I-MBC-185E Installation, Setup and Operation INSTRUCTIONS for SUNNEN PRECISION HONING MACHINE Model: MBC-1805 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE SUNNEN PRECISION HONING MACHINE. SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST. LOUIS, MO 63143, U.S.A. PHONE: 314-781-2100
GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care and maintenance this equipment will give years of service. READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE 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, & 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 Instructions. If you cannot find what you need, call for technical support. Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in the literature packaged with your equipment. Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the following information available: Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it. Have Model Number and Serial Number printed on your equipment Specification Nameplate. Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data. For Troubleshooting, additional information may be required: Power distribution information (type - delta, wye, power factor correction; other major switching devices used, voltage fluctuations) Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding). Use of any optional devices/equipment between the Drive & 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: sunnen@sunnen.com NOTE: Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding. ESD PREVENTION REVIEW Let's review the basics of a sound static control system and its effective implementation. First, in the three step plan: 1. Always ground yourself when handling sensitive components or assemblies. 2. Always use a conductive or shielded container during storage or transportation. These materials create a Faraday cage which will isolate the contents from static charges. 3. Open ESD safe containers only at a static safe work station. At the static safe work station, follow these procedures before beginning any work: A. Put on your wrist strap or foot grounding devices. B. Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of static charges. C. Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics. D. Anti-static bubble wrap has been included for use at the machine when an ESD safe workstation is not available. You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you: GROUND ISOLATE NEUTRALIZE ii
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 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 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 ANY RIGHTS AFFORDED BY LAW TO BUYER, SPC's LIABILITY, IF ANY, FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS, AND BUYER'S SOLE AND EXCLUSIVE REMEDY THEREFORE, SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE. Shipping Damages Except in the case of F.O.B., Buyer's destination shipments, SPC will not be liable for any settlement claims for obvious and/or concealed shipping damages. The customer bears the responsibility to unpack all shipments immediately and inspect for damage. When obvious and/or concealed damage is found, the customer must immediately notify the carrier's agent to make an inspection and file a claim. The customer should retain the shipping container and packing material. SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you, as user and licensee (Licensee), and Sunnen Products Company (SPC) with respect to preprogrammed software (Software) provided by SPC for use on SPC Equipment. By using the Software, you, as Licensee, agree to become bound by the terms of this Agreement. In consideration of payment of the license fee (License Fee) which is part of the price evidenced by your receipt (Receipt), SPC grants to you as Licensee a non-exclusive right, without right to sub-license, to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software. SPC reserves all rights including rights not otherwise expressly granted, and retain title and ownership to the Software including all subsequent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied on removable media (floppy disk), you, as Licensee, may copy the Software only for back up purposes; or you may request that SPC copy the Software for you for the same purposes. All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement. The Software and accompanying written materials (including the user's manual, if any) are provided in an "as is" condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct, indirect, consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use. It is recognized that some states do not allow the exclusion or limitation of liability for consequential or accidental damages and to the extent this is true, the above limitations may not apply. Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement. SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement. iii
SAFETY INSTRUCTIONS READ FIRST This machine, like any equipment, may be dangerous if used improperly. Please read all warnings and instructions before attempting to use this machine. Always disconnect power at main enclosure before servicing machine. 1 Always wear eye protection when operating this machine. WARNING: Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tear-away type. NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing this equipment. 1 DO NOT attempt any repair or maintenance procedure beyond those described in this book. Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions. Due to the wide variety of machine configurations, all possibilities cannot be described in these instructions. Instructions for safe use and maintenance of optional equipment ordered through Sunnen, will be provided through separate documentation and/or training provided by your Sunnen Field Service Engineer or Technical Services Representative. DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment. If specially built automation components are added to this system, be sure that safety is not compromised. If necessary, obtain special enlarged work area safety system from Sunnen Products Co. Indicates CE version ONLY. 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. SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. Copyright 2002 by Sunnen Products Company Printed in U.S.A. iv
TABLE OF CONTENTS Page TABLE OF CONTENTS................................................................ v LIST OF APPENDIXES................................................................ vi INTRODUCTION.................................................................... vi GENERAL INFORMATION & SPECIFICATIONS........................................ vii FLLOR PLAN LAYOUT.............................................................. viii INSTALLATION Purpose.............................................................................. 1 Tools & Materials...................................................................... 1 Installation............................................................................ 1 Electrical Connection................................................................... 4 Filling Fluids.......................................................................... 5 Operational Check...................................................................... 5 PREPARING FOR OPERATION General.............................................................................. 7 Location of Major Components............................................................ 7 Operator Controls..................................................................... 10 Description of Safety Symbols........................................................... 10 Setup - General....................................................................... 10 Setup - Manual Stroke Honing........................................................... 17 Setup - Power Stroke Honing............................................................ 17 Setup - Zero Shutoff................................................................... 20 Setup - ASC Sensing Tip................................................................ 21 Setup - ASC Sensing Unit............................................................... 21 Setup - Automatic Size Control........................................................... 23 Setup - Stone Save..................................................................... 25 OPERATION General............................................................................. 27 Safety Precautions..................................................................... 27 Operating Modes...................................................................... 27 Manual Stroked Honing................................................................. 27 Power Stroked Honing with Zero Shutoff................................................... 28 Power Stroked Honing with ASC......................................................... 30 ROUTINE SERVICE General............................................................................. 33 Cleaning............................................................................ 33 Lubrication.......................................................................... 33 Coolant Level Check................................................................... 33 Check Coolant Level................................................................... 33 Coolant Filter Replacement.............................................................. 33 Filter Canister Cleaning................................................................. 34 Cleaning Coolant Reservoir.............................................................. 35 Pneumatic Lines Check................................................................. 36 Filter Element Replacement............................................................. 36 Drain Filter Regulator.................................................................. 36 Pedal Adjustment...................................................................... 36 Pedal Adjustment................................................................... 37 Brake Strap Tension Adjustment.......................................................... 37 Brake Strap Replacement............................................................... 38 Zero Shutoff Adjustment................................................................ 38 Automatic Cycle Stop Adjustment......................................................... 39 Motor V-Belt Replacement.............................................................. 40 Spindle V-Belt Replacement............................................................. 40 Stroker Drive Belt Replacement.......................................................... 41 v
TABLE OF CONTENTS Page TROUBLESHOOTING General............................................................................. 43 Operational Troubleshooting Index........................................................ 43 General Troubleshooting Index........................................................... 46 APPENDIXES A Pneumatic Flow Diagram.............................................................. 47 B Coolant Flow Diagram................................................................ 49 LIST OF TABLES 2-1 Operator Controls................................................................ 11 2-2 Other Machine Controls & Symbols.................................................. 12 2-3 Pressure Control Initial Setting...................................................... 14 2-4 Cutting Pressure................................................................. 17 2-5 Stroke Length................................................................... 19 2-6 Stroke Speed.................................................................... 21 2-7 Sensing Tips.................................................................... 22 2-8 Sensing Units................................................................... 23 2-9 Micrometer Settings.............................................................. 23 2-10 Stone Expansion................................................................. 26 3-1 Stone Expansion................................................................. 28 4-1 Lubrication Chart................................................................ 33 5-1 Operational Troubleshooting Index................................................... 43 5-2 General Troubleshooting Index...................................................... 46 INTRODUCTION This Instruction Manual is provided to give the information required to install and operated the Sunnen Precision Honing Machine. The MBC-1805 Precision Honing Machine is to be used for finishing bores in small workpieces. In finishing bores, this machine can achieve any or all of the following results: fast stock removal, consistent final size, a high degree of cylindricity, fine surface finish. As there are numerous workpieces which can be honed on this machine, all the possible combinations cannot be discussed here. The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop. When ordering parts for, or requesting information about your machine, include the serial number of your machine. In this book the symbol indicates steps or information that are only for the CE version of this machine. The CE version is constructed to meet the highest level of safety standards as required by the European Machinery Directive. Required for the European market, this CE version is availabe 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 the risks operator carelessness. READ THE FOLLOWING INSTRUCTIONS THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE PRECISION HONING MACHINE. vi
GENERAL INFORMATION & SPECIFICATIONS Model: MBC-1805 DIAMETER (ID) RANGE - Automatic Sizing: 3,2 to 51,0 mm (.125 to 2.00 in.) Power Stroking: 1,5 to 95,0 mm (.060 to 3.75 in.) Manual Stroking: 1,5 to 165,0 mm (.060 to 6.50 in.) STROKE LENGTH - Open End Bores: up to 254 mm (up to 10 in.) Open or Blind Bores: up to 406 mm (up to 16 in.) SPINDLE SPEED: 200, 250, 320, 400, 500, 640, 800, 1000, 1270, 1600, 2000 & 2500 rpm STROKE RATE: 80, 110, 160, 220 & 310 spm STROKE MOTOR: 1/2 Hp SPINDLE MOTOR: 1 Hp PUMP MOTOR: 1/2 Hp COOLANT PUMP: 5,6 liters/minute (1.5 GPM) COOLANT CAPACITY: 106 liters (28 gal) FLOOR SPACE - Deep: 1830 mm (72 in.) Wide: 1250 mm (49 in.) Height: 1700 mm (67 in.) FLOOR WEIGHT (W/Oil): 530 kg (1160 lbs) FLOOR LOAD: 739 kg/sq meter (151 lbs/sq ft) POWER REQUIREMENTS: 208 V, 60 Hz, 3Ph (9.7 Amps) (Max. current load) 230 V, 60 Hz, 3Ph (9.9 Amps) 460 V, 60 Hz, 3Ph (5.9 Amps) 220 V, 50 Hz, 3Ph (8.5 Amps) 380 V, 50 Hz, 3Ph (5.8 Amps) 400 V, 50 Hz, 3Ph (5.8 Amps) 440 V, 50 Hz, 3Ph (6.1 Amps) PNEUMATIC REQUIREMENTS: 5,5 Bar (80 psi) NOISE EMISSION: Less than 71 db (A) continuous Less than 84 db (A) peak 1 Diameter range, length range, and workpiece weight are contingent on workpiece and application. vii
230 mm (9 in.) WITH DOOR OPEN 280 mm (11 in.) 15,9 mm (0.625 in.) DIA. (4 HOLES) 1270 mm (50 in.) WITH PAN RETRACTED 1830 mm (72 in.) WITH PAN EXTENDED OUTLINE LAYOUT Scale: 1 mm = 48 mm 1/4 in. = 1 ft. 1250 mm (49 in.) TOP VIEW Weight Installed: Approximately 530 kg. (1160 lbs.) including coolant. Floor Loading: Less than 739 kg/sm (151 lbs/sf). 1700 mm (67 in.) 762 mm (30 in.) 83 mm (3.25 in.) 587,4 mm (23.125 in.) 72 mm (2.8125 in.) FRONT Approx. 1016 mm (Approx. 40 in.) 730 mm (28.75 in.) 6,5 mm (0.25 in.) ADJUSTABLE 930 mm (36.5 in.) FRONT VIEW SIDE VIEW FIGURE 1-A, Floor Plan Layout viii
SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking, inspecting, and installing Sunnen MBC-1805 Precision Honing Machine. Hereafter, referred to as the Machine (see Figure 1-1). LEFT FRONT RIGHT FIGURE 1-1, Precision Honing Machine TOOLS & MATERIALS The following tools and materials are required for unpacking and installing the machine: Knife Hammer Crow Bar Tin Snips Hex Wrench Wire Cutters/Strippers Screwdriver (Std. Nose) Slip-Joint Pliers Open End Wrenches Cleaning Solvent INSTALLATION Read the following instructions carefully and thoroughly before unpacking, inspecting and installing your Machine. All references to right and left in these instructions are, unless otherwise noted, as seen by the operator as one looks at the front of the Machine or assembly being described (refer to Figure 1-1). 1. Remove top and front of shipping carton by cutting along edges. 2. Remove items shipped inside carton. 3. Remove machine from carton and inspect Machine and Components for dents, scratches, or damage resulting from improper handling, by carrier (see Figure 1-2). If damage is evident, immediately file a claim with carrier. 4. Move Machine to desired location. 5. Level Machine in both left to right and front to back directions (see Figure 1-3). LEVELING BOLTS FIGURE 1-2, Unpacking FIGURE 1-3, Leveling Machine 1
NOTE: For permanent installation, secure Machine's Support Feet to floor with four (4) Fasteners. 6. Open access Door on front of the Machine. 7. Remove Reservoir Retainers, by removing two (2) Screws (see Figure 1-4). 8. Remove and discard cardboard packing. 9. Open left Belt Guard 10. Open access Door to Filter Canister. 11. Loosen Screws in Mounting Bracket and raise Filter Canister Assembly 115 mm (4.5 in.) so hoses will clear Coolant Reservoir and allow Coolant Reservoir to be pulled out (see Figure 1-5). 12. Tighten Screws in Mounting Bracket. 13. Push Drain Pipe to the left and up. 14. Pull Reservoir out far enough to remove all packing paper and tape from the reservoir. 15. Remove packing material and tape from the Settlement Tray, and install tray in Coolant Reservoir. 16. Push the Reservoir all the way in and reinstall Reservoir Retainers, using two (2) Screws removed in step 7. 17. Pull Drain Pipe down and to the right. 18. Loosen Screws in Mounting Bracket and lower Filter Canister Assembly back into operating position. Tighten Screws. 19. Close access Door to Filter. 20. Close Belt Cover Guard. 21. Open access Door to Power Stroke Unit, remove strapping from Power Stroke Motor; then close Door. 22. WORK TRAY. Install Work Tray on left side of machine as follows (see Figure 1-6): Remove Nuts on left side of machine. Install Work Tray using Nuts just removed. Install Tray Pad in Work Tray. 23. DRIP TRAY. Install Drip Tray on right side of machine as follows (see Figure 1-7): Remove Nuts on bottom of Operator Control Station. Install Drip Tray using Nuts just removed. Install Tray Pad in Drip Tray. Slide Retaining Bushing over end of Drain Tube and insert tube into hole in Machine Tray. Allow 13 mm (.500 in.) of Drain Tube to project through side of Machine Tray. Secure Drain Tube by inserting Retaining Bushing into hole Attach other end of Drain Tube to Drip Tray. 24. Raise the work area cover. OIL RESERVOIR 1/4 IN. SCREW RESERVOIR RETAINER SETTLEMENT TRAY LEFT WORK TRAY DRAIN PLUG FIGURE 1-4, Coolant Reservoir (190 mm) (115 mm) (190 mm) CLAMP (300 mm) OIL RESERVOIR CLAMP MOUNTING BRACKET OIL RESERVOIR 7!s IN. 4!s IN. } 7.5 in. FIGURE 1-5, Filter Canister NUT 12 IN. MOUNTING BRACKET FIGURE 1-6, Left Work Tray OPERATING POSITION 2
DRAIN TUBE FIGURE 1-8, Automatic Size Control Unit EXTENSION BARS CROSS ARM HOOK FIGURE 1-7, Right Drip Tray FIGURE 1-9, Work Area Cover OPERATOR CONTROL PANEL DRIP TRAY PROBE BODY TRAY PAD 25. MOVEABLE TRAY. Adjust Moveable Tray as follows: Lift and pull out the Moveable Tray to a position that will be comfortable for the job to be honed. 26. AUTOMATIC SIZE CONTROL UNIT. Remove packing material and tape from the Automatic Size Control (ASC) Unit (see Figure 1-8), and attach unit to bracket in Movable Tray. 27. Close work area cover. 28. WORK AREA COVER. Loosen the two Knobs on the top of the cover and move the cover out until the Target Piece on the cover is over the Magnetic Switch on the Front Splash Gate (see Figure 1-9). Tighten the knobs. Adjust the Pressure Regulator on the Cover Counterbalance Cylinder so that the Cover will remain in any position in which it is placed. 29. FOOT PEDAL. To install Foot Pedal Assembly, proceed as follows (see Figure 1-10). NOTE: DO NOT attempt to fork machine with the Pedal Tube Assembly and Pedal Assembly installed. Loosen Socket Head Screw (1/4 in. Hex Wrench) securing Extension Bar to Cross Bar, and slide Extension Bar out of Cross Bar. Slide Cross Bar under machine so U-Shade Hook on end of Bar engages Machine s Foot Pedal Extension Bars. Slide Bar in at an angle; engage one side, then straighten out Bar to engage other side. Slide Cross Bar back and hook over Machine s Cross Arm. Remove Foot Pedal from Accesory Pack. Lay Foot Pedal Assembly (Extension Bar) on its side. Slide Foot Pedal over Cross Arm on Extension Bar and tighten Socket Head Screw (1/4 in. Hex Wrench). Slide Extension Bar into Cross Bar and tighten Socket Head Screw (1/4 in. Hex Wrench). CROSS BAR CROSS BAR SCREW AIRLINE FITTING EXTENSION BAR PEDAL ASSSEMBLY ON ITS SIDE EXTENSION BAR SCREW EXTENSION BAR FIGURE 1-10, Pedal Assembly PEDAL ASSEMBLY FIGURE 1-11, AIR FILTER REGULATOR 3
30. Open access Door on top right of the machine. NOTE: machines require no tools to open doors. 31. Route a 6,350mm (1/4") air supply line (Parker Push Lok-801-4 Air Line or its equivalent is recommended) under back panel of machine and up to Barb Fitting on Inlet Side of Air Filter/Regulator (see Figure 1-11). NOTE: An air supply of at least 5.5 Bar (80 psi) must be connected to machine for Automatic Cycle Start to operate properly. 32. Route Drain Hose to Coolant Reservoir. 33 Close access Door. ELECTRICAL CONNECTION The 230 V Machine requires a 5,3mm 2 (#10/4, Type SO, 600 Volts) electrical supply cord. (The Machine requires 230 V, 3 Phase, 50 or 60 Cycle Power. Maximum current load is 35 amps.) The 460 V Machine requires a 3,3mm 2 (#12/4, Type SO, 600 Volts) electrical supply cord. (The Machine requires 460 V, 3 Phase, 50 or 60 Cycle Power. Maximum current load is 35 amps.) 1. Loosen Safety Latches on Electrical Control, and remove padlock if installed. 2. Turn OFF Main Power Disconnect and open door to enclosure. 3. Punch a 22mm (.875") Diameter Hole through the bottom of Enclosure (see Figure 1-12). 4. Insert Electrical Supply Cord through Entrance Hole, using a Cord Connector (not supplied) to provide an oil tight fitting. Allow for approximately 610mm (24") of cable from where it enters enclosure and cut off excess. 5. Strip 250mm (10 in.) of outer jacket from cable. 6. Strip 10mm (.375 in.) of insulation from each wire. 7. Connect green wire (electrical supply cord) to Terminal E or PE (Earth Ground). 8. Connect other three wires (electrical supply cord) to top of Electrical Disconnect Block as noted on block. 9. Replace plastic cover on Electrical Disconnect Block. 10. Close and lock door to Electrical Control Enclosure. 11. Connect Electrical Supply Cord to power source. 12. Turn ON power at Main Power Disconnect and check spindle shaft rotation. NOTE: Rotation of Spindle Shaft should be counterclockwise, as viewed from output end of Spindle Drive Motor. If rotation is incorrect reverse any two wires, connected in step 8. 13. Turn OFF power. MAIN POWER DISCONNECT OKAY HERE (76mm) 3 IN. PREFERRED AREA ELECTRICAL SUPPLY CORD (76mm) 3 IN. (90mm) 3.5 IN. (230mm) 9 IN. OKAY HERE OKAY HERE FIGURE 1-12 Electrical Control Enclosure 1/4 IN. SCREW RESERVOIR RETAINER OIL RESERVOIR SETTLEMENT TRAY DRAIN PLUG FIGURE 1-13, Coolant Reservoir NOT HERE WIRES: RED WHT BLK GROUND WIRE: GRN ELECTRICAL DISCONNECT BLOCK OIL TIGHT FITTING 4
FILLING FLUIDS Fill Coolant Reservoir with Sunnen Industrial Honing Oil or Sunnen Water-Based Coolant as follows (see Figure 1-13): NOTE: Maximum capacity of the Coolant Reservoir is 106 liters (28 gallons). A minimum capacity of 38 liters (10 gallons) is needed for proper pump operation. 1. Open Door on front of Machine. 2. Remove Settlement Tray from Coolant Reservoir. 3. Pour approximately 90 liters (23 gallons) of coolant into the machine Work Tray or pump coolant directly into Reservoir. 4. Replace Tray and close door. OPERATIONAL CHECK Read Sections 2 and 3 thoroughly and carefully before performing the Operational Check. 1. Power up the Machine and check that motors and spindle are operating properly. 2. Bleed Coolant System: Direct Coolant Nozzles downward and open Knobs on Flow Control Manifold. Turn ON power and let pump run until all coolant nozzles are delivering a steady stream of coolant. Pour an additional 19 liters (5 gallons) of approved coolant into the Machine Work Tray, to top off the system as the Filter Canister fills. The Coolant System holds a total of 106 liters (28 gallons) of coolant. Push POWER OFF Button. 3. After unpacking and installing the Machine, clean and lubricate. Refer to Section 4. 5
LIGHT CUTTING PRESSURE CONTROL FEED RATE KNOB STONE SAVER BELT GUARD STOCK REMOVAL ADJUSTMENT KNOB AUTO SIZE CONTROL WORK TRAY FEED DIAL HONING DIAL STROKE ADJUSTMENT WORK TRAY OPERATOR CONTROL PANEL HEAVY CUTTING PRESSURE CONTROL DRIP TRAY MOVABLE TRAY LITERATURE POCKET (INSIDE DOOR) UNIVERSAL HONING FIXTURE POWER STROKER UNIT ADJUSTABLE PEDAL SIZE CONTROL PROBE BODY FIGURE 2-1, Major Components 6
SECTION 2 PREPARING FOR OPERATION GENERAL This section should be consulted when preparing the Machine for operation. LOCATION OF MAJOR COMPONENTS For location of major components on the machine see Figure 2-1. 1. BASE ASSEMBLY Base Assembly consists of the following components (see Figure 2-2): Machine Base. The Precision Honing Machine is equipped with a heavy base to support Hone Head Assembly and house the operating components. Access Doors. Access Doors are located on top and front of machine to provide easy access to machine operating components. ACCESS DOOR WORK TRAY MOVABLE TRAY ACCESS DOOR ACCESS DOOR FIGURE 2-2, Base Assembly WORK TRAY DRIP TRAY Literature Pocket. The Literature Pocket is located inside front access Door. Pocket is used to store literature. Movable Tray. The Movable Tray is located on top front of machine. It adjusts to accommodate honing units and workpieces of varying lengths. The machine is equipped with two (2) Work Trays located to left and right of Movable Tray and Drip Tray located on right side of machine just below Operator Control Station. 2. PEDAL ASSEMBLY The Pedal Assembly is located on front and inside of Machine Base (see Figure 2-3). Depressed assembly starts spindle drive motor, stroking drive motor, expands stones and if used, sets Automatic Cycle Stop. Assembly consist of the following components: NOTE: Not required when Stroke Switch is set to AUTO. Adjustable Pedal Bar & Pedal is located on lower front of machine. Both the Bar and Pedal are adjustable to accommodate individual operator. Air Actuated Pedal Depressor is located inside top right of Machine Base and is accessible through top right access Door. It is pneumatic linkage between manually operated Pedal and machine controls. Air Line Filter Regulator is located inside Machine Base and supplies pneumatic pressure to operate Pedal Depressor. 3. HONE HEAD ASSEMBLY The Hone Head Assembly consist of the following components (see Figure 2-4): FIGURE 2-3, Pedal Assembly FIGURE 2-4, Hone Head Assembly 7
Light Cutting Pressure Control Dial is located on top left of assembly. It is used to adjust cutting pressure of honing stone in small diameter bores, in soft materials, for rough bores or for fine finishes. Feed Dial is located on top left of assembly below Light Pressure Control Dial. It is used to set maximum honing stone expansion. Honing Dial is located on front center of assembly. It measures expansion of stone as wedge moves forward, and indicates that maximum stone expansion point has been reached when the needle reads "0". Heavy Cutting Pressure Control Dial is located on lower left of assembly. It is used to adjust cutting pressure of honing stone where heavy stock removal is required. Spindle Drive Motor is located on top of assembly. It supplies power for honing operation. 4. UNIVERSAL HONING FIXTURE ASSEMBLY Universal Honing Fixture Assembly is located on front of machine in Moveable Tray (see Figure 2-5). It consists of the following components: Universal Honing Fixture is used to hold workpiece. Stroke Release Handle is located on right front of assembly. It manually disconnects Stroking Arm from Power Stroking Unit. Stroke Brake Release Handle is located on back of Stroking Drive Motor, inside Power Stroking Unit. It releases Stroking Motor Brake so stroke may be changed. Power Stroking Unit is located on right front of Machine. It supplies power to operate Stroking Arm. Stroking Arm is located on top front of Machine inside Movable Tray. Power Torque Support is located on left side of assembly. This adjustable support is used to take torque from holding fixture (or workpiece) when operating Machine in Power Stroke Honing Mode. Knee Support is located just below Power Torque Support. Power Torque Support rides on Knee Support. Like Power Torque Support it is used to take torque. It also controls vertical position of Stroking Arm. Clamp Screws are used to attach Torque Support Bar, Coolant Support Bar, etc. to Stroking Arm. Three screws are provided. Shaft Cover is located on right rear of assembly. It protects shaft from dirt and activates safety interlock on Power Stroking Unit. Spindle Cover is located in center on assembly. It is a protective cover for Spindle Assembly. 5. COOLANT PUMP ASSEMBLY. Coolant Pump Assembly is located inside top left of machine (see Figure 2-6). It consists of following components (all directional references are as viewing assembly from left side of machine): COOLANT PUMP FIGURE 2-5, Universal Honing Fixture PUMP MOTOR HIGH PRESSURE RELIEF VALVE FIGURE 2-6, Coolant Pump Assembly MAIN POWER DISCONNECT OKAY HERE (76mm) 3 in. PREFERRED AREA (76mm) 3 in. (90mm) 3.5 in. (230mm) 9 in. OKAY HERE FIGURE 2-7, Electrical Components OKAY HERE NOT HERE 8
PLUNGER ADJUSTMENT KNOB FLOW CONTROL VALVES PROBE BODY SENSING TIP FIGURE 2-8, Automatic Size Control Unit Coolant Pump is located on left front of assembly. It circulates Coolant at rate of 5,7 liters/minute (1-1/2 GPM). Pump Motor is located behind Coolant Pump and supplies power to operate Pump. There are two Relief Valves on Coolant Pump Assembly. The High Pressure Relief Valve is located on left side of Coolant Pump. It dumps excess Coolant into Coolant Reservoir when Coolant pressure in system becomes too high. The Low Pressure Relief Valve is located under Filter Canister. It dumps excess coolant back into circulating system when coolant pressure builds up at Coolant Flow Manifold. Coolant Solenoid is located on bottom of Filter Canister. It controls flow of coolant to Coolant Flow Control Manifold. It shuts off flow of coolant when cycle stops and turns it back on when cycle starts. Filter Canister is located to right of Coolant Pump. It holds Filter Element for filtering Coolant. Filter Element is located inside Filter Canister. It filters Coolant as it is pumped from Coolant reservoir, before it reaches workpiece. Air Vent is located on top of Filter Canister. It is used to vent canister when filling or draining system. Cover Clamp is located on top of Filter Canister. It must be locked in place to operate system. Coolant Flow Control Manifold is located on left front of machine. It provides independent regulation of coolant flow to each Coolant Nozzle through total volume control valve and individual coolant nozzle control valves. The total volume valve is used to turn on and off supply of coolant, eliminating readjustment of individual coolant nozzle control valve setting. Coolant Support Arm is located on front of machine in Movable Tray. It attaches to Stroking Arm with Clamp Screws. It is used to support Coolant Nozzles. Coolant Nozzles attaches to Coolant Support Arm. The nozzles supply coolant to workpiece and mandrel. Three independently controlled coolant nozzles are easily positioned to assure an even flow of coolant through workpiece and over full length of mandrel. 6. ELECTRICAL COMPONENTS. The Sunnen Precision Honing Machine is available in 230/460 Volt, 60 Hz, 3 Phase. Its major electrical components are as follows (see Figure 2-7): Automatic Cycle Stop (Automatic Shutoff) is located on right front of Hone Head Assembly. It controls honing cycle when Zero Shutoff or Automatic Size Control is in operation. Cycle Lockout is located on lower right front of Hone Head Assembly. It is used to lock out Automatic Cycle Stop for Manual Honing or for Power Honing without Zero Shutoff or Automatic Size Control. Operator Control Panel is located on right front of machine, below Automatic Cycle Release Lever. Electrical Control Enclosure is located on right side of machine. Electrical power to machine is controlled at this by Main Power Disconnect. 7. AUTOMATIC SIZE CONTROL UNIT. Automatic Size Control Unit is located front of machine inside Movable Tray (see Figure 2-8). It consists of the following components: Position of Unit is controlled by Plunger Adjustment Knob, Position Bracket, Bearing Shaft Clamp, and Probe Body Positioning Cylinder. The Lift and Retract Time of Probe Body Positioning Cylinder is adjusted by two (2) Inlet Port Flow Control Valves located on each end of Cylinder. Probe Body Assembly is the unit onto which Sensing Tips (Units) for Automatic Size Control are mounted. Probe automatically retracts away from workpiece at end of cycle, so workpiece can be unloaded and a new workpiece loaded, then the Probe returns to proper position at beginning of next cycle. Bearing Shaft is the unit on which Probe Body Assembly rides as it moves in and out of position. Assembly rides on a Guide Rod which is adjustable so Assembly is clear of Stroker Carriage during loading and unloading of the workpiece. Automatic Size Control Switch is located inside top right of machine. Toggle switch controls power for Automatic Size Control. Rate Adjustment Knob is located inside top right of machine, above Automatic Size Control Switch. It is used to adjust Automatic Size Control for stroke rate being used. Automatic Size Control will ONLY function when Rate Adjustment Knob is set for stroke rate lower than that being used. 9
8. STONE SAVER ASSEMBLY. Stone Saver Assembly is located on right side of Hone Head Assembly (see Figure 2-9). It controls stone expansion rate from a size smaller than bore before it is honed. This feathers stone into a rough bore surface just as a good operator does by carefully riding pedal during first seconds of honing. It consists of the following components: Stone Saver Control Lever is located inside assembly and is reached through access hole on right side of assembly. Feed Rate Knob is located to right of Feed Dial on front of Hone Head Assembly. It is used to adjust rate at which stone saver feeds. Stock Removal Adjustment Knob is located on top of Stone Saver Assembly. It is used to adjust stone saver to amount of stock to be removed from workpiece. 9. ACCESSORIES. The following accessories come with machine. Hex Key Wrenches. Metric Wrenches. 4 & 6 mm wrenches for adjusting Automatic Size Control Unit. T-Wrench. MAN-700 Diamond Dresser. Used to break glaze on aluminum oxide and silicon carbide honing stones. Manual Torque Support. Adjustable support used to absorb torque from holding fixture (or workpiece) when honing manually. Manual Torque Support Arm. Used to hold Manual Torque Support when manually honing. Torque Support Bar. Attaches to Stroking Arm and used to adsorb honing torque when Universal Honing Fixture is not being used. Short Rod. May be used in place of long rod on right side of Stroking Arm Assembly when Universal Honing Fixture is not being used. 10. WORK AREA COVER. Work Area Cover must be closed before any power stroked cycle can start (see Figure 2-10). Also, if opened during a cycle machine will stop honing cycle just as if Cycle Stop was pressed. Cover is attached to a counterbalance Cylinder with an adjustable air pressure regular. Cover length is adjustable to fit Moveable Tray, and air pressure regulator can be adjusted to balance cover at any position. 11. OPTIONS. The following options are available for Your Sunnen Precision Honing Machine. Gage Mount, Model MB-2370A. Mounts on left front of machine and is used to rest Sunnen PG Gage on for easy access during honing. Work Light, Model MBC-200. Mounts on top left of Hone Head Assembly and provides glareless illumination for honing and gaging. Setup Faceplate, Model KKN-265A. Mounts on front of Stroking Arm Assembly and is used in aligning stroker. FIGURE 2-9, Stone Saver FIGURE 2-10, Work Area Cover Indicator Support Bar, Model KKN-260A. Mounts in Spindle Nose and is used for aligning stroker and for squaring Faceplate. Wrench, Model CRF-546. A 1 in., thin open end wrench used to adjust roller position on Power Torque Support. Wrench, Model KKN-196A. A 1/2 in.-5/8 in. thin open end wrench used to adjust support bushings which mount Faceplate to Stroking Arm. Safety Shield, Model KKN-680A. Attaches to Universal Honing Fixture. Its purpose is to deflect workpiece in event that one of smaller mandrels bends and throws workpiece out of fixture during a power stroked honing cycle. OPERATOR CONTROLS For location of controls see Figure 2-11; and refer to Table 2-1 for function of controls. OTHER MACHINE CONTROLS For a description of other machine controls and saftey symbols used on this machine see Table 2-2. SETUP - GENERAL 1. Press E-STOP Button to ensure power is OFF and lock is engaged. 2. Turn ON Main Power Disconnect at Main Electrical Control Enclosure. 3. Set Mode Selector Switch to MANUAL. 10
TABLE 2-1, Operator Controls FIGURE 2-11, Operator Control Station SYMBOL DESCRIPTION FUNCTION (POWER ON) Controls electrical power to START the Coolant Pump White Motor; closes circuits to Spindle Motor and Stroker Pushbutton Motor. White light indicates power to Machine is ON. Switch (POWER OFF) Shuts off electrical power to Coolant Pump, Spindle and Red Stroker Motors. Pushbutton Switch (AUTO CYCLE START) STARTS honing cycle when Mode Selector Switch is Green set to ZERO SHUT-OFF or ASC. Pushbutton Switch (CYCLE STOP/RESET STOPS honing cycle and resets cycle Red Pushbutton Switch MODE SELECTOR MANUAL Selects manual stroke honing (AUTO/MANUAL/ SEMI-AUTO) 3 Position ZERO SHUT-OFF Selects power stroked honing with Selector Zero Shut-off Switch ASC Selects power stroked honing with automatic size control (Emergency Stop) Red Locking Pushbutton Switch Controls electrical power to STOP ALL Machine functions; opens circuits to Spindle Motor and Stroker Motor. Must be rotated counterclockwise before Machine can be restarted. 11
TABLE 2-2, Other Machine Controls & Symbols SYMBOL DESCRIPTION FUNCTION (Light Cutting Pressure) Indicates setting of Light Cutting Pressure. Rotatory Dial (Heavy Cutting Pressure) Indicates setting of Heavy Cutting Pressure. Rotatory Dial (Feed Dial) Adjacent table indicates the amount of stone feed Rotatory per dial graduation for various tools. Dial (Manual Honing) Turn clockwise to a stop to set machine for manual stroked honing. O (Stone Saver) Indicates location of Stone-Saver controls. (Stone Saver OFF) Control lever up turns Stone Saver Off. (Stone Saver ON) Control Lever down turns Stone Saver On. (Stone Saver Feed Rate) (Stone Saver Initial Diameter) Stroker Disengage Rotation Arrow Warning Label Warning Label Turning to the right increases the controlled feed rate. Turning counterclockwise increases the starting diameter (decreases the stock removal). Pulling forward releases the stroker carriage. Indicates proper direction of rotation. Warns not to hold workpiece in hand without a torque resisting fixture. Indicates that safety glasses are recommended for operation. n m n n m i n Stroke Speed Spindle Speed Stroke Length Foot Pedal Starts the honing cycle and controls stone expansion. 12
FIGURE 2-12, Feed Dial FIGURE 2-13, Mandrel Wedge STONE SAVER 4. Turn OFF Coolant supply, by turning Total Volume Control Valve, Coolant Flow Control Manifold, fully clockwise. 5. IF APPLICABLE: Deactivate Stone Saver, by moving Rod Tip to inactive position (see instructions on Stone Saver cover). 6. Turn Cycle Lockout fully clockwise. 7. Pull Stroker Release Handle forward and raise Stroker Arm. 8. Set Automatic Size Control Switch to ZERO SHUT-OFF position (located inside top right of machine). 9. Select Honing Unit and Stone from Sunnen Honing Supplies Catalog. 10. Assemble Honing Unit: According to instructions packed with Honing Unit. 11. Turn Feed Dial counterclockwise until you meet resistance, then advance dial clockwise about 5 turns (see Figure 2-12). 12. Pull Mandrel Wedge straight back as far as possible, using hook on end of T-Wrench (see Figure 2-13). 13. IF REQUIRED: Install Spindle Sleeve (LN-570A, not supplied) on Honing Unit (see Figure 2-14). 14. Remove Spindle Cover. 15. Press Pedal slightly to release brake. 16. Rotate Spindle so Large Set Screw points up (Screw is in 12 O'clock position). 17. Insert Honing Unit into Spindle Nose as far as it will go; rotate unit 1/4 turn clockwise to engage Wedge with Feed Rod; then push Honing Unit all the way in until it bottoms (see Figure 2-15). 18. Test Wedge hookup by pulling Honing Unit straight out; if Wedge comes out repeat steps 12 thru 17. 19. Push unit back into Spindle Nose until it bottoms. SPINDLE SLEEVE LARGE SET SCREW FIGURE 2-14, Spindle Sleeve FIGURE 2-15, Install Mandrel 13
20. Tighten Large Set Screw with T-Wrench. 21. Set Spindle Speed for 200 rpm (setup speed) as follows: Open left Belt Guard. Using Chart on inside of Belt Guard, position belts for a Spindle Speed of 200 rpm (setup speed). Pull Idler Handle down (see Figure 2-16). Move upper V-Belt to 200 rpm position. Move lower V-Belt to the Low Speed Range groove. Release Idler Handle by pulling and raising. Close and secure Belt Guard. 22. Set Light Cutting Pressure Control to 1. 23. Set Heavy Cutting Pressure Control to 0. 24. Reduce Mandrel Runout as follows: Place a concentric Truing Sleeve on Honing Unit. Depress Pedal and turn Feed Dial clockwise until Honing Dial reads 5 in.; release Pedal. Rotate E-STOP Button counterclockwise to release lock. Press POWER ON Button. WARNING Power to the machine is ON. Spindle will rotate when Foot Pedal is pressed. Depress Pedal all the way down (allow Truing Sleeve to rotate with Honing Unit). Touch a marking pencil to Sleeve, near front and back (see Figure 2-17). The resulting marks indicate high point(s). Push E-STOP Button. Loosen Numbered Set Screws in Spindle Nose on same side as pencil marks; and tighten Numbered Set Screws on opposite side (see Figure 2-18). Release E-STOP Button. Wipe Truing Sleeve and repeat step as required, until minimum runout is obtained. Release E-STOP Button. Press CYCLE STOP/RESET Button and remove Truing Sleeve. Push E-STOP Button. 25. Set Light Cutting Pressure Control according to Table 2-3 or Your Sunnen SMOPS Guide. 26. True in Mandrel and Stone as follows: Turn Feed Dial counterclockwise until you feel resistance. Place a Truing Sleeve or a suitable undersized workpiece in a torque absorbing workholding fixture. Install Truing Sleeve (in Workholding Fixture) on mandrel. Depress Pedal and turn Feed Dial clockwise until Honing Dial Needle reads 3 in. MARK FIGURE 2-16, Idler Handle IDLER HANDLE FIGURE 2-17, Mandrel Runout FIGURE 2-18, Numbered Set Screws TABLE 2-3, Pressure Contorl Initial Setting NUMBERED SET SCREW BORE SIZE PRESSURE CONTROL millimers inches INITIAL SETTING 1,5-2,5.060 -.100 0 2,5-5,0.100-.185 1/8 5,0-6,0.185 -.245 1/4 6,0-9,0.245 -.370 1/2 9,0-12,0.370 -.495 3/4 12,0-25,0.495-1.000 1 25,0-92,0 1.000-3.625 2 92,0-165,0 3.625-6.500 2-1/2 14