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1. O gt UJ Adjust coolant nozzle Short stroke tight end Use hardtip stone Provide sufficient relief Decrease feed Change method of fixturing 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 Make sure that honing oil is neither diluted or cut with other oils Keep solvents and cleaning fluids away from honing machine 17 TABLE 5 1 Operational Troubleshooting PROBLEM PROBABLE CAUSE SOLUTIONS Rough Finish 1 Improper feed Decrease feed 2 Improper stone Use finer stone Use softer stone 3 Improper or Diluted coolant Check coolant Scratches in Bore 1 Improper feed Decrease feed Random 2 Improper stone Use finer stone Use softer stone 3 Improper or diluted coolant 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 Make sure that honing oil is neither diluted or cut with other oils Keep solvents and cleaning fluids away from honing machine 18 APPENDIX A COOLANT SYSTEM FLOW DIAGRAM FLOW CONTROL VALVE NOZZLE d TRAY DRAIN LO
2. Designates this machine is CE compliant Warning Warns that a hazard from objects falling off work table exists and that proper Label precautions should be taken Warning Label Warns that an arc flash hazard exists SECTION 2 PREPARING FOR OPERATION GENERAL OPERATOR CONTROLS Consult this section when preparing Machine for For location and function of Operator Controls see operation Figure 2 2 amp Table 2 1 MAJOR COMPONENTS HONING TOOL For location of major components on machine see Assembly and install Honing Tool per instructions Figure 2 1 packaged with Tooling SAFETY SYMBOLS 1 Assemble Honing Tool For a description of safety symbols that may be 2 Slide Honing Tool into Spindle and tighten used on this machine refer to Table 2 1 el 19 M 0 jw i 2 E SUNNEN FIGURE 2 2 Operator Control Panel TABLE 2 2 Operator Control Panel LCD Display and Operation of the machine can generally be done via the touch screen which means Touch Screen that a function may be started by touching the corresponding key on the screen Operator Panel Cycle Stop the honing cycle STOP Button Cycle Start the honing cycle when the machine is in AUTO START Button Manual Feed Manual expand or retract tool Switch Manual Stroke Manual movement of the carriage for setup left right movement Left Right Buttons Acknowledge Used in conjunction with Manual Stroke Buttons
3. C Y A KS BZ wn LI per FT 16 Press Spindle Options Icon next icon on bottom bar Accept Spindle Options setting No action required Spindle Option Icon on bottom bar will be green A gel 17 Click Close on bottom right of screen v 8 2 NN c OL A B 3 2 8 5 5 82 Mi I 0 1 En E BE unio ME E I en i a 0 000 in 62 992 in Main Screen will appear BASIC SETUP IS COMPLETE For a complete list of screen functions and more detail setup instructions refer Sunnen HTE Screen Manual shipped with your Machine SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements WARNING Turn OFF electrical power when performing service on your machine which does not require power Disconnect Machine from main power supply before any work is performed inside of Electrical Enclosure 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 CLEANING Daily Wipe ex
4. so Spindle and Drive Pulleys remain aligned PNEUMATIC LINES CHECK MONTHLY Trace out Pneumatic Lines and inspect for leaks severe dents or kinks Tighten any leaking Fittings and replace damaged parts COOLANT LINES CHECK MONTHLY Trace out oil Lines and inspect for leaks severe dents or kinks Tighten any leaking Fittings and replace damaged parts COOLANT RESERVOIR Clean Coolant Reservoir and replace Coolant as follows using only Sunnen Industrial Honing Oil see Figure 4 4 1 Direct one or more Coolant Nozzles into an approved waste container 2 Open Coolant Control Valves 3 Power up the Machine 4 Go to Run Screen 5 Press Coolant ON Button and pump waste coolant into waste container 6 As coolant flow drops off press Coolant ON Button 7 Press E Stop and turn OFF all power to the Machine 8 Close Coolant Control Valves 9 Return Coolant Nozzle s to Work Tray 10 Slide Reservoir out from under the Machine 11 Dip or siphon out any remaining coolant from j the Reservoir l 12 Clean Sludge from Reservoir and wipe clean 5 i S 13 Fill Reservoir by pumping or pouring only approved Sunnen Industrial Honing Oil into the WE Coolant Reservoir FIGURE 4 5 Filter Element 14 Slide Reservoir under the Machine OPTIONAL LIGHT CURTAIN CLEANING Accumulation of oil dirt and grease on the front filter of the light curtain tr
5. Never insert test object into dangerous parts of machine 3 Recover from Light Curtain Trip fault Press the flashing Blue button to reset the machine 4 Press the AUTO software key on Main Menu to prepare machine for a cycle 5 With machine at rest interrupt detection zone with test object 6 With detection zone interrupted press CYCLE START button Machine should not start with the test object in detection zone 7 Verify that system is working properly With machine running interrupt detections zone with test object Machine must come to a quick controlled stop when light curtain is interrupted Drive faults spindle coasting and stroker coasting are unacceptable OPERATIONAL CHECK Read Sections 1 and 2 thoroughly and carefully before performing Operational Check 1 Operate Machine and check proper function Spindle Coolant Pump and any optional equipment 2 Set up and test all machine functions refer to Section 3 Setup amp Operation 3 After unpacking and installing Machine clean and lubricate refer to Section 4 Routine Maintenance OPERATOR LIGHT Ser CONTROL CARRIAGE re CURTAIN ELECTRICAL ENCLOSURE Au ji COOLANT j FILTER RESERVOIR UNITS FIGURE 2 1 Major Components TABLE 2 1 Safety Symbols SYMBOL DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists CN Warning Label Warns that safety glasses should be worn at all times when operating this machine
6. supply lines to machine Connect coolant intake supply lines to Filter Unit Route and connect Pump Electrical Plug to Main Electrical Enclosure 14 Loosen bolts securing Electrical Enclosure to Machine Base 15 Using a machinist level level machine by adjusting Leveling Setscrews in feet using a 1 1 8 Open End Wrench as follows NOTE Way Bars should be level within 005 ft which is one mark on a Starrette No 98 Level Install steel Pads under Support Feet Start by getting the base level across the Way Bars at both ends Then raise the low end to level the base along its length For permanent installation secure Machines Support Feet to Floor with appropriate fasteners not supplied 16 With Electrical Enclosure resting on its feet tighten bolts securing Enclosure to Machine Base 17 Clean Spindle Carriage Ways with solvent to remove antirust and any foreign materials Lightly lubricate with Mobil Way Oil 300 or equivalent All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate Bg B 8 E gt pum d 5 1 Eg RIGIIDRE 1 5 Eiltar lin it IVA ihe me J 5 E sli tO xy i a L J O mE a FIGURE 1 9 Manual Chuck
7. table lists problems encountered possible causes and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting PROBLEM PROBABLE CAUSE For suggestions on correcting problems with bore conditions or with honing operation consult Table 5 1 SOLUTIONS Stone not cutting Slow stock removal 1 Stone Glazing Stone looks clean 2 Stone Loading Metal particles on stone surface Improper spindle speed Inadequate stone feed up Improper stone Dress stone Increase feed Increase stroking speed Use softer stone Dress stone Increase stroking speed Use softer stone Use coarser stone Check coolant Increase spindle speed Increase feed Use softer stone Use coarser stone Poor stone life Bellmouth Barrel Excessive stone feed up Inadequate spindle speed Improper stone Improper overstroke Improper stone Improper overstroke Improper stone Decrease feed Increase spindle speed Use harder stone Use coarser stone Shorten overstroke Use softer stone Increase overstroke Use finer stone Taper in Blind End Out Off Round Inadequate coolant flow Part Material Inadequate relief in blind end Workpiece flexing thin wall gt gt D gt DID PIP gt 0 gt gt gt u gt gt PII O gt
8. 000 49 64 039370 10000 13 2 103188 25 82 111906 27 64 00756 15875 11 0000 51 84 1 9844 7116 111125 13 16 078740 2000 29 64 11 5094 2 3813 15 92 119063 53 64 27781 120000 27 2 s temo 3000 31 64 123081 55 64 31750 12 12 7000 3 5719 13 0000 78 3 9688 33 64 13 0969 57 64 e 187480 4000 17 32 34938 4 3656 35 64 136906 20 82 4765 140000 58 64 196850 5000 ene 142875 15 16 5 1594 37 64 146844 55553 150000 61 84 59531 19 32 150813 3182 Ll 236220 60000 3964 15 4781 6 500 58 15 8750 63 64 6 7469 16 0000 r9 70000 4 64 6278 1 16 FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS m MULTIPLY BY MILLIMETERS mm x 0 03937 METERS m 3 281 TO GET INCHES in FEET ft INCHES in FEET ft BRAZIL SUNNEN DO BrasiL LTDA Phone 55 11 4177 3824 Fax 4 55 11 4362 3083 www sunnen com br e mail Sbrasil sunnen be BELGIUM SUNNEN BENELUX BVBA Phone 32 3 880 28 OO Fax 32 3 844 39 O1 www sunnen be e mail info sunnen be CHINA SHANGHAI SUNNEN MECHANICAL Co LTD Phone 86 21 5813 3990 Fax 86 21 5813 2299 www sunnensh com e mail shsunnen sunnensh com CZECH REPUBLIC SUNNEN S R O Phone 420 383 376 317 Fax 420 383 376 316 www sunnen cz e mail sunnen sunnen cz FRANCE SUNNEN SA Phone 33 0 1 69 30 OO OO Fax 33 0 1 69 30 11 11 www sunnen
9. 1 1 Lifting Machines lt ol Console FIGURE 1 2 Operator Contr INSTALLATION Read the following instructions carefully and thoroughly before unpacking inspecting and installing the 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 1 Remove heavy duty plastic wrap from around shipping crate WARNING Use safety glasses or goggles when cutting bands 2 Cut remove and discard shipping bands 3 Remove Components from crate 4 Remove items shipped inside Coolant Reservoir 5 Remove nuts and bolts securing Hone to bottom of crate 6 Lift Hone and Enclosure from crate using a fork lift 7 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 8 Place Machine in desired location using a fork lift see Figure 1 1 9 Remove all packing materials 10 Position Operator Control Console see Figure 1 2 Slide Console into Mounting Bracket on side of machine Align Console and tighten two 2 Setscrews in Mounting Bracket 11 If not installed Install and position optional Steady Rest on carriage ways see Figure 1 3 di eel 1 impair L__ 12 Install Coolant Reservoir under machine and connect coolant hoses Connect coolant outlet
10. 5 75 in Workholding Fixture Dependent 1 600 mm 63 in 1 500 mm 59 in 0 75 kW 1 hP AC gear motor variable speed controlled 5 2100 rpm 2 17 kW 2 9 hP belt drive 1 30 mpm 3 3 98 4 fom 0 42 kW 0 56 hP Servo Controlled linear push pull 182 L 48 gal Sunnen Industrial Honing Fluids Manual paper bed filter with two PF filter Computechnic Touchpanel OF 12270 English German Italian French Spanish 5190 L x 1482 W x 1406 H mm 204 x 58 3 x 55 4 in opindle center height to floor 1 100 mm 43 3 in 1240 kg 2733 7 lbs 460V 60Hz 3Ph 400V 50Hz 3Ph 20 lpm 0 65 0 85 MPa 5 3 pgm 94 123 psi Diameter range length range and workpiece weight are contingent on workpiece and application Dependent on Workholding Fixture option contact your local Sunnen Field Service Engineer Vii 0 0 108 0 FLOOR PLAN Sunnen Tube Hones viii SECTION 1 INSTALLATION PURPOSE This Section is designed to aid user in unpacking inspecting and installing Sunnen Tube Hone models HTE 1600 Hereafter referred to as the Machine TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing machine Wire Cutters Strippers Knife Screw Driver Std nose Hammer Slip Joint Pliers Crowbar Cleaning Solvent Tin Snips Hex Wrench Metric Open End Wrenches Machinist Level accuracy 0005 ft 55 FORKS POSITION FIGURE
11. Button RESET Press to reset machine after recovering from a fault EMERGENCY Stop the machine in a emergency situation STOP NOTES SECTION 3 SETUP amp OPERATION GENERAL This section describes a step by step operating procedure for the Machine Prior to starting the Machine Operator shall ensure All prerequisites described in sections and 2 are complete All personnel are clear of machine SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel while working on or around the Machine Always follow proper lockout tagout procedures DO NOT initialize the system with a connected honing tool e Stay clear of all moving parts Remove keys and wrenches from machine before honing Ensure all guards are in place before operating Ensure area is clear of other personnel before operating machine e Keep loose tools and other foreign objects clear of machine Wear proper safety items such as safety glasses gloves non slip safety shoes and other personal safety equipment as necessary or required DO NOT wear loose fitting clothes or jewelry while working on or around machine When lifting Work piece or tooling use proper lifting procedures Turn OFF Power Switch on Electrical Enclosure when ever performing service and no power is needed Turn OFF electrical power at Main Power Source when performing maintenance on or cleaning of Ele
12. E 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 without rig
13. I HTE 600 SINNEN ORIGINAL INSTRUCTIONS Installation Setup and Operation INSTRUCTIONS for SUNNEN HTE SERIES TUBE HONE Model HTE 1600WE WCE amp HTE 1600WG WCG READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN TUBE HONE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information for proper installation operat
14. N yd 17 Operational Troubleshooting KK KK KK KK KK KK KK KK 17 APPENDIXES A Coolant Flow Diastam 24 2 4558 40 aA 22k k8 rs roedd Deed bee Node die nS pa eq aa 19 B D claration or CODLOPHITD o cak s E h a 0 bo RUE Q0 OR 0 50 HOS OS EEO EE rb diha kn dad 21 INTRODUCTION This Instruction Manual is provided to give the information required to install operate and maintain the Sunnen HTE Series Tube Hones models HTE 1600 As there are numerous Workpieces that can be honed on this machine all possible combinations cannot be discussed here The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop When ordering parts for or requesting information about your machine include the serial number of your machine READ THE FOLLOWING INSTRUCTION THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN TUBE HONE Vi GENERAL INFORMATION amp SPECIFICATIONS WORKPIECE Y RANGE ID WORKPIECE RANGE 0D MAXIMUM STROKE LENGTH MAXIMUM BORE LENGTH SPINDLE MOTOR SPINDLE SPEED STROKE MOTOR STROKE RATE FEED MOTOR COOLANT CAPACITY COOLANT REQUIREMENTS FILTER SYSTEM CONTROLS LANGUAGES FLOOR SPACE FLOOR WEIGHT Dry ELECTRICAL REQUIREMENTS PNEUMATIC REQUIREMENTS SUNNEN HTE SERIES TUBE HONES HTE 1600WE HTE 1600WG 4 19 0 1
15. Note model electrical supply requirement printed on machine nameplate or electrical specification plate Do not attempt to connect machine if supply voltage is not following acceptable limits as noted on nameplate or electrical specification plate If supply voltage is not within these limits MACHINE WILL BE DAMAGED 1 Verify supply voltage is same as voltage on Machine Nameplate or Electrical Specifications Plate 2 Route and connect Electrical Supply Cord to power source see Figure 1 8 PLUG Machine s Electrical Supply Cord into a properly polarized grounding type wall receptacle OPTIONAL ACCESSORIES Optional Manual Chuck Sunnen offer an optional Manual Chuck To install the Manual Chuck proceed as follows see Figure 1 10 e Mount Fixture to Plate on Threaded Column and Base Assembly using four Mounting Bolts supplied Requires 8mm Hex Wrench Optional Pneumatic Chuck Sunnen offers an optional Pneumatic Chuck For installation refer instructions packaged with the Pneumatic Chuck Optional V Block Chain Fixture Sunnen offer an optional V Block Chain Fixtures for use on the HTE Tube Hone Optional Coolant Cup Sunnen offers an optional Coolant Cup Kit for use on the HTE Tube Hone Optional Coolant System Sunnen offers an optional OT SVF Coolant System Adapter Kit for use on the HTE Tube Hone Optional Automatic Size Control Sunnen offers an optional Automatic Size Control System for use on the HTE Tube Hone
16. Optional Automation Interface Sunnen offers an optional Part Handling Automation Interface for use on the HTE Tube Hone Optional Transformer Sunnen offers an optional 230 VAC 60 Hz 3 phase to 460 VAC 60 Hz 3 phase Transformer for use on the HTE Tube Hone Status Indicators af the reoolver Status indleaters of tha sander LIGHT CURTAIN ma receiver nas six LES which indicate the operating status The sender bees bo LEDS which ids the operating shabu tem LED col Indicator Lattin Bem Indicata red green DEED status indicator ar 1 vedo Status indicator Faun indication ERA 2 Red Fauft indication Arment quality 12 314 Blue LEDS in combination with the red Tlasming ERA LED asso denote Tault imdications Optional Splash Guards Sunnen offers optional Splash Guards for use on the MOUNTING HTE Tube Hone BRACKET OPTIONAL CE GUARDING This CE guarding option would have been offered to you by your Sunnen sales representative at the time of sale If this option was not offered to you and you wish to have this installed or need more information please contact Sunnen Products Company LIGHT IMMEDIATELY prior to powering up the machine i CURTAIN CE Machines Only CE machines come with optional Light Curtain and CE Guarding installed Light Curtain alignment must be tested for proper function after machine installation To check procee
17. W PRESSURE RELIEF VALVE f FILTER CANISTER DIRTY OIL CLEAN OIL t COOLANT RESERVOIR FIGURE C 1 PF 401 Filter Unit 19 NOTES 20 APPENDIX B DECLARATION OF CONFORMITY CE aA SUNNEN HTA 0000 1001 EC Declaration of Conformity According to the EU Machinery Directive 2006 42 EG Annex Il 1 A Manufacturer Sunnen Products Co 7910 Manchester 63143 St Louis Missouri USA Person residing within the Community authorized 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 HTA XOOOCE 0 meter Horizontal Hone Serial No 1001 Project Number XXXXX Project Name HTA Itis expressly declared that the machinery the machinery fulfils all relevant provisions of the following EU Directives 2006 42 EG 2006 05 17 EU Machinery Directive 2006 42 EG 2006 95 EC 2006 12 12 Voltage limits Directive of the European Parliament and of the council of 12 December 2006 on the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits codified version 2004 108 EC 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 Refe
18. able at hitp www sunnen com or e mail sunnen sunnen com NOTE Sunnen reserves the un to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges C Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics D Anti s
19. ad and follow operation of equipment to MANUFACTURED UNDER ONE OR MORE DF THE FOLLOWING UNITED STATES PATENTS 4 428 160 4 796 353 41 909 220 4 966 955 4 993 199 3 022 196 5 183 969 2 209 015 2 222 525 2 234 295 oes 792 5 178 643 5 255 476 J a EO ALE 2 433 555 2 41413 411 7 563 856 3 7117 275 6 074 232 8 327 620 6 740 034 7 371 149 7 375 802 7 127 051 instructions for 8 096 853 2 056 579 8 277 280 2 044 718 2 500 073 OTHER U S AND FOREIGN PATENTS PENDING SS ee ee EE O ee ee ee ee ee Sian TUNNEN FEDODCT LIOBRHPBAMY EXT LIIS wo LT WARNING An Arc Flash Hazard Exists Follow safe work practices and wear appropriate Personal Protective Equipment Follow proper lockout tagout procedures Failure to comply can result in death or injury DO NOT WEAR COTTON OR HEAVY GLOVES WHILE OPERATING THIS EQUIPMENT IL1198 PNP520 23 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART ze ss 2 Z O MILLIMETER ERACTION DECIMAL MILLIMETER FRACTION DECIMAL 009087 01000 92 7 1438 21 32 Ll 007874 02000 19 64 7 5406 omem osoo sn 7 9875 4364 03999 s oooo 11 16 015748 04000 2164 8 3344 45 64 019685 05000 11 32 8 7313 023622 06000 9 0000 23 32 027559 07000 2364 9 1281 47 64 07998 sie 9 5250 001496 08000 25 64 9 9219 34 035433 0 9000 100
20. ansmitter and receiver can affect the system operation Clean filters with a mild detergent or glass cleaner Use a clean soft lint free cloth Painted light curtain surfaces may be cleaned with a mild de greasing cleaner or detergent COOLANT FILTER UNIT To replace Filter Element on Optional Filter Unit proceed as follows see Figure 4 5 1 Turn OFF power to the Machine 2 Place a suitable waste container under Draincock 3 Open Air Vent in Canister Cover 4 Open Draincock on bottom of Canister and drain about 4 Liters of Coolant from the Canister 5 Close Draincock and Air Vent 6 Loosen Cover Clamp Ring and remove Cover Clamp Ring 7 Slowly pull dirty Filter Element out of Canister and place in the waste container to drain 8 Insert new Filter Element into Canister rotate element slightly so it will slide down the center post easily 9 Replace Canister Cover and Cover Clamp Ring Then tighten Ring 10 Open Air Vent in Filter Canister Cover 2 turn counterclockwise 11 Switch the Coolant ON OFF Key ON As coolant fills the Filter Canister air will escape through the air Vent When coolant appears in the partially opened Vent close the Vent Then wipe any coolant from around Vent 15 NOTES GENERAL This section contains Troubleshooting information in table form which should be used when problems SECTION 5 TROUBLESHOOTING OPERATIONAL TROUBLESHOOTING occur with machine The
21. are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE ORSCONDEINTS 023440455505 cou en eee dime Pe quads V LIST OF APPENDIXES eeee Rh RR hh hh hh hh hh V INTRODUCTION 22240286008 Ba a PUB Behe LEME MIM II I I I DDMDMDMDMD gt D vi GENERAL INFORMATION SPECIFICATIONS vil FLOOR LAYOUT 0 80 08 viii AE P Nue c 1 gt ggpg e 5X5Xb59b vbbvDn 55 85 r mm 1 Toone amp Materials 2 22223 54542855800 eras e soe RESO od eee ie doses bas wee 1 111 1 92 5 59 9 8 A 1 Electrical RequitenietilS uu a e debes lb does ob ica aa ads 2 OBDDDOLXOCEBSOLIOS 27 6 m 3 Optional Light Curtain s ss kk k db Ea ya elb l deh y nes 4 Light Curtain Function Check osorno di ar bda vex ud ace ad eid a4 4 Operalionalicheek oras eo ol added a o aaa E citas e 5 PREPARING POR OPERATION 422524 sk k W o d
22. ctrical Enclosure Clean up lubricant spills immediately SETUP amp OPERATION The following Setup and Operating procedure is provided as an example The Setup and Operating procedure for machine and application may vary For a complete list of screen functions and more detail setup instructions refer Sunnen HTE Screen Manual shipped with your Machine Start Up 1 Turn ON Main Power Switch 2 Release all Emergency STOP Buttons 3 Press RESET Blue Button on Control Panel NOTE Machine automatically comes up in Manual Mode when Machine is initialized 4 Once machine has initialized and the Main Screen comes up precede to Setup Workpiece Setup Workpiece To install a new workpiece proceed as follows ae Workpiece BS SETUP 4 10 14 i seen ZEY Tool LFT D10P70 9 s Em E co 660 ja cy 2 3 8 ay E lt gt EaR imin coB 3E 2 8 gt 1 Press Workpiece Setup Icon on bottom of Main Screen Wool LFT G10P75324 Ta BIE 95 2 Press New Workpiece Icon on bottom of Workpiece Setup Screen 3 Enter Job Name and Press OK 19 37 40 y 15 34 12 3 Worktime 0 00 Worktime 0 00 66 ft min 4 Enter Bore End Diameter 7 Enter Start Position Example 742 en Example 0010 19 38 58 y Worktime 0 00 E BC Sui xi ei Fh 2 E Select tool from the tool library Only tools according to the diameter range are li
23. d as follows see Figure 1 10 1 Install Guarding see Figure 1 11 2 Mount Light Curtain Bars to Machine Base using the hardware provided see Figure 1 11 e Check for signs of external damage to the light curtain transmitter receiver or cables and wiring 3 Connect Light Curtain Cables to Light Curtain Receiver and Transmitter e Inspect electrical connections between guarded machine s control system and light curtain Verify they are properly connected LIGHT CURTAIN MOUNTING HARDWARE 4 Turn on power to machine 5 Verify that curtain is in alignment Individual beam indicators located on receiver will illuminate when alignment of a beam is not met refer fo Figure 1 11 LIGHT CURTAIN FUNCTION TEST CE Machines Only Check Light Curtain operation as follows see Figure 1 13 FIGURE 1 12 Light Curtain Alignment CAUTION As a safety precaution it is recommended that the tooling be removed during this test A honing cycle will be initiated during the test and even through the cycle should not start there 1s always potential that it could 1 Interrupt light curtain system with proper size test object Test object size 30 mm diameter When using the test object guide it through the detection zone as shown below 2 Start machine While machine 1s 1n motion interrupt detection zone with test object Machine should stop immediately
24. d tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply Electromagnetic or radio frequency interference from surrounding equipment EMI RFI Storm lightning flood or fire damage Failure to perform regular maintenance as outlined in SPC manuals 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 INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENU
25. fr e mail info sunnen fr ITALY SUNNEN ITALIA S R L SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or gt SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Road St Louis MO 63143 U S A Phone 1 314 781 2100 Fax 1 314 781 2268 R L U S A Toll Free Sales and Service 1 800 325 3670 poor cians ME E com TN International Division Fax 314 781 6128 POLAND SUNNEN POLSKA SP Z 0 0 Phone 48 22 814 34 29 Fax 48 22 814 34 28 www sunnen pl e mail sunnen Q sunnen pl RussiA SUNNEN RUS Phone 7 495 258 43 43 Fax 7 495 258 91 75 www sunnen ru e mail sunnen sunnen russia ru SWITZERLAND SUNNEN AG Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch UK SUNNEN PRODUCTS LTD Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk COPYRIGHT SUNNEN PRODUCTS COMPANY 2014 ALL RIGHTS RESERVED accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that u
26. ht 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 exclu sion or limitation of liability for consequential or accidental damages and to the extent this is true the above limitat
27. ion 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 the USA contact your local authorized Sunnen Distributor Additional information avail
28. ions may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any equipment may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing this equipment DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment If specially built automation components
29. ra ear ados desa 7 11 6 9 E 7 Major Components 25 122 5s 00 100000 Pad arena search 7 Sally SVM0 lS aa e nn Ben e o pede B64 n 7 Operator COMICS avere eds ee ee eels Keen er o WEL ee eee eee ete er 7 Homme TOOL sn zen aueh E ee ae a ds HNH J JM 7 SEIUP AND OPPERALEJN S yy dd Rane be aaa 9 General sapos soso Pa dee 9 Safety Precautions 6 2 522 209 3 5 9 9 k A lata BOGE ee Fedora ea S rina 9 Delp e OPELAUON 1222 oa O hee E se poe E eds bungee EU NE qupd mad dE EE NS 9 FOCIINEMAINTENANCE 231952 2991399 22 0 293 23 309 hoe ee 13 E rr 13 AA O 5 5 13 1 11111 111 11 22 2 2 6 9 sand ea picado y be eee ee ir 13 LING a 14 Coolant Line Check sa ss sa2 rear Sul na Eb 3 PEE HIE Dan saure 4444544400008 2 14 COOL DER in eTTP T 14 Light Curtam C eant ss aska szay ewan ees igd Rebar Q hdd 8 d dR EOS ad eee 9 54 14 Coblant tte WGN d P 15 TROUGLESHOOUING sun can 208 ss tas see Pad en Wi lav le ide edes 17 E ql O Ro A A
30. rence to the harmonized standards used as referred to in Article 7 2 EN 349 1993 04 Safety of machinery minimum gaps to avoid crushing of parts of the human body EN ISO 12100 1 2003 11 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 2003 11 Safety of machinery Basic concepts general principles for design Part 2 Technical principles EN ISO 13850 2006 1 1 Safety of machinery Emergency stop Principles for design EN 5 1385 6 2008 03 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs EN ISO 14121 1 2007 Safety of machinery Risk assessment Part 1 Principles 1EC60204 1 2005 A1 Safety of machinery Equipment electrics of the machines Part 1 General rules EN 60439 1 1999 A1 Low voltage switchgear and control gear assemblies Part 1 Typetested and partially type tested assemblies EN 953 1997 10 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards Reference to the technical standards and specifications used EN ISO 13849 1 2006 11 Safety of machinery Safety related parts of control 2 Part 1 General principles for design N Signature St Louis Missouri USA 2010 04 08 o Mike Haughey Chief Operating Officer 21 NOTES 22 Like any machinery this equipment may be dangerous if used improperly Be sure re
31. ser verify discrepancy with Sunnen before proceeding http www sunnen com e mail sunnen Osunnen com PRINTED IN U S A 1404
32. sted Example LFT GL8P75412 pe sna 193432 4 w Worktime 0 00 WP v lA 8154 Tool Setup Icon on bottom bar will turn green E e NE 8 Press Sizing Method Icon next icon on bottom Worktime 0 00 bar 5 gt A BIC EH a Fil P v 6 Press Stroke Position Icon next icon on bottom bar 10 O 2 E Enter Maximum Time in minutes Example 10 00 V lid il o Tool Sizing Method Icon on bottom bar will turn green BERGE T HEHE ey ti ze Press Speed Icon next icon on bottom bar 10 11 C1 184135 4 gje Bil s ES er j simin Ji 283 In EN ti ze le 1 11 R Enter Spindle Speed Load in RPMs RPMs should be set 1 3 slower to start Tool Speed Icon on bottom bar will turn green 66 ftimin BEE 66 ftimin BEE gen 1 13 E Enter Spindle Load in Set at 10 0 to start Tool Power Feed Icon on bottom bar will turn green 19 58 35 y 14 Press Dwell Icon the next icon on bottom bar Accept default Dwell setting No action required Dwell Icon on bottom bar will turn green 15 Press Options Icon next icon on bottom bar Accept Options setting No action required Option Icon on bottom bar will be green e Normal 2 Tm xw mn B
33. tatic 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 sensi tive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace 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 subject to wear an
34. terior of Machine with a clean dry cloth to remove any coolant dust and grime Empty Filter Paper Tray as required NS FIGURE 4 1 Spindle Carriage Ways Monthly Wipe exterior of Machine with a clean dry cloth Then clean the exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water and wipe dry Lightly lubricate following lubrication instructions LUBRICATION NOTE The intervals between lubrication will vary with amount of use your Machine receives Lubricate all components at least once every three 3 months CAUTION Be careful not to get oil grease on drive belts 1 SPINDLE CARRIAGE WAYS A manifold is provided on the end of the Spindle Carriage for Lubricating Spindle Carriage Ways see Figure 4 1 Lubricate as required Every Three Months 2 STROKER GEARBOX Gearbox is a sealed and maintenance free 3 STEADY REST Grease Fittings are provided on each of the Ways Bearing for the Steady Rest see Figure 4 2 Lubricate as required TIMING BELT Check Tension of spindle Drive Timing Belt every 200 hours see Figures 4 3 NOTE Timing belt should be replaced every 3000 hours 1 Turn OFF power to the Machine 2 Take off with Cover on spindle carriage 3 Measuring belt deflection Belt should deflect 8mm 1 3in when pressure is applied GREASE FITTINGS Adjust belt tension using all four 4 Threaded Pins M12x70 equally

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