Phone 86 21 5813 3990 Fax 86 21 5813 2299 z www sunnensh com mail shsunnen su
4. CAUTION Weight is approx 5756 kg 12 6901b 6 Remove bolts securing machine to skid 7 Using a forklift slide forks minimum 7 feet long under machine as shown Refer to Figure 1 3 Fork Lift Lift machine and install leveling feet Refer to Figure 1 5 Leveling Foot 8 Using a forklift remove machine from skid and move to desired location and lower into place NOTE Machine should be located on a leveled concrete floor away from heavy traffic Allow at least 1 meter 38 inches around enclosure to any adjacent equipment and walls Refer to Figure I A Floor Plan Layout Figure 1 3 Fork Lift 9 Once machine 15 in desired location move main electrical enclosure away from machine base and reinstall straight section of wire way removed for shipping Refer to Figure 1 4 Electrical Wireway ELECTRICAL ENCLOSURE a ii Figure 1 4 Electrical Wireway 10 Place a machinist s level on machine table and level machine by adjusting leveling bolts on the leveling feet using a 24mm open end wrench Adjust leveling bolt in six leveling feet as required Tighten jam nuts to lock bolt in place Refer to Figure 1 5 Leveling Foot Machine does not need to be bolted to floor but should be set on a solid concrete floor of six inch minimum thickness Figure 1 5 Leveling Foot NOTE The cable track has been disconnected from column for
5. D 5 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 SENSITIVE DEVICES MAKE SURE YOU GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY SUNNENG PRODUCTS COMPANY AND ITS SUBSIDIARIES SPC WARRANT THAT ALL NEW SPC HONING MACHINES GAGING EQUIPMENT TOOLING AND RELATED EQUIPMENT WILL BE FREE OF DEFECTS IN MATERIAL AND OR WORKMANSHIP FOR A PERIOD OF ONE YEAR FROM THE DATE OF ORIGINAL SHIPMENT FROM SPC UPON PROMPT NOTIFICATION OF A DEFECT DURING THE ONE YEAR PERIOD SPC WILL REPAIR REPLACE OR REFUND THE PURCHASE PRICE WITH RESPECT TO PARTS THAT PROVE TO BE DEFECTIVE AS DEFINED ABOVE ANY EQUIPMENT OR TOOLING WHICH IS FOUND TO BE DEFECTIVE FROM IMPROPER USE WILL BE RETURNED AT THE CUSTOMER S COST OR REPAIRED IF POSSIBLE AT CUSTOMER S REQUEST CUSTOMER SHALL BE CHARGED CURRENT RATES FOR ALL SUCH REPAIR PRIOR TO RETURNING ANY SPC PRODUCT AN AUTHORIZATION RMA AND SHIPPING INSTRUCTIONS MUST BE OBTAINED FROM THE CUSTOMER SERVICE DEPARTMENT OR ITEMS SENT TO SPC WILL BE RETURNED TO THE CUSTOMER WARRANTY LIMITATIONS AND EXCLUSIONS THIS WARRANTY DOES NOT APPLY TO THE FOLLOWING NORMAL MAINTENANCE ITEMS
6. The machine comes with a sump pump within the base of the machine for return of dirty coolant Because of the numerous application possibilities the machine 15 not supplied with a coolant system however optional coolant systems are available Placement and system requirements will vary with coolant system used Sunnen provides several optional coolant systems Check with your local Sunnen Products Company representative or authorized distributor for available systems or before installing another manufacturer s system NOTE Operating Instructions and Repair Parts Manuals 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 coolant systems manufacturer s instructions Coolant System Connection CAUTION Supply coolant pressure should not exceed 20 psi 0 14 MPa The machine comes with a sump pump within the machine base Intake and outlet connections are located near the bottom of the back of the machine base A flow sensor is installed inline with the supply line connection on the right side of the machine base when viewed from the machine s back A return line without flow sensor connects on the left side of the machine base when viewed from the machine s back COQLART SUPP ne BP Figure 1 9 Coolant System Connection MAGNETIC SEPARATOR OPTIONAL Like the coolant system t
7. 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 e HAVE ALL MANUALS ON HAND THE CUSTOMER SERVICES REPRESENTATIVE OR TECHNICIAN WILL REFER TO IT e HAVE MODEL NUMBER AND SERIAL NUMBER PRINTED ON YOUR EQUIPMENT SPECIFICATION NAMEPLATE e WHERE APPLICABLE HAVE DRIVE MODEL AND ALL NAMEPLATE DATA MOTOR TYPE BRAND AND ALL NAMEPLATE DATA FOR TROUBLESHOOTING ADDITIONAL INFORMATION MAY BE REQUIRED e POWER DISTRIBUTION INFORMATION TYPE DELTA WYE POWER FACTOR CORRECTION OTHER MAJOR SWITCHING DEVICES USED VOLTAGE FLUCTUATIONS e INSTALLATION WIRING SEPARATION OF POWER amp CONTROL WIRE WIRE TYPE CLASS USED DISTANCE BETWEEN DRIVE AND MOTOR GROUNDING e USE OF ANY OPTIONAL DEVICES EQUIPMENT BETWEEN THE DRIVE 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 INFORMATI
8. burrs or bent parts that might affect operation e DO NOT force tools when operating Tools will do a better and safer job when operated at the rate for which they were designed e Turn OFF electrical power when performing service on your machine which does not require power e Disconnect machine from main power supply and allow drives to drain before any work is performed inside of electrical enclosure 9 Ensure all Guards are in place and are in proper working order 9 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 9 Use proper lifting procedures when loading and unloading the machine e Keep all non essential persons clear of work area Visitors especially children should not be permitted near the work area 9 DO NOT use machine for other than its intended use Using these machines for other purposes could result in damage to machine and loss of warranty e Be sure to work in a well lit area e 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 e 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
9. visi ITL 9 SETUP INDEXING zT 9 Machines Equipped with a Rotary Indexing 9 SETUP FIXTURE INSTALLA ION 10 SETUP TOOL INSTALLATION u u uu 10 COLUMN A and B SETUP Specific to Husqvarna Application 11 1 H9 12 SAFE SHUTDOWN TURNING MACHINE OFF a a 12 SECTION 4 ROUTINE MAINTENANCE 13 GENERAD 13 GL DNI M 13 LUBRICATION nasa 13 Grease S USES uuu au 13 ROUTINE MAINTENANCE SCHEDULIE 13 PNU MATICLINES CHECK uuu 14 Filler Element 14 Aes 14 CMe ir uu 14 Filter Element uuu u u u
10. ELECTRICAL All wiring is to be performed by a competent licensed electrician 1n accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate CAUTION This machine was wired for 460V AC If it 1s to be run at 400V AC the taps on the control transformer must be changed All wiring is 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 if supply voltage is not within following acceptable limits as noted on nameplate or electrical specification plate If supply voltage is not within these limits MACHINE WILL BE DAMAGED Verify supply voltage is the same as voltage on machine nameplate or electrical specifications plate located on front of enclosure Electrical Connection A pre drilled hole has been provided in the electrical enclosure for electrical supply cord not supplied Refer to Figure 1 8 Electrical Connection and connect cord as follows PE TERMINA ect 14 ef ga DISCONNECT 4 BLOCK Figure 1 8 Electrical Connection 1 Unlock door to electrical control enclosure using key
11. Inadequate coolant flow A Adjust coolant nozzle 2 Part A Short stroke tight end 3 Material A Use hardtip stone 4 Inadequate relief in blind end A Provide sufficient relief Out Off Round 1 Workpiece flexing thin wall A Decrease feed B Change method of fixturing 17 TABLE 5 1 Operational Troubleshooting continued PROBLEM PROBABLE CAUSE SOLUTIONS Rough Finish 1 Improper feed Improper stone Improper or Diluted coolant Scratches in Bore Random Improper feed Improper stone Improper or diluted coolant Decrease feed Use finer stone Use softer stone Check coolant Decrease feed Use finer stone Use softer stone Check coolant Many honing problems such as poor cutting action poor stone life and rough finish are caused by wrong honing oil insufficient honing oil dirty honing oil or contaminated honing oil Use only clean full strength Sunnen Industrial Honing Oil Verify that honing oil is neither diluted or cut with other oils Keep solvents and cleaning fluids away from honing 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 gua
12. PREPARING FOR OPERATION GENERAL OPERATOR CONTROL PANEL Consult this section when preparing machine for For location and function of operator controls refer to operation Figure 2 1 Operator Control Panel and Table 2 1 Operator Control Panel 1 cese d i 4 5 Figure 2 1 Operator Control Panel TABLE 2 1 Operator Control Panel FUNCTION LCD Display and Touch Operation of the machine can generally be done via the Screen Operator Panel touch screen which means that a function may be started by touching the corresponding key on the screen Left Palm Button Press both palm buttons left and right simultaneously to start cycle Stroker Tool Positioning Select either Tool Position or Tool Feed Mode on Handwheel Operator Touch Screen then Tool Position Mode Dial can be used to position tool vertically in bore up or down Tool Feed Mode Dial can be used to expand or retract stones in bore Emergency STOP Shuts all power to the machine functions OFF Button E Stop Button must be released before power ON button can be pushed available opportunity when any axis is in motion Manual Dwell Button Switch is used to make stroker dwell while machine is honing NOTE Under Run screen Run Settings Control Tab Column A Bore Profile there are five marks in middle of screen that represent five locations in bore Use the up or down arrow keys to move this marker to desired location of dwell When d
13. and use wrist strap to reduce the chances of static discharge 9 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 Machines equipped with uninterrupted power supply UPS please wait 3 minutes before restarting the system after power has been shut off at main power supply 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 SETUP INDEXING TABLE Machines Equipped with a Rotary Indexing Table On top of the table is a round tooling plate This plate is the mounting surface for the work piece 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 take
14. lines APPENDIX TYPICAL COOLANT SYSTEM FLOW DIAGRAM Figure A 1 Coolant System Flow Diagram APPENDIX B DECLARATION OF CONFORMITY CE dide SUNNEN EC declaration of conformity according to the EU Machinery Directive 2006 42 EG Annex II 1 A Manufacturer Sunnen Products Co 7910 Manchester 63143 St Louis Missouri USA Person residing within the Community authorised to compile the relevant technical documentation Julian Hooper Sunnen Products Ltd Centro 1 Maxted Rd HP2BL Hemel Hempstead Hertfordshire Description and identification of the machinery Make SV 2015 2LB 298 2 Spindle Vertical Honing Machine Serial no XXXX It is expressly declared that the machinery fulfils all relevant provisions of the following EU Directives 2006 42 EG 2006 05 17 EU Machinery Directive 2006 42 EG 2004 108 EG 2004 12 15 Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC Reference to the harmonised standards used as referred to in Article 7 2 EN 349 1993 A1 2008 Safety of machinery Minimum gaps to avoid crushing parts of the human body EN 574 1996 A1 2008 Safety of machinery Two hand control devices Functional aspects Principles for design EN 614 1 2006 A1 2009 Safety of machinery Ergonomic design principles Part 1 Termin
15. supplied with machine 2 Turn disconnect ON OFF switch to OFF position and open door Door WILL NOT open unless disconnect ON OFF switch is 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 CAUTION Door is equipped with lockable safety door latch Door should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Door latch should be locked out and tagged out during servicing to prevent machine from being powered up 4 Remove hole plug located on top right side of the enclosure Then install an oil tight fitting 5 Insert electrical supply through oil tight fitting and route to electrical disconnect block Allow for approximately 305 mm of cable from where it enters enclosure then cut off excess Electrical supply must include a proper earth ground 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 earth ground to terminal PE on electrical disconnect switch earth ground 9 Connect other three wires to disconnect block 1DISC as noted on block 11 1 31 2 51 3 10 Route and secure cord inside of enclosure 11 Tighten oil tight fitting 12 Close and secure lock door s to enclosure 13 Remove lock out tag out device Turn disconnect ON OFF switch ON COOLANT SYSTEM
16. 006 A1 2009 EN 61310 1 2008 EN 61310 2 2008 EN 61310 3 2008 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards Safety of machinery Prevention of unexpected start up Safety of machinery Interlocking devices associated with guards Principles for design and selection Pneumatic fluid power General rules and safety requirements for systems and their components Safety of machinery General principles for design Risk assessment and risk reduction Safety of machinery Safety related parts of control systems Part 1 General principles for design Safety of machinery Safety related parts of control systems Part 2 Validation Safety of machinery Emergency stop Principles for design Safety of machinery Positioning of safeguards with respect to the approach speeds of parts of the human body Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs Safety of machinery Electrical equipment of machines Part 1 General requirements Safety of machinery Indication marking and actuation Part 1 Requirements for visual acoustic and tactile signals IEC 61310 1 2007 Safety of machinery Indication marking and actuation Part 2 Requirements for marking Safety of machinery Indication marking and actuation Part 3 Requirements for the location and ope
17. E 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 1 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 1 DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment If specially built automatio
18. Fill grease reservoir with Kluberplex BEM34 132 or its equivalent Refer to Figure 4 1 Lubrication System Fill grease reservoir through grease fitting with grease gun equipped with air relief valve It is important to the operation of the grease pump that no air is In the grease reservoir System is equipped with a pressure switch which flashes a warning on the operator display screen when the level and or pressure drops below the minimum requirement R Figure 4 1 Lubrication System 13 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 9 Check coolant level of attached coolant system and add coolant as necessary e fusing Sunnen Coolant Concentrate check concentration and add water or concentrate as necessary Every 1000 Hours e Remove the large plastic cover and the sheet metal covers that are attached to the carriage 9 Examine the way covers for breaks or tears If the way covers fall down rather than stay in place on the ways then they must be replaced The replacement way cover assembly number is Sunnen SV 32820A NOTE When installing a replacement way cover assembly it is important to note that it is shipped with two screws one in each e
19. I SV 109 ENS SUNNE Installation Setup and Operation INSTRUCTIONS FOR SUNNEN 2 COLUMN VERTICAL HONING MACHINE MODEL SV 2015 2LB READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN SV20152LB 2 COLUMN VERTICAL HONING MACHINES 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 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 THE 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
20. ITHOUT 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 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 EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR ACCIDENTAL DAMAGES AND TO THE EXTENT THIS IS TRUE TH
21. OMPONENTS For location and function of major components on this machine refer to the following list and Figure 1 1 Major Components la The machine base is equipped with Ib Leveling bolts for stabilizing machine and Stainless steel guard doors 2a Column electrical enclosure 2b Machine electrical enclosure 3a The operator station houses all electronic hardware and software for hone control It is also main operator interface with machine 3b The carriage controls Not Shown 4a A ball screw stroker assembly which provides stroking power to Not Shown 4b the spindle carriage which 15 mounted on Not Shown 4c the column assembly which houses Not Shown 4d the spindle motor which by way of a belt drives Not Shown 4e the spindle nose which imparts stroking and rotational motion from spindle to honing tool Not Shown 5a An indexing table optional allows the Not Shown 5b Workholding fixture optional to be indexed and aligned with tool Not Shown 6a The adjustable coolant lines allow manual regulation of honing fluid flow Not Shown 78 The sump pump pumps coolant from the machine base reservoir Not Shown Tb A coolant interface allows an optional coolant system to be attached to the machine Not Shown 8a A coolant system optional can be added to ensure debris is removed from coolant Not Shown 8b Coolant maintenance kit optional Not Shown 9a Gagin
22. ON AVAILABLE AT HTTP WWW SUNNEN COM OR E MAIL SUNNEN SUNNEN COM NOTE SUNNEN RESERVES THE RIGHT TO CHANGE OR REVISE SPECIFICATIONS AND PRODUCT DESIGN IN CONNECTION WITH ANY FEATURE OF OUR PRODUCTS CONTAINED HEREIN SUCH CHANGES DO NOT ENTITLE THE 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 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 STATIC CHARGES C MAKE SURE THAT YOUR WORK SURFACE IS CLEAN AND CLEAR OF UNNECESSARY MATERIALS PARTICULARLY COMMON PLASTICS
23. Press check parts button and set part status on index table 35 Close all Guards 36 Press CYCLE START button and run a honing cycle 37 Open Guards 38 Remove and check gage work piece s 9 To edit Press F4 Edit Setup Then press F4 to edit Part Specifications or F5 to edit Column Setup Machine 38 Press OK when finished 30 Press F1 to return to Main Menu 40 Press F2 to return to Run Menu 41 Load parts 42 Continue Honing SPINDLE sx COLLAR f 9 4 PUSH UP ON SPINDLE COLLAR gt B DISCONNECT WEDGE COLLET NUT MOUNTING 753 FLANGE Figure 3 1 Collet TC TOOLSe Consult the following procedure when installing TC Series Tools HONING TOOL 3 1 Go to Setup Menu Click on Column A Setup and select Tool Then follow directions on screens l Figure 3 2 Install Tool 2 Install collet and collet nut on spindle shaft Refer to SHUTDOWN TURNING 3 Refer to Figure 3 2 Install Tool and Install tool as MACHINE OFF follows NOTE To turn the machine OFF properly DO NOT Just turn off the disconnect switch Please follow the following steps e Insert tool into collet until bottom flange of tool is seated firmly against the bottom of the collet nut making sure there is no gap If the tool is not in the correct position the tool could be positioned down 1 Press SAFE SHUTDOWN button too far
24. SUBJECT TO WEAR AND TEAR BELTS FUSES FILTERS ETC DAMAGES RESULTING FROM BUT NOT LIMITED TO SHIPMENT TO THE CUSTOMER FOR ITEMS DELIVERED TO CUSTOMER OR CUSTOMER S AGENT F O B SHIPPING POINT INCORRECT INSTALLATION INCLUDING IMPROPER LIFTING DROPPING AND OR PLACEMENT INCORRECT ELECTRIC POWER BEYOND 1096 OF RATED VOLTAGE INCLUDING INTERMITTENT OR RANDOM VOLTAGE SPIKES OR DROPS INCORRECT AIR SUPPLY VOLUME AND OR PRESSURE AND OR CONTAMINATED AIR SUPPLY ELECTROMAGNETIC OR RADIO FREQUENCY INTERFERENCE FROM SURROUNDING EQUIPMENT EMI RFI STORM LIGHTNING FLOOD OR FIRE DAMAGE FAILURE TO PERFORM REGULAR MAINTENANCE AS OUTLINED IN SPC MANUALS IMPROPER MACHINE SETUP OR OPERATION CAUSING A CRASH TO OCCUR MISAPPLICATION OF THE EQUIPMENT USE OF NON SPC MACHINES TOOLING ABRASIVE FIXTURING COOLANT REPAIR PARTS OR FILTRATION INCORRECT SOFTWARE INSTALLATION AND OR MISUSE NON AUTHORIZED CUSTOMER INSTALLED ELECTRONICS AND OR SOFTWARE CUSTOMER MODIFICATIONS TO SPC SOFTWARE THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANT ABILITY 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 RE
25. VENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC S LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE SHIPPING DAMAGES EXCEPT IN THE CASE OF F O B BUYER S DESTINATION SHIPMENTS SPC WILL NOT BE LIABLE FOR ANY SETTLEMENT CLAIMS FOR OBVIOUS AND OR CONCEALED SHIPPING DAMAGES THE CUSTOMER BEARS THE RESPONSIBILITY TO UNPACK ALL SHIPMENTS IMMEDIATELY AND INSPECT FOR DAMAGE WHEN OBVIOUS AND OR CONCEALED DAMAGE IS FOUND THE CUSTOMER MUST IMMEDIATELY NOTIFY THE CARRIER S AGENT TO MAKE AN INSPECTION AND FILE A CLAIM THE CUSTOMER SHOULD RETAIN THE SHIPPING CONTAINER AND PACKING MATERIAL SUNNEN SOFTWARE LICENSE AGREEMENT THIS DOCUMENT IS A LEGAL AGREEMENT BETWEEN YOU AS USER AND LICENSEE LICENSEE AND SUNNEN PRODUCTS COMPANY SPC WITH RESPECT TO PREPROGRAMMED SOFTWARE SOFTWARE PROVIDED BY SPC FOR USE ON SPC EQUIPMENT BY USING THE SOFTWARE YOU AS LICENSEE AGREE TO BECOME BOUND BY THE TERMS OF THIS AGREEMENT IN CONSIDERATION OF PAYMENT OF THE LICENSE FEE LICENSE FEE WHICH IS PART OF THE PRICE EVIDENCED BY YOUR RECEIPT RECEIPT SPC GRANTS TO YOU AS LICENSEE A NON EXCLUSIVE RIGHT W
26. Y j VALVE L t aw 1 R GULA OR H t Figure 4 2 Pneumatic Line Check The filter element in the air line regulator should be cleaned or replaced when there is a noticeable drop in air pressure To clean or replace the filter element refer to Figure 4 2 Pneumatic Line Check and proceed as follows 1 Turn power to machine OFF at disconnect ON OFF switch located on the electrical enclosure 2 Turn red safety valve to OFF and disconnect incoming factory air line 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 during disassembly to prevent O ring from being damaged 5 Unthread the 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 thread baffle into place NOTE Replacement elements and 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 incoming factory air line at quick disconnect 14 10 Turn red safety valve ON 11 Turn power to the machine ON at disconnect ON OFF switch located on the electrical enclosure COOLANT LINES CHECK Inspect coolant line
27. and could make contact with the bottom of 2 Then press YES This will allow the machine the bore mounting flange on tool is flush with face to prepare for shut down of collet 3 After a few moments the screen will go 9 Push mandrel up against collet while tightening blank At this time you can turn the collet nut until hand tight disconnect switch OFF e Tighten collet nut to 68 N m 50 ft Ibs using BASIC SETUP IS COMPLETE spanner wrench For a complete list of screen functions and more detailed setup instructions refer to Sunnen SV 124 SE Series Screen Manual shipped with your machine 12 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 according to its particular requirements WARNING ALWAYS have power OFF when hoods 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 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 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 Grease Lubricating System
28. cated on Electrical Enclosure 5 Release Emergency STOP Button on Operator Control Console 6 Press POWER ON Button 7 Press 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 15 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 10 NOTE An alternate method is to mount a special close fitting alignment bar in the spindle adjust its run out to nearly zero see run out adjustment 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 fr
29. d wheel expand tool CW or retract tool CCW until tool feels snug in bore 16 Press TEACH to set Snug Diameter Box to right will turn green and display the snug size is set 11 17 Press NEXT and continue the follow direction on display screen to set spindle speeds feed rates on each tab Helpful hint Use file SAVE AS Windows make changes to new set ups without affecting the current setup 18 Press NEXT and continue the follow direction on display screen for setting stroke use manual stroker function set up found on the honing tab page 19 With Manual stroker function you must also set limits it is also important that you check the lock out bottom of stroke button This will keep the operator from making adjustments to the bottom stroke position due to a blind bore 20 Press NEXT when stroke is set and follow directions on display screen for setting load position 21 Press FINISH when stroke 15 set 22 Repeat steps 17 21 for Column B following the directions on the screen 23 Press FINISH when stroke is set 24 Press Yes to save setup 25 Select location to save file Name the File Then Press Save 26 Press F1 to return to Main Menu 27 Press F2 to access Run Menu 28 Install work piece in fixture 29 Press F2 Run Settings 30 Click on Machine Tab 3 Toggle ON Coolant Green light to check flow and position 32 Under Cycle Mode click Single 33 Press APPLY and then press OK 34
30. g system optional Not Shown Ob Air gage feedback interface optional Not Shown 10 An automatic lubricator provides grease to the major components of the machine Not Shown 118 Tooling optional Not Shown 110 Tool alignment stand optional Not Shown 2b MACHINE ELECTRICAL ENCLOSURE COLUMN ELECTRICAL ENCLOSURE 1c STAINLESS STEEL GUARD 1b LEVELING DOORS FEET 3a OPERATOR STATION 1a MACHINE BASE Figure 1 1 Major Components 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 machine or assembly being described Refer to Figure 1 2 Vertical Honing Machine NOTE When ordering parts for or requesting information about your machine include model number and serial numbers that are printed on the nameplate LEFT FRONT Figure 1 2 Vertical Honing Machine 1 Move machine to staging unpacking area 2 Remove carton and plastic wrap Cut remove and discard shipping bands 3 Remove all loose components from carton 4 Check all components against items ordered 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
31. he SV Machines DO NOT come with a Coolant System The Coolant System is an option and MUST be ordered separately 3 Work Area may vary with machine configurations and options ordered Vii 3081 MM N 836 7 MM 32 9 IN 1038 2 MM 40 9 IN 3200 MM 126 IN TOP VIEW gt rs 2824 MM 3695 MM 111 2 IN 145 5 IN FRONT VIEW SIDE VIEW Figure 1 A Floor Plan Layout viii 2429 MM 95 6 IN SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen 2 Column Vertical Honing Machine hereafter referred to as the machine SAFETY SYMBOLS For a description of safety symbols that may be used on this machine refer to Table 1 1 Safety Symbols TABLE 1 1 Safety Symbols TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing of your machine Knife Hex Wrenches Hammer Open End Wrench Crow Bar Cleaning Solvent Tin Snips SYMBOL DESCRIPTION FUNCTION r3 Warning Label Warns that an electrical hazard exists Warning Label machine Warns that safety glasses should be worn at all times when operating this RI Designates this machine is CE compliant Warning Label Warns that a hazard from objects falling off work table exists and that proper precautions should be taken A Warning Label Warns that an arc flash hazard exists MAJOR C
32. he machine 15 not supplied with a magnetic separator If your application produces large amounts of metal residue it is recommended that you employ a magnetic separator or filter system or both Check with your local Sunnen Products Company representative or authorized distributor for available options or before installing another manufacturer s system FIXTURE OPTIONAL Because of the numerous applications possibilities the machine is not supplied with any fixturing however optional fixtures are available Check with your local Sunnen Products Company representative or authorized distributor 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 1 Release E STOP and press power ON button 2 Power up machine and check rotation of sump pump motor Rotation of shaft should be as shown on motor cover 3 rotation 15 incorrect turn power to machine OFF and reverse any two wires red white or black of electrical supply cord where they connect to disconnect block 4 Operate machine and check rotation of optional equipment according to installation instruction package with optional equipment 5 Set up and test all machine functions Refer to Section 3 Safety and Shutdown 6 After unpacking and installing machine clean and lubricate Refer to Section 4 Routine Maintenance SECTION 2
33. n 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 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 SV20152LB 2 Column Vertical Honing Machines 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 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 TABLE OF CONTENTS 1 uuu uuu hs B B TION u u M vi GENERAL INFORMATION amp SPECIFICA TIONS vii SECTION LINSTALELA TON 1 1
34. n off the tooling plate for any reason they must be aligned to the spindles when they are reinstalled The tooling plate is bolted and pinned to the rotary indexing table The roll pin provides precise repeatability of location if the tooling plate 15 ever removed The rotary indexing table can be made to Index only through simultaneously touching palm buttons on the side of the operator control panel Refer to Figure 2 1 Operator Control Panel The control program will only allow this indexing motion at points in the Setup or in Diagnostics Modes where it is 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 At some points during the setup and operation the indexing table will only move one station at a time the table may continue to move until the required position is 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 lo
35. nd to hold all the spring loaded components together Once the new cover is installed on the ways these two screws must be removed to assure proper operation e Verify the operation of the lubrication system as follows Wipe all excess grease from the ball screw and the ball spline Under the diagnostics section of the software set the lube system to cycle 100 times After this is complete move the carriage up and down once by hand Verify that new grease rings have been left on the ball screw and ball spline The presence of this excess grease indicates adequate lubrication is being delivered e Inspect the ball spline and ball screw grooves for pitting or wear Pitting or wear in a region where the machine strokes during the honing cycle indicates that a failure is imminent therefore replacement should be planned for the near future e Check the tension of the motor and spindle belts Belt tension should be no less than 780 N for used belts A newly installed belt should be tensioned to 1210 N to allow for some relaxation after break in CAUTION Both belts can be tensioned with the aid of screws placed in the assembly These screws are only to assist in belt tensioning Care must be taken that belts are not over tightened by attempting to tighten these screws PNEUMATIC LINES CHECK Inspect pneumatic lines and fittings monthly for leaks or damaged parts Replace parts as required Filter Element Replacement RED SAFET
36. nnensh com entitle the buyer to corresponding www sunnensh com e mail shsunnen sunnensh co Czech Republic Sunnen S R O i Phone 420 383 376 317 420 383 376 316 changes improvements additions SUNNEN PRODUCTS COMPANY s se sumen sumnen oz rance Sunnen replacements for equipment supplies or 7910 Manchester Road St Louis MO 63143 U S A Phone 33 011 89300000 33 0 1 69 9011 11 accessories previously sold Information Phone 13147812100 Fax 1 314 781 2268 Sunnen ltalia U S A Toll Free Sales and Service 1 800 325 3670 Phone 39 02 383 417 1 Fax 390238341750 ella ides IS 2 p International Division Fax 314 781 6128 www sunnenitaia com e uet x nm 99 9 Should iulio Russia S RUS Phone 17 495 95043 43 FaciT 495258 9175 discrepancy of information arise Sunnen witzeriand Sunnen recommends that user verify discrepancy http www sunnen com Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch with Sunnen before proceeding e mail sunnen sunnen com UK Sunnen Products Ltd Phone 44 1442 39 39 39 Fax 44 1442 39 12 1 www sunnen co uk e mail hemel sunnen co uk PRINTED IN U S A 1504 COPYRIGHT SUNNEN PRODUCTS COMPANY 2014 ALL RIGHTS RESERVED
37. ology and general principles EN 614 2 2000 A1 2008 Safety of machinery Ergonomic design principles Part 2 Interactions between the design of machinery and work tasks EN 626 1 1994 A1 2008 Safety of machinery Reduction of risks to health from hazardous substances emitted by machinery Part 1 Principles and specifications for machinery manufacturers EN 626 2 1996 A1 2008 Safety of machinery Reduction of risk to health from hazardous substances emitted by machinery Part 2 Methodology leading to verification procedures EN 894 1 1997 A1 2008 Safety of machinery Ergonomics requirements for the design of displays and control actuators Part 1 General principles for human interactions with displays and control actuators EN 894 2 1997 A1 2008 Safety of machinery Ergonomics requirements for the design of displays and control actuators Part 2 Displays EN 894 3 2000 A1 2008 Safety of machinery Ergonomics requirements for the design of displays and control actuators Part 3 Control actuators EN 894 4 2010 Safety of machinery Ergonomics requirements for the design of displays and control actuators Part 4 Location and arrangement of displays and control actuators 20 EN 953 1997 A1 2009 EN 1037 1995 A1 2008 EN 1088 1995 A2 2008 EN ISO 4414 2010 EN ISO 12100 2010 EN ISO 13849 1 2008 AC2009 EN ISO 13849 2 2008 EN ISO 13850 2008 EN ISO 13855 2010 EN ISO 13857 2008 EN 60204 1 2
38. om 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 additional information is needed at any time during set up refer to the related setup overview which follows Consult the Operating Display Screen manual I SV 124 SE for more detailed Explanation of feature with definitions Machine s control software will walk you through the setup procedure step by step on the view screen Follow all instructions carefully 1 Install Workpiece 2 Release E stop by turning clockwise 3 Press Power ON button NOTE After E Stop Button is pushed Power ON button must be pushed once to reset E Stop relay and again to turn ON control power 4 Once Main Menu display screen appears press Setup Menu 5 Then press F2 New Setup 6 Follow direction on display screen for entering a new setup 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 Key in desired length Press OK to accept MATERIAL Select material Press OK to accept HARDNESS Select hardness Press OK to accept SELECT BLIND BORE OPTION Enter blind bore amount Press OK to accept 7 Press NEXT and continue to Diameters page e Change start and finish diameter for Column A e Change Start and finish Diameter for Column 8 P
39. ostics 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 is with the grease line It either is clogged or has a leak In either case the grease line 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 is 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 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 15 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
40. ower to the machine ON SECTION 5 TROUBLESHOOTING reference to section of manual where detailed GENERAL instructions may be found to correct problems This section contains troubleshooting information in OPERATIONAL TROUBLESHOOTING table form which should be used when problems occur with machine The table lists problems encountered For suggestions on correcting problems with bore possible causes and solutions for problems along with conditions or with honing operation refer to Table 5 1 Operational Troubleshooting TABLE 5 1 Operational Troubleshooting PROBLEM PROBABLE CAUSE SOLUTIONS Stone not cutting 1 Stone Glazing Stone looks clean A Dress stone B Increase feed C Increase stroking speed D Use softer stone 2 Stone Loading A Dress stone Metal particles on stone surface B Increase stroking speed C Use softer stone D Use coarser stone E Check coolant Slow stock removal 1 Improper spindle speed A Increase spindle speed 2 Inadequate stone feed up A Increase feed 3 Improper stone A Use softer stone B Use coarser stone Poor stone life 1 Excessive stone feed up A Decrease feed 2 Inadequate spindle speed A Increase spindle speed 3 Improper stone A Use harder stone B Use coarser stone Bellmouth 1 Improper overstroke A Shorten overstroke 2 Improper stone A Use softer stone Barrel 1 Improper overstroke A Increase overstroke 2 Improper stone A Use finer stone Taper in Blind End 1
41. ration of actuators St Louis Missouri USA 2015 02 06 Place date Signature Michael C Haughey Chief Operating Officer 21 Like any machinery this equipment may be dangerous if used improperly Be sure 10 read anq follow operation of equipment Instructions for MANUFACTURED UNDER ONE OR MORE OF FOLLOWING UHITED STATES PATENTS 8 196 853 26 6 4 428 160 5 178 543 5 255 476 6 074 282 4 796 363 4 809 420 4 856 855 4 993 189 9 022 196 2 185 968 9 209 615 2 222 525 2 234 295 2 243 792 3 2 1 445 0423 606 2 113 417 0 663 866 AFA 8 327 520 6 780 084 7 371 149 7 373 902 Jg ip O51 8 796 859 B 277 2B0 2 348 718 5 358 373 it UTHER Uo AND FOREIGN PATENTS PER DING va COMPANY XT LOWS Nx USA 218 LELIT mmo 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 NOT WEAR COTTON HEAVY GLOVES WHILE OPERATING THIS EQUIPMENT _ 22 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART x INCH x MILLIMETER meter MILLIMETER 00897 00786 0200 08 03090 2068 806 0 76 0400
42. rds 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 15 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 install that injector in the open port NOTE If you cannot hear the grease pump cycling then either the pump is defective or there is a loose electrical connection 5 When all 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 18 6 After all grease lines have been reconnected allow the system to finish the 100 cycles If no faults occur in those 100 cycles then the air has been successfully bled out of the system 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 diagn
43. ress NEXT and continue to follow direction on display screen for Index Table Check all required boxes for table position part status e Thisscreen allows for the setting of the vartous airlines e Active Airlines by clicking in boxes 9 Press NEXT and continue to follow direction on display screen e This screen allows for the setting of the Fixture Interlocks e These settings are calculated based on preprogrammed information Do Not change these settings at this time COLUMN A AND B SETUP SPECIFIC TO HUSQVARNA APPLICATION e Column A Tool Selection This will display your tool selection options e Select Tool Adapter Husqvarna Select Tool Family User Select Tool TC xxxx xx 10 Press NEXT and continue to follow direction on display screen for Column A Setup e Column Tool Selection This will display your tool selection options 9 Select Tool Adapter Husqvarna e Select Tool Family User 9 Select Tool TC xxxx xx 11 Press NEXT and continue to follow direction on display screen for Column B Setup 12 Press NEXT and select Install New Tool 13 Press NEXT and follow direction on display screen for installing tool NOTE Refer to instructions for Tool Installation 14 Once tool is installed press NEXT and then press YES 15 Set tool SNUG Automatic snug is the preferred method used with a multiple spindle machine With manual snug moving tool around in bore while using han
44. rkpiece Length Work Area Envelope Table Carriage Travel Carriage Speed Reciprocation Speed Stroke Column Motor Spindle Speeds Spindle Motor Feed Force Sump Pump Sump Pump Motor Sump Pump Rate Coolant System Coolant Requirements Floor Space Doors Open amp Column at Top of Travel Floor Weight Dry Floor Load Pneumatic Requirements Electrical Requirements Color Noise Emission COLUMN A 3 65 mm 0 12 2 56 in 250 mm 9 8 in 175 175 150 7 7 6 in 630 mm 24 8 in 0 001 to 0 800 mps 2 to 2000 ipm 30 400 spm 7 5 kW 10 hp 100 to 4000 rpm 7 5 kW 10 hp Up to 3800 newtons 850 lbs force COLUMN B 3 65 mm 0 12 2 56 in 250 mm 9 8 in 175x175x150 mm 7x7x6 in 630 mm 24 8 in 0 001 to 0 800 mps 2 to 2000 ipm 30 400 spm 7 5 kW 10 hp 100 to 4000 rpm 7 5 kW 10 hp Up to 3800 newtons 850 Ibs force Centrifugal Pump 0 67 kW 5 hp 208 LPM 4 m 55 GPM 15 feet Optional Sunnen Industrial Honing Fluids 3200 W x 4956 D x 2946 H mm 126 x 195 x 116 in 6668 kg 14700 Ibs 2050 kg sq meter 415 lbs sq ft 5 5 to 6 9 Bar 80 to 100 psi 460V 60Hz 3Ph 400V 50Hz 3Ph Black Stainless Steel Less than 76 dB A continuous Less than 78 dB A peak Load max noise condition in a typical 1 Diameter range length range and workpiece weight are contingent on workpiece and application 2
45. s and fittings monthly for leaks or damaged parts Replace parts as required Sump Tank Cleaning Periodically check and clean sump tank Sump tank should be checked and cleaned if a Sump overflow detected error occurs and is displayed on the control screen Filter Element Replacement Periodically check and clean air intake filter element located on the side of the column and replace as required To clean or replace the filter element refer to Figure 4 3 Air Filter Access Panel and Figure 4 4 Air Filter Element and proceed as follows e y Figure 4 3 Air Filter Access Panel AIR FILTER ACCESS PANEL x E 2 FILTER COVER Figure 4 4 Air Filter Cover 1 Turn all power to machine OFF at disconnect ON OFF switch 2 Remove access panel at the rear of machine by removing four button socket head capscrews refer to Figure 4 3 Air Filter Access Panel 3 Snap filter cover off filter refer to Figure 4 4 Air Filter Cover 4 Remove filter element 5 Clean filter element and filter cover 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 NOTE Replacement elements and parts are available through Sunnen or your local supplier 15 8 Snap filter cover into place over filter element 9 Reinstall access panel 10 Repeat steps 2 9 for each honing column 11 Turn p
46. shipping purposes 11 Reattach cable track to top of column using bolt and washer supplied Refer to Figure 1 6 Cable Track Figure 1 6 Cable Track 12 Wipe all protective shipping oil and grease from machine PNEUMATICS Refer to Figure 1 7 Air Line Routing and connect pneumatic line air line as follows NOTE The factory air supply line 15 not supplied minimum of 0 55 MPa 80 psi clean dry compressed air 15 required for proper operation 1 Connect factory air supply to air line port on filter regulator NOTE Air line port is 1 2 Rc BSPT Figure 1 7 Air Line Routing CAUTION Do not connect machine to any air supply with a pressure greater than 1 4 MPa 200 psi 2 Filter regulator has been factory set to 55 MPa 80 psi Air supply to machine must be at least this or machine s special fixturing and accessories will not operate properly With air supply connected check regulator gage for 55 MPa 80 psi If not set correctly lift knob on top of regulator and turn to adjust After setting correct regulated pressure push knob down to lock LUBRICATING SYSTEM The machine is equipped with an automatic grease lubricating system Grease reservoir 15 filled at the factory with Kluberplex BEM 34 132 or its equivalent System 1s equipped with a pressure switch which flashes a warning on the operator display screen when the level pressure drops below minimum requirement
47. well button is pressed stroker will dwell in that location for two seconds For continuous dwell hold the Dwell Button for the desired length of time Power ON Button Light Turns control power to the machine ON Light illuminates when power is ON 8 USBPor Allows for connection of a USB device Right Palm Button Press both palm buttons left and right simultaneously to start cycle 10 Ethernet Port Optional Allows Sunnen Service personnel to connect to oimotion for diagnostics purposes or to the Internet SECTION 3 SETUP amp OPERATION GENERAL This section gives step by step setup and operating Procedures for Sunnene 2 Column Vertical Honing Machine SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around the machine e Wear proper safety items such as safety glasses and other personal safety equipment as necessary or required 9 DO NOT wear loose fitting clothes or jewelry while working on or around machine e Keep area around machine free of paper oil water and other debris at all times e Keep machine and area around machine cleaned of excessive lubricant and lubricant spills 9 Keep tools and other foreign objects clear of machine while in operation e Keep tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life 9 Inspect Tools before using Check for cracks
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