I-SV-410F Installation, Setup and Operation INSTRUCTIONS for SUNNEN® VERTICAL HONING MACHINE Models: SV-410 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE SUNNEN® SV410 VERTICAL 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.
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.
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).
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. NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing this equipment.
TABLE OF CONTENTS Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii ESD Prevention Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Sunnen® Limited Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION & SPECIFICATIONS Sunnen® Vertical Honing Machines - SV410 Sump Pump Motor2: 0,5 kW @ 225 LPM/2m head (.67 hp @ 68 GPM/6ft head) Coolant Requirements: Sunnen Industrial Honing Fluids Work Area (View A)3: 3842 W x 4075 D x 3065 H mm (151 x 160 x 121 in.) Floor Space (Machine Foot Print): 2546 W x 2309 D x 2436 H mm w/o Optional Coolant System (100 x 91 x 96 in.) Floor Weight (Dry): 4350 kg (9590 lbs.) Floor Load: 1500 kg/sq. meter (301 lbs./sq.
SECTION 1 INSTALLATION GENERAL 1. Move Machine to staging/unpacking area. Consult this section when unpacking, inspecting, and installing Sunnen® Vertical Honing Machine (see Figure 1-1). Hereafter referred to as the machine. 2. Remove shipping carton and plastic wrap. (Cut, remove and discard shipping bands.) 3. Remove all loose components. TOOLS & MATERIALS 4. Check all components against packing list.
• Then check to see if any of the feet are not touching the floor or touching the floor only loosely. If so, bring foot down to just touch floor. • Place Level front to back on right side of table and adjusting Leveling Bolts in each of the right front & rear feet as required, until table base is within 0,0003 m/m. • Re-check and adjust any feet that are loose or not touching, until they just touch the floor. • Repeat for left side of table.
14. Wipe all protective shipping oil and grease from Machine. (Clean rust preservative from way bars and any other bright metal surfaces.) 15. If applicable: Position optional coolant system on right side of base. LUBRICATING SYSTEM The machine is equipped with an automatic grease lubricating system. Grease Reservoir is filled at the factory with Sunnen 90123 (Kluberplex #BEM34-132 or its equivalent) (see Figure 1-6).
CAUTION Door is equipped with lockable Safety Door Latch. Door should be closed and latched during operation to prevent accidental interruption of operation from doors being opened. Door Latch should be LockedOut and Tagged during servicing to prevent machine from being powered up. INTAKE 2. Turn Master ON/OFF Switch to OFF position and open Door. (Door WILL NOT open unless Master ON/OFF Switch is in OFF position.) 3. Open Door to enclosure. MAGNETIC SEPARATOR WARNING You must use the hole provided.
5. In run settings you can toggle the coolants lines to check the rotation of the Sump Pump Motor. (Rotation of Shaft should be as shown on Motor Cover.) OPERATIONAL CHECK Read Sections 1, 2 and 3 thoroughly and carefully before performing the Operational Check. NOTE: Power up and start machine to check for proper operation. 6. If rotation is incorrect, turn OFF power to Machine and reverse any two wires (red, white, or black) of electrical supply cord, where they connect to Disconnect Block. 1.
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SECTION 2 PREPARING FOR OPERATION 1b. Leveling Bolts for stabilizing Machine and 1c. Stainless Steel Guard Doors. 2a. Electrical Enclosure. Located on rear of Machine. 2b. Column Enclosure. Located on rear of column. 3a. The Operator Station houses all electronic hardware and software for hone control. It is also main operator interface with machine. 4a. The Spindle Carriage is mounted on GENERAL Consult this section when preparing the Machine for operation.
xYCOM POWER DISK COM INPUT FAULT - PF1 PF11 A + CTRL ESC SHIFT ( ALT PF2 DEL TAB PF12 B ) PF3 F BACKSPACE SPACE A PF13 C END ? PF4 PF14 D & PF5 PF15 E 1 2 4 5 7 8 . 0 xYCOM 3 6 % PF6 PF16 F 9 $ PF7 POWER DISK COM INPUT FAULT - + = PF17 G @ + PgUp PgUp PF8 PF18 H < PF9 PF19 I > PF10 PF20 J HOME PF1 - PgDn A ENTER SHIFT ALT TAB DEL A SPACE BACKSPACE & 1 2 3 PF15 4 5 6 7 8 9 .
4b. The Transverse Column Assembly which allows the Spindle Carriage to move left or right to align Spindle with bore. It is powered by 4c. The Spindle Motor which by way of a belt, drives 4d. The Drive Tube which imparts stroking and rotational motion from spindle to honing tool. Houses feed rod. 4e. A Ball Screw Stroker Assembly located inside of Column provides stroking power to Spindle Carriage. 5. Workholding Fixture (opt) 6.
HONING TOOL SETUP When using CK/CV or GHSS/GHTS Series Hone Heads proceed to, Installing Hone Head. When using P20/P28 Mandrel and CV1010 Mandrel Adapter, proceed with the following steps: DRIVE TUBE DRIVE TUBE SETSCREW P20/P28 Mandrel & Mandrel Adapter Following is a setup guide using mandrel adapter. MANDREL ADAPTER 1. Using an adjustable wrench, turn feed rod in Mandrel Adapter counterclockwise until wedge hook in adapter nose is fully extended. MANDREL ADAPTER 2.
If graduated slide reads "15" or less, no additional shims should be added; if slide reads over "15", remove assembly from Gage and add one shim. 4. Place Master Stoneholder in fixture. Brush all loose chips from Stoneholder grooves and slots. 5. Place Stone in Master Stoneholder (see Figure 2-5). Lugs on stone sides should fit into cross slots of Master Stoneholder. NOTE: A properly shimmed assembly will slip into gage easily.
snugly. Take mounted stoneholder in one hand; look at it lengthwise from one end, into a light to see if there is any light between stoneholder and bottom of abrasive. The abrasive should sit completely flat in the holder. ABRASIVE Install Stoneholders and Expander Plates Always install stoneholders and expander plates in sets. To install, proceed as follows: 1. Verify the hone head is fully retracted. SCREW 2.
1. Verify hone head is fully retracted. Both sets of expander plates should be flush against the hone body once inserted into their correct numbered slot. GHTS-Series Hone Heads Sunnen GHTS-Series Two Stage Honing Tool uses Sunnen GH Stone Sets and PHT Brush Sets. Install GH-Series Hone Head by sliding Hone Head Drive Tube into Machine Drive Tube; align Locating Screw in Hone Head Drive Tube with one of the holes in the Machine Drive Tube; then, tighten screw (see Figure 2-12). 2.
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SECTION 3 SETUP & OPERATION Where interlocking systems rely on special actuators or keys, DO NOT keep spare/master actuators or keys on, around or near machine. • Use proper lifting procedures when loading and unloading the Machine. • Keep all non-essential persons clear of work area. Visitors, especially children, should not be permitted near the work area. • DO NOT use machine for other than its intended use. Using these Machines for other purposes could result in damage to machine and loss of warranty.
load graph to determine RUL, ideal condition is to have trend of graph be horizontal. If trend is upward, RUL is too low. If trend is downward, RUL is too high. (see Figure 3-1). Using up and down ARROW keys, you can move this marker to a place in bore that you would like to dwell. When you press dwell button, stroker will dwell for two seconds in location that you selected with arrow keys. This button can be held in to make machine dwell longer. Tool with Mandrel Adapter 1.
• Key in desired value using key pad - Press OK to accept. BORE LENGTH: 3.50000 • Select Material - Press OK to accept. MATERIAL: Tool Steel • Select Hardness - Press OK to accept. HARDNESS: 2 15. Set tool SNUG diameter by moving tool around in bore, while using handwheel, expand tool (CW) or retract tool (CCW), until tool feels snug in bore. 16. Press TEACH to set Snug Diameter. Box to right will turn green and display “the snug size is set.” 17.
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SECTION 4 ROUTINE MAINTENANCE GENERAL CAUTION ALWAYS fill grease canister using filling port. Ensure no air is inside grease canister. The following procedures are given as guides only and are not to be construed as absolute or invariable. Each machine must be maintained individually according to its particular requirements. Grease Lubricating System Fill Grease Reservoir with Sunnen 90123 (Kluberplex #BEM34-132 or its equivalent) (see Figure 4-1).
• Verify the operation of the lubrication system as follows: Remove sheet metal covers attached to carriage to get to points where grease lines enter ball screw and ball spline. Disconnect both grease lines at these locations. Under Diagnostics section of software, set lube system to cycle 50 times. Verify that grease is coming out of both grease lines. (There may be some delay in grease coming out of lines. This is normal.
6. Rinse thoroughly with clean hot water and allow to dry. 7. Reinstall Filter Element. SUMP DRAIN CLEANING Periodically check and clean Sump Drain (see Figure 4-3). Sump Drain should be cleaned when there is a noticeable drop in coolant pressure. 1. Turn OFF power at Master ON/OFF Switch. 2. Remove Drain Cover in right side of machine base, by removing six (6) button socket head capsrcews. NOTE: Replacement Elements and parts are available through the Sunnen or your local supplier. 8.
7. Loosen tension on Idler Pulley, by loosening tension Screw in Tension Block Assembly (see Figure 4-8). SCREWS SPINDLE STRAP 8. Remove old belt and replace with new belt. 9. Use tension Screw to tension belt. (New Belt: Tension belt so that deflection at midway between pulleys is approximately 9,5mm (.38in) when a 40N (9 lb) load is applied.) BELT IDLER PULLEY IDLER PULLEY SPROCKET STRAP NOTE: Used Belt: Tension belt so that deflection at midway between pulleys is approximately 9,5mm (.
AIRLINES O RING VALVE FILTER ELEMENT BAFFLE FILTER BOWL FIGURE 4-10, PH Tooling (Optional) DRAIN NOTE: When using Sunnen PH-Series Precision Multi-Stone Honing Tools with integral air gage available for in-process measurement for optimum control of the bore diameter; inspect Pneumatic Lines (airlines) and Fittings running to tool monthly for leaks or damaged parts. Replace parts as required (see Figure 4-10).
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SECTION 5 TROUBLESHOOTING GENERAL OPERATIONAL TROUBLESHOOTING This section contains Troubleshooting information in table form which should be used when problems occur with machine. The table lists problems encountered, possible causes, and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems. For suggestions on correcting problems with bore conditions or with honing operation; consult Table 5-1.
TABLE 5-1, Operational Troubleshooting Index (cont’d) PROBLEM Taper in Open Hole Taper in Blind Hole Out-Of-Round PROBABLE CAUSE 1. Improper overstroke 2. Workpiece and Spindle not aligned 3. Part/tool geometry 1. Improper stroke length 2. Inadequate relief in blind end 3. Inadequate oil flow 1. Undersize honing tool 2. Workpiece flexing (thinwall) Waviness 3. Improper tool 4. Excessive float in tool(s) 5. Fixture not properly Aligned 1. Improper tool length Rainbow 1. Improper tool length 2.
MACHINE OPERATION TROUBLESHOOTING PROBLEM: Routine inspection of lubrication system shows that grease is not coming out of one or more grease lines. Error Messages: The SV Series Machines have built in error messages that will appear on display screen to alert operator when machine has stopped due to an error, problem, or incorrect setup. SOLUTIONS: - Remove the grease lines from the tops of the grease injectors. Under the Diagnostics section of the software, set the lube system to cycle 50 times.
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A - COOLANT SYSTEM (OPT) FLOW DIAGRAM OPTIONAL COOLANT SYSTEM with PAPER FILTER SUMP PUMP OPTIONAL COOLANT SYSTEM with MAGNETIC SEPARATOR & FILTER FLOW CONTROL ON/OFF VALVE WORKPIECE SUMP PUMP PUMP MACHINE RESERVOIR PAPER FILTER CLEANED FLUID OPTIONAL COOLANT SYSTEM with PAPER FILTER MAGNETIC SEPARATOR OPTIONAL COOLANT SYSTEM with FILTER OPTIONAL COOLANT SYSTEM with MAGNETIC SEPARATOR FIGURE A-1, Coolant System Flow Diagram 29
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B - GREASE LUBRICATION SYSTEM FLOW DIAGRAM LUBRICATOR FILLER PORT HOUSING TO BALLSCREW (STROKER) TO BALLSPLINE (STROKER) TO BALLSCREW (X-AXIS) FIGURE B-1, Grease Lubrication System Flow Diagram 31
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C - OPTIONAL PNEUMATIC SYSTEM FLOW DIAGRAM O RING VALVE FILTER ELEMENT BAFFLE FILTER BOWL MVH7120 DRAIN RESIDUAL PRESSURE RELEASE FILTER REGULATOR MOUNTING BRACKET SPACER POPPET VALVE AIR PRESSURE SWITCH REGULATOR REDUCER BUSHING CROSS SPACER PIPING ADAPTER MUFFER FILTER PFC1501 FILTER REGULATOR FILTER PFC235 MICRO-MIST SEPARATOR SV07005 FIGURE C-1, Optional Pneumatic System 33
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APPENDIX D DECLARATION OF CONFORMITY (CE) E L P T N M SA OCUME D E C 35
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WARNING An Arc Flash Hazard Exists. Follow safe work practices and wear appropriate Personal Protective Equipment. Follow proper lockout/tagout procedures. Failure to comply can result in death or injury. Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment.
FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART INCH FRACTION DECIMAL MILLIMETER INCH FRACTION DECIMAL MILLIMETER INCH FRACTION DECIMAL MILLIMETER .... .003937 0,1000 9/32 .281250 7,1438 21/32 .656250 16,6688 .... .007874 0,2000 19/64 .296875 7,5406 .... .669291 17,0000 .... .011811 0,3000 5/16 .312500 7,9375 43/64 .671875 17,0656 1/64 .015625 0,3969 .... .314961 8,0000 11/16 .687500 17,4625 .... .015748 0,4000 21/64 .328125 8,3344 45/64 .703125 17,8594 .
