X-HTB-1001A Repair Parts CATALOG for SUNNEN TUBE HONING MACHINES HTB-S SERIES HTB-1000S, -2000S, -3000S, -4000S, -5000S, -6000S, -8000S, -10000S1 Version: HTB-S100, S101, S201 File: htbsr-s101.doc Date: 18 October, 2006 READ THE FOLLOWING REPAIR PARTS THOROUGHLY AND CAREFULLY BEFORE PREFORMING ANY SERVICE ON THE HTB-S SERIES TUBE-HONING-MACHINES. SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD SAINT LOUIS, MO 63143, U.S.A. PHONE: 314-781-2100 SUNNEN AG Fabrikstrasse 1 8586 ENNETAACH SWITZERLAND PHONE: + 41 71 649 33 33
TABLE OF CONTENTS TABLE OF CONTENTS 1 INTRODUCTION 2 SPINDLE DRIVE 3 CARRIAGE 5 STROKE MECHANISM 1 7 STROKE MECHANISM 2 9 MOVING SUPPORT 10 COVERS AND COOLANT 11 TOOL SUPPORT (TS-405) 13 SAFETY UNITS 14 SAFETY ARCH (US Version) 15 HOLDING FIXTURE 16 FEED UNIT 18 PNEUMATIC SYSTEM (HTB) 20 ELECTRICAL Main Enclosure 22 ELECTRICAL Operator Panel 25 PF-401 FILTER UNIT (Optional) 27 Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow the instructions for the operation of the equipment. 1
INTRODUCTION Illustrations show all major components in exploded detail. Item numbers on each illustration are keyed to he s corresponding parts list, providing a descriptive identification of each part. The parts list includes assemblies as well as detail parts. Items listed without a part number can be optioned as a component of the complete assembly of which it is a part. SUNNEN AG reserves the right to make changes, without ice, to materials, specifications, colors, designs and accessories includes with units. HOW TO ORDER When ordering replacement parts are sure to include the following information to insure prompt shipment of correct parts: 1. The part number and description of each part desired, obtained from this parts catalog. 2. The quantity of each part desired. 3. The voltage, frequency and phases, when ordering electrical parts. 4. The model and serial number of the honing machine, obtained from the nameplate, when there is any question concerning a part. HOW TO USE THIS PARTS LIST Step 1. - Locate desired part on illustration. Note item number. Step 2. - Locate item number in the parts list. Step 3. - If the item has a part number listed, order by part number and the description. Part numbers lightface type indicates that it is a component of the last preceding part number in bolt face type. ORDER ONLY BY PART NUMBER AND DESCRIPTION - NOT by item number. Step 2 ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 SR-220 1 Movable Fixture (including Item 2-10) 2 SR-1023 1...T-Slide Step 3 3 SR-1024 1...Holder 4 SR-1025 1...Positions Plate 5 SR-1026...Hole Plate 2
SPINDLE DRIVE 1 8 6 7 S717, S718 9 FIGURE; Spindle Motor 3
SPINDLE DRIVE PARTS LIST COVERING FIGURE Spindle Motor ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 R47-2125-300-2B 1 STANDARD, RPM Range: 30 400 RPM Gearbox + Spindle Motor (RPM 57-287), 400V, 50Hz 1 R47-2283-300-2 OPTIONAL 1, RPM Range: 14 178 RPM Gearbox + Spindle Motor (RPM 25-127), 400V, 50Hz 1 R47-2180-300-2 OPTIONAL 2, RPM Range: 21 279 RPM Gearbox + Spindle Motor (RPM 40-199), 400V, 50Hz 11 117.0018 1 Friction Ring R47 (see STÖBER Spare Parts List 440929/34, Item 11) 66 117.0035 1 Drive Cone R47 for Gear Boxes with Standard Motor Coupling (see STÖBER Spare Parts List 440934.01, Item 66) shown PEC-139A PEC-144 PEC-146 1 3 1 Connector MPS...CLAMP (Spindle Drive)...SOCKET (Spindle Drive)...PLUG (Spindle Drive) PEC-139A PEC-141 PEC-146 1 3 1...CLAMP (MPS-100)...PIN (MPS-100)...PLUG (MPS-100) shown 0934 010 0404 0934 016 2601 1 Plug male X131 6 119.0004 1 Speed Changing Wheel shown 0934 010 0304 0934 016 2701 1 Plug female X131 7 MPS-205 1 Spindle Nose 8 MPS-100 1 Remote Feed Unit 9 HT-2017 2 Safety Block (Pkg. of 1) S717 XCMD2515L1 1 Safety Switch S717 S718 XCMD2515L1 1 Safety Switch S718 4
CARRIAGE 1 2 5 2 3 6 4 7 8 S1022 S115/S116 9 Carriage under side FIGURE; Carriage 5
CARRIAGE PARTS LIST COVERING FIGURE Carriage ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 HT-2002 1 Lock Bolt Plate 2 HT-2005-1 1 Lock Bolt and Taper Sleeve 3 HT-2004 1 Lock Bolt Sleeve 4 HT-2008 1 Piston 5 JZK M10x20 1 Cap Head Screw 6 11 6241 0110 1 Airzet Seal ø 60 7 11 6241 0107 1 Airzet Seal ø 40 8 HT-2006 1 Air Cylinder Housing 9 HT-2007 1 Air Cylinder Cover shown 60x2 1 O-Ring shown 1703-240-70 4 Linear Bearing (Pkg. of 1) DIAGRAM NO. ORDER BY PART NUMBER QTY. DESCRIPTION S1022 XCMD 2510L1 1 Position switch S115, S116 BES-516-377-S49-C 2 Sensor BKS-S49-1-PU0.3 2 Plug for Sensor 6
STROKE MECHANISM 1 1 2 8 6 7 3 4 9 FIGURE; Chain Adjuster 7
STROKE MECHANISM 1 PARTS LIST COVERING FIGURE Chain Adjuster ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 HT-2112 1 Duplex Chain Wheel with two Bearings 2 HT-3018 2 Spacer 3 HT-3019 1 Bolt 4 HT-3017 1 Duplex Chain Adjuster 6 MF-30x2x200 1 Spindle 7 HT-2046 1 Washer 8 MF-30x2-M 2 Nut 9 HT-3038 1 Chain Guard shown HT-3020 1 Damper Holder shown HT-3025 1 Back Stop Washer shown 12.2101.0403 1 Damper shown JZK-M12x80 1 Cap Head Screw 8
STROKE MECHANISM 2 FIGURE; Stroke Drive ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 RLD 1600 5571 1 Clamp Sleeve ø 55 / 71 2 HT-2110 1 Duplex Chain Wheel 3 HT-3104 1 Gear Flansh with Screws 4 16B-2 Duplex Chain 1 x17mm (Pkg., of 1 meter) 5 16B-2NR3 1 Chain Locker 6 P822SGR250ME 1 Stroke Gear SERVOFIT ø 55x80 (i=25) 9 102265 1 Servomotor Stroke DBL5N01050 9
MOVING SUPPORT (for machines above 5000mm stroke length) 1 2 3 4 8 6 5 7 FIGURE; Moving Support 9 10 ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 SR-1001 1 Slide Block 22mm (for Portahone - Extensions) 1 SR-1002 Slide Block 38mm (for MPS - Extensions) 1 SR-1003 Slide Block 60mm (for SUNNEN AG - Extensions) 1 SR-1004 Slide Block 64mm (for Giant - Extensions) 2 SR-1010 1 Slide Block Holder 3 1691-294-10 1 Linear Rail 4 SR-1023 1 T-Slide 5 SR-1024 1 Holder 6 SR-1025 1 Positions Plate 7 1607-204-31 1 Rail Way 8 GN 617-6-AK 1 Position Bolt 9 SR-1014 1 Sprocket Z9 10 SR-1011 1 Break Pad shown EVM131-F01-01 1 3/2 Lever Air Valve mechanical shown CD75E32-20B 1 Air Cylinder 10
COVERS AND COOLANT 1 2 11 3 13 FIGURE; Covers and Coolant 11
COVERS AND COOLANT PARTS LIST COVERING FIGURE COVERS AND COOLANT ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 HT-3049 2 Main Splash Guard (Pkg. of 1) shown HT-3050 1 Splash Left side shown HT-3051 1 Splash Right side 2 HT-3008 2 Splash Guard Holder with Screws (Pkg. of 1) 3 HT-2019 4 Rails (Pkg. of 1) shown 626-ZZ 20 Bearings for Rails shown HT-2045 4 Guard Guide green Plastic (Pkg. of 1) shown GN 565-20-112-EL 1 Handle shown RB-1700 1 Flow Control Valve shown 004-01 1 Tube 0,75m includes 004-61500 1...Tube 004-61502 1...Nozzle 004-61505 1...Fitting 3/4 11 TB 100/270-G1 1 Coolant Pump 12 TEM141/270 1 Coolant Pump (for machines above 5000mm stroke length) 13 F-DMP.150 1 Magnetic Separator 12
TOOL SUPPORT (TS-405) 4 7 8 9 10 1 2 6 5 FIGURE; Tool Support ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION TS-405 1 Tool Support 1 TS-4011 1 Holder 2 TS-4002 1 Arm shown TS-4003 1 Spindle 4 TS-2007 1 Plastic plate 5 TS-4004 / BN325-25 1 Clamp Ring 6 TS-4005 1 Clamp piece 7 SA-001390 1 Stop 8 GN300-92-M10-OR 1 Lever 9 BES516 324E5CS49 1 Sensor 10 BKS-S49-1-PU-0.3 1 Plug for Sensor 13
SAFETY UNITS S710 (CE Version only) S706 (US Version only) S711 (CE Version only) FIGURE; Safety Units DIAGRAM NO. ORDER BY PART NUMBER QTY. DESCRIPTION S706 XALK174F 1 Emergency Stop (US Version only) S710 FGSS600-21 1 Light Barrier Transmitter (CE Version only) S711 FGSE600-21 1 Light Barrier Receiver (CE Version only) 14
SAFETY ARCH (US Version) 1 4 3 5 2 7 ITEM NO. FIGURE; Safety Arch (US Version) ORDER BY PART NUMBER QTY. DESCRIPTION HT-517 1 Safety Arch with wire protection 1 HT-51701 1 Arch 2 HT-51702 1 Holder 3 HT-51703 1 Cover 4 BN1359-12x35/M10 1 Screw 5 GN 617-6-AK 1 Bolt with Nut M12x1,5 shown NM12RB 1 Limit Swicht S714 7 GN616-M8-S 1 Spring screw M8 shown MR105-ZZ 2 Miniature Bearing shown 0534 21480 1 Spring D= 13.75x1.25/L= 27 mm 15
HOLDING FIXTURE FIGURE; Holding Fixture 16
HOLDING FIXTURE PARTS LIST COVERING FIGURE Holding Fixture ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 HT-2031 1 Prism 2 820.152 2 Clamp Shims with Screws (Pkg. of 2) 3 HT-2035 1 Chain Anchors (Pkg. of 2) 4 JSS-M8x12 2 Set Screws 5 HT-2030 1 Chain Roller 6 ZSG-10x80 1 Pin ø 10 mm 7 HT-2033 1 Clamp Screw Block 8 JZK-M8x80 2 Cap Head Screw 9 E-2395 1 Spindle 10 E-3171X 1 Handle 11 RZK 1922-V 1 Chain (Pkg. of 1,3m) 12 HT-2037 / HT-3005 1 Prism Plate and Spindle Assembly TR 60 13 JZK-M10x20 4 Cap Head Screws 14 DIN-580/M20 1 Eyebolt 15 HT-2038 1 Adjusting Nut TR 60 16 HT-2036 / HT-3006 1 Base Plate Assembly ø 60 17 HT-3007 2 Clamp Locks (Pkg. of 1) 18 JZK-M12x30 4 Cap Head Screw (Pkg. of 1) 19 JZK-M12x80 1 Cap Head Screw 20 HT-2047 1 Sleeve 17
FEED UNIT FIGURE; Feed Unit 18
FEED UNIT PARTS LIST COVERING FIGURE FEED UNIT ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION MPS-205 1 Spindle Nose Adapter 32mm includes 1 1...Input Hub 2 MPS-R203 1...Disassembly Rings (Pkg. of 2) 3 1...Screw Cap 4 1...Screw (16mm x 40mm Soc. Flat Head Cap) 5 PHR-341A 1 Retaining Ring 6 MPS-172A 1 V Ring 7 MPS-155A 1 Brush Housing and Cord Assembly includes 8 4...Set Screws 9 MPS-157A 4...Brush Holders 10 MPS-168A 4 Slip Ring Brushes (Pkg. of 4) 11 MPS-169A 4 Caps (Pkg. of 4) 12 MPS-250A 1 Torque Bracket includes 13 1...Screw 14 1...Washer 15 MPS-140A 1 Slip Ring Assembly includes Item 15A 16 MPS-135A 1 Motor Housing includes Item 15 17 PMO-105A 1 Motor includes shown PMO-105-1A 2...Motor Brushes (Pkg. of 2) MPS-110A 1 Flange Assembly includes Item 22 and 18 6...Screws (5mm x 12mm Soc. Head Cap) 19 1...Flange 20 4...Screws (1/4-20 x 1 ) 21 2...Wear Ring PHM-101A * 1 Harmonic Drive Gear includes 22 1...Circular Spline 23 1...Flexspline and Wave Generator 24 MPS-113 1...Key shown PHR340 1...Seeger Ring 25 1...Dynamic Spline (Chamfered) MPS 115A 1 Output Shaft Assembly includes Item 21, 25 and 26 1...Output Shaft 27 3...Sleeves 28 3...Screw (5mm x 16mm Soc. Head Cap) 29 MPS-125A 1 Yoke with Bearing (Bearing sold separately) 30 4 Screws (1/4-20 x ½ Soc. Head Cap) 31 4 Screws (10-32 x1½ Soc. Head Cap) 32 MPS-185A 1 Universal Ring includes 33 PBR-24A 2...Inner Races shown PBR-23A 2...Needle Bearings 34 2...Washers 35 2...Screws (5/16-24 x 1 But. Head Cap) 36 MPS-175A 1 Universal Joint includes 37 1...Set Screw (10-32 x ¼ Plain Cup Point) 19
PNEUMATIC SYSTEM (HTB) 2 1 3 8 Y2014 CARRIAGE RELEASE 14 10 Y2012 Y2013 TOOL SUPPORT (Optional) MOVING SUPPORT above 5000 mm length 9 Y2011 11 Y2015 Y2016 AUTOMATIC SIZE CONTROL (Optional) 4 FIGURE; Pneumatic System R (out) 20
PNEUMATIC SYSTEM PARTS LIST COVERING FIGURE PNEUMATIC SYSTEM ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 AW20-F02C 1 Filter Regulator 2 IS1000E-2F02Y-X215 1 Pressure switch 1-6 bar (Optional) 3 K8-10-50 1 Manometer 4 AN200-KM10 1 Filter 5 SX5000-52-1A 1 End-Plate left 6 SX5000-51-1A 1 Supply-Plate 7 SX5000-50-1A-C6 Ground Plate 8 SY5140-5LOU 5/2 Air Valve Y2014 (Carriage Release) 9 SY5140-5LOU 5/2 Air Valve Y2011 (Moving Support for machines above 5000 mm stroke length) 10 SY5440-5LOU 1 5/3 Air Valve Y2012, Y2013 (Tool Support) 11 SY5440-5LOU 1 5/3 Air Valve Y2015, Y2016 (Optional Automatic Size Control) 12 SX5000-53-1A 1 End-Plate right 13 SY100-60-A-20 Plug with wire 14 EVM130-F01-00 1 3/2 Air Valve mechanical 21
ELECTRICAL Main Enclosure S100 A110 Q311 Q312 Q314 A144 K715 G71 A700 K2006 K2007 K2008 Q100 K705 Q110 Q310 F413/F414 K2002/K2003 M417 T410 T142 A3000 A2520 FIGURE; ELECTRICAL Main Enclosure 22
R132 A130 FIGURE; ELECTRICAL Main Enclosure 23
ELECTRICAL Main Enclosure PARTS LIST COVERING FIGURE ELECTRICAL Main Enclosure DIAGRAM NO. ORDER BY PART NUMBER QTY DESCRIPTION S100 P3-63/EA/SVB/N 1 Main switch 3L+N A110 89703 1 Servo Drive Stroke motor SR-610 Q311 PKZM0-1 1 Motor protection switch Q312 PKZM0-0.63 1 Motor protection switch Q314, Q411 PKZM0-1.6 2 Motor protection switch Q100 CL-PKZ0 1 Current limiter Q110, Q132, Q142 PKZM0-16 3 Motor protection switch Q310 PKZM0-10 1 Motor protection switch K705 DILM 32-XH/11 1 Contactor with Auxiliary switch K2006, K2007, K2008 DILEM-10-G 3 Contactor K715, K716 DILER-22-G 2 Auxiliary contactor K2002, K2003 DILER-22-G 2 Auxiliary contactor (CE Version only) A144 CTVIO10200 1 Feed controller G71 UE401-A0010 1 Safety monitoring device light barrier (CE Version only) A700 PNOZ/X3 1 Emergency Relays F413, F414 FAZ-C10 2 Circuit Breaker switch 10A T410 6EP14361SH01 1 Power Supply 24VDC A3000 6ES7314-6CF02-0AB0 1 S7-300 CPU314-C-DP2 A3000 Not shown 6ES7953-8LG11-0AA0 1 Memory Card 128 Kbyte S7-300 A2520 6ES7332-5HB01-0AB0 1 Analog output, S7-300 T142 EEJ 1035 1 1Phase Transformer Pri. 400-480V Sec. 115V M417 3322207 1 Fan for cabinet A130 ATV71HU30N4Z 1 Frequency Changer R132 VW3CHR100W00300 1 Brake Resistor 24
ELECTRICAL Operator Panel H2000 P2522.1 P2522 S1016 S1014 S707 S1013 S1011 S1012 A3003 H2000 S1014 A S1013 S707 FIGURE; ELECTRICAL Operator Panel 25
ELECTRICAL Operator Panel PARTS LIST COVERING FIGURE ELECTRICAL Operator Panel DIAGRAM NO. ORDER BY PART NUMBER QTY DESCRIPTION P2522 RQ96M 1 Load Meter (Europe Version only) P2522.1 230211-V02-2-1 1 Load Meter (US Version only) A3003 6AV6642-0AA11-0AX0 1 Touch Panel, TP177A S1014 I-HW1M-0202-F20 1 Crossbar-switch complete S1013 ZB4BP6837 1 Reset Key BLUE with Silicon Cover S1013 ZB4-BW0B61 1 Contact S1011 ZB4BP3837 1 Start Key GREEN with Silicon Cover S10011 ZB4-BZ101 1 Contacts S707 ZB4BS54 1 Emergency Button red S707 ZB4BZ104 2 Contacts S1012 ZB4BP4837 1 Stop Key RED with Silicon Cover S1012 ZB4BZ102 1 Contact H2000 XB4BVB3 1 LED Indicator lamp Green complete S1016 XB4BD53 1 Feed Switch complete A 182.000.100 1 Wire for Panel 12x0.75 mm2, Length = 4,6 M 26
PF-401 FILTER UNIT (Optional) FIGURE; PF-401 FILTER UNIT 27
PF-401 FILTER UNIT PARTS LIST COVERING FIGURE PF-401 FILTER UNIT ITEM NO. ORDER BY PART NUMBER QTY. DESCRIPTION 1 CK1279A 3 Street Elbow (3/4 NPT) Pkg. of 1 2 CK1389A 1 Relief Valve (High Pressure) 3 CK5724 1 Pump Motor (50Hz) 3 CK5721 1 Pump Motor (60Hz) 4 PF405 1 Canister 5 PF243 2 Cover 6 PF246A 2 Air Vent Pkg. of 1 7 PF244 2 Clamp Ring 8 PF261 2 Clamp 9 PF270A 2 Tee Handle Pkg. of 1 10 PF259A 2 Draincock Pkg. of 1 11 PF426A 1 Hose 12 PPP152A 3 Nipple (3/4 NPT) Pkg. of 1 13 PPP154A 2 Side Outlet Elbow (3/4 NPT) Pkg. of 1 14 PPP168A 1 Reducer Coupling (3/4 to 1 ) 15 PPP195A 1 Nipple (3/4 NPT x 4 Long) 16 PPP196A 2 Street Tee (3/4 NPT) Pkg. of 1 17 PPP197A 4 Swivel Adapter (3/4-14 NPT) Pkg. of 1 18 PPP198A 1 Valve (3 Way) 19 PPP199A 1 Shutoff Valve 20 PPP200A 1 Nipple (3/4-14 NPT x 3 Long) 21 PPP201A 1 Tee (3/4-14 NPT) 22 PPP204A 1 Nipple (3/4-14 NPT x 5-3/4 Long) 23 PPP205A 1 Nipple (3/4-14 NPT x 6-1/2 Long) 24 PPP209A 2 Coupling (3/4 NPT) 25 PPPM445 2 Coupling 26 PPP208A 1 Relive Valve (Low Pressure) 27 PF1104* 1 Filter Elements (10-Micron) Pkg. of 4 28 PPP37A 1 Hose Assembly 29 PPP39A 1 Hose Assembly 30 PPP43A 1 Hose Assembly shown PPP45A 1 Hose Assembly shown PF440A 1 Intake Strainer & Hose Assembly * Note: If 5 micron filter elements are required, order PF-105-4. 28
NOTES
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 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 the user verify the discrepancy with Sunnen before proceeding. SUNNEN PRODUCTS COMPANY 7910 Manchester Road St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. Toll-Free Sales and Service - Auto: 1-800-772-2878 Ind: 1-800-325-3670 International Division - Telex: 4312052 SUNNEN PRODSTL http://www.sunnen.com e-mail: sunnen@sunnen.com 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 www.sunnen.co.uk e-mail: hemel@sunnen.co.uk SUNNEN AG Fabrikstrasse 1 8586 Ennetaach-Erlen, Switzerland Phone: ++ 41 71 649 33 33 Fax: ++ 41 71 649 34 34 www.sunnen.ch e-mail: info@sunnen.ch SHANGHAI SUNNEN MECHANICAL CO., LTD. 889 Kang Qiao East Road, PuDong Shanghai 201319, P.R. China Phone: 86 21 5 813 3322 Fax: 86 21 5 813 2299 www.sunnensh.com SUNNEN ITALIA S.R.L. Viale Stelvio 12/15 20021 Ospiate di Bollate (MI) Italy e-mail: sales@sunnensh.com Phone: 39 02 383 417 1 Fax: 39 02 383 417 50 www.sunnenitalia.com e-mail: sunnen@sunnenitalia.com PRINTED IN U.S.A. 0610 COPYRIGHT SUNNEN PRODUCTS COMPANY 2006, ALL RIGHTS RESERVED