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1. COOLANT MANIFOLD N HIGH PRESSURE RELIEF VALVE 40 PSI MAX CANISTER FLOW CONTROL ON OFF VALVE LOW PRESSURE RELIEF VALVE 13 PSI MAX FLUID PUMP DIRTY FLUID FILTER ELEMENT FIGURE C 1 COOLANT FLOW DIAGRAM 49 NOTES 50 IS PUMP ROTATING DOES PUMP ROTATION CORRESPOND TO RESERVOIR OPEN CANISTER OVERFLOWING OR RISING IS EITHER FUSE 4 FU OR 5 FU BLOWN COOLANT SYSTEM TROUBLESHOOTING IS CHECK WIRES OVERLOAD NO amp CONNECTIONS 10L TRIPPED IF NOT REPLACE MOTOR YES RESET 10L REVERSE 2 LEADS ON SUPPLY CORD TO MACHINE IS RELIEF PUMP COMPONENTS VALVE DUMPING ARE WORN SIGNIFICANT SEE PUMP COOLANT MAINTENANCE YES APPENDIX D HAS FILTER BEEN REPLACED RECENTLY ON REPLACE BLOWN FUSE REPAIR OR REPLACE CHECK WIRES amp CONNECTIONS IF NOT REPLACE CLEAN COOLANT PUMP RELIEF VALVE NOTE 4FU AND 5FU MUST BE 1 AMP FUSES OLDER MACHINES MAY HAVE SMALLER FUSES BUT MUST BE REPLACED WITH 1 AMP FUSES 51 REPLACE FILTER FRACTION DECIMAL MILLIMETER EQUIVALENTS CHA
2. 10 Repeat steps 6 thru 9 for Drive 2 11 Press E Stop Button 12 Use a wrench to turn Main Disconnect Switch OFF 1 4 turn counterclockwise 13 Close and lock door to Electrical Enclosure Telemechanique Drives Complete steps 1 thru 5 Machine Conversion 6 Verify that Display Adjustment Controller keypad is installed on Drive 1 If not move it to Drive 1 with Power OFF 7 Release E Stop Switch on console and press Power ON 8 On Drive 1 press down arrow until uns is displayed 9 Press DATA Nominal motor voltage is now displayed 10 Press up or down arrow until desired voltage is displayed 11 Press PROG New nominal motor voltage is saved 12 Press E Stop on console 13 Wait until green LEDs on both drives are no longer illuminated 14 Using a screwdriver remove Display Adjustment Controller from Drive 1 15 Remove programming cover plate from Drive 2 WARNING HAZARDOUS VOLTAGE Do not remove any other cover besides programming cover plate when installing controller 16 Install programming cover on Drive 1 17 Plug Display Adjustment Controller in Drive 2 18 Repeat steps 7 12 for DRIVE 2 19 Press E Stop 20 Use a wrench to turn Main Disconnect Switch off 1 4 turn counterclockwise 21 Close and lock door to Electrical Enclosure Connect Air Supply CAUTION Do not connect EC 3500 to any air supply with a pressure greater than 1 4 MPa 200 psi 1 Ro
3. gt L FRONT WEDGE CONTACT 1 16 in 1 5 mm SEE lle ALTERATION FOR BLIND HOLES Extremely Short Some improvement can be obtained in honing blind holes where no relief is possible at blind end by using a HARD TIP stone Front section of abrasive has a harder bond than rest of stone This harder abrasive reduces excessive wear that stone tip is exposed to when no relief is present We can supply hard tip stones in most stone sizes Minimum order quantity is one standard package of any individual part number Allow one week for shipment A customer made alteration can achieve same results as a hard tip stone Select a stone considerably harder than one normally used for job and alter as illustrated For additional techniques on blind hole honing refer to Troubleshooting Guide and request copies of Sunnen Bore Sizing amp Finishing Technology Data Files 102 and 103 ALTERATIONS FOR TANDEM HOLES Sunnen honing units can be used to size two or more in line or tandem bores in perfect alignment Stone and guide shoes must be of proper length so that entire stone surface will contact one or other of bores at some time during honing stroke To keep honing unit true during operation STONES AND GUIDE SHOE LENGTH MUST BE AT LEAST TWICE CENTER TO CENTER TANDEM DISTANCE OF BORES see illustration When honing unit meets this requirement alteration is not required It may be necessary to reverse
4. PIVOT LOCK LEVER FIGURE 3 1 Runout Indicator NOTE Roughing Feed Force cannot be adjusted to a value lower than Finishing Feed Force setting It may be necessary to turn Finishing Feed Force Dial down so that Roughing Feed Force can be set to desired level If FINISHING FEED FORCE selector is set on OFF Roughing Feed Force dial may be difficult to turn If FINISHING FEED FORCE selector is set to AFTER ROUGH TO FINISH DIAMETER or to DURING EXTRA STROKES ONLY then Finishing Force Dial may be difficult to turn During setup only you may turn this selector to position that frees feed force dial you are trying to turn If you do this remember always to return this selector to its original position after setting feed force 33 Eliminate conical and parallel spindle runout Select a concentric alignment bushing with a bore size close to final honed bore size see Sunnen Honing Supplies Catalog Place alignment bushing on mandrel so that it is centered on stone and shoe section of mandrel WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed Turn FEED selector to EXPAND to lock alignment bushing on mandrel Look to Honing Indicator If needle reads somewhere on scale then alignment bushing is properly locked on If not turn STONE FEED DIAL until there is an indicator reading Turn Dial same direction as you wish needle to move Rel
5. This switch prevents interference between the ASC arm and large fixtures and or Square Honing fixtures At the beginning of a cycle the ASC arm will rise 0 5 seconds before the spindle and stroker are start ed The ASC arm will stay up at the end of a cycle until the stroker stops A4 Start at The Back of Stroke This switch will require the operator to start a cycle with the carriage at the back of stroke If the carriage is at the front of stroke when cycle start is pressed an Error 12 will be reported on the opera tor station display A5 Ignore Oversize Workpiece In ASC mode if the plunger fails to strike the workpiece within the first few strokes the machine determines that the workpiece is oversize Turning this switch on will prevent the EC 3500 from reporting an Error 5 condition A6 Limit ASC Wear When using ASC mode and placing this switch to the ON position the ASC arm will NOT raise at the beginning of the cycle The arm will rise at the point set by the Rough Finish Diameter knob when the green LED illuminates This mode limits the amount of wear on the ASC probe A T Stroker Front Proximity Switch Installed When this switch is in the ON position it informs the machine that a second proximity switch is installed on the stroker pulley The proximity switch allows the machine to determine the difference between the front and back of stroke If this DIP switch setting is in the OFF positio
6. Turn FINISHING FEED FORCE selector to OFF Needle on Honing Dial will drop some Do not turn STONE FEED dial to move it up again Turn ROUGH gt FINISH DIAMETER knob fully counterclockwise Light next to knob should now be off If it is not on then try using indicator scale Turn INDICATOR SCALE HONING TOOL selector to scale for tool you are using and go back to step 55a If indicator scale selected is already and light is not off with ROUGH gt FINISH DIAMETER knob rotated fully counterclockwise then either Finishing Force selected is too low or finishing stock removal amount is too small for this finishing feed force mode to work properly If this is case you must either increase finishing stock removal or decrease difference between roughing and finishing forces or use During Extra Strokes Only method 24 Turn ROUGH gt FINISH DIAMETER knob slowly clockwise until light next to it just turns on Trigger point is now set Turn then FINISHING FEED FORCE selector to AFTER ROUGH TO FINISH DIAMETER Turn stone feed dial until needle on Honing Indicator reads amount of stock to be removed from diameter of workpiece on mandrel NOTE There is some backlash in STONE FEED dial For best accuracy in setup always turn dial until Honing Indicator reads some amount less than stock removal and then feed up counterclockwise until needle reads correct amount of stock removal
7. 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 are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Su
8. vi SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen EC 3500 Power Stroked Honing Machine SUGGESTED TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing of your Machine Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips INSTALLATION 1 To lift and move EC 3500 fork only from front or rear of machine Place one fork under machine base and one under electrical enclosure but close to machine base see Figure 1 1 Structural steel under electrical enclosure is welded to machine base to pre vent actually lifting machine by enclosure CAUTION Foot Pedal and its conduit to machine are located loosely in front opening of machine Be careful not to pinch conduit with forks Place Foot Pedal assembly on a fork so that it does not drag when moving machine 2 After machine is placed in desired location it will be necessary to stabilize machine with screw located on bottom of right rear corner of machine base For best results place a small block of steel 5 to 8 mm thick 3 16 to 5 16 under stabilizing screw Adjust screw until machine cannot be made to rock on two corners Then tighten jam nut to lock screw in place 3 Remove any packing materials from outside and inside machine To open machine covers use a 4mm hex key wrench to release quarter turn latch near rear corn
9. 1 Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required 2 DO NOT wear loose fitting clothes or jewelry while working on or around Workstation 3 Keep area around Workstation free of paper oil water and other debris at all times 4 Keep Workstation and area cleaned of excessive lubricant and lubricant spills 5 Keep Workstation clear of tools and other foreign objects 6 Keep Tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life 7 Inspect Tools before using Check for cracks burrs or bent parts that might effect operation 8 DO NOT force Tools when operating Tools will do a better and safer job when operated at the rate for which they were designed 9 Use proper lifting procedures when loading and unloading the Workstation 10 Keep hands clear of air cylinder and moving parts at all times to avoid pinch hazards which may lead to loss of limb 11 DO NOT use this Workstation or Power Head for applications other than those for which it was designed cylinder head assembly and disassembly 12 Safety glasses must be worn at all times when using this workstation 13 Use care when advancing or retracting Power Head to ensure tools do not damage head or create an unsafe condition 14 Be careful of dropping heavy items onto feet 15 Always tighten lock handle securely so t
10. ral HH 28 FOOT PEDAL Depressing Foot Pedal will start honing cycle if power is ON Feed system wedge travel is controlled by foot pedal so that speed at which stone contacts workpiece bore is related to speed of operator s foot Likewise raising foot will move wedge back If STROKING is set to MANUAL spindle will run only when Pedal is depressed and honing cycle will stop when Foot Pedal is released If STROKING is set to AUTOMATIC Foot Pedal will control feed until it is completely depressed As soon as Foot Pedal is at bottom of its travel feed system will be controlled by machine and foot pedal can be released without stopping cycle Releasing foot pedal prior to that point will stop cycle 29 STROKE POSITION LOCK This hand lever tightens a screw to lock stroker in position To adjust stroke position this hand lever screw must be loosened 30 STROKE POSITION HANDWHEEL When Stroker Position Lock is loosened this handwheel changes position of stroke relative to spindle and honing tool Graduations are in millimeters Turning in direction of increasing numbers moves carriage out away from spindle 31 MASTER ON OFF SWITCH Disconnects power from switch to components in electrical enclosure Enclosure doors cannot be opened with this switch in ON position 32 ASC UNIT CLAMP Turning this knob clockwise locks Automatic Size Control unit in place Counterclockwise rotation frees unit so that it can be position
11. Error 1 Unexpected Start Signal When power is turned on the machine verifies that the foot pedal cycle start button is not pressed down to prevent any unexpected start up Error 2 Switch Has Changed During a Cycle In order for this error to occur one of the following switches was changed while the machine was honing Expand Retract Size Control Mode Stroker Mode Finishing Feed Force Mode or Stroker Enable These switches cannot be moved during a honing cycle Error 3 Spindle or Stroker Speed Set to Zero speed must be set for both the spindle and stroker before the machine can start a cycle Error 4 Safety System Was Triggered The safety system determined that an unsafe condition has occurred Le the light curtain was broken Error 5 Workpiece Oversized The original workpiece was oversized The ASC probe never stuck the workpiece If the ASC is not being used this error should be bypassed See Appendix A Dip Switch Settings Error 6 ASC is Not Aligned Properly Extra Strokes count had decrement by three or more when an additional ASC probe hit was detected Error 7 Feed System is Expanded honing cycle cannot be started with the feed system expanded Place the feed selector switch to Retract Error 8 Stroker Was Unlatched honing cycle cannot be started with the stroker unlatched Place the stroker mode selector switch to Auto Error 9 In Manual Honing Mode honing cyc
12. Move Gate Fixture assembly on fixture support bars to a position where workpiece will be held with minimal end clearance approx 1mm more if workpiece length is expected to vary widely APPENDIX A Move collars to back up both sides of Hinge and Latch and tighten them in place Leave just enough clearance for gate to open and close freely NOTE Position pin between two collars backing up Hinge so that it holds gate upright when gate is opened Torque Arm Torque arm is shipped assembled to a split collar on left fixture support bar For very short workpieces there may not be room for this collar Collar may be removed and torque arm can be attached to top of stroker carriage An extra screw of appropriate length is provided for that purpose Hints f there is difficulty in reassembling Finger Fixture refer to exposed view in Repair Parts Catalog f you need to change frequently between applica tions requiring finger fixture and applications requiring gate fixture you may purchase an extra Gate Hinge and Latch and keep each fixture built up and ready to change Order Sunnen Part Numbers Hinge EC 6116A Gate EC 6117A Latch EC 6118A f you need to hone very long workpieces and standard fixture support bars are not long enough longer bars are available as an option 370mm long Sunnen Part Number EC 7190 STROKER STOP POSITION MODIFICATION EC 3500 is wired to stop at end of stroke any time E
13. stone cannot be expanded far enough to reach diame ter to be honed within range of honing unit Use high wedge plate e g Y56H W when necessary to reach diameter to be honed MANDREL SHIMS Furnished with all P28 honing units They are inserted between mandrel body and guide shoe when necessary to reach SHIM maximum diameter especially when guide shoes are worn They can also be used to help compensate for mandrel runout 44 ALTERATION OF HONING UNITS HOW TO ALTER STONES MANDREL AND SHOES When alteration of honing stone is necessary cut through abrasive with an old hacksaw blade and break unwanted section of stone from stoneholder with a pair of pliers Do not cut into die cast stoneholder except as described under blind hole alterations Use a file or bench grinder to shorten guiding surfaces of shoe Both stone and guide shoe should be altered identically and in same relative position ALTERATIONS FOR SHORT OPEN HOLES Always consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units Individual parts if they have at least one flat face with bore lengths of 1 4 diameter or less can also be honed by holding parts flat against face plate of square honing fixture For precision sizing of short open holes STONE AND GUIDE SHOE LENGTH SHOULD BE BETWEEN 2 3 and 1 1 2 TIMES BORE LENGTH to be honed ALTERATION FOR SHORT OPEN HOLES COMPLETED ALTE
14. 524 13 00 12 83 13 31 ASC 0531 7 32 521 540 13 50 13 23 13 72 ASC 0547 35 64 540 559 14 00 13 72 14 20 ASC 0562 9 16 552 571 14 29 14 02 14 50 ASC 0578 37 64 568 587 14 68 14 43 14 91 ASC 0594 9 32 583 602 15 00 14 81 15 29 ASC 0609 39 64 599 618 15 48 15 22 15 70 ASC 0625 5 8 615 634 15 88 15 62 16 10 ASC 0630 620 639 16 00 15 75 16 23 ASC 0641 41 64 631 650 16 27 16 03 16 51 5 0656 21 82 646 665 16 67 16 41 16 89 ASC 0672 43 64 661 680 17 00 16 79 17 27 ASC 0688 11 16 678 697 17 46 17 22 17 70 ASC 0703 45 64 697 716 18 00 17 70 18 19 ASC 0719 23 32 709 728 18 26 18 01 18 49 ASC 0734 47 64 724 743 18 65 18 39 18 87 ASC 0750 3 4 740 759 19 00 18 80 19 28 ASC 0766 49 64 756 775 19 45 19 20 19 69 ASC 0781 25 32 775 794 20 00 19 69 20 17 ASC 0797 51 64 787 806 20 24 19 99 20 47 ASC 0812 13 16 802 821 20 64 20 37 20 85 ASC 0828 53 64 818 837 21 00 20 78 21 26 ASC 0844 27 37 834 853 21 43 21 18 21 67 ASC 0859 53 64 853 872 22 00 21 67 22 15 ASC 0875 7 8 86s 884 22 22 21 97 22 45 ASC 0891 57 64 881 900 22 62 22 38 22 86 ASC 0906 29 32 896 915 23 00 22 76 23 24 ASC 0922 54 64 912 931 23 42 23 17 23 65 ASC 0938 15 16 932 951 24 00 23 67 24 16 ASC 0953 61 64 943 962 24 21 23 95 24 44 ASC 0969 31 32 959 978 24 61 24 36 24 84 ASC 0984 63 64 972 991 25 00 24 69 25 17 ASC 1000 1 930 1 009 25 40 25 15 25 63 ASC 1016 1 1 64 1 011 1 030 26 00 25 68 26 16 37 If St
15. Expand If needle goes immediately to a position below zero then there is no machine problem Feed force selected is probably too low for application try increasing feed force If needle stops at some position above zero try following Are you trying to feed up past maximum size of tool you are using Is tool running out Try adjusting tool runout Spindle runout can make feed system stick at low feed force Lubricate feed rod at grease fitting inside machine Try using a slightly higher feed force If problem persists contact a Sunnen Service Technician see next problem PROBLEM application that ran well at a certain feed force on another EC 3500 or at another time on this machine runs differently now SOLUTION Small differences in honing performance can be attributed to slight differences in individual machines machine changes over time or usually to normal variations in cutting performance of abrasive Machines are calibrated to exact specifications before leaving factory Over time they may change slightly It will be easiest to merely adjust feed force to get optimum performance If you suspect that honing performance has changed significantly or if you find it to be significantly different from another EC 3500 machine then contact a Sunnen Service Technician to check Feed System calibration PROBLEM Increasing roughing pressure makes no difference in honing rate SOLUTION Is Feed Regulator tur
16. Regulator at higher feed forces Initial Diameter where needle begins to slow down on Honing Indicator may appear different dur ing a cycle than it did when it was set by recom mended procedure This is normal behavior caused by amount of compression in feed system However this indicates that stones are contacting workpiece bore immediately after cycle begins although not at full feed force selected If this initial contact still seems too rough then turn Initial Diameter knob counter clockwise some to make Feed Regulator begin at a smaller diameter When using FINISHING FEED FORCE set to AFTER ROUGH TO FINISH DIAMETER When feed force changes from roughing to finishing needle on honing indicator rises as observed when setting ROUGH gt FINISH DIAMETER Amount of this needle shift can be subtracted from initial diameter when setting FEED REGULATOR This will save cycle time Turn FEED selector to EXPAND Watching Honing Indicator turn up MAXIMUM RATE dial until desired speed is reached Turn FEED selector to RETRACT 58 Set AUTOMATIC STONEWEAR COMPENSATOR NOTE Use of AUTOMATIC STONEWEAR COM PENSATOR is optional If it will not be used then skip this step and go to step 59 If using ASC it is recommended that Automatic Stonewear Compensator be used If it is not it will be necessary to manually advance STONE FEED dial to keep feed system operating in a range where needle on Honing Indicator can be ob
17. STONES Honing stone made with crushed diamond particles bonded together It is only abrasive material capable of honing very hard materials such as tungsten carbide glass and ceramics DIAMOND DRESSER Diamond abrasive used to dress aluminum oxide and silicon carbide honing stones GLAZED STONE Stone with cutting action impaired because abrasive particles failed to break out of bond when cutting edges wore off This condition shows up when bond is too hard and or cutting pressure is too low GUIDE SHOES Part of honing unit that stabilizes bore being honed on tool HARDNESS As applied to honing stone describes strength of bond that holds abrasive particles together A hard bond will hold abrasive grains longer a soft bond will permit stone to break down faster exposing new sharp abrasive grains HARD TIP STONE Honing stone having a tip or end of harder abrasive than remaining length of stone Used for honing blind holes where sufficient relief cannot be provided See Alterations for Blind Holes for how to make hard tip stones 47 APPENDIX B HONING Abrasive machining process primarily used for stock removal precision sizing and surface finishing of internal and external cylindrical sur faces Characterized by use of a self sharpening abrasive stone a relatively large area of contact with work and relatively low cutting speeds HONING LENGTH Actual length of surface being honed HONING STONE Abra
18. Too much drag will make knob difficult to turn and components will wear out faster PROBLEM Needle on Honing Indicator will not go all way to top of scale when Feed is Retracted SOLUTION Is Indicator Scale Honing Tool selec tor set to red D2 tool family If so it is normal for needle to rest about three quarters from bottom of scale when retracted This will not interfere with honing when using these tools If selector is not set to red D2 scale then Stone Feed dial has been turned back too far Advance Stone Feed dial counterclockwise until needle goes up past maxi mum scale reading PROBLEM When using Zero Shut Off when Feed Force is changed final bore size is different from previous workpiece SOLUTION This is normal Components in Feed System compress to a greater degree when feed force is greater This means anytime you reduce feed force needle on honing dial will rise and sub sequently final bore size will be greater than previ ous part Assuming stonewear is negligible or properly compensated Opposite is true when feed force is increased Therefore to avoid making oversized bores never reduce feed force by more than 0 5 without turning Stone Feed dial back clockwise some to compensate for this change in compression PROBLEM Needle on Honing Indicator hangs up cutting appears to stop at very low feed force SOLUTION With Feed Regulator off and no workpiece on tool turn Feed selector to
19. immediately following the honing cycle Refer to DIP Switch Settings on page 40 If ASC mode of size control is selected but ASC unit is disconnected then honing cycle will be a timed cycle lasting for only number of strokes displayed on counter 14 SPINDLE SPEED Return to center selector switch changes spindle speed setting displayed above switch Chart below recommends spindle speed in RPM based on workpiece bore diameter 15 STROKER SPEED Return to center selector switch changes stroker speed setting displayed above switch Chart below recommends stroker speed in SPM strokes per minute based on stroke length 16 STROKE LENGTH INDICATOR amp LOCK Index mark on clear piece indicates stroke length setting Tightening handle locks stroke length in place Loosening handle frees stroker for setting a different stroke length with STROKE LENGTH Handwheel 17 STROKE LENGTH Handwheel changes stroke length as indicated by index piece when handle is unlocked A Stroke Length Guide printed on front panel shows how to use bore length and stone length to determine proper stroke length for most applications 18 ROUGHING FEED FORCE Sets roughing feed force level as indicated on dial above knob NOTE Knob may be difficult to turn if OFF is selected on FINISHING FEED FORCE selector switch Also Roughing Feed Force Dial can never be set to a value below value shown on Finishing Force Dial even if Finishing Force i
20. job Sunnen general purpose shoes meet these requirements When work being honed is unusually rough or out of round or has burs or wire edges hardened steel guide shoes are usually more economical Hardened shoes are also more economical when CBN Borazon or diamond honing stones are being used When material being honed is very soft or subject to galling or if very fine finish is required bronze guide shoes are recommended Should your particular application require special guide shoes not described in our catalog please contact Customer Service Department Industrial Division in St Louis or your local Field Engineer IMPORTANT Guide shoes of different materials should never be mixed on a multi stone length mandrel When shoes are removed from a mandrel to be used later they should be re assembled in their original position WEDGES Wedges are subject to wear and to assure best performance they should be replaced when they show signs of wear Old wedges should be discarded Wedges supplied with all permanent type mandrels have long life but should be inspect ed regularly and replaced if showing any wear This is especially important in AK20 BAL20 AL20 and Y32 honing unit groups WEDGE PLATES High and low wedge plates are supplied with Y Keyway mandrels of 35 mm 1 365 size and larger to provide coverage of man drel diameter range even with worn guide shoes and stones Use low wedge plate e g X56L W unless
21. need to have finishing force for more stock removal than that and you have selected scale then switch to B scale for tool you are using and go back to step 5 11 Turn then FINISHING FEED FORCE selector to AFTER ROUGH TO FINISH DIAMETER 12 Turn stone feed dial until needle on Honing Indicator reads amount of stock to be removed from diameter of workpiece on mandrel NOTE There is some backlash in STONE FEED dial For best accuracy in setup always turn dial until Honing Indicator reads some amount less than stock removal and then feed up counterclockwise until needle reads correct amount of stock removal 13 Ready to hone NOTE When actually honing trigger point or actual finishing stock removal amount may vary from settings made while spindle was off Watch honing dial carefully during first cycle to see how much stock is removed after feed force changes and needle shifts up If it is different from desired amount then move Rough to Finish Dial some to adjust keeping in mind that and refer to diameter at which trigger point will occur Deciding Which Trigger Method Is Best For Application Test trigger method to use depends on size control method being used and which of three benefits of Finishing Force is most important to achieve 1 If improvement of surface finish is only reason for using Two Stage Feed Force then During Extra Strokes Only will almost always be b
22. part end for end on honing unit to obtain identical bore sizes Never stroke either of tandem bores completely off stone and guide shoes APPENDIX B CENTER TO CENTER TANDEM DISTANCE CS NW IF STONE AND GUIDE SHOE LENGTH IS EQUAL TO AT LEAST TWICE TANDEM DISTANCE ALTERATION IS NOT REQUIRED fa UL TOOLING FOR TANDEM BORES Should stone and guide shoe length be less than twice tandem distance center area of stone and guide shoe will not wear and a resulting hump in honing unit will bellmouth inside ends of both bores of tandem In some tandem applications it is necessary to alter honing unit by cutting away area of stone and guide shoe that would become hump Remove from center of both stone and guide shoe an amount egual to amount stone and guide shoe is short of being twice tandem distance For example a part having a 2 3 4 tandem spacing would require a 5 1 2 stone and guide shoe but honing unit has a stone and guide length of only 4 1 2 This honing unit can be used by removing 1 from center of 4 1 2 stone and guide shoe length Multiple stone honing units P20 and P28 can sometimes be used by setting up honing unit to leave out center stones and shoes Special tandem type mandrels can generally be supplied for those applications which have too long a tandem distance for honing with altered honing units Contact your Sunnen Field Engineer or factory Additional discussion on honing ta
23. up production HONE BEFORE HARDENING When a part is to be hardened always hone first leaving only as little Stock as necessary to correct heat treat distortion When needed use a deburring stone to remove heat treat scale prior to sizing and finishing operation AMOUNT OF STOCK FOR HONING Previous operation should leave just enough stock so that tool marks can be cleaned up and bore inaccuracies corrected Less stock allowance is needed for Sunnen honing because Sunnen Honing Units are self centering in bore When going from a stock removal to a surface finishing operation leave only enough stock to remove cross hatch pattern of coarser stone usually only a few ten thousandths of an inch PROVIDE RELIEF IN BLIND HOLES Honing of a blind hole can be greatly assisted by providing relief in bottom corner of bore This allows for at least some overstroking The relief need be only a few thousandths deep and can even blend in as hole is honed The ideal length of relief is 1 3 stone length Any length of relief is much better than none PARTS CAN BE STACKED Frequently parts with short bores can be stacked and honed as one long bore Parts must have flat and parallel faces KEEP YOUR HONING TOOLS TRUE Cutting surface of stone and guide surfaces of shoes must be kept straight and parallel to produce accurate work Occasional use of a truing sleeve will assist in keeping tools true USE ONLY PROPER HONING OIL Best h
24. 000 531250 13 4938 905512 23 0000 171875 3 16 187500 4 3656 4 7625 546875 551181 13 8906 14 0000 906250 921875 23 0188 23 4156 196850 5 0000 562500 14 2875 937500 23 8125 13 64 203125 5 1594 578125 14 6844 944882 24 0000 7 32 218750 5 5563 590551 15 0000 953125 24 2094 15 64 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 984252 25 0000 1 4 250000 6 3500 625000 15 8750 984375 25 0031 17 64 265625 6 7469 629921 16 0000 1 000000 25 4000 Sur 275591 FORMULAS MULTIPLY INCHES in FEET ft 7 0000 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 PRINTED IN U S A 0111 640625 16 2719 TO GET MILLIMETERS mm METERS m SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone
25. 2 maybe more if a large reduction is necessary More important is selection of finishing force Typically finishing force should be no more than half of roughing force for any significant improvement in surface finish For dramatic improvements in finish reducing surface finish by more than half finishing pressure needs to be extremely low compared to roughing force 2 If Finishing Force is used primarily to improve cylindricity Amount of Finishing Stock Removal must be at least as much as cylindricity defect that must be corrected during finishing stage For example a bore 50 out of round or with 50u bellmouth will take at least 50u of stock removal to correct Finishing force will probably need to be significantly lower than roughing force A very crude rule of thumb is that distortion will probably be proportional to feed force So for example a bore distorted to 50u out of round at a force of 10 will probably be close to 25u out of round if finished at a force of 5 3 If Finishing Force is used primarily for size control In this case feed force is reduced only so that cutting rate is not too fast when size control device finds its target bore size It is only necessary to reduce feed force when bore is just a few microns from finish size Also Finishing Feed Force need not be much lower than Roughing Feed Force sometimes only reduced to 8096 of roughing value to slow cutting rate sufficiently to achieve size control rep
26. 3 8 Attachment of Sensing Tip d Determine proper micrometer setting for ASC 50 Setting Fixture or ASC 50M Metric Setting Fixture by following formula Desired Bore Size 1 or 25 4mm 2 Set micrometer to this size and lock micrometer spindle e Adjust sensing screws in sensing body so that size is somewhat smaller than desired bore size Insert sensing unit into setting fixture see Figure 3 7 f Line up one of four screws with micrometer spindle and tighten clamp screw on setting fixture As you tighten clamp screw press downward on sensing unit as shown see Figure 3 7 Downward force assures that sensing unit is flat against frame of setting fixture This is necessary for best accuracy With wrenches provided adjust sensing screw to just touch micrometer spindle tip and tighten locking nut Repeat step for each sensing screw g Note micrometer reading Loosen micrometer spindle lock and back off spindle Check each of four sensing screws with micrometer ratchet sensing screws should read within 0 03 mm 001 Be sure to hold sensing unit flat on setting fixture frame each time you tighten clamp screw h Back off adjustment screw slightly so that first part honed will be undersized rather than oversized if there was any inaccuracy in setting 1 Sensing tip or sensing unit is adjusted by turning adjustment screw inside stem of tip with a 1 16 hex wrench Sensing tip or sensing unit can be set
27. 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 http www sunnen com e mail sunnenQsunnen com MULTIPLV MILLIMETERS mm METERS m 1 062500 26 9880 TO GET INCHES in FEET ft SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 648 1616 Fax 41 71 648 31 31 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Via Stelvio 12 15 20021 Ospiate di Bollate MI Phone 02 33301580 Fax 02 33301572 Fax 86 21 5 813 2299 OCOPYRIGHT SUNNEN PRODUCTS COMPANY 2001 ALL RIGHTS RESERVED
28. 57 Set FEED REGULATOR NOTE Use of FEED REGULATOR is optional If it is not to be used on this application then skip this step and go to step 58 See Appendix A for guidelines on when Feed Regulator may be beneficial Turn MAXIMUM RATE dial to slowest speed Turn INITIAL DIAMETER knob counterclockwise about two turns With workpiece removed from tool turn FEED selector to EXPAND while watching Honing Indicator Needle will drop quickly to initial diameter point and then move very slowly If point that needle stops is not desired point then turn FEED selector to RETRACT adjust INITIAL DIAMETER knob and expand again while watching indicator NOTE To use FEED REGULATOR efficiently initial diameter should be set to a point just smaller than smallest starting bore diameter that you expect to encounter It may be necessary to measure several workpieces to know how they will vary Set initial diameter to point where Honing Indicator reads difference between initial diameter and final bore size There are trade offs to setting this initial diameter If it is too large a workpiece slightly smaller than expected may be contacted at full feed force possibly damaging stone or tool If initial diameter is set too small cycle time gets excessively long with significant time spent just cutting air Use your best judgement based on your knowledge of variability of starting diameter of workpieces When using Feed
29. A scale shows stock removal up to 240 009 and scale shows stock removal up to 480 018 23 STONE FEED Handwheel feeds up tool to set amount of stock removal to adjust final bore size and to compensate for stone wear manually Three scales are color coded to match three sets of tool families displayed in HONING TOOL box above Counterclockwise rotation increasing numbers feeds tool to a larger diameter 24 AUTOMATIC STONEWEAR COMPENSATOR ADJUSTMENT When used Automatic Stonewear Compensator will automatically index Stone Feed Dial to compensate for stonewear If size control mode is Zero Shut Off this indexing will occur at beginning of each cycle Unless previous cycle was halted by depressing CYCLE STOP If size control mode is ASC this indexing will occur only when needle on Honing Indicator reaches zero Rotating adjustment knob counterclockwise increases amount of stonewear compensation Rotating adjustment knob clockwise decreases amount of stonewear compensation Rotating clockwise until knob stops will turn off Automatic Stonewear Compensator 25 AUTOMATIC STONEWEAR COMPENSATOR CHECK To check amount of Automatic Stonewear Compensation press this button and hold it in until Stone Feed Dial stops moving Observe amount of feed up on dial 26 FEED REGULATOR MAXIMUM RATE Feed Regulator is a system to limit maximum rate of feed MAXIMUM RATE dial is turned to set maximum feed rate limit On
30. BARREL SHAPE A condition where extreme ends of a bore are smaller in diameter than middle 4 BELLMOUTH condition where extreme end ends of a bore are larger in diameter than middle iia a BLIND HOLE A bore that is constricted or closed at one end BOND Material that holds abrasive grains together in a honing stone CBN Cubic Boron Nitride A synthetic abrasive that is second in hardness to more chemically stable than and as costly as diamond CBN is best suited for steels especially tool steels high speed steels and superalloys General Electric tradename for CBN is Borazon CBN is designated by letter N in Sunnen stone code example K12 NR53 d Ww CONICAL RUNOUT Honing unit not parallel to rotation centerline which causes eccentric motion of one end of workpiece CORK BOND Bonding material for abrasive composed of powdered cork and a phenolic resin Cork bonded honing stones are used where extremely fine finishes say 2 to 4 microinches on non ferrous materials are required DEBURRING Honing process used to remove burrs sharp edges or similar material from rough bores DIAMOND Hardest abrasive known to man but chemically not suited for honing materials such as steel Diamond is only Sunnen abrasive capable of honing very hard materials such as tungsten carbide ceramics and glass It is designated by letter D in Sunnen stone code example K12 DV57 DIAMOND
31. CIFICATIONS Sunnen Power Stroked Honing Machines Model EC 3500 Diameter Range I D Manual Stroking Power Stroking Range of Standard Probes for Automatic Sizing Stroke Length Spindle Speeds Stroke Rate Spindle Motor Stroker Motor Feed System Type Patented Constant Feed Force System with Size Control Pump Motor Coolant Pump Coolant Capacity Coolant Requirements Floor Space Deep Wide Height Color Machine Weight Less Coolant Cart Coolant Cart Weight Dry Pneumatic Requirements Power Requirements Voltage Maximum Current Load Noise Emission 1 5 165 mm 060 6 5 1 5 100 mm 060 3 94 3 1 51 mm 125 2 0 6 170 mm 24 6 7 200 3000 rpm Variable in fine increments 60 500 strokes min Variable in fine increments 4 0 KW 5 5HP 1 1 KW 1 5HP Two Stage Feed Force Roughing amp Finishing in 1 cycle Variable Maximum Feed Rate Regulator Automatic Stonewear Compensator Zero Shut Off or Automatic Size Control ASC Coolant System Roll Out Coolant Cart with Integral Work Area Drip Tray Pump Filtration System 18 KW 1 4HP 5 6 L Min 1 5 GPM 120 L 32 Gal Sunnen Industrial Honing Fluids 1 9 m 75 with covers open Pearl Gray Pewter Gray Burgundy Trim 725 kg 1600 165 125 kg 275 lbs 0 55 MPa 80 PSI EC 3500D EC 3500E 208 230 v 380 460 v 3 Phase 3 Phase 50 60 Hz 50 60 Hz 30A 16A Le
32. D is selected RETRACT Retracts honing tool 9 EMERGENCY STOP Opens electrical circuits to stop all machine functions Cancels all setup information requiring operator to re enter setup before continuing Button must be rotated clockwise until it pops up before machine can be re started with POWER ON button 10 SIZE CONTROL Two position selector switch sets size control mode ZERO SHUT OFF Honing cycle will end when needle on Honing Indicator reaches zero This corresponds to a consistent feed system position If stone and shoe wear are negligible or properly com pensated then this position will correspond to a consistent final bore size ASC Automatic Size Control unit will determine when honing cycle is complete by checking workpiece bore size with a plug gage type probe once every stroke 11 STROKING Three position selector switch sets stroking mode MANUAL Stroker will not operate in this mode Stroking must be done manually Honing cycle can be started only with Foot Pedal UNLATCH In this mode Stroker Carriage is disengaged from power stroking unit This mode is used only during setup Machine will not run in this mode AUTOMATIC Stroker will operate during honing cycle at speed and stroke length selected Cycle can be started with Foot Pedal or CYCLE START button 12 FINISHING FEED FORCE Three position selector switch sets Finishing Feed Force mode OFF Finishing Feed Force is not
33. E 2 1 OPERATOR CONTROL SECTION 2 CONTROLS LOCATION amp FUNCTION For location function and descriptions of Machine s major controls refer to Figures 2 1 thru 2 3 1 POWER OFF Turns machine power off All functions are disabled however spindle speed stroker speed and extra stroke settings are retained 2 POWER ON Turns machine power on Lighted button is an indication of power on status 3 STROKER JOG Pressing this and holding it down causes stroker carriage to move slowly to one end of stroke Repeating this will cause stroker to move slowly to other end of stroke Releasing button will stop stroker immediately even though end of stroke may not have been reached 4 CYCLE STOP Stops honing cycle 5 CYCLE START Starts honing cycle if STROKING selector is set to POWER 6 COOLANT Two position selector switch CONSTANT Coolant flow at all times when power is on CYCLE ONLY Coolant flow only during honing cycle 7 ASC PROBE Two position selector switch UP Automatic Size Control actuator lifts probe into gaging position DOWN Automatic Size Control actuator moves probe to its retracted position 8 FEED Two position selector switch EXPAND Used for setup only Expands hon ing tool until stone contacts workpiece for setting Stock Removal amount Locks an alignment bush ing on honing tool for checking and adjusting tool runout Honing cycle cannot be started when EXPAN
34. EL i Codes E Press DATA FREQUENCY REF 995 DATA ACCESS LEVEL ENTER U1 01 0 00HZ ENTER ADVANCED LEVEL V LLL _ d P ETTE ress MAIN MENU 9 GPD 515 drive is now configured for 208V Return MENU OPERATION 5 29 eo keypad interface to operation only level as follows Press DATA FREQUENCY REF ENTER U1 01 0 00HZ KEYPAD SEQUENCE DISPLAY AFTER KEY IS PRESSED NOTES WA 99 2 8 Change voltage setting to 208V as follows Press SERE MENU OPERATION KEYPAD SEQUENCE DISPLAY AFTER KEY IS PRESSED NOTES Press MAIN MENU i MAIN MENU MENU OPERATION Y INITIALIZE n Press s Twice MAIN MENU Press DATA SELECT LANGUAGE PA PROGRAMMING ENTER ENGLISH Press DATA GROUP B press ACCESS LEVEL ENTER APPLICATIONS ADVANCED LEVEL Press 34 3 Times GROUPE E Press DATA A1 01 4 FAN MOTOR ENTER ADVANCED LEVEL M Press DATA FUNCTION E1 Press Ga TOP fn ENTER V F PATTERN OPERATION ONLY D oaas SS a A 2 0 M EO Press T ATA INPUT VOLTAGE Press DATA ACCESS LEVEL ENTER E1 01 230VAC ENTER OPERATION ONLY M S S M Press DATA INPUT VOLTAGE The 2 will be Press MAIN MENU ENTER 230VAC flashing MENU OPERATION Press EF INPUT VOLTAGE The 3 will be Press DATA FREQUENCY REF RESET 230VAC flashing ENTER U1 01 0 00HZ MM
35. I EC 351B TN SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN POWER STROKED HONING MACHINE Model EC 3500 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN POWER STROKED HONINGMACHINE SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS MO 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information for proper installation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructio
36. NSING TIPS FOR DIAMETERS 1 8 to 1 1 64 in 3 18 to 26 mm FIGURE 3 6 Sensing Tip TABLE 3 1 ASC Sensing Tips INCHES MILLIMETERS SENSING TIP NOMINAL DIAMETER RANGE NOMINAL DIAMETER RANGE PART NUMBER DIAMETER LOW HIGH DIAMETER LOW HIGH ASC 0125 1 8 120 139 3 18 3 05 3 53 ASC 0141 9 64 135 154 3 57 3 42 3 91 ASC 0415 5 32 150 169 4 00 3 81 4 29 ASC 0172 11 64 166 185 4 36 4 22 4 70 ASC 0188 3 16 180 199 4 76 4 57 5 05 AC 0203 13 64 191 210 5 00 4 85 5 33 ASC 0219 7 32 211 230 5 56 5 36 5 84 ASC 0234 15 64 226 245 6 00 5 74 6 22 ASC 0250 1 4 240 259 6 35 6 10 6 58 ASC 0266 17 64 256 275 6 75 6 50 6 99 ASC 0281 9 32 269 288 7 00 6 83 7 32 ASC 0297 19 64 2B7 306 7 54 7 29 7 77 ASC 0312 5 16 304 323 8 00 7 72 8 20 ASC 0328 21 64 318 337 8 33 8 0 8 56 ASC 0344 11 32 334 353 8 73 8 48 8 97 ASC 0359 23 64 347 366 9 00 8 81 9 30 ASC 0375 3 8 365 384 9 53 9 27 9 75 ASC 0391 25 64 383 402 10 00 9 73 10 21 ASC 0406 3 32 396 415 10 32 10 06 10 54 ASC 0422 27 64 412 431 10 72 10 47 10 95 ASC 0438 7 16 426 445 11 00 10 82 11 30 ASC 0453 29 64 443 462 11 51 11 25 11 74 ASC 0469 5 32 461 480 12 00 11 71 12 19 ASC 0484 31 64 474 493 12 30 12 04 12 52 ASC 0500 1 2 490 509 12 70 12 45 12 93 ASC 0516 33 64 505
37. NY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Softwar
38. O WE BA EA epe D RR ORE Ae dece e ens 9 Operator Controls ies put ee PER ba 9 SETUP amp OPERATION maale ot eee Rs 13 General br dc gud An Gaon bho art dvd A 13 Safety Pfecuations cuu ota Rom aa virer EP awe PEP e qa dot c e Roe 13 Operating Tips espada qua tel kae PE qued qu Ai ep has tege tad uad xia Beaded 13 Manual Honing Set p is ge e Rem Ro setae Sealed Kona ARA pa puha pa 13 Manual Honing Operation nnn iii 15 Power Stroked Honing Setup us wie EROR A CRURA ala 16 Power Stroked Honing Operation 25 ROUTINE MAINTENANCE General once be ARM Ae ee ae e e Rote 27 Lubricati l eh ed eee be OSS 27 Routine Maintenance Schedule nents 27 TROUBLESHOOTING General A 31 Operational Troubleshooting 2 0 cc I Ih 31 Machine Operation Troubleshooting eee 9 cfr 32 APPENDIXES A Sp cial TOPICS s cse ee B ait eale X ace add is 35 B General Honing Information e e ee 43 C C lant Flow Diagram e epe ode to ADR a RO RP l Re wal 49 D Coolant System Troubleshooting nee I e 51 GENERAL INFORMATION amp SPE
39. RATION FOR SHORT OPEN HOLES ALTERATION OF HONING STONE Sel WEDGE CONTACTS GUIDE SHOE L REMOVE STONE AS SHOV GK REMOVE GUIDE SHOE AS SHOWN ALTERATION OF INTEGRAL GUIDE SHOE REMOVE GUIDE SHOE AS SHOWN ALTERATION OF REPLACEABLE GUIDE SHOE When alteration is necessary both stone and guide shoe must be shortened by same amount Any alteration of this type should shorten stone and shoe equally from both ends so that honing area remaining is centered over wedge contacts on stoneholder If greater accuracy is required than is obtained after alteration refer to Troubleshooting Chart on page 31 Additional information is provided in Data File 102 Honing Short Bores Write for free copy ALTERATIONS FOR BLIND HOLES If at all possible provide a relief undercut at closed end of hole to permit stone to overstroke honed surface Relief does not have to be more than a few thousandths deep and can actually blend in with bore when finish honed but it should be as long as possible preferably 1 3 length of stone Sunnen honing units in J K AK J AK BL L BAL AL and P28 groups can be utilized for honing bores that have one end closed In honing blind holes it is necessary for stone and guide shoe to extend flush with tip of honing unit If your application utilizes one of P28 group of honing units install blind hole wedge and R28 honing stones see Honing Supplies Catalog Remaining mandrel groups h
40. RCE selector is set to desired position NOTE If FINISHING FEED FORCE mode is AFTER ROUGH TO FINISH DIAMETER skip steps 54 and 55 and go to step 56 54 Turn stone feed dial until needle on Honing Indicator reads amount of stock to be removed from diameter of workpiece on mandrel NOTE There is some backlash in STONE FEED dial For best accuracy in setup always turn dial until Honing Indicator reads some amount less than stock removal and then feed up counterclockwise until needle reads correct amount of stock removal 55 Skip step 56 and go to step 57 56 Set ROUGH to FINISH DIAMETER and stock removal amount by following procedure NOTE Changing level of feed force changes amount of compression in feed rod inside machine This makes needle on Honing Indicator move The following steps are necessary to compensate for this needle movement when feed force changes from roughing to finishing With a measured workpiece seated on mandrel turn STONE FEED dial until needle on Honing Indicator is near zero Turn FINISHING FEED FORCE selector to OFF and then again to AFTER ROUGH TO FINISH DIAMETER a couple of times to help seat feed system and wedge Return selector to AFTER ROUGH TO FINISH DIAMETER Turn STONE FEED dial up until needle on Honing Indicator reads amount of stock that you want removed during finishing stage NOTE See Appendix A for guidelines on how much finishing stock to set
41. RT H DECIMAL 003937 INC FRACTION INCH MILLIMETER FRACTION 0 1000 DECIMAL 281250 7 1438 INCH MILLIMETER FRACTION DECIMAL MILLIMETER 656250 16 6688 007874 0 2000 296875 7 5406 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 328125 8 3344 703125 17 8594 019685 0 5000 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 031250 0 7000 0 7938 359375 375000 9 1281 9 5250 734375 748031 18 6531 19 0000 031496 0 8000 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 046875 1 0000 1 1906 406250 421875 10 3188 10 7156 781250 787402 19 8438 20 0000 062500 1 5875 433071 11 0000 796875 20 2406 078125 1 9844 437500 11 1125 812500 20 6375 078740 093750 2 0000 2 3813 453125 468750 11 5094 11 9063 826772 828125 21 0000 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 484375 12 3031 859375 21 8281 125000 140625 3 1750 3 5719 500000 511811 12 7000 13 0000 866142 875000 22 0000 22 2250 156250 3 9688 515625 13 0969 890625 22 6219 157480 4 0
42. TE If setting up ASC for first time on a new machine it may be necessary to adjust ASC unit Only necessary for a new machine or a new ASC unit b Select and adjust proper Sensing Tip or Sensing Tip Unit for final bore size to be gaged see Table 3 1 amp Figure 3 6 NOTE A sensing tip is adjustable to any size within its diameter range However once adjusted to a bore size near maximum sensing tip may take a permanent set and not return to minimum sizes Therefore it may be necessary to have more than one sensing tip if you have more than one application with different sizes within same diameter range Also changeover time from one job to next will be minimized if once adjusted a sensing tip is dedicated to one particular application only four segments of sensing tip or sensing unit must contact taper on adjustment screw If one or more seg ments has been bent away from screw then back out screw and squeeze sensing tip back into shape If final bore size is smaller than 26 mm 1 03 skip steps c through j and go to step k c If using Sensing Unit back out adjustment screw until it is loose in sensing body Then tighten this screw one full turn after initial contact is made between tapered portion of adjusting screw and sensing body This initial setting of adjustment screw will allow you to increase or decrease sensing unit size when final size adjustment is made 22 FIGURE
43. TION Do not force STONE FEED DIAL or damage to feed system may result 16 Pull Mandrel Wedge straight back as far as possible 17 If required install Spindle Sleeve LN 570A not supplied with machine on Honing Unit 18 Rotate spindle by hand until large set screw is up 12 o clock position 19 With set screw indentation on honing unit in 9 o clock position insert honing unit as far as it will go Rotate honing unit 1 4 turn clockwise to engage wedge with feed rod then push honing unit all way in until it bottoms 20 Test wedge hookup by pulling honing unit straight out do not rotate If wedge is hooked up it will not allow unit to come out If honing unit comes out repeat step 19 Push honing unit back in until it bottoms 2 Tighten large set screw in spindle 22 Release Emergency Stop and turn power on 23 Set Roughing Feed Force Dial to desired level NOTE Roughing Feed Force cannot be adjusted to a value lower than Finishing Feed Force setting It may be necessary to turn Finishing Feed Force Dial down so that Roughing Feed Force can be set to desired level If FINISHING FEED FORCE selector is set on OFF Roughing Feed Force dial may be difficult to turn If FINISHING FEED FORCE selector is set to AFTER ROUGH TO FINISH DIAMETER or to DURING EXTRA STROKES ONLY then Finishing Force Dial may be difficult to turn During setup only you may turn this selector to position that frees feed force dial yo
44. TROKES Desired cycle time 1 5 x Stroker Speed 60 SPM WORKPIECE amp FIXTURE WEIGHT LIMITS On EC 3500 workpiece and fixture is mounted on Stroker Carriage Because all this has to stroke during honing process it is desirable to keep weight of fixture to a minimum If fixture and workpiece weigh too much stroker speed may have to be reduced A general rule of thumb is If combined mass of workpiece and all fixturing mounted to carriage is less than 5 kg 11 Ib then strokes speeds recommended on chart on operator panel will be acceptable If combined mass of fixture and workpiece is greater than 5 kg 11 Ib then stroke speed recommendations should be reduced by 10 for every kilogram over 5 kg 5 for every pound over 11 Ib seconds NOTE For safety always start heavy setups at 60 strokes per minute then while cycle is running turn stroke speed up slowly to desired speed If at any point stroker begins to knock labor or vibrate excessively then reduce stroke speed to a point that is no more than 80 of that speed UNIVERSAL FIXTURE EC 3500 is equipped with a standard Universal Fixture see Figure A 1 Universal Fixture is completely adjustable so that virtually all workpieces can be stroked automatically workpieces are captured axially but not held rigidly so that they can float on tool so that tool can follow existing hole without moving its centerline Fixture includes a torque arm so that a ri
45. Torque Arm to resist torque of workpiece as shown see Figure 3 3 Adjust bar so that torque is taken as far from honing tool as possible but with out risk of workholding fixture slipping past torque bar refer to Appendix A 4 If using an optional fixture purchased from Sunnen Products carefully follow all setup instructions supplied with that fixture If constructing your own special fixture make sure that honing torque will be resisted adequately and that workpiece is captured axially for stroking but free to float and align itself on tool 42 Set stroke position With hands clear from Work area press Stroker Jog and hold it in until stroker carriage stops at one end of stroke Measure overstroke distance from end of stone to end of workpiece bore Place workpiece in fixture or hold it next to tool to measure Press Stroker Jog and hold it in until stroker carriage moves to other end of stroke Measure overstroke on that end If overstroke is not equal on both ends then adjust stroke by loosening Stroke Position Lock and then turning Stroke Position Handwheel Handwheel is graduated in millimeters with numbers increasing as carriage is moved away from spindle Tighten Stroke position Lock and recheck overstroke on each end 43 Set coolant lines to supply a continuous supply of coolant to front and back of bore Coolant nozzles are attached to small aluminum bases that can be attached to stroker carriage see Figure 3 4 T
46. Use same Overstroke at each end of stroke If possible frequently stop machine and reverse workpiece on mandrel NOTE If bore is shorter than stone then Overstroke is amount bore extends past stone at end of stroke If stone is shorter than bore then Overstroke is amount that stone extends past end of bore at end of stroke Overstroke should be 1 3 to 1 2 of bore length or stone length whichever is shorter 10 If needle on Honing Indicator appears to be moving too slowly then increase Roughing Feed Force But never increase feed force to point that it is difficult to stroke workpiece smoothly and consistently by hand CAUTION Very small mandrels may break before you encounter significant resistance to stroking With very small mandrels do not increase feed force unless needle on Honing Indicator shows that cutting has virtually stopped 11 Hone until needle on Honing Indicator reaches zero Do not hone below zero Below zero feed force drops from set value which can cause glazed stones poor accuracy and an unnecessarily long honing cycle 12 Gage hole size If workpiece was correctly seated on mandrel when stock removal was set and if Stone Feed Dial or Roughing Feed Force dial has not been moved then bore should be undersized by amount that stone has worn Advance Stone Feed Dial by this amount and hone again to zero 13 If more than one workpiece is to be honed then place next workpiece on mandrel a
47. XTRA STROKES counter is set to some number 0 99 If set to then stroker will stop immedi ately When set to stop at end of stroke sometimes stroker must move slightly after spindle has stopped rotating In fine finishing applications this can sometimes cause axial scratches that are unacceptable To avoid this change Dip Switch S1 2 to set machine to stop immediately regardless of number showing on EXTRA STROKES counter Dip Switch Settings There are two sets of DIP switches located on the PED 1081 console board that select different modes of operation Do not attempt to change any settings while power is on 40 To Change a DIP Switch Setting 1 Turn main disconnect off 2 Open console 3 Locate DIP switches 4 Move switch to desired setting Example 2 is ON Stroker positioning is ON ON I BANKA MTEL 23456 123456 7 8 BANK B 5 Close and fasten Console 6 Turn main disconnect on Switches Bank A Al Slow Extra Strokes This causes the Stroker to run a Jog speed for the number of Extra Strokes selected The program will limit the number of Extra Strokes to 10 A2 Stroker Positioning ON When this is selected the machine will return the stroker carriage to the front of stroke at the end of every cycle When this switch is off the machine will stop immediately following the honing cycle A3 ASC Up Before Cycle or Square Honing
48. arriage for manual honing Push Stroker Carriage back until it stops Turn STROKING selector to MANUAL NOTE Hand lever on stroker shaft must be up for internal stroker latch to engage properly e Set STROKER LENGTH to 6 mm 1 4 in Loosen Stroke Position Lock and turn Stroke Position Handwheel to move Stroker Carriage in until it stops Tighten Stroke Position Lock 27 Remove any fixturing components that do not provide adequate clearance for manual honing 28 True mandrel and stone For safety start truing with a very low Roughing Feed Force 1 for tools smaller than 6mm 25 1 2 for larger tools Place a truing sleeve or suitable undersized work piece in a torque absorbing fixture and on mandrel Set FEED selector to EXPAND and turn STONE FEED DIAL until HONING INDICATOR shows a reading Return FEED selector to RETRACT Set COOLANT selector to CONSTANT Slowly open main coolant valve on coolant manifold until there is flow at one or more coolant nozzle Wet shoes and stone with coolant then turn coolant off Center truing sleeve over stone and shoes Grasp truing sleeve and holding fixture firmly with your left hand and slowly depress foot pedal As mandrel begins its rotation stroke truing sleeve forward and back Use short strokes at first then gradually lengthen strokes until stroke is about as long as sleeve or stone whichever is longer Reverse truing sl
49. ate may be excessively fast Turn feed force down until stone has worn to where itis mak ing full contact with bore Also be careful setting up Automatic Stonewear Compensator before stone is making full contact because actual stonewear may be less after that point is reached NOTE Truing should NOT be considered optional in following situations Honing bores with keyways or similar interrup tions where full contact is required for stones to bridge keyway Very close tolerance work where a high degree of cylindricity is required When stone and shoes have worn grossly out of parallel from continued use of a bad setup ASC UNIT NOTES 1 Disconnecting and Removing If Automatic Size Control Unit is not necessary for an application it can be removed from machine if it is in way of fixturing 38 Disconnect electrical cable and two air lines where they enter machine to left of spindle Air fittings here are self sealing so there is no need to plug ports Loosen Clamp Screw on ASC unit several turns until unit can be lifted free from its guiding rail 2 Timed honing cycles For applications where some deburring or polishing is required for just a small amount of time EC 3500 can be setup to produce cycles of consistent duration This type of operation is available by placing dip switch B3 in the ON position See Appendix A Dip Switch Settings before making any dip switch changes Set EXTRA STROKES to S
50. ave a tip which extends slightly beyond front end of stone and guide shoe For all blind hole work this tip must be cut off as illustrated below Mandrels which have been altered in this manner can still be used for honing open holes using a full length stone and guide shoe Blind hole Y mandrels are available on special order but P20 and D Honing Unit groups are not adaptable for honing blind holes hu 3 4 BORE ALTERATION FOR BLIND HOLES In honing blind holes STONE AND GUIDE SHOE LENGTH SHOULD BE 2 3 to 3 4 OF BLIND HOLE LENGTH including relief length This is necessarv to provide for proper stroking When alteration of stone and shoe length is necessarv remove material only from back end as shown To maintain stability of stone in mandrel it is important that at least 5096 of stone be behind forward wedge contact on stoneholder Otherwise stone could rock causing bore inaccuracies as work is stroked over honing unit To avoid any chance for stoneholder to rock when honing extremely ALTERATION OF INTEGRAL SHOE MANDREL 45 APPENDIX B shallow or short blind holes it may be necessary to cut back die cast stoneholder as well as abrasive mandrel shoes and wedge tip so that only 1 5 mm 1 16 extends beyond front wedge contact Pressure from wedge is then applied evenly to stoneholder NOTE THAT AT LEAST HALF OF STONE 3 4 BORE LENGTH IS BEHIND LENGTH FRONT WEDGE CONTACT i
51. back lower left corner of work area Connect white air line by pushing into place into air fitting with white washer Connect black air line to other fitting WARNING Keep hands away from ASC unit when turning ASC PROBE selector to move ASC probe up or down 3 Turn ASC PROBE selector switch back and forth between UP and DOWN ASC unit movement should be smooth and crisp without bouncing If necessary adjust speeds by turning flow control valves on black and white air lines inside left hood of machine NOTE Following steps 4 amp 5 are used to adjust ASC unit to machine They are listed here because they need only be done once However it may be easier to do this during first setup where ASC will be used See Section 3 Setup Power Stroked Honing step 49 4 Set coarse vertical position of Probe Select and install honing unit according to instructions Adjust runout of tool using concentric part or alignment bushing Lock bushing onto mandrel with EXPAND switch leaving about 12mm 1 2 of bore extended past tool Select ASC probe of correct size to fit bushing hole size and screw onto stud on Probe Body Center Probe Body in ASC Arm by loosening Probe Clamp Knob repositioning and reclamping Turn ASC PROBE selector switch to UP Loosen Clamp Knob and slide ASC unit forward until Probe meets bushing bore Retighten Clamp Knob Loosen Angle Plate screw and reposition Angle Plate to set Probe at same height as bushing
52. bushing or sleeve rotating on honing unit touch a marking pencil to sleeve to indicate high side Turn FEED selector to EXPAND This stops spindle while keeping sleeve locked on mandrel This also will disable Foot Pedal to prevent accidental starting Loosen numbered set screw on spindle nose that is on same side as high pencil mark and tighten screw on opposite side Turn FEED selector to RETRACT and repeat steps e g as necessary until minimum runout is obtained 25 Set Spindle Speed Use chart on operator station as a guideline for determining speed WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing 26 Position Stroker Carriage for manual honing Push Stroker Carriage back until it stops Turn STROKING selector to MANUAL NOTE Hand lever on stroker shaft must be up for internal stroker latch to engage properly Set STROKER LENGTH to 6 mm 1 4 in Loosen Stroke Position Lock and turn Stroke Position Handwheel to move Stroker Carriage in until it stops Tighten Stroke Position Lock 27 Remove any fixturing components that do not provide adequate clearance for manual honing 28 Install and position Torque Bar on stroker carriage so that work hol
53. crew o Loosen locknut on ASC Fine Position Screw Look through hole near top of ASC arm to red light on proximity switch Turn ASC Fine Position Screw until point is reached where light is just turned on From that point turn ASC Fine Position Screw 1 1 2 turns clockwise Tighten locknut on Fine Position Screw p Loosen Probe Body Clamp Knob and move whole Probe Body to center Sensing Tip on workpiece bore Tighten Probe Body Clamp Knob q Press STROKER JOG repeatedly to see how Sensing Tip engages bore and to see if Proximity Switch is being made at end of stroke It may be necessary to reposition Probe Body or to adjust Fine Position Screw 23 NOTE STROKER JOG will not operate if FEED selector is set to EXPAND r Return ASC PROBE selector to DOWN 50 Set EXTRA STROKES to desired value NOTES If Size Control is Zero Shut Off Extra Strokes will only occur if FINISHING FEED FORCE is set to DURING EXTRA STROKES ONLY Otherwise machine control system will disregard any numerical value displayed If Size control is ASC Extra Strokes can be used with Finishing Feed Force in either mode or with Finishing Feed Force off Regardless of Size Control mode selected follow ing feature of Extra Strokes display is always active If a numerical value is displayed stroker will always stop at a consistent end of stroke front or back If display shows then stroker will stop immediately once size control dev
54. ded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen Sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the following Normal maintenance items subject to wear and tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered
55. ding fixture can bear against it to resist honing torque 29 True mandrel and stone For safety start truing with a very low Roughing Feed Force 1 for tools smaller than 6 mm 25 1 2 for larger tools Place a truing sleeve or suitable undersized work piece in a torque absorbing fixture and on mandrel Set FEED selector to EXPAND and turn STONE FEED DIAL until HONING INDICATOR shows a reading Return FEED selector to RETRACT Set COOLANT selector to CONSTANT Slowly open main coolant valve on coolant manifold until there is flow at one or more coolant nozzle Wet shoes and stone with coolant then turn coolant off Center truing sleeve over stone and shoes Grasp truing sleeve and holding fixture firmly with your left hand and slowly depress foot pedal As mandrel begins its rotation stroke truing sleeve forward and back Use short strokes at first then gradually lengthen strokes until stroke is about as long as sleeve or stone whichever is longer Reverse truing sleeve frequently WARNING Always release pedal before removing truing sleeve or workpiece from tool 15 f honing indicator needle is not moving and feed force feels too light then stop and increase Roughing Feed Force by a small amount f needle on honing indicator goes below zero then stop and feed stone up If mandrel dries out apply a little more coolant Concentrate truing on area where y
56. e SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclu sion or limitation of liability for consequential or accidental damages and to the extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement
57. e bores see Troubleshooting SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures are given as guides only and are not to be construed as absolute or invari able Each machine must be maintained individually according to its particular requirements LUBRICATION WARNING Some troubleshooting procedures require examining parts inside machine enclosure ALWAYS have power OFF when hoods are open If problem cannot be diagnosed by Power Off inspection then consult a Sunnen Service Technician Spindle Only Lithium complex base grease Viscosity ISO VG 150 NLGI Grade 0 Tribol Molub Alloy 860 150 0 or equivalent Sunnen SML 110 1 Gal Can All other lubrication Lithium complex base grease Viscosity ISO VG 220 NLGI Grade 1 Tribol Molub Alloy 860 220 1 or equivalent Sunnen SML 120 Cartridge Feed Regulator Oil ISO VG 150 Oil ROUTINE MAINTENANCE SCHEDULE Daily Check coolant level Gage on front of Coolant System and add coolant as necessary CAUTION DO NOT overfill system FIGURE 4 4 27 f using Sunnen Coolant Concentrate check concentra tion and add water or concentrate as necessary Every 500 Hours CAUTION Over filling spindle can cause it to run hot Apply two or three pumps of grease to spindle see Figure 4 1 Apply grease to Feed Force Screw Stop Blocks see Figure 4 2 Apply grease all other grea
58. e its accuracy is limited by amount of stock being removed each stroke In some applications material is removed so rapidly that more than 3u 00015 is being removed every stroke Likewise accuracy of using Extra Strokes to compensate for probe wear is reduced if stock removal rates are excessive relative to stroke rate Even when using Zero Shut Off variations in spindle and stroker stopping time can cause size variations if stock removal rate is very high Switching to Finishing Force right before end of cycle will slow cutting rate and improve repeatability of final size Any of three benefits above translate to reduced cycle time and reduced cost Even applications that run acceptably well with only a single feed force can potentially be improved by changing to a harder abrasive and then using Two Stage Feed Force to correct finish cylindricity or size control problems usually associated with higher feed forces required for harder abrasive With harder abrasive stonewear is often reduced and productivity improved 35 Selecting Finishing Force amp Finishing Stock Removal Optimum finishing force and optimum amount of stock removal during finishing depends on application and can only be determined by experiment However following guidelines can help 1 If Finishing Force is being used primarily to improve finish Only a small amount of Finishing Stock Removal is required to improve finish typically 15 30u 0006 001
59. e one with higher grit shorten guide shoes longer stone and shoe Overcorrection of R number on both ends barrel will lead VIZZZZZZ2 to bellmouth condition TAPER IN True stone and shoes Change stroke so tight Reverse work on f power stroking make OPEN HOLE with truing sleeve end of bore is stroked mandrel more often sure spindle and stroker over stone further are in alignment TAPER IN Shorten stone and True stone and shoes If hole has insufficient Provide sufficient Provide adequate oil BLIND HOLE shoes to about 3 4 frequently with truing or no relief at bottom relief at bottom of flow at bottom of hole shorten stone more sleeve use hard tip stone hole to wash cutting out if taper persists OUT OF ROUND ake sure honing tool is recommended Thoroughly true stone and shoes to exact f thin wall part decrease cutting f stone stops cutting at decreased pressure If power stroking make sure spindle size for diameter to hole diameter pressure use stone with lower and stroker are in be honed hardness number alignment WAVINESS Use honing tool with sufficient stone length to bridge waviness or lands and ports in bore RAINBOW Use L BL or multi stone mandrel Stone Use shorter stroke Use stone with lower YZ LLL L122 length should be at least 1 1 2 times the length of bore for best bow correction length less overstroke hardness number to avoid part flexing FINISH TOO ROUGH F or extremely fine pres
60. e set for a Two Stage Feed Force honing cycle With this feature honing begins at a selected roughing feed force and then later switches to a lower finishing feed force to complete cycle Both magnitude of finishing force and amount of stock removed during finishing stage are selectable by operator Although this feature is not always necessary many applications perform better with addition of Finishing Feed Force Stage Two Stage Feed Force has three potential benefits 1 Improved surface finish When feed force is reduced toward end of cycle surface finish may improve A few applications have been found where using Two Stage Feed Force can reduce RA surface finish to half value generated by roughing feed force alone But usually improvement is not that dramatic Amount of improvement in finish is limit ed by grit size of honing stone and many applica tions will still require a secondary operation with a finer stone 2 Improved cylindricity When removing material quickly with a relatively high feed force a workpiece with a non uniform cross section or a thin wall can distort Reduction of feed force also reduces distortion but increases cycle time With Two Stage Feed Force often majority of material can be removed quickly at a relative high feed force then finishing force can be used to improve cylindricity while taking workpiece to its final size 3 Improved size control ASC system can only check size once a stroke Therefor
61. ease stroker carriage and pull it out toward front of work area Attach RUNOUT INDICATOR supplied with machine to threaded stroker drive shaft as shown see Figure 3 1 Position aluminum indicator base so that letters EC are up and facing you with that surface approximately level Move clamp handle until plastic cone on cam grips threaded stroker drive shaft Note reference gaging point and indicating gaging point on indicator see Figure 3 2 They should be spaced as far apart as possible without exceeding length of alignment bushing If necessary remove Knob A reference gage point by unscrewing it and inserting it in another hole Sliding Block will slide out to provide even greater separation of gaging points Position stroker carriage so that gaging points will contact alignment bushing Move pivot lock lever to Release position so that entire indicator will follow alignment bushing by contact of reference gaging point e With pivot lock lever in Release position Runout Indicator is now set to measure conical runout of honing unit Rotate spindle by hand while observing indicator If necessary turn Knob A to get an indicator reading Turn spindle until high point is found Loosen nearest lettered screw A B C D on front of spindle nose and tighten screw on opposite side Repeat this procedure until conical runout is within acceptable limits Conical runout of less than two divisions on indicator is accep
62. eatability required Setting Two Stage Feed Force Feature The change to Finishing Force can be triggered in two ways Rough to Finish Diameter When needle on honing indicator reaches a trigger point set by operator feed force switches from roughing to finishing Assuming that stonewear is either negligible or properly compensated either manually or automatically then zero represents a consistent final bore size and trigger point represents a consistent bore diameter where finishing force starts APPENDIX A During Extra Strokes Only In this case trigger point is size control device selected by operator either zero on honing indicator or point where ASC sensing tip enters bore The second method of triggering is easy to set up Merely set Finishing Feed Force to desired setting select During Extra Strokes Only and set extra stroke counter to some desired value The first method of triggering is less intuitive to set up The following procedure is recommended 1 Set Roughing and Finishing Feed Force to desired values 2 Measure a workpiece and place it on tool over abrasive 3 Select After Rough to Finish Diameter on Finishing FEED Force selector 4 Expand tool 5 Turn STONE FEED dial until needle on Honing Indicator is approximately on zero 6 Turn Finishing Force Selector from Rough to Finish Diameter to Off and back again a couple of times to seat workpiece on tool ending with selec
63. ecifications 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 Always ground yourself when handling sensitive components or assemblies 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 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work Put on your wrist strap or foot grounding devices Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly groun
64. ed Stone Saver Without Feed Regulator at beginning of each cycle machine feeds rapidly until stone contacts workpiece This high speed contact at full feed force in a rough bore can cause some stone break down resulting in greater stonewear Without Feed Regulator EC 3500 Feed System is a constant force feed system cutting rate will varying depending on condition of bore fully or partially cleaned up hardness of bore and condition of stone free cutting or glazing Feed Regulator can provide three benefits 1 Stone Saving Limiting feed rate just before stone contacts bore can eliminate excessive stone breakdown 2 Very Low Feed Force Honing There are practical limitations in applying a very low feed force consistently while tool expands very slowly In many applications with extremely small mandrels D2 family optimum feed force is somewhere less than machine minimum of 1 Using Feed Regulator set at a very slow speed restrains feed system and effectively delivers less than a feed force of 1 to stone 3 Elimination of glazing If stones are glazing first recommendation is to use a softer stone or to increase feed force If this is not possible or produces unac ceptable results then setting Feed Regulator to desired cutting rate and increasing feed force signifi cantly will produce cycles of consistent duration with out glazing APPENDIX A Feed Regulator has an adjustable MAXIMUM RATE control and a
65. ed ee a 29 keypad interface operates in operation only level Press RESET 200VAC flashing hal ka IMPORTANT Press INPUT VOLTAGE The 8 will be If machine is currently in powered up state turn OFF A 208VAC flashing X ne machine and allow display screens to extinguish Press DATA INPUT VOLTAGE i ENTER E1 01 208VAC 6 Release E Stop Switch on console and press Power ON Button Display on drives 1 amp 2 screens 4 Times gt MAX VOLTAGE inside enclosure should now be ON AR E1 05 230 0VAC 7 On Drive 1 Change keypad interface to Press EA UE uj advanced level as described in following chart DATA MAX VOLTAGE The 2 will be ENTER 230 0VAC flashing KKK KEVPAD SEQUENCE DISPLAV AFTER KEV IS PRESSED NOTES f SETT ara aT UH S e Press gt MAX VOLTAGE The 3 will be MAIN MENU RESET 230 0VAC flashing MENU OPERATION Press 3 Times MAX VOLTAGE The first 0 will be ress MAIN MENU 200 0 flashing PAN INITIALIZE EE Press lt MAX VOLTAGE The middle 0 will A DATA SELECT LANGUAGE RESET 200 0VAC be flashing ENTER ENGLISH Press 8 Times MAX VOLTAGE _ The 8 will be iis ACCESS LEVEL 208 0VAC flashing Y OPERATION ONLY ess ga Press PE n Press DATA MAX VOLTAGE DATA Al 01 0 ENTER E1 05 208 0VAC ENTER OPERATION ONLY n 8 plese MAIN MENU li A1 01 4 MENU OPERATION RL ADVANCED LEV
66. ed to gage workpiece at end of stroke With further loosening entire ASC unit can be removed from machine 33 ASC FINE POSITION SCREW Adjusts position of ASC unit Clockwise rotation moves ASC unit closer to workpiece 1mm per revolution This direction of rotation is matched to STROKE POSITION HANDWHEEL rotation for easy adjustment after making a stroke position adjustment A knurled locknut holds screw in place after making adjustment 34 PROBE BODY CLAMP KNOB Locks ASC Probe Body to actuator arm When loosened probe body can be aligned with workpiece bore then locked in position 35 COOLANT MANIFOLD Valves regulate flow of coolant through each of four coolant lines and one Main Valve controls total amount of coolant flow 36 SPINDLE SPLASH GUARD Attaches to rear of stroker carriage with a knurled thumb screw Contains coolant spinning off spindle in most applications May have to be removed if stroker carriage must stroke too close to spindle housing 37 STROKER DISABLE SWITCH Models EC 3500CE and EC 3500CD only With a key this switch can be turned to disable stroker for manual honing When DISABLE is selected automatic stroker cannot run and light curtain is also disabled SECTION 3 SETUP amp OPERATION GENERAL This section gives step by step setup and operating procedures SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around the Unit
67. eeve frequently WARNING Always release pedal before removing truing sleeve or workpiece from tool f honing indicator needle is not moving and feed force feels too light then stop and increase Roughing Feed Force by a small amount f needle on honing indicator goes below zero then stop and feed stone up f mandrel dries out apply a little more coolant Concentrate truing on area where you feel most pull or resistance Frequently stop and examine shoes and stone For most applications at least a full line of contact should be seen on stone and both shoes If wear does not show sufficient contact use truing sleeve some more NOTE When using keyway mandrels stone and shoes must fully radius to within 0 13 mm 005 before bores with keyways can be honed When finished truing return STROKER key switch to ENABLE and remove key 29 Return Spindle Speed setting to zero for safety 30 If Two Stage Feed Force is not desired set Finishing Feed Force selector to OFF If Two Stage Feed Force is desired select mode of operation either After Rough to Finish Diameter or During Extra Strokes Only Refer to Appendix A for guidelines to determine when Two Stage Feed Force is useful and how to determine best mode of operation 31 Set Roughing Feed Force to desired level 32 If using Two Stage Feed Force set Finishing Feed Force to desired level SLIDING ALIGNMENT BUSHING
68. ension belt before tightening screws on base plate Tension belt so that deflection at midway between pulleys is approximately 4mm 158in when 33N 7 4 Ib load is applied NOTES 30 GENERAL Refer this section when troubleshooting your machine TROUBLESHOOTING TABLE 5 1 Operational Troubleshooting SECTION 5 OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore con ditions or with honing operation consult Table 5 1 Standard Sunnen Tooling and Procedures will satisfy all ordinary honing requirements If problems are encountered they can usually be solved by following procedure suggested below For detailed information on difficult or unusual honing problems contact your local Sunnen Field Engineer or Sunnen Customer Service Department in St Louis Missouri USA CONDITION TO BE CORRECTED STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STONE GLAZED Sharpen A stone Increase cutting Increase stroking Use a softer stone Check oil to be STONE Stone surface looks with MAN 700 pressure speed one with a lower sure you are using NOT clean but cutting diamond dresser use hardness number Sunnen Industrial CUTTING grains are dulled LBN 700 dressing stick Honing Oil on all other stones Honing dial STONE LOADED Clean stone with ncrease stroking Use a Softer stone Use a coarser gr
69. er bleeding air out of canister with pump running 5 Replace sediment tray NOTE Omission of Sediment Tray will reduce life of filter COOLANT MANIFOLD N HIGH PRESSURE RELIEF VALVE 40 PSI MAX FLUID PUMP FILTER ELEMENT FILTER CANISTER FLOW CONTROL ON OFF VALVE LOW PRESSURE RELIEF VALVE 13 PSI MAX FIGURE 4 6 Coolant System Pump Maintenance Dirty honing coolant which must pass through pump before it can be filtered contains many aggressive abrasive Fparticles The progressing cav ity pump used on coolant system provides superior life when compared with other common types of pumps However some of pump components can be expected to wear in this difficult application The most common part to wear is Nitrile Stator although eventually Rotor and Seal will also wear out All of these parts are available from Sunnen or directly from pump manufacturer Stator and Rotor can be replaced easily without having to remove pump from coolant system that is required is removing four screws on suction housing NOTE Because pump is below coolant level break hose connections near top of coolant system preferably inside to prevent hoses from acting as a siphon when suction housing is opened Replace Spindle Belt 1 Remove two screws holding feed rod thrust bearing cover to thrust bearing housing 2 Slide feed rod and thrust bearings forward out of thrust bearing hou
70. er of each cover Place hood prop securely into bracket on hood to hold it open see Figure 1 2 4 After removing packing material from inside machine close both hoods and make sure hoods are latched securely WARNING Hoods do not need to be opened for setup Never have hoods open when power is on Access to internal systems is only necessary for maintenance which should only be done with power turned off FIGURE 1 1 Placement of Forks for Lifting FIGURE 1 2 Hood Prop ELECTRICAL POWER SUPPLY 1 Connect Electrical Supply Cord and Oil Tight Fitting not supplied to Machine as follows see Figure 1 3 NOTE Model EC 3500D requires a 10 4 Type SJO or SO 600V 6 0mm2 electrical supply cord This machine requires 208 or 230 V 3 phase 50 or 60 Cycle Power Maximum current load is 30 amp Model EC 3500E requires a 12 4 Type SJO or SO 600V 3 5mm2 electrical supply cord This machine requires 380 400 460 V 3 phase 50 or 60 Cycle Power Maximum current load is 16 amp CAUTION Do not attempt to connect machine if supply voltage is not within following acceptable limits Model EC 3500D between 200 and 255 V Model EC 3500E between 380 and 480 V If supply voltage is not within these limits MACHINE WILL BE DAMAGED 2 Verify supply voltage is same as voltage on ELECTRICAL SPECIFICATION PLATE NOTE If supply voltage does not match voltage stated on Electrical Specification Plate b
71. est trigger method regardless of size control method Best improvement in finish occurs only with drastic reductions in feed force At these low feed forces stone essentially stops cutting nearly glazing Cutting rate becomes so slow that it would require an inordinate amount of time to hone to zero shut off point or to ASC probe diameter if After Rough to Finish Diameter method is used With extremely low feed force and During Extra Strokes Only effectively there is a timed sparkout stage before stopping Exception Although stone may appear to stop cutting there must in reality be some stock removal for finish to improve If this final slow rate of feed is not consistent over time or from one part to next then addition of a significant amount of extra strokes after size control device has tripped can introduce inconsistencies in final bore size If this is unacceptable then After Rough to Finish method must be used 2 If improvement of cylindricity is primary reason for using Two Stage Feed Force and Zero Shut Off is to be used then After Rough to Finish Diameter will probably be best method To improve cylindricity a significant amount of stock must be removed during finishing stage If Extra Stroke method is used a large count will be required and again this can introduce inconsistencies in final bore size 3 If improvement of cylindricity is primary reason for using Two Stage Feed Force and ASC is being u
72. gid torque absorption point is provided for workpiece or a special workholding fixture to bear against during honing cycle Universal Fixture is configured at factory to be a Finger Fixture where a small lever can be used to quickly open outside fingers with a scissors type motion This configuration will probably be most APPENDIX A FIGURE A 3 Gate Fixture Configuration convenient for small and medium sized workpieces see FIgure A 2 However if a larger opening is required to load workpieces fixture can be quickly reconfigured to be a Gate Fixture where entire gate can be lifted 90 to clear work area see Figure 3 Extra pieces that are packed with fixture are used in this configuration Universal Fixture is designed for maximum flexibility In both configurations fixture can be reversed from left to right to suit operator s preference Also Hinge and Latch may be unscrewed from outside of gate piece and reattached on inside for longer workpieces 39 NOTE To mirror fixture from left to right requires removing components from gate reversing gate and then reattaching components If entire assembly is simply reversed then fingers will end up in a position where they are not adequately supported to resist high stroking loads Adjusting Finger Fixture Set fixed fingers on carriage to contact workpiece as close as possible to tool leaving enough clearance between tool and fingers s
73. gnment bushing 34 Set stroke length Loosen Stroke Length Lock on front panel 1 4 turn is usually sufficient and turn Stroke Length Handwheel until Stroke Length Indicator is aligned with desired stroke length For most applications set stroke length to a value that is 95 of bore length or abrasive length whichever is longer See Stroke Length Guide printed on front panel of Machine NOTE Maximum stroke length is bore length or stone length whichever is longer NOTES If workpieces have long counterbores or large overhangs shorten stroke length to gain stability For workpieces with blind holes maximum stroke length should be bore length including relief minus 2 3 stone length For workpieces with tandem holes using a solid line of stones stroke length should equal total stone length minus tandem distance For workpieces with tandem holes using separated tandem stones maximum stroke length is tandem land length or individual stone length whichever is longer 35 Lock stroke length by tightening Stroke Length Lock securely 36 Engage Stroker Carriage with power stroking unit Push Stroker Carriage back until it stops Turn STROKING selector to AUTOMATIC NOTE Hand lever on stroker shaft must be up for internal stroker latch to engage properly 20 FIGURE 3 4 Coolant Line ME FIGURE 3 5 Coolant Line SENSING TIP gt KN ADJUSTMENT SCREW SE
74. hat the table is locked securely prior to cylinder head assembly or disassembly 16 Be sure to work in a well lit area and to use the light supplied to avoid dangerous unseen conditions which may exist otherwise 13 OPERATING TIPS The EC 3500 can be setup and operated a number of different ways The use of many features is optional Not all features are beneficial in any given application Appendix A explains some of these optional features and outlines some guidelines for determining when they might be beneficial Usually experimentation will be required to find optimum setup Although EC 3500 is intended for production honing manual stroked honing is possible Manual honing should only be used for honing a very small number of workpieces such as for tooling or repairs The ease of setting up stroker and fixture makes it practical to power stroke even as few as five or ten workpieces Power stroking is always more precise more consistent and safer Manual Honing Manual Honing Safety Instructions READ FIRST Follow ALL steps in this section carefully ALWAYS start with Feed Force set to no more than 1 1 and Spindle Speeds set to no more than 1 2 of recommended speeds The danger of manual honing increases as speed or feed force is increased For Models EC 3500CE and EC 3500CD When finished manually honing return Stroker Key Switch to ENABLE and remove Key so that spindle can not start if an operator is in
75. hole Retighten Angle Plate screw To help guide Probe toward work piece loosen Bumper screw slide Bumper to contact Fine Position Rod and retighten Screw 5 Set horizontal position of Probe Note distance from center of Probe to center of bushing Loosen Clamp Knob and slide ASC unit toward front of machine to access two Base screws Loosen two Base screws and slide Base along screw slots distance noted Retighten Base screws and slide ASC unit forward to bring Probe in front of bushing Probe should be centered in front of bushing Set this horizontal position so that Clamp Knob will not touch machine frame when ASC Unit is slid along Rail Side Tray Unpack side tray Place mat provided into tray Tray can hang on either side of machine or on side of coolant cart Plastic spacers on bottom of tray bracket can be placed in two different positions to accommodate different widths of machine side and coolant cart side see Figure 8 Only one tray is provided as standard If needed a second tray can be ordered Sunnen part EC 6510 14 SPINDLE SPEED FINISHING FEED FORCE EXTRA STROKES AFTER a 44 15 STROKER 12 FINISHING SPEED FEED FORCE 13 EXTRA STROKES 10 SIZE CONTROL 11 STROKING 9 EMERGENCY PY Poza m A STOP 817 6 COOLANT 8 FEED CYCLE START CYCLE STOP STRORER JOG POWER ON POWER OFF 5 CYCLE START CO 4 CYCLE STOP 1 POWER OFF 3 STROKER JOG 7 ASC PROBE FIGUR
76. i tialize system ACTIVE light on Sender should now be lit and GUARD light on Receiver should be lit If these lights are not on move coolant cart from side to side to align beam If Opto Electronic Screen is still not active then realign mirrors Mirrors are adjusted by rotating and tilting them to proper position To rotate Mirror Assembly slightly loosen Locking Set Screws and Base Positioning Sender Unit lights START lights approximately 10 seconds until Sender and Receiver are synchronized OPTO ELECTRONIC SCREEN RECEIVER MIRROR ACTIVE remains on to show Sender and ASSEMBLY Receiver are synchronized and operational Receiver Unit lights GUARD green sensing field is uninterrupted LOCKING and active ET SCREW BS 5 CLEAR yellow sensing field is uninterrupted but System is awaiting initializing beam break BREAK red sensing field has been interrupted or is inactive BASE POSITIONING WEAK SIGNAL orange signal strength gh SET SCREWS is low for upper or lower beams Check Z alignment and lens cleanliness CAPSCREWS FIGURE 1 6 Opto Electronics Screen Screws then turn Mirror Assembly to proper position loosen spindle side Base Positioning Set Screw and and retighten set screws To tilt Mirror Assembly first tighten side Base Positioning Set Screw Lastly retight slightly loosen 2 Locking Set Screws tilt Mirror en Locking Set Screws Assembly
77. ice is trig gered The feature is only necessary when try ing to obtain extremely high size repeatability when using Zero Shut Off or when it is feared that stroker motion at end of cycle may cause scratches on extremely fine finishes If using the feature with ASC note that all size corrections must come from adjusting screw in sensing tip body If ASC size control mode is selected but ASC Unit is disconnected machine control will begin count ing down extra strokes 1 1 2 seconds after honing cycle begins This produces honing cycles of con sistent duration lasting only specified number of strokes This can be useful when only some debur ring or polishing is required Changing amount of Extra Strokes is an easy way to compensate for ASC sensing tip wear However keep in mind that more extra strokes there are more final bore size can vary since bore is being plug gaged before extra strokes If honing rates vary over time more or less extra material may be removed during finishing If final size tolerances are close keep amount of extra strokes to a minimum 51 Using Sunnen Precision Bore Gage measure bore size of a workpiece and place it on honing tool WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed 52 Turn Feed Selector to EXPAND Rotate workpiece by hand some to get it to seat fully on mandrel 53 Make sure FINISHING FEED FO
78. it Recheck freeplay PROBLEM Stroker knocks at one or both ends of stroke SOLUTIONS Is anything in work area being struck by carriage or fixture Press STROKER JOG to check Is stroke length set to a point above 170mm Is Stroke Position Lock tightened If so try turn ing Stroke Position Handwheel If it turns easily see solution to next listed problem Stroking load may be excessive see solution above to Stroke length changes over time PROBLEM Cannot set stroke speed to anything above 200 SPM SOLUTION Look at stroke length setting If it is at 90mm or above machine control will not allow stroke speed to be set over 200 SPM which would be dan gerous to operator and destructive to stroker PROBLEM When setting up to adjust conical and parallel tool runout stroker carriage cannot be placed in a position where runout indicator can pick up concentric bushing centered on abrasive section of tool SOLUTION Runout indicator can be pulled off of pin that it pivots on and aluminum base that holds that pin can be turned upside down and rotated so that pin is in a different position when aluminum base is clamped on threaded stroker shaft If indicator 33 still cannot reach required position it may be neces sary to make a special pin for indicator to pivot on mounting to front of stroker carriage PROBLEM When attempting to hone a workpiece with only a very small amount of material to remove 1 t
79. it Check oil to be needle moves Stone surface looks LBN 700 dressing pressure one with a lower stone one with a Sure you are using too slowly smeared and stick hardness number ower grit number Sunnen Industrial clogged with chips Honing Oil SLOW STOCK REMOVAL Increase spindle speed ncrease cutting Check oil to be Use a Softer stone Use a coarser grit Honing dial needle moves too slowly pressure Sure you arc using Sunnen Industrial Honing Oil one with a Lower hardness number stone one with a lower grit number POOR STONE LIFE Honing dial needle moves too fast Decease cutting pressure Use faster spindle speed one with higher hardness number stone one with lower grit number Check oil to be sure you are using Sunnen Industrial Honing Oil BELLMOUTH True stone and shoes Use softer stone f Bore is LONGER Shorten STONE only If bellmouth persists with truing sleeve OK with lower than 2 3 stone length or row of stones shorten stones still If part is short or hardness number slightly on both ends more but do not shorten ZZZZZZZZZ unbalanced shorten shoes any further stroke length f Bore is SHORTER Shorten STONES and CAUTION EZLLLLLZZI than 2 3 stone length SHOES equallv to Overcorrection of l 1 2 times bore bellmouth will lead length to barrel condition BARREL True stone and shoes Use finer grit stone Use longer stone or Use mandrel with CAUTION with truing sleev
80. it is already on adjust amount of automatic stonewear compensation by turning AUTOMATIC STONEWEAR COMPENSATOR knob counterclockwise some Write down or make a mental note of STONE FEED dial position Press check button and hold in to check amount of compensation Adjust if necessary Return STONE FEED dial to original position 11 If using Two Stage Feed Force Is amount of finishing too long or too short If using AFTER ROUGH TO FINISH mode amount of finishing can be increased by turning AFTER ROUGH gt FINISH knob clockwise slightly If using DURING EXTRA STROKES ONLY amount of finishing can be increased by adding extra strokes However if using extra strokes with ASC this may change final bore size and sensing tip may have to be adjusted 12 Is honing rate reasonable Is cylindricity of finished bore acceptable Feed forces may have to be adjusted In general increase Feed Force if honing is too slow and finished bores are round and straight and of consistent size Also in general decrease Feed Force if bores are not as cylindrical as desired if size is inconsistent or if stonewear is excessive If not using Two Stage Feed Force it may be beneficial 13 Is stroker stopping at desired end of stroke End of stroke that stroker will stop on can be changed by pressing STROKER JOG and holding in until stroker stops at opposite end Every cycle thereafter will stop at that end 14 To correct other problems with workpiec
81. l for small amounts of finishing stock removal because again a large extra stroke count can introduce inconsistencies in final bore size 4 If improvement of size control is reason for using Two Stage Feed Force then After Rough to Finish Diameter method must be used because cut ting rate must be slowed before size control device whether zero shut off or ASC finds its target size 37 APPENDIX A Note Only a very small amount of finishing stock removal is necessary for improvement of size control but if ASC is used it is subject to same limitations listed above Therefore a fairly generous amount of finishing stock removal should be used to avoid potential problems Note about Honing Workpieces that are Only Slightly Undersize When honing without Two Stage Feed Force or Extra Strokes it is common to take a part that was honed slightly undersize and re hone it immediately to bring it right to size However with these new special features in use this is inadvisable In time it takes for finishing force to actuate or for extra strokes to count off workpiece will probably go oversize It is recommended that any such work pieces be set aside until end and then honed with finishing force off but with roughing feed force set to same value as finishing force had been and with no extra strokes FEED REGULATOR Feed Regulator on EC 3500 is a feed rate limiter On earlier model Sunnen Honing Machines this feature was call
82. le cannot be started with the stroker mode in manual Place the stroker mode selector switch to Auto Error 10 Stroker Enable Key is Off cycle will not be started when the stroker enable key is in the OFF position Turn the stroker enable key to the ON position Error 11 Electrical Fault The machine has had an electrical fault Check circuit breakers drives overloads and motor temperature 32 FIGURE 5 1 Stroker Pivot Free Play Error 12 Stroker at Back of Stroke The machine was started with the stroker carriage at the front of stroke If starting from the front or stroke is needed this error should be bypassed See Appendix A Dip Switch Settings Problems Solutions WARNING Some troubleshooting procedures require examining parts inside machine enclosure ALWAYS have power OFF when hoods are open If problem cannot be diagnosed by Power Off inspection then consult a Sunnen Service Technician PROBLEM Machine does not start when Cycle Start is pressed SOLUTIONS Is power on 15 FEED selector set to RETRACT Is foot pedal cover in place Is STROKING selector on AUTOMATIC For Models EC 3500CE and EC 3500CD only Is STROKER key switch set to ENABLE Is green LED on Light Curtain lit If red LED is lit then something is blocking a light beam If yellow LED is lit then light curtain needs to do its startup self check routine Put your hand through light bea
83. load is applied then belts can be tightened Loosen four bolts holding motor assembly in place Tighten belt tightening screw against its wedge slightly until appropriate tension is achieved Retighten mounting bolts If belt tension is correct and Spindle Stroker is still stalling then reduce feed force being used Continued operation under these loads can be detrimental to machine life PROBLEM Machine stops during or at end of a cycle and power to machine is automatically turned off SOLUTIONS Are Spindle and Stroker Drives configured for voltage that 18 being supplied to machine See Machine Conversion in Installation section at beginning of this book For Models EC 3500CE and EC 3500CD only Did something enter Opto Electronic Screen during honing cycle If so machine will turn its power off so that operator will be aware that workpiece in machine has not been honed to completion PROBLEM No Coolant flow or insufficient coolant flow SOLUTIONS First check coolant level gage for sufficient coolant in reservoir and check plastic valves in work area to be sure they are open Pull coolant system out far enough to view it but leave it connected electrically Open reservoir cover and remove sediment tray to view inside of coolant system Turn machine power on and set coolant selector to CONSTANT Refer to Appendix C APPENDIX A SPECIAL TOPICS TWO STAGE FEED FORCE GUIDELINES Feed System of EC 3500 can b
84. ly locked on If not turn STONE FEED DIAL until there is an indicator reading Turn Dial same direction as you wish needle to move Turn FEED selector to RETRACT Set Spindle Speed to 200 rpm CAUTION Do not attempt to adjust mandrel runout at any speed higher than 200 rpm Depress Foot Pedal fully to start spindle with alignment bushing on mandrel If runout does not seem excessive proceed to step 25 If runout is excessive center honing unit as follows With bushing or sleeve rotating on honing unit touch a marking pencil to sleeve to indicate high side Turn FEED selector to EXPAND This will stop spindle while keeping sleeve locked on mandrel This also will disable foot pedal to prevent accidental starting by stepping on foot pedal Loosen numbered set screw on spindle nose that is on same side as high pencil mark and tighten screw on opposite side Turn FEED selector to RETRACT and repeat steps e g as necessary until minimum runout is obtained 25 Set Spindle Speed for truing Use chart on operator station as a guideline for determining speed WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING and TRUING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing or truing 26 Position Stroker C
85. m path and then pull it out again to trigger self check routine PROBLEM One or more of switches on operator panel do not seem to work SOLUTION Some setup functions such as STROKER JOG will not work if other switches are set improperly Check following Is power on Is FEED selector set to RETRACT Is foot pedal cover in place Is STROKING selector on AUTOMATIC For Models EC 3500CE and EC 3500CD only Is STROKER key switch set to ENABLE Is green LED on Light Curtain lit If red LED is lit then something is blocking a light beam If yellow LED is lit then light curtain needs to do its startup self check routine Put your hand through light beam path and then pull it out again to trigger self check routine PROBLEM Stroke Length slowly changes over time SOLUTION Check Stroke Length Clamp Handle for tightness If handle is already tight then stroking load is exceeding capacity of stroking mechanism Reduce stroking load by one or more of following Reduce Stroker Speed Reduce Feed Force Reduce weight of fixturing Also check Stroker Pivot Assembly free play With power OFF open right hood Move large stroker pulley by hand until Crossbeam is vertical see Figure 5 1 Lift end of Pivot Assembly lightly with a finger and let go It should drop between 4 and 10mm Measured at nut If drop is greater than 10 loosen jam nut and then loosen nut slightly and retighten jam nut against
86. machine off Verify Coolant Cart is not installed Open Electrical Control Enclosure Set Overload 1OL to 1 6 A for 208 V supply 0 9 A for 380 V supply 360 voltage for other voltages Eo pub de 5 Use a wrench to turn shaft of Main Disconnect Switch a quarter turn clockwise to ON position WARNING Power is now on inside Enclosure Only touch key pad of DRIVE as instructed NOTE Remaining steps in Machine Conversion Procedure depend on brand of drives that are in your machine Identify brand of drives and then follow appropriate section below Saftronics or Magnetek GPD 515 Drives This procedure gives step by step instructions on configuring a GPD 515 drive in a EC 3500 low voltage machine so that it can operate at 208V When a EC 3500 low voltage machine leaves facto ry it is programmed to operate at 230V Complete steps 1 thru 5 Machine Conversion NOTE Before programming operating voltage KEYPAD SEQUENCE DISPLAY AFTER KEY IS PRESSED NOTES reconfigure drive to allow keypad interface to operate Press 7 NE INPUT VOLTAGE The middle 0 will A 200 be flashi in advanced level During normal operation machine s TIAE
87. n the machine will ignore the second proximity switch This is used when it is desirable to have the machine seek the back of stroke at the completion of a honing cycle A8 Delay Stonewear Compensation During ASC operation the EC 3500 normally advances the Stonewear Compensator when the honing indicator needle reaches zero Turning this switch on will delay the advancing of the Stonewear Compensator until the beginning of the next cycle 41 Switch Bank B B1 B2 Factory Settings These switches should be left in the default factory position DO NOT attempt to change these settings unless specified by a Sunnen Representative B3 Stroke Count Honing Turning this switch on tells the EC 3500 to hone for the number of strokes set in the Extra Strokes dis play This is useful for deburring or polishing operations The machine must be in the ASC mode of operation for this switch setting to take effect B4 B8 Not used These switches are not currently used by the EC 3500 They should be placed in the OFF position NOTES 42 APPENDIX B GENERAL HONING INFORMATION GOOD HONING PRACTICES ALWAYS DEBURR A ROUGH HOLE If a bore is rough or has burrs prior to honing a quick deburring operation with a very hard deburring stone prevents damage to stock removal or finishing stone reduces stone costs and speeds
88. n INITIAL DIAMETER setting knob INITIAL DIAMETER knob should be set so that feed system feeds rapidly at its normal rate up to some point slightly smaller than smallest bore you expect to encounter At this initial diameter Feed Regulator takes over slowing feed to rate that is set with MAXIMUM RATE dial From that point feed will continue at that rate or slower if normal cutting rate at selected feed force is slower than maximum rate selected For details on setting Feed Regulator see Setup Power Stroking TRUING Sunnen mandrels shoes and stones are manufactured to close tolerances so that in many low to medium precision applications it will not be necessary to true stone and shoes A proper setup will generate and maintain parallelism between stone and shoes If you choose not to true honing unit remember fol lowing Hone first workpiece undersize by a fair amount so that you can check straightness of bore If is not acceptable you will have to adjust stroke length or stroke position or stop honing cycle frequently and flip part end for end Continue to hone parts under sized until bore straightness is acceptable If bores do not straighten out after a few workpieces then truing should be considered new stone or a used stone placed in an applica tion with a different bore size will not make full contact with bore until it has worn a radius to match bore Before it does this stonewear will be high and cutting r
89. n STONE FEED dial clockwise until you meet resistance then advance it counterclockwise approximately 10 turns CAUTION Do not force STONE FEED DIAL or damage to feed system may result 13 Pull Mandrel Wedge straight back as far as possible 14 If required install Spindle Sleeve LN 570A not supplied with machine on Honing Unit 15 Rotate spindle by hand until large set screw is up 12 o clock position 16 With set screw indentation on honing unit in 9 o clock position insert honing unit as far as it will go Rotate honing unit 1 4 turn clockwise to engage wedge with feed rod then push honing unit all way in until it bottoms 17 Test wedge hookup by pulling honing unit straight out do not rotate If wedge is hooked up it will not allow unit to come out If honing unit comes out repeat step 16 Push honing unit back in until it bottoms 18 Tighten large set screw in spindle 19 Release Emergency Stop and turn power on NOTE Steps 20 through 29 are instructions for truing stone and shoes of honing tool Truing is not always necessary If you don t need to true mandrel then skipping these steps can save considerable time in set up See Appendix A for guidelines on when truing is necessary and when it can be considered optional 20 Set STROKING selector to MANUAL Set STROKER key switch to DISABLE 21 Turn SIZE CONTROL selector to ZERO SHUT OFF 22 Set Roughing Feed Force Dial to some low
90. nd repeat honing operation Do not advance Stone Feed dial at beginning of a cycle unless you are confident that stone will wear at least that much If you feed up more than stone actually wears then bore will be oversized when you hone to zero Setup Power Stroked Honing Press Emergency Stop to clear any previous setup 2 Turn OFF coolant supply by turning Main Control Valve on Coolant Manifold fully clockwise 3 If ASC unit is attached to machine loosen Clamp and slide unit out away from spindle Turn ASC PROBE selector to DOWN Unit can also be removed from machine entirely 4 Set FEED selector to RETRACT 5 Turn FEED REGULATOR off by turning INITIAL DIAMETER knob fully clockwise 6 Turn AUTOMATIC STONEWEAR COMPENSATOR off by turning knob fully clockwise 7 Remove Spindle Splash Guard 8 Disengage Stroker Carriage from power stroking unit Turn STROKING selector to UNLATCH Pull Stroker Carriage forward to provide access to spindle 9 Select correct honing unit and stone from Sunnen Honing Supplies Catalog 10 Assemble Honing Unit according to instructions 11 Set HONING TOOL INDICATOR SCALE selector to position that matches tool being used and scale you wish to read NOTE For most applications it is recommended that scale be used unless stock removal is expected to be more than 240 009 Finer resolution on scale gives a clearer indication of honing rate 12 Tur
91. ndem and multiple land bores is contained in Data File 106 Write for free copy CENTER TO CENTER TANDEM DISTANCE 4 N N A IF STONE AND GUIDE SHOE LENGTH IS LESS THAN TWICE TANDEM DISTANCE ALTERATION IS REQUIRED SEE TEXT Ie REMOVE sl ALTERATION FOR TANDEM BORES 46 ALTERATIONS FOR SHORT BORES USING AUTOMATIC SIZE CONTROL Always consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units For precision sizing of open holes stone and guide shoe length should be between 2 3 and 1 1 2 times bore length to be honed 2 3 TO 1 2 T THE BORE ALTERATION OF INTEGRAL SHOE MANDREL Mandrels can be altered as illustrated to hone short bores using automatic size control Alteration allows sensing tip to be positioned closer to end of honing stone Alteration is necessary if overstroke of a short bore does not depress sensing tip a sufficient amount to allow automatic size control to work GLOSSARY OF TERMS ADAPTER A part used with certain mandrels to adapt them to fit spindle on honing machine ALTERED STONE A standard honing stone which has been shortened or otherwise changed for specific application ALUMINUM OXIDE abrasive material generally most suitable for fast stock removal in tough materials such as most types of steel It is designated by letter in Sunnen stone code example K17 A57 2777774
92. ne DO NOT hone without installing workpiece in a workholding fixture that transmits honing torque to a solid machine member Never try to absorb honing torque by holding workpiece with your hand 3 Slide workpiece on mandrel and center workpiece over stone It may be necessary to back off Stone Feed Dial clockwise to get workpiece on mandrel 4 Turn POWER ON 5 Make sure that Roughing Feed Force is set to desired setting and then turn FEED selector to EXPAND Turn workpiece several revolutions on mandrel to seat workpiece on stone WARNING Do NOT step on foot pedal to set stock removal amount Spindle will turn if foot pedal is depressed 6 Turn Stone Feed Dial until needle on Honing Indicator shows amount of stock to be removed Make sure that Honing Tool Indicator Scale Selector is set to appropriate mandrel family 7 Turn FEED selector to RETRACT 8 Check Spindle Speed setting and verify that STROKING selector is set to MANUAL WARNING Recommended speeds may not be suitable for all applications For MANUAL HONING always start with a speed that is no more than half speed recommended on chart then increase speed in small increments only when job seems to be running safely Never exceed recommended speed when manually honing 9 Slowly depress Pedal while stroking workpiece If bore is rough or out of round DO NOT fully depress Pedal until bore has smoothed out as evidenced by diminishing vibration
93. ned on If so increasing pressure may make no difference in honing rate because honing rate is limited by maximum rate selected on Feed Regulator If Feed Regulator is turned off then check Air Pressure Regulator Pressure should be 0 55 MPA If it is low then adjust it by turning knob on top of Regulator PROBLEM When using Feed Regulator at higher feed forces Initial Diameter where needle begins to slow down on Honing Indicator appears different during a cycle than it did when it was set 34 by recommended procedure SOLUTION This is normal behavior caused by amount of compression in feed system However this indicates that stones are contacting workpiece bore immediately after cycle begins although not at full feed force selected If this initial contact still seems too rough then turn Initial Diameter knob counterclockwise some to make Feed Regulator begin at a smaller diameter PROBLEM Turning INITIAL DIAMETER knob on FEED REGULATOR smaller does not seem to change point where FEED REGULATOR begins working SOLUTION Damper Cylinder inside machine may be low on oil Fill cylinder and try again To fill cylinder without removing it from machine requires a long spout with a flattened tip to fit in fill slot in cylinder PROBLEM Spindle and or Stroker seems to stall under high honing load SOLUTION Check belt tension If deflection midway between pulleys is greater than 4mm 158in when a 33N 7 4 Ib
94. nnen Products Co Indicates CE version ONLY 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE OF CONTENTS pd E CRUS uri eb pete ond EORR eh V nts LIST OF ILLUSTRATIONS RR e e e e 3 es GENERAL INFORMATION amp SPECIFICATIONS th vi INTRODUCTION ue RR XE eed Eee a ERE EE deed ca pee es vi INSTALLATION was l epo po dag de e qc DR deb Sabre aedis e pios abd eds 1 Tools amp Materials Jets px UR noe ng Boe ai a wae Le PECAN a ee or hcc 1 Installation kind ts l ESAE GR eR X E keda qm Rr Keds 1 Electrical 2 22 xen uer males ak Meee w w RP Roe A 2 CONVETSION CX RUN NR RE SUR CORN eR ed edd 2 PAEUMALIGS a i he eas Stato ess d nO rc uc P V dad ue RUD MUR Beste qux e ede e ba o a Re eic teg d 3 Coolant SYSTEM 22222 cR e dE au edad pe ene ac Saag za Sa a 4 ItgOpto Electronic Screen Installation uu used ee vag veces RR Odd REAL E KES EGS WA 5 Automatic Size Control 00 6 Gn M cV MP EMT 7 PREPARING FOR OPERATION General pend bibegrem dd edo nb one ble pe beds howe do kt 9 Major Components duoc keke ed ER
95. ns If you cannot find what you need call for technical support Where aes 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 available at http www sunnen com or e mail sunnenQsunnen com NOTE Sunnen reserves the right to change or revise sp
96. numbered scale larger numbers indicate faster maximum rates Setting dial to 9 or higher will effectively turn off regulator Note This system is similar to STONE SAVER feature on earlier model Sunnen Honing Machines 20 ROUGH gt FINISH DIAMETER 19 FINISHING FEED FORCE 18 ROUGHING FEED FORCE 17 STROKE LENGTH 21 HONING TOOL INDICATOR SCALE SELECTOR 37 STROKER DISABLE SWITCH 16 STROKE LENGTH INDICATOR STONEWEAR COMPENSATOR ADJUSTMENT 25 AUTOMATIC STONEWEAR 27 FEED REGULATOR COMPENSATOR INITIAL DIAMETER CHECK 22 HONING 26 FEED REGULATOR INDICATOR MAXIMUM RATE FIGURE 2 2 Front Panel 30 STROKE POSITION HANDWHEEL 36 SPINDLE SPLASH 29 STROKE GUARD POSITION 31 MASTER ON OFF SWITCH 32 ASC UNIT CLAMP 33 ASC FINE POSITION SCREW 35 COOLANT MANIFOLD 28 FOOT PEDAL 34 PROBE BODY CLAMP KNOB FIGURE 2 3 Machine Controls 11 27 FEED REGULATOR INITIAL DIAMETER This knob sets feed system position at which Feed Regulator begins to limit maximum feed rate If stone and shoe wear are negligible or properly compensated then this position corresponds to a consistent tool diameter Counterclockwise rotation reduces diameter where Feed Regulator starts longer regulated honing cycle Clockwise rotation increases diameter where Feed Regulator starts shorter regulated honing cycle Turning knob clockwise until it stops will turn off Feed Regulator System
97. o 5 cycle stops immediately without removing required amount of material SOLUTION Feed System normally feeds up rapid ly and there is somewhat of an impact when stone contact workpiece Sensitive electronic transducer that reads feed rod position will sometimes pick up this vibration and read a position that is less than Zero for a fraction of a second thus ending cycle To prevent this turn Feed Regulator Initial Diameter knob on counterclockwise about 2 1 2 to 3 turns and turn Maximum Rate knob to fastest speed about 9 1 2 This will damp any feed rod vibra tion without lengthening cycle time and allow even very small amounts of material to be removed accu rately PROBLEM When using Two Stage Feed Force Roughing Feed Force slowly increases over time OR Finishing Feed Force slowly decreases over time SOLUTION Force Screw attached to that Feed Force dial is too free Some drag must be applied to that Force Screw Drag adjustment screw is pro vided for each Force Screw Drag screw to tighten Finishing Force Screw is located down a hole on left side of top surface of casting that Force Screws thread into Drag screw to tighten Roughing Force Screw is located up a hole on right side of bottom surface of that casting Tighten drag screw 1 4 turn only and then see if problem persists If so tighten screw another 1 4 turn and recheck DO NOT tight en more than 1 4 turn at a time without rechecking to see if problem exists
98. o Stage Feed Force feature operating properly every cycle Compensator will probably actuate more than once each cycle but amount of stock removed during finishing will be relatively consistent However be careful not to set compensator too low relative to cutting rate or else it will not be able to keep up with rate of stock removal Return STONE FEED dial to position it was at when you started NOTE STONE FEED dial has some backlash When you feed back down always feed down beyond and then up to point desired 59 Set Spindle Speed Use chart below knob to determine spindle speed based on bore diameter 60 Set Stroke Speed Use chart below knob to determine stroke speed based on stroke length WARNING Recommended speeds may not be suitable for all applications and for all fixtures Always start a new setup with speeds that are much lower than recommended to test stability of tooling and fixturing OPERATION POWER STROKED HONING NOTE machine Before honing review your setup of 1 Install workpiece in workholding fixture WARNING To prevent personal injury and damage to machine DO NOT hone without installing workpiece in a workholding fixture 2 Install workpiece with workholding fixture in Gate Fixture or other stroking fixture and close fixture so that workpiece is captured for stroking 3 Turn POWER ON 4 Turn COOLANT to CONSTANT to check flow of coolant to tool and work
99. o that there is no danger of contact during honing Likewise set moveable fingers on fixture First make sure that fingers are closed move hand lever in toward tool Then loosen two knurled lock nuts on bottom of fixture and turn finger stop screws until fingers are positioned in desired position Tighten knurled lock nuts There are two aluminum collars on each fixture support bar backing up Hinge and Latch Loosen screws holding these collars and move collars out of way NOTE Collars with Hinge have a loose pin spacing them apart This pin may be omitted when using Finger Fixture configuration but it will be necessary for use with Gate Fixture configuration Move finger fixture assembly on fixture support bars to a position where workpiece will be held with minimal end clearance approx 1mm more if workpiece length is expected to vary widely Move collars to back up both sides of Hinge and Latch and tighten them in place Changing to Gate Fixture Configuration Remove all components that are attached to gate piece of fixture NOTE Use caution when disassembling there are several small loose pieces Store all these parts together in such a way that they can be reassembled to gate if required Detach gate from Hinge and Latch and turn it upside down Reattach it to Hinge and Latch Attach two extra fixed fingers provided to inside of gate Loosen aluminum collars on fixture support bar
100. of extra strokes Over time as sensing tip wears size can be adjusted easily with this feature NOTE In general if workpiece is honed slightly undersized you may adjust STONE FEED dial and immediately rehone that workpiece However when using Two Stage Feed Force or Extra Strokes feature it is not recommended that you try to hone workpieces that are only slightly undersized In time it takes for finishing force to actuate or for extra strokes to count off workpiece will probably go oversize It is recommended that any such workpieces be set aside until end and then honed with finishing force off but with roughing feed force set to same value as finishing force had been and with no extra strokes The following adjustments may require running several cycles to observe pattern of stonewear cutting rate etc 26 9 Is finished bore tapered from one end to other with direction of taper consistent with workpiece s orientation in stroking fixture If so loosen Stroker Position Lock and adjust stroke by turning Stroke Position Handwheel slightly to move stroker carriage in direction that workpiece bores are larger WARNING NEVER adjust stroke length or stroke position while machine is running 10 If using Zero Shut Off do you have to advance STONE FEED dial by a consistent amount after each cycle If so and AUTOMATIC STONEWEAR COMPENSATOR is OFF then see Setup Power Stroking step 58 to turn it on and adjust it If
101. oning results are obtained only when proper Sunnen Industrial Honing oil is used Cutting oils coolants and other fluids are generally not satisfactory for honing and may result in excessive stone wear or glazing low stock removal rates and poor surface finish and frequently cause galling or scoring of part Sunnen Industrial Honing Oil is especially compounded for honing needs It keeps stone clean and sharp reduces stone wear increases rate of stock removal and is invaluable in producing fine 43 surface finishes A free flow of honing oil should be provided both for Sunnen Honing Machines and for Sunnen Portable Hones Do not dilute cut or change honing oil in any way LONGER STONE LIFE May be obtained by eas ing stone into bore when starting honing operation When in use feed regulator does this automatically When not using feed regulator stone can be dam aged by tramping on pedal especially in a rough bore KEEP STONE CUTTING PRESSURE LIGHT Just heavy enough to get good cutting action Excessive stone pressure will only increase stone wear it will not make stone cut faster UNUSUAL HONING PROBLEMS Can be referred to Sunnen Honing Laboratory Be sure to include all data concerning problem such as toler ances surface finish requirements stock removal type of material material hardness and production quantities REMOVING WORKPIECE FROM MANDREL Never begin removing workpiece from mandrel un
102. ou feel most pull or resistance Frequently stop and examine shoes and stone For most applications at least a full line of contact should be seen on stone and both shoes If wear does not show sufficient contact use truing sleeve some more NOTE When using keyway mandrels stone and shoes must be fully radius to within 13 mm 005 of final size before bores with keyways can be honed 30 Set coolant lines to supply a continuous supply of coolant to front and back of bore Coolant nozzles are attached to small aluminum bases that can be attached to stroker carriage Turn COOLANT selector to CONSTANT and adjust valves on coolant manifold Use as much coolant as possible without losing any to splashing or spraying out of machine NOTE There are two sizes of coolant nozzles provided Black nozzles have small openings for delivering a steady narrow jet of coolant from a distance Use these if it is difficult or inconvenient to place nozzle close to workpiece Orange nozzles have larger openings and can deliver a larger volume of oil with less splash Larger nozzles are preferred if they can be positioned close to workpiece Operation Manual Honing NOTE machine Before honing review your setup of 1 Gage bore size using Sunnen Precision Bore Gage to determine amount of stock to be removed 2 Install workpiece in workholding fixture WARNING To prevent personal injury and possible damage to machi
103. piece Return selector to CYCLE ONLY if that is desired mode of operation 5 Start cycle by either pressing Cycle Start or stepping on Foot Pedal In general it should be not necessary to use Foot Pedal for operation However by using it on first workpiece you can make feed system engage workpiece slowly to possibly prevent damage from an improper setup NOTE Cycle stop can interrupt any cycle before final size has been reached 6 When cycle stops automatically gage final bore size WARNING To avoid personal injury allow stroker and spindle to come to a complete stop before removing workpiece 7 If you are using ZERO SHUT OFF for size control then move STONE FEED dial to adjust size if size is not correct NOTE STONE FEED dial has some backlash If you must feed down always feed down beyond and then up to point desired CAUTION Advancing STONE FEED dial while machine is running is not recommended If you must advance dial while machine is running be careful not to have your hand on dial when Automatic Stonewear Compensator is about to actuate at beginning of cycle if using Zero Shut Off when needle reaches zero if using ASC 8 If you are using ASC then adjust final bore size by either adjusting screw in sensing tip or by changing number of extra strokes Large adjustments should be made by adjusting sensing tip Small adjustments can be quickly and conveniently made by changing number
104. pump is rotating backwards turn power off and turn off main power supply to machine Reverse any two leads from electrical supply cord coming into machine Do not change any machine or motor wiring or pump may not rotate in right direction if coolant system is moved to another machine 9 Turn POWER on With air vent slightly open air will bleed out of filter canister When oil appears in partially open vent about 1 to 2 minutes close vent clockwise 10 Place sediment tray in top of coolant system Note that orientation is import Lower discharge side should be to back of coolant system 11 Pour additional coolant into reservoir by filling sediment tray and allowing it to overflow Watch coolant level gage during filling Do not overfill coolant system Level of main reservoir must be below top of clean coolant reservoir or oil delivered to work area will not be clean 12 Foot pedal assembly must slide under coolant cart as coolant cart is pushed in First make sure machine power is off WARNING Never remove foot pedal cover with power on Machine cycle will start any time foot pedal is depressed with power on 13 Squeeze lower front corners of foot pedal cover together to disengage it from foot pedal assembly and lift it off Lift safety latch with a finger and depress foot pedal by hand Release safety latch and then release pedal Pedal will be locked in an intermediate position so that whole assembly can slide unde
105. rneath coolant cart 14 Pull foot pedal assembly under coolant cart so that it is in front of cart 15 Push down on foot pedal Lift foot pedal safety latch and hold it up while releasing foot pedal Let go of safety latch and replace foot pedal cover When replacing cover reach inside and hold safety latch up Make sure that latch will be held up by brace on inside of foot pedal cover see Figure 1 5 Squeeze lower front corners of cover together to insert pins on cover in holes on foot pedal base plate 16 Push coolant cart into machine Be sure that flexible conduit retracts into opening in machine base as cart is pushed in 17 Place cart in a position where no coolant can escape work area and where operator has comfort able access to front panel and work area Lock cast ers on coolant cart to keep it from moving during operation OPTO ELECTRONIC SCREEN INSTALLATION CE Machines Only 1 Fastening Mirror Assemblies to coolant cart see Figure 1 6 Set Mirror Assembly on coolant cart in position shown Match two alignment pins on cart not shown with two holes in bottom of Mirror Assembly Fasten each Mirror Assembly to coolant cart by tight ening three Hex Cap Screws with a 10mm open end wrench as shown Tighten Hex Cap Screws a little at a time in rotation so Mirror Assembly is not put into a bind 2 Aligning Mirror Assemblies Turn on power to machine Place a hand in sensing field and then remove it to in
106. roker Carriage is very close to spindle then loosen Stroke Position Lock and turn Stroke Position Handwheel to move It away from spindle 38 Install Workpiece Fixturing Workpiece must be fixtured to resist honing torque and to drive workpiece back and forth for stroking EC 3500 includes follow ing standard fixturing components A Universal Fixture with Fingers for stroking and small Torque Arm to absorb honing torque These can be used for most applications however other fixturing components are available from Sunnen Products Company for certain types of applications such as square honing See Catalogs or contact your Sunnen Sales Representative for more information 21 NOTE No standard fixture is provided to grip workpiece to transmit honing torque to torque bar Several optional fixtures are available Also some types of workpieces are easily fixtured with common hardware items Contact your Sunnen Sales Representative for fixturing 39 If using standard Universal Fixture adjust fingers on gate and on stroker carriage to contact workpiece as close to tool as possible without risking accidental contact with tool Position gate so that workpiece is captured but not held tightly between fingers There should be only a small amount of clearance between fingers and workpiece Less than 1 mm 04 is preferable but more is acceptable if workpiece length is expected to vary 40 If using standard Universal Fixture position
107. s free to function properly 2 Remove filter cover clamp and filter cover 3 Remove filter element from its protective bag and insert it into filter canister Rotate filter element slightly while inserting to make it slide down center post more easily 4 Make sure that sealing ring in filter cover is seated properly in its groove then replace filter cover 5 Replace filter cover clamp and tighten Close air vent all way clockwise then crack it open 1 4 to 1 2 turn to vent canister during filling 6 Move coolant cart close enough to machine to connect coolant system cable from machine Close latch on fixed connector base to secure connection Attach coiled Airline on rear of Coolant Cart to the bulkhead fitting on the front inside face of the machine base see flow diagram packaged with your machine FIGURE 1 5 FOOT PEDAL SAFETY LATCH 7 Fill coolant system with coolant until coolant level gage is somewhere between full and 20 liters NOTE Use only Sunnen Industrial Honing Fluids Substituting other cutting fluids or diluting Sunnen Honing Oil can adversely affect workpiece surface finish and stone tool life If using Sunnen Coolant Concentrate dilute with water as specified and check concentration daily 8 On operator station turn coolant selector to CONSTANT and turn machine power on momentarily to check pump motor rotation An arrow marked on pump indicates proper direction for rotation If
108. s not being used 19 FINISHING FEED FORCE Sets finishing feed force level as indicated on dial above knob NOTE Knob may be difficult to turn if AFTER ROUGH TO FINISH or DURING EXTRA STROKES ONLY is selected on FINISHING FEED FORCE selector switch Also Finishing Feed Force Dial can never be set to a value above value shown on Roughing Force Dial 20 ROUGH gt FINISH DIAMETER When AFTER ROUGH TO FINISH is selected on operator station this knob sets feed system position at which feed force changes from roughing to finishing If stone and shoe wear are negligible or properly compensated then this position corresponds to a consistent bore diameter Turning clockwise makes feed force change at a smaller diameter more finishing Turning counterclockwise makes feed force change at a larger diameter less finishing Light to left of knob will be on when machine is in finishing during honing cycle During setup light will be on anytime needle on honing dial is below selected change position or it will be on if DURING EXTRA STROKES ONLY is selected 21 HONING TOOL INDICATOR SCALE SELECTOR Four position selector switch sets Honing Indicator for honing tool used and indicator scale desired 22 HONING INDICATOR Needle shows feed system position This position corresponds to amount of stock to be removed from bore diameter if Zero Shut Off is size control mode Two scales have different levels of magnification
109. se fittings see Figure 4 2 amp 4 3 Apply grease to contact points on Indicator Assembly see Figure 4 4 Apply grease see Figure 4 5 to Cam Assembly Connection Pins Every 1000 Hours Clean and repack feed rod thrust bearings NOTE This service period can be stretched to 2000 hours if machine is only used at low speeds less than 1500 rpm and low feed forces less than 6 nspect belts for cracks and excessive wear Coolant System Replace Filter when flow to work area is insufficient see Figure 4 6 1 To change filter it will be necessary to remove Sediment Tray Scoop sediment out of tray before attempting to remove it from coolant system If Sediment Tray is nearly full it may be too heavy to lift out Furthermore cleaning this tray every time filter is changed will maximize filter life 2 Filter Canister can be raised by loosening clamp handle securing canister to reservoir wall Lift canister as far up as it will go and then rotate it slightly Then let it down until it s two protrusions on side of canister rest on canister bracket In this position drain valve at bottom of canister can be opened Also open air vent at top to allow air into canister as coolant drains out bottom FIGURE 4 5 3 Open Filter Canister and replace filter element It may be necessary to clean inside of canister 4 Close drain valve and canister and lower it back into reservoir Close air vent aft
110. sed then After Rough to Finish Diameter method is recommended but there are some limita tions With ASC selected Automatic Stonewear Compensator will actuate when indicator reaches zero Therefore trigger point must be set above zero or else trigger point will never be reached Note amount of indicator needle movement when feed force is changed from roughing to finishing It is impossible to consistently remove less stock in finishing stage than amount of this needle move ment Amount of stock removed during finishing will vary somewhat due to stonewear To keep this varia tion to a minimum stonewear compensation must be set exactly to actual stonewear However this is difficult to do A more practical method is to set compensator to some small amount since compen sator can work more than once per cycle as needed Be careful not to set compensator too low relative to cutting rate or else it will not be able to keep up with rate of stock removal Therefore best applications for using ASC with After Rough to Finish Diameter trigger will be where Finishing Stock Removal can acceptably be significant ly larger than stonewear and significantly larger than indicator needle rise for desired feed force change and where some variation in amount of stock removed dur ing finishing is acceptable If application does not meet these criteria then During Extra Strokes Only method must be used However this is only practica
111. served and where feed system can deliver its full selected feed force When starting a new application where stonewear is not known it is recommended that several workpieces be honed without Compensator on so that an accurate estimate of stonewear can be determined Write down or make a mental note of position of STONE FEED dial e Turn Knob on AUTOMATIC STONEWEAR COMPENSATOR counterclockwise some to turn it on Press check button and hold it in until STONE FEED dial stops moving Release button and note new Feed Dial Position NOTE Be sure to read appropriate scale for honing tool family selected f amount STONE FEED dial moved was not amount of stonewear expected for each workpiece then adjust knob accordingly and press check button again Repeat until compensator is advancing STONE FEED dial by correct amount NOTE When using ASC with FINISHING FEED FORCE set to OFF or EXTRA STROKES ONLY it is not necessary to have Compensator set to exact stonewear amount Compensator will actuate any time that needle on Honing Indicator reaches zero provided that compensator is not turned off However be careful not to set compensator too low 25 relative to cutting rate or else it will not be able to keep up with rate of stock removal When using ASC with FINISHING FEED FORCE set to AFTER ROUGH TO FINISHING DIAMETER compensator should be set to approximately 1 4 to 1 2 of expected stonewear to keep Tw
112. sing 3 Loosen four screws holding spindle motor base plate to deck 4 Loosen one screw on wedge that bears against motor base plate 5 Slide spindle motor in toward spindle to loosen belt 6 Remove and replace belt 7 It is recommended that feed rod thrust bearings be cleaned and repacked with grease at this time 29 Loosen screw in end of feed rod holding bearing in place Pull bearings off of feed rod Note back to back arrangement of these bearings Wide faces of outer races are in contact Clean and repack Replace bearing keeping same back to back arrangement NOTE One bearing takes a much greater load than other Bearing life will be extended if both bearings held together are reversed when they are replaced so that over time both bearings wear evenly 8 Reverse steps above to reassemble When tightening two screws fastening cover alternate between two to seat bearings evenly 9 Use screw against wedge to tension belt before tightening screws on base plate Tension belt so that deflection at midway between pulleys is approximately 4mm 158in when a 33N 7 4 Ib load is applied Replace Stroker Belt 1 Loosen four screws holding stroker motor base plate to stroker frame 2 Loosen one screw on wedge that bears against motor base plate 3 Slide stroker motor up to loosen belt 4 Remove and replace belt 5 Reverse steps above to reassemble Use screw against wedge to t
113. sive stick consisting of thousands of small abrasive grains bonded together cemented to metal holder HONING UNIT Complete honing tool consisting of adapter if required mandrel and wedge stone s guide shoe s truing sleeve and stone retainer or tension block LOADED STONE Honing stone with cutting action impaired due to cutting surface being partial ly covered with foreign material usually material being honed This condition is sometimes encoun tered when honing soft materials MANDREL Part of honing unit which holds and positions honing stone and guide shoes in their cor rect relative positions METAL BOND Metallic bond used with diamond or CBN Borazon grit to provide a very long lasting honing stone WORKPIECE AT ONE END OF STROKE peo sx b MANDREL TVPICAL A STONE OVERSTROKE B PART OVERSTROKE OVERSTROKE Distance that workpiece is stroked over end of stone it can also be distance stone extends beyond end of workpiece at end of each stroke This distance is generally one half length of stone or of part whichever is shortest If for any reason a shorter stroke is used the follow ing formulas are useful Stone or shoe overstroke on either end Stroke length Stone length Part length 2 Part overstroke on either end Stroke length Part length Stone length 2 APPENDIX B PARALLEL RUNOUT Off center rotation of honing unit which causes eccentric mo
114. ss than 72 db A continuous Less than 74 db A peak load max noise condition in a typical factory environment INTRODUCTION This Instruction Manual provides information required to install operate and maintain Sunnen EC 3500 Power Stroked Honing Machine When ordering parts for or requesting information about your Machine include model and serial numbers located on Electrical Enclosure of your Machine In this book symbol lt indicates steps or information that are only for CE version of this machine The CE version is constructed to meet highest level of safety standards as required by European Machinery Directive Required for European market this CE version is available for any customer The regular version of this machine is quite safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing risks of operator carelessness READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN POWER STROKED HONING MACHINE The EC 3500 Production 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 cylindricity fine surface finish To achieve best results and ensure safe operation ONLY Sunnen Tools and Abrasives are to be used in EC 3500
115. sure Decrease cutting one with higher grit number Use finer grit stone you are using Sunnen ndustrial Honing Oil Check oil to be sure to exact hole diameter Thoroughly true shoes finishes in soft or exotic material use bronze mandrel or bronze shoes RANDOM SCRATCHES Decrease cutting Use finer grit stone Use softer stone If hard steel mandrel is Check oil to be pressure one with higher grit one with lower being used change to sure you are using number hardness number soft steel mandrel If Sunnen Industrial soft steel mandrel or Honing Oil shoes are being used change to bronze mandrel or shoes 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 S unnen 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 31 MACHINE OPERATION TROUBLESHOOTING Error Messages EC 3500 has built in error messages that will appear in the spindle speed screen to alert operator when machine has stopped due to an error or incorrect setup The following is a list of errors and directions on how to clear them Once the problem is resolved pressing the Cycle Stop button will clear the error from the display
116. table for most honing applications For close tolerance applications conical runout should be less than one division With runout indicator remaining on alignment bushing move pivot lever to Lock and turn Knob A counterclockwise two or three revolutions ALIGNMENT BUSHING REFERENCE GAGING POINT INDICATING GAGING POINT FIGURE 3 2 Runout Indictor Gaging Point 19 With pivot lock lever in Lock position Runout Indicator is now set to measure parallel runout of honing unit Rotate spindle by hand while observing Runout Indicator If necessary turn Knob B to get an indicator reading Turn spindle until high point is found Loosen nearest numbered screw 1 2 3 4 on rear of spindle nose and tighten screw on opposite side Repeat this procedure until parallel runout is within acceptable limits Parallel runout of less than two divisions on indicator is acceptable for most honing applications For close tolerance applications parallel runout should be less than one division Conical runout should not be affected by adjustment of parallel runout however it is a good practice to double check conical runout again If amount of parallel adjustment was large then conical runout may have changed slightly If it is necessary to readjust conical runout then always recheck parallel runout after that Remove indicator from threaded stroker drive shaft Set FEED selector to RETRACT and remove ali
117. til spindle stops When pedal is released or auto matic shutoff occurs your spindle should also stop HONING DIAL Each number on dial indicator is equal to a certain amount of stone expansion To determine this refer to chart on front of machine HONING STONE Select from Honing Supplies Catalog from stone cabinet or from SMOPS Guide WORN OUT MANDRELS When truing sleeve or workpiece makes contact with any part of mandrel other then shoe replace mandrel or guide shoes TECHNICAL DATA GUIDE SHOES INTEGRAL SHOE MANDRELS Soft shoe mandrels are recommended for all general honing operations Mandrels with hardened steel shoes can be used for honing carbide ceramic or glass for extremely rough holes and for some long production jobs Where extremely fine finishes are required and a 600 grit stone is used solid bronze mandrels with integral shoes are required Occasionally unusual specifications do not permit use of honing oils that contain sulfur and it may be necessary to use bronze mandrels to prevent galling GUIDE SHOES REPLACEABLE SHOE MANDRELS General purpose guide shoes are supplied as original equipment on mandrels with replaceable shoes Guide shoes of other materials are available and can frequently be beneficial in certain specific applications APPENDIX B While it is desirable to provide guide shoes of mate rial with long wearing qualities they must be soft enough to be trued in for any particular
118. tion of workpiece yu n A RAINBOW or bow Sometimes called camber or banana shape Condition where a bore s diameter may be same over its full length but whose axis or center line is curved RELIEF Enlargement of diameter at bottom of blind hole which makes it possible for end of honing stone to pass beyond bottom end of surface being honed SILICON CARBIDE Hard and brittle synthetic abrasive for stock removal in soft materials such as brass bronze aluminum cast iron etc and in extremely hard material such as tool steel Silicon Carbide is also used for obtaining fine fin ishes in all materials It is designated by letter J in Sunnen stone code example K12 J85 48 nimia STACKING Technique for honing short parts Faces of parts must be square with bore prior to honing holding fixture is necessary for aligning and holding parts on a common center L9 4949 9 944 TAPER Bore condition where diameter of bore gradually increases from one end of bore to other TRUING SLEEVE Cylinder or workpiece whose purpose is to make guide shoes and stone straight and parallel to each other and radius to approximate diameter to be honed 222 WAVINESS Longitudinal wave series of waves or ripple in a bore surface WEDGE Part of Honing Unit that expands honing stone and applies cutting pressure APPENDIX C COOLANT FLOW DIAGRAM
119. to customer or customer s agent F O B Shipping Point Incorrect installation including improper lifting dropping and or placement Incorrect electric power beyond 10 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 gt 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 ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF A
120. to size with a micrometer or by inserting it into a workpiece that has already been honed to final size Set adjustment screw so that sensing tip lightly drags on honed bore Then back off adjusting screw about 1 4 turn This will make first part honed undersized by approximately 0 025 mm 001 NOTE Final size can be adjusted after first workpiece by either turning adjustment screw or by changing number of Extra Strokes displayed on operator panel j Screw Sensing Tip or Sensing Unit on to stud on Probe Body see Figure 3 8 If required use Probe Extension to reach into counterbore in workpiece or reach past fixturing k Press STROKER JOG and hold in to get stroker to front of stroke 1 Turn spindle by hand until shoes are up and then place a workpiece on mandrel WARNING Keep hands away from ASC unit when turning ASC Probe Selector to move ASC probe up or down m Make sure that ASC unit is a safe distance from honing tool and with hands away from work area turn ASC PROBE selector to UP n Loosen Clamp Screw on ASC unit and slide unit up to workpiece Sensing Tip should be depressed about 3 mm 1 8 Tighten Clamp Screw NOTE If desired use Stop Clamp supplied with ASC unit to allow quick return to ASC setup position again if unit needs to be moved back along Rail for honing tool runout adjustment or replacement Attach Stop Clamp to ASC Rail against back of ASC unit with supplied brass tipped set s
121. tor in After Rough to Finish Diameter position NOTE Needle on honing dial will move as feed force is switched This is normal Higher feed force compresses wedge and feed rod more which results in a different indicator reading 7 Turn STONE FEED dial up until needle on Honing Indicator reads amount of stock that you want removed during finishing stage 8 Turn FINISHING FEED FORCE selector to OFF Needle on Honing Dial will drop some Do not turn STONE FEED dial to move it up again 9 Turn ROUGH gt FINISH DIAMETER knob fully counterclockwise Light next to knob should now be off If it is not on then try using indicator scale Turn INDICATOR SCALE HONING TOOL selector to scale for tool you are using and go back to step 5 If indicator scale selected is already and light is not off with ROUGH gt FINISH DIAMETER knob rotated fully counterclockwise then either Finishing Force selected is too low or finishing stock removal amount is too small for this finishing feed force mode to work properly If this is case you must either increase finishing stock removal or decrease difference between roughing and finishing forces or use During Extra Strokes Only method 10 Turn ROUGH FINISH DIAMETER knob slowly clockwise until light next to it just turns on Trigger point is now set 36 NOTE Trigger point cannot be set to any point higher than half of full indicator scale If you
122. towards operator loosen operator side Base A technique for aligning mirrors is to look from Positioning Set Screw and tighten spindle side Base Sender Unit into mirrors and position mirrors so Positioning Set Screw To tilt Mirror Assembly away Receiver Unit mirror reflection can be seen Do from operator loosen spindle side Base Positioning Set same for Sender Unit mirror reflection Screw and tighten operator side Base Positioning Set Screw tilt Mirror Assembly to right or left away AUTOMATIC SIZE CONTROL from machine loosen side Base Positioning Set Screw Install Automatic Size Control ASC Unit as fol and tighten spindle side Base Positioning Set Screw lows see Figure 1 7 tilt Mirror Assembly to right or left toward machine Unpack Automatic Size Control ASC Unit PROBE BODY PROBE CLAMP pe BODY BUMPER SCREW ANGLE PLATE FINE POSITION ROD CLAMP KNOB CLAMP PIVOT BLOCK FIGURE 1 7 Automatic Size Control 6 FIGURE 1 8 Side Tray Turn Clamp Knob on ASC unit counter clockwise and pivot Clamp Pivot Block clockwise to open clamp Position clamp on Rail as shown and tighten clamp to secure ASC unit to machine frame 2 Check that ASC unit movement will not interfere with stroker or fixturing Turn ASC PROBE selector switch to DOWN Pull Actuator Arm away from machine so that cylinder is extended and Arm is horizontal Plug in and thread on keyed Cable End to connector at
123. u are trying to turn If you do this remember always to return this selector to its original position after setting feed force CAUTION When manually honing always start at a low feed force for safety 24 Reduce Mandrel Runout Reducing mandrel runout by following simple method is all that is usually required for truing and manual honing For more accurate elimination of runout refer to Setup for Power Stroking step 33 Select a concentric alignment bushing or truing sleeve with a bore size close to final honed bore size see Sunnen Honing Supplies Catalog Place alignment bushing on mandrel so that it is centered on stone and shoe section of mandrel WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed Turn FEED selector to EXPAND to lock alignment bushing on mandrel Look to Honing Indicator If needle reads somewhere on scale then alignment bushing is properly locked on If not turn STONE FEED DIAL until there is an indicator reading Turn Dial same direction as you wish needle to move Turn FEED selector to RETRACT Set Spindle Speed to 200 rpm WARNING Do not attempt to adjust mandrel runout at any speed higher than 200 rpm Depress Foot Pedal fully to start spindle with alignment bushing on mandrel If runout does not seem excessive proceed to step 25 If runout is excessive center honing unit as follows With
124. urn COOLANT selector to CONSTANT and adjust valves on coolant manifold Use as much coolant as possible without losing any to splashing or spraying out of machine NOTE There are two sizes of coolant nozzles provided Black nozzles have small openings for delivering a steady narrow jet of coolant from a distance Use these if it is difficult or inconvenient to place nozzle close to workpiece Orange nozzles have larger openings and can deliver a larger volume of oil with less splash Larger nozzles are preferred if they can be positioned close to workpiece For convenience one coolant nozzle can be clamped in back of stroker carriage on a rib nearest spindle pointing up to rear of workpiece bore see Figure 3 5 Note that almost all workpieces will be positioned with rear of bore in this location so this one nozzle will not require adjusting when changing setups 44 Return COOLANT selector to CYCLE ONLY 45 Replace Spindle Splash Guard on back of Stroker Carriage Press STROKER JOG to check Splash Guard clearance 46 Set STROKING selector to AUTOMATIC 47 Set SIZE CONTROL selector to desired size control mode 48 Set FINISHING FEED FORCE to desired mode NOTE Refer to Appendix A for guidelines on when Two Stage Feed Force feature is beneficial If using ZERO SHUT OFF go to step 50 49 Set Automatic Size Control ASC Unit a If ASC Unit has been removed from machine then it must be installed NO
125. used Feed Force remains at level set with Roughing Feed Force Dial throughout entire honing cycle If selected feed system will be at roughing feed force level when not honing AFTER ROUGH TO FINISH DIAMETER Feed Force will switch from roughing level to fin ishing level at point set by Rough to Finish Diameter Dial on front panel This point corre sponds to a consistent feed system Honing Indicator position If stone and shoe wear are neg ligible or properly compensated then this position corresponds to a consistent bore diameter If select ed feed system will be at finishing feed force level when not honing DURING EXTRA STROKES ONLY Feed Force will switch from roughing level to finishing level when honing dial reaches zero if ZERO SHUT OFF is size control mode or when ASC probe enters workpiece bore if ASC is size control mode Feed Force is only at finishing level during Extra Strokes If selected feed system will be at finishing feed force level when not honing 13 EXTRA STROKES After size control device either Zero Shut Off or ASC signals completion of honing cycle honing cycle will continue for number of strokes shown on display before stopping Return to center selector switch changes number of extra strokes up or down to a maximum of 99 If dip switch A2 is set to stroker positioning on honing cycle will always finish with stroker stopped at front end of stroke If switch A2 is set to off machine will stop
126. ut is within acceptable limits electrical connection can proceed but Machine Conversion below will be necessary ELECTRICAL DISCONNECT BLOCK 555 je eje else SOngs HSS o 299 FIGURE 1 3 Electrical Connection Machine ConveRSion Conversion of machine to a different voltage than stated on Electrical Specification Plate CAUTION Do not attempt to convert machine to a voltage outside acceptable limits given above 3 Unlock doors to Electrical Control Enclosure using key supplied with machine Door to Enclosure is equipped with Key Lock Safety Latches 4 Turn Master ON OFF Switch to OFF position and open doors Doors will not open unless Master ON OFF Switch is in OFF position 5 Insert Electrical Supply Cord through Entrance Hole and Oil Tight Fitting 6 Route to Electrical Disconnect Block see Figure 3 7 Strip 250mm 10 off cable s outer jacket 8 Strip 6mm 1 4 of insulation off each wire 9 Connect Green Wire GRN to Ground Terminal PE 10 Connect other three wires to Electrical Disconnect Block 11 Route and secure cord inside of Enclosure Tighten Oil Tight Fitting 12 Close and lock Door to Electrical Control Enclosure 13 Route and connect Electrical Supply Cord to power source NOTE If supply voltage matches voltage stated on Electrical Specification Plate then proceed to Connect Air Supply Turn disconnect at
127. ute a 6 mm or 1 4 ID air supply line through slot in bottom of machine base up through openings in top of base to air filter regulator see Figure 1 4 Do not route air supply line over top of base or hood will not be able to close properly and will pinch air supply line Filter regulator has a hose barb fitting where air supply line can be fastened with a hose clamp If anoth er style of fitting is desired hose barb can be removed FIGURE 1 4 Air Line Routing NOTE Elbow has 1 8 NPT threads Elbow and adapter can be removed to access R 1 8 BSPT threads in inlet port of filter regulator 2 Filter regulator has been factory set to 55 MPa 80 psi Air supply to machine must be at least this or machine 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 Coolant System Remove packing materials from coolant system Pump and motor are mounted on flexible vibration isolators Packing materials have been added to secure pump and motor during shipping Make sure all such material is removed and assembly is free to float on isolators To remove packing materials inside reservoir lift out plastic work area liner open reservoir cover and lift out sediment tray Make sure all packing material is removed from coolant level float so it i
128. value approximately 1 for tools smaller than 6 mm 25 1 2 for larger tools NOTE Roughing Feed Force cannot be adjusted to a value lower than Finishing Feed Force setting It may be necessary to turn Finishing Feed Force Dial down so that Roughing Feed Force can be set to desired level If FINISHING FEED FORCE selector is set on OFF Roughing Feed Force dial may be difficult to turn If FINISHING FEED FORCE selector is set to AFTER ROUGH TO FINISH DIAMETER or to DURING EXTRA STROKES ONLY then Finishing Force Dial may be difficult to turn During setup only you may turn this selector to position that frees feed force dial you are trying to turn If you do this remember always to return this selector to its original position after setting feed force CAUTION When truing always start at a low feed force for safety 23 Turn FINISHING FEED FORCE to OFF 17 24 Reduce Mandrel Runout Select a concentric alignment bushing or truing sleeve with a bore size close to final honed bore size see Sunnen Honing Supplies Catalog Place alignment bushing on mandrel so that it is centered on stone and shoe section of mandrel WARNING Do NOT step on foot pedal to lock alignment bushing on mandrel Spindle will turn if foot pedal is depressed Turn FEED selector to EXPAND to lock alignment bushing on mandrel Look to Honing Indicator If needle reads somewhere on scale then alignment bushing is proper
129. work area 1 Press Emergency Stop to clear any previous setup 2 Turn OFF coolant supply by turning Main Valve on Coolant Manifold fully clockwise 3 If ASC unit is attached to machine loosen Clamp and slide unit out away from spindle Turn ASC PROBE selector to DOWN Unit can also be removed from machine entirely 4 Set FINISHING FEED FORCE selector to OFF 5 Set SIZE CONTROL selector to ZERO SHUT OFF 6 Set STROKER key switch to DISABLE Set Stroking selector to MANUAL 7 Set FEED selector to RETRACT 8 Turn FEED REGULATOR off by turning INITIAL DIAMETER knob fully clockwise 9 Tum AUTOMATIC STONEWEAR COMPENSATOR off by turning knob fully clockwise 10 Remove Spindle Splash Guard 11 Disengage Stroker Carriage from power stroking unit Turn STROKING selector to UNLATCH Pull Stroker Carriage forward to provide access to spindle 12 Select correct honing unit and stone from Sunnen Honing Supplies Catalog 13 Assemble Honing Unit according to instructions 14 Set HONING TOOL INDICATOR SCALE selector to position that matches tool being used and scale you wish to read NOTE It is recommended that scale be used unless stock removal is expected to be more than 240u 009 Finer resolution on A scale gives a clearer indication of honing rate 15 Turn STONE FEED dial clockwise until you meet resistance then advance it counterclockwise approximately 10 turns CAU

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