SPECIAL INSTRUCTIONS for SUNNEN MLU1850 TOOL CALIBRATION KIT For Use on Sunnen ML-Series and EC-Series Honing Machines

Transcription

1 SPECIA INSTRUCTIONS for SUNNEN MU18 TOO CAIBRATION KIT For Use on Sunnen M-Series and EC-Series Honing Machines I-M-51 INTRODUCTION This calibration procedure assumes that the VDT has not been adjusted since the machine left the factory. If the VDT has been adjusted, you will need to contact Sunnen Products Co. for the proper procedures and tooling to calibrate the VDT. TOOS & MATERIAS The following tools and materials are required for unpacking and installing of your Machine: Knife Hex Wrenches (4mm) Tin Snips Open End Wrench (13mm) Screwdriver (Small Std Nose) MU18 Tool Calibration Kit Cleaning Solvent INSTAATION Read the following instructions carefully and thoroughly before unpacking, inspecting and installing the Kit. To install Kit, proceed as follows: 1. Check machine nameplate on Electrical Enclosure to be sure it agrees with supply line voltage and frequency. 2. Turn ON electrical power at Master ON/OFF Switch (see Figure 1). 3. Front Panel: Set both Roughing and Finishing Feed Force to 1 (maximum) (see Figure 2). 4. Front Panel: Place Honing Tool/Indicator Scale Selector Switch in "Yellow A" position. 5. Operator Station: Use Feed Switch to Expand Feed System (see Figure 3).. Turn OFF electrical power. MASTER ON/OFF SWITCH WARNING AWAYS have power OFF when hoods are open or performing service not requiring power. 7. Open Hood Assembly, to gain access to inside of machine (see Figure 4). 8. Inside of Machine: oosen Jam Nut (13mm) on Overtravel Setscrew (refer to Figure 4). 9. Adjust Overtravel Setscrew (4mm) to hold Main ever vertical (perpendicular) to deck of machine. Check it visually with a square. 10. Remove Cover Panel on VDT Box (see Figure 5). 11. VDT Box: Adjust R22 on PED1057 assembly until Honing Indicator reads exactly zero (refer to Figure 5). 12. Inside of Machine: Backoff Overtravel Setscrew one turn, and tighten Jam Nut. 13. Turn ON electrical power at Master ON/OFF Switch. 14. Front Panel: Set both Roughing and Finishing Feed Force to Front Panel: Turn Stone Feed Dial until a gap of -mm is obtained between Feed Rod Flex Joint Housing and Fixed Feed Rod Guide. Stone Feed Dial must be on zero upon completion of this adjustment. Final movement of Stone Feed Dial must be in counter-clockwise direction. 1. Jog stroker to front of stroke. 17. Turn OFF electrical power. 18. Open Door to Electrical Enclosure (see Figure ). 19. Press MENU Button on Stroker Drive (2VFD), to prevent accidental startup of stroker motor during calibration process.. Front Panel: Adjust Stroke ength Indicator to mm (.in). 21. oosen Stroke Position ock until it rotates freely (see Figure 7). 22. Rotate Stroke Position Handwheel until carriage has moved out mm (2in). 23. Insert Spindle Calibration Plug (2) into Spindle Nose. Plug must be free to move in and out. 24. Attach Carriage Calibration Plate (3) to Carriage. (Rotate Stroke Position Handwheel if more clearance is required.) FIGURE 1, Master Switch SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST. OUIS, MO 3143, U.S.A. PHONE:

2 R R M-299CE / I-1148 M-1484CE / I FINISHING FEED FORCE M-00 PRECISION HONING MACHINE PATENTED 29 ROUGH > FINISH DIAMETER 28 STROKE ENGTH 18 HONING TOO / INDICATOR SCAE SEECTOR AK AN-0 A BA JAK JK B BR D2 K KR R P P28 R28 Y YY A B A B A mm IN STROKER DISABE SWITCH 19 STONE FEED ROUGHING FEED FORCE 40 AUTOMATIC STONEWEAR COMPENSATOR ADJUSTMENT ( A > B ) = 0.95 A A B ( B > A ) = 0.95 B A STROKE ENGTH INDICATOR.3. B 21 AUTOMATIC STONEWEAR COMPENSATOR CHECK 22 HONING INDICATOR 23 FEED REGUATOR MAIMUM RATE 24 FEED REGUATOR INITIA DIAMETER FIGURE 2, Front Panel 1 PSC & CTC FEATURES M-00 PRECISION HONING MACHINE PATENTED 1 SPINDE SPEED FINISHING FEED FORCE ETRA STROKES SPINDE SPEED STROKER SPEED 2 FINISHING FEED FORCE OFF AFTER ROUGH TO FINISH DIAMETER DURING ETRA STROKES ONY STROKER SPEED 3 ETRA STROKES 4 SIZE CONTRO 5 STROKING STROKER SIZE CONTRO UNATCH ZERO MANUA AUTO SHUT ASC OFF FEED EPAND RETRACT mm RPM IN mm..3.4 WARNING.5. OPERATING 40 SPEED MAY.8 NOT BE SUITABE 1.0 FOR A APPICATIONS USE CAUTION WHEN STARTING NEW SETUP 170 SPM IN ASC PROBE COOANT UP DOWN CONSTANT CYCE ONY COOANT EMERGENCY STOP 7 FEED CYCE START CYCE STOP STROKER JOG POWER ON POWER OFF 8 CYCE START 9 CYCE STOP 10 STROKER JOG 11 ASC PROBE 12 POWER ON 13 POWER OFF FIGURE 3a, Operator Station (Non-CE Machines) 2

3 R M-1484CE / I M-00 PRECISION HONING MACHINE PATENTED 1 + /MIN /MIN mm 8 10 /MIN IN mm /MIN IN ! FIGURE 3b, Operator Station (CE Machines) 13 HOOD ASSEMBY MAIN EVER JAM NUT MAIN EVER FIGURE 4, Hood Assembly 3 OVERTRAVE SETSCREW OVERTRAVE STOP BAR

4 . Adjust Stroke Position Handwheel until Carriage Calibration Plate (3) starts to make contact with Spindle Calibration Plug (2). 2. Tighten, but do not over tighten, Stroke Position ock. This will help remove any "play" in Carriage Position Adjustment Rod. 27. Adjust Stroke Position Handwheel until Honing Indicator reads exactly zero. NOTE: The following steps must be followed exactly and must be repeatable. Do not be alarmed if these steps have to be repeated ten or more times. This is a very tedious and time consuming process. 28. Front Panel: Rotate Stone Feed Dial counterclockwise to 1µ or.008" position on outer yellow scale. 29. VDT Box: Adjust R21 on PEDI057 until Honing Indicator reads correctly on "A Scale" within ± 1 division.. Front Panel: Rotate Stone Feed Dial clockwise until Honing Indicator reads exactly zero. You must be able to repeat steps 28-, obtain required values without adjustments, before you can proceed to next step. 31. Front Panel: Change Honing Tool/Indicator Scale Selector Switch to "Yellow B/Blue A" position. CAUTION The following steps must be followed exactly and must be repeatable. Do not be alarmed if these steps have to be repeated ten or more times. This is a very tedious and time consuming process. 32. Front Panel: Rotate Stone Feed Dial counterclockwise to the lµ or.008" position on the center blue scale. 33. VDT Box: Adjust R18 on PEDI057 until Honing Indicator reads correctly on "A Scale" within ± 1 division. 34. Front Panel: Rotate Stone Feed Dial clockwise until Honing Indicator reads exactly zero. You must be able to repeat steps 32-34, obtain required values without adjustments, before you can proceed to next step. R18 R22 R19 R VDT BO R21 FIGURE 5, VDT 4

5 35. Front Panel: Change Honing Tool/Indicator Scale Selector Switch to "Blue B" position. MASTER ON/OFF SWITCH MENU BUTTON STROKER DRIVE FIGURE, Master Switch CAUTION The following steps must be followed exactly and must be repeatable. Do not be alarmed if these steps have to be repeated ten or more times. This is a very tedious and time consuming process. 3. Front Panel: Rotate Stone Feed Dial counterclockwise to 3µ or.01" position on center blue scale. 37. VDT Box: Adjust R on PED1057 until Honing Indicator reads correctly on "B Scale" within ± I division. 38. Front Panel: Rotate Stone Feed Dial clockwise until Honing Indicator reads exactly zero. You must be able to repeat steps 3-38, obtain required values without adjustments, before you can proceed to next step. 39. Front Panel: Change Honing Tool/Indicator Scale Selector Switch to "Red A" position. CAUTION The following steps must be followed exactly and must be repeatable. Do not be alarmed if these steps have to be repeated ten or more times. This is a very tedious and time consuming process. 3 SPINDE SPASH GUARD STROKE POSITION HANDWHEE 29 STROKE POSITION OCK FIGURE 7, Carriage 5

6 40. Front Panel: Rotate Stone Feed Dial counterclockwise to µ or.003" position on inner red scale. 41. VDT Box: Adjust RI9 on PED1057 until Honing Indicator reads correctly on "A Scale" within ± I division. 42. Front Panel: Rotate Stone Feed Dial clockwise until Honing Indicator reads exactly zero. You must be able to repeat steps 40-42, obtain the required values without adjustments, before you can proceed to the next step. 43. Remove all tooling (Spindle Plug) that was installed during calibration. 44. "Dry Cycle" machine in Zero Shutoff mode using Feed Regulator to slow feed rate down to where you can visually check to see if machine does Shutoff at zero on Honing Indicator +/- one division on yellow "A" scale. 45. While performing above test, select "AFTER ROUGHING TO FINISH DIAMETER" on Finishing Force Feed and turn Sparkout Pot fully clockwise. Sparkout light should come on somewhere around when Honing Indicator reaches halfway mark when using yellow "A" scale. 4. Replace all covers and turn main disconnect off. CAIBRATION IS COMPETE 2 SPINDE CAIBRATION PUG TOO CAIBRATION KIT Item Pt # QTY Description 1 MU Spindle Calibration Fixture (Not Used) 2 MU Spindle Calibration Plug 3 MU Spindle Calibration Plate including Capscrews (mm ) 4 IM51 1..Tool Calibration Kit Instruction 1 SPINDE CAIBRATION FITURE (Not used in this application) 3 SPINDE CAIBRATION PATE SUNNEN AND THE SUNNEN OGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding. SUNNEN PRODUCTS COMPANY 7910 Manchester Road, St. ouis, MO 3143 U.S.A. Phone: Fax: U.S.A. Toll-Free Sales and Service Automotive: Industrial: International Division Fax: sunnen@sunnen.com UK SUNNEN PRODUCTS TD. Phone: Fax: hemel@sunnen.co.uk SWITZERAND SUNNEN AG Phone: Fax: info@sunnen.ch CHINA SHANGHAI SUNNEN MECHANICA CO., TD. Phone: Fax: sales@sunnensh.com SUNNEN ITAIA S.R.. Phone: Fax: sunnen@sunnenitalia.com FRANCE SUNNEN SAS Phone: Fax: info@sunnen.fr RUSSIA SUNNEN RUS Phone: Fax: sunnen@sunnen-russia.ru CZECH REPUBIC SUNNEN S.R.O. Phone: Fax: sunnen@sunnen.cz POAND SUNNEN POSKA SP. Z O.O. Phone: Fax: sunnen@sunnen.pl PRINTED IN U.S.A COPYRIGHT SUNNEN PRODUCTS COMPANY 08, A RIGHTS RESERVED