Transcript
I-PF-410F http://www.sunnen.com
INSTALLATION INSTRUCTIONS for SUNNEN® PF-401 FILTER UNIT KIT For Sunnen Tube Hones, Models STH & HTC
GENERAL
CONTENTS
The following instructions are for installing optional PF-401 Filter Unit on Sunnen Tube Hones (see Figure A). The Filter Unit is designed to remove contamination from Honing Oil. STH Series Hones and HTC Series Hones
TOOLS & MATERIALS The following tools and materials are required for unpacking and installing of your Machine: Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips
TITLE
PAGE
For Sunnen Tube Hones Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Repair Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 8 For Machines other than Sunnen Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WARNING This unit was designed and tested for use only with Sunnen Honing Coolants. Performance or safety cannot be assured if other fluids are used.
FIGURE A, PF-401 Filter Unit “SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
SUNNEN ® PRODUCTS COMPANY • 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100
INSTRUCTIONS FOR SUNNEN TUBE HONES
OIL LINE CLAMP
T-PLUG
SOCKET HEAD CAPSCREW
T-PLUG CENTRIFUGAL PUMP HOSE
MOUNTING BARS
OIL RESERVOIR
INTAKE FITTING
OUTLET FITTING
FILTER COVER
FILTER COVER CLAMP
FILTER UNIT BRACKET
FILTER UNIT BRACKET
FIGURE 1, PF-401 Filter Unit
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INSTRUCTIONS FOR SUNNEN TUBE HONES
INSTALLATION To install Filter Unit, Model PF-401 (see Figure 1) proceed as follows:
PF-401D
NOTE: Coat all threaded fittings with appropriate sealant. 1. Remove Filter Unit from packing carton and inspect for damage resulting from improper handling, by carrier. If damage is evident, immediately file a claim with carrier.
GREEN
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2 3
12
4
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PET-714
WHITE
BLACK
RED
PEC-138
2. Loosen two (2) Oil Line Clamps on rear of Hone, by loosening two (2) Socket Head Capscrews in each clamp; use a 5mm Hex Wrench.
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10 11
PET-714
PET-714
PF-401G
PET-714
FIGURE 2, Cable
14. Attach Intake Strainer and Hose Assembly (PF-440, supplied) to Filter Unit Pump.
3. Remove T-Plug from Oil Line T-Connection, for Filter Unit. (Save T-Plug for reinstallation, if a Centrifugal Pump is not being installed on machine.)
15. Place Intake Strainer in Honing Oil Reservoir: • If Centrifugal Pump is in place, slide Oil Reservoir Cover slightly and insert Intake Strainer between cover and side of reservoir. • If Centrifugal Pump is not mounted in reservoir, insert Intake Strainer into reservoir through pump mounting bracket.
4. Remove two (2) Mounting Bars, by removing two (2) Socket Head Capscrews in each bar; use a 6mm Hex Wrench. 5. Slide Mounting Bars into Filter Unit and Bolt into place, using four (4) Hex Head Bolts (supplied). Tighten Bolts.
ELECTRICAL CONNECTIONS Electrical Supply Cord is supplied with PF-401 units (see Figure 2). Use this cable to connect the filter unit to the machine.
NOTE: Right upper bolt is already in Filter Unit Bracket and must be removed. Bolt supports Filter Pump Torque Bracket; ensure bracket is reinstalled. Mounting Bars can only be mounted so machined radius will fit behind Oil Line.
NOTE: Filter Unit and Centrifugal Pump CAN NOT be in operation at the same time; therefore only one receptacle is provided.
6. Remove Filter Cover Clamps and Filter Covers.
For PF401G filters, connect supplied power cord with 16 pin plug to matching receptacle on the machine. For PF-401D filters, connect supplied cable through cord grip of the motor and route into machine electrical enclosure. • Terminate ends going into the motor with ring terminals of adequate size to fit around the motor lead screws. • Connect cable according to the motor connection diagram (this can be found on the underside of the motor junction box lid). • Connect green wire to ground lug of the motor junction box.
7. Install Hose Assembly (PPP-45, supplied) on Outlet Elbow, on Filter Unit. 8. Use a hoist to lift unit into place. NOTE: Machined radius on Mounting Bars must fit behind Oil Line. 9. Reinstall Mounting Bars on Machine, using Socket Head Capscrews removed in step 4. 10. Attach Hose Assembly to Oil Line T-Connection. K. Tighten Oil Line Clamps. 11. Remove new Filter Elements from protective bags and insert into filter canisters. Rotate elements slightly to make them slide down centerpost more easily.
3. POWER UP filter unit and check the motor rotation according to the rotation sticker on the motor. • If rotation is reversed, swap two of wires on the motor leads to achieve proper rotation direction.
12. Replace Covers, centering carefully on rubber gaskets to assure no leakage. Then replace Clamps and tighten Hex Bolt in Clamp Halves until halves meet, then tighten T-Handle.
4. Bleed Filter Canisters: NOTE: Flow Control Valve (Oil Nozzle) MUST be closed to Prime system.
13. If optional Centrifugal Pump IS NOT installed on machine: Remove Adapter in Oil Line T-Connection, for Centrifugal Pump, and install T-Plug (removed from Filter Unit T-Connection in step 3). 3
INSTRUCTIONS FOR SUNNEN TUBE HONES
ADJUSTMENTS FIlter Elements Replacement (see Figure 3 ) 1. TURN OFF all electrical power to machine. 2. Place a suitable container under Draincocks. 3. Open Air Vent in Canister Covers (turn counterclockwise). 4. Open Draincocks on bottom of Filter Canisters and drain about 2 quarts (2 liters) of oil from each Canister. 5. Close Draincocks and Air Vents. 6. Loosen Cover Clamps and remove clamps and Canister Covers. 7. Slowly pull out dirty Filter Elements and place in bucket to drain. FIGURE 3, Filter Elements
8. Remove new Filter Elements from protective bag and insert into Filter Canister; rotate element slightly so it will slide down center post more easily. 9. Replace Covers, centering carefully on rubber gaskets to assure no leakage. 10. Replace Clamps and tighten Hex Bolt in Clamp Halves until halves meet, then tighten T-Handle. 11. TURN ON electrical power. 12. Bleed Filter Canisters: NOTE: Flow Control Valve (Oil Nozzle) MUST be closed to Prime system. • Press Honing Oil START Button. • Open Air Vents slightly. • As oil fills Filter Canisters, air will escape through Air Vents. When oil appears through vents, close vents. • Press Honing Oil STOP Button.
FIGURE 4, Filter Canister
5. After oil is completely drained, close Draincocks and Air Vents. 6. Loosen Cover Clamps and remove clamps and Canister Covers.
13. Wipe any excess oil from Filter Canisters. 14. Discard old Filter Elements.
7. Slowly pull out dirty Filter Elements and place in bucket to drain.
15. Pour oil drained from elements and from Filter Canisters into Honing Oil Reservoir.
8. Remove Standpipes from Filter Canisters; use 1-1/2" (38mm) open end wrench.
Filter Canisters Cleaning (see Figure 4) 1. TURN OFF all electrical power to machine. 2. Place a suitable container under Draincocks.
9. Scrape Sludge from insides of Canisters; use a long piece of wood or other soft material.
3. Open Air Vents in Canister Covers (turn counterclockwise).
10. Flush out remaining sludge with solvent. Dispose of sludge.
4. Open Draincocks on bottom of Filter Canisters and drain completely.
11. Clean Standpipe and threaded fitting in Filter Canister.
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INSTRUCTIONS FOR SUNNEN TUBE HONES
16. Replace Covers, centering carefully on rubber gaskets to assure no leakage.
T-HANDLE COVER
17. Replace clamps. Tighten Hex Bolt in Clamp Halves until halves meet, then tighten T-Handle.
AIR VENT
18. TURN ON electrical power.
CLAMP HALVES
19. Bleed Filter Canisters: FILTER ELEMENT
NOTE: TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET, THEN TIGHTEN T-HANDLE.
FIGURE 5, Filter Element
12. Inspect Standpipe Seal Rings and replace as necessary. 13. Coat Standpipes (threaded fittings) with Sealant and reinstall in Filter Canisters.
NOTE: Flow Control Valve (Oil Nozzle) MUST be closed to Prime system. • Press Honing Oil START Button. • Open Air Vents slightly. • As oil fills Filter Canisters, air will escape through Air Vents. When oil appears through vents, close vents. •Press Honing Oil STOP Button. 20. Wipe any excess oil from Filter Canisters. 21. Discard old Filter Elements. 22. Pour oil drained from elements and from Filter Canisters into Honing Oil Reservoir.
14. Close Draincocks. 15. Remove new Filter Elements from protective bag and insert into Filter Canister; rotate element slightly so it will slide down center-post more easily (see Figure 5).
FLOW DIAGRAMS For illustration of Filter System on Wide Range Honing Machines see Figure 6 on page 6.
INSTRUCTIONS FOR SUNNEN TUBE HONES
FIGURE 6, Flow Diagrams For Filter System on Wide Range Honing Machines
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INSTRUCTIONS FOR SUNNEN TUBE HONES
DECLARATION OF CONFORMITY (CE)
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8
PF-401 Filter Unit
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1
1
12
20
21
11
16
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24
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8
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2
17
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29
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7
10
18
24
5
28
22
9
12
17
6
14
12
30
13
25
25
16
15
1
13
4
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INSTRUCTIONS FOR SUNNEN TUBE HONES
INSTRUCTIONS FOR SUNNEN TUBE HONES PARTS LIST
ITEM NO.
1 2 3 3 N/S N/S N/S N/S
4 5 6 7 N/S N/S N/S N/S
8 9 10 N/S N/S
11 N/S
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 N/S N/S
ORDER BY PART NUMBER
CK1279A CK1389A CK5721 CK5724 KN172 KN568 PHS644 PNP345 --PF405 PF301 PF246A PF244 PF263 PHW119 TN30 --PF261 PF270A PF259A PF257 PF258 PF426A --PPP152A PPP154A PPP168A PPP195A PPP196A PPP197A PPP198A PPP199A PPP200A PPP201A PPP204A PPP205A PPP209A PPPM445 PPP208A PF1104* PPP37A PPP39A PPP43A PPP45A PF440A
DESCRIPTION
QTY.
3 1 1 1 4 4 4 1 Ref. 1 2 2 2 2 6 2 2 2 2 2 2 2 1 2 3 2 1 1 2 4 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1
....Street Elbow (3/4 NPT) Pkg. of 1 ....Relief Valve (High Pressure) ....Pump Assembly (60Hz) ....Pump Assembly (50Hz) ......Nut ......Washer ......Screw ......Label, Motor Rotation ....Filter Canister Assembly includes ......Canister ......Cover ......Air Vent (Pkg. of 1) ......Clamp Ring ......Clamp Seal ......Washer ......Bolt ......Nut ......Clamp ......Tee Handle (Pkg. of 1) ......Draincock (Pkg. of 1) ......Nut ......Seal ....Hose Includes ......Hose Clamps ....Nipple (3/4 NPT) Pkg. of 1 ....Side Outlet Elbow (3/4 NPT) Pkg. of 1 ....Reducer Coupling (3/4 to 1) ....Nipple (3/4 NPT x 4 Long) ....Street Tee (3/4 NPT) Pkg. of 1 ....Swivel Adapter (3/4-14 NPT) Pkg. of 1 ....Valve (3 Way) ....Shutoff Valve ....Nipple (3/4-14 NPT x 3 Long) ....Tee (3/4-14 NPT) ....Nipple (3/4-14 NPT x 5-3/4 Long) ....Nipple (3/4-14 NPT x 6-1/2 Long) ....Coupling (3/4 NPT) ....Coupling ....Relief Valve (Low Pressure) ....Filter Elements (10-Micron) Pkg. of 4 ....Hose Assembly ....Hose Assembly ....Hose Assembly ....Hose Assembly ....Intake Strainer & Hose Assembly
N/S indicates Not Shown * Note: If 5 micron filter elements are required, order PF-105-4
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INSTRUCTIONS FOR MACHINES OTHER THEN SUNNEN TUBE HONES
Electrical Requirements
10in. (254mm)
Pump Motor Rating: 1/2 HP 3.2 A @ 230 V, 60 Hz, 3 Ph 1.6 A @ 460 V, 60 Hz, 3 Ph
10in. (254mm)
INSTALLATION The following instructions are for installing PF-401 Filter Unit on any machines other than Sunnen Tube Hones (see Figure 7). Although Filter Unit is designed to remove contamination from Honing Oil, it can also be used to filter other fluids. 1. Remove existing electrical cable from unit.
7/16in. (11mm) DIAMETER HOLES
2. Wire Pump Motor directly to Starter (not supplied), using 4 conductor, 14 AWG, 600 Volts, Stranded Copper Conductor Cable, Type SO.
BRACKET (not supplied)
FIGURE 7, Filter Unit Bracket
NOTE: Starter should be NEMA size 00 or 0, FULL VOLTAGE MAGNETIC STARTER with properly sized thermal over-load protection. Install Starter in accordance with Local and National Electrical Codes.
User-supplied Flow Control Valve MUST be closed to initially charge filtering system with fluid.
MOUNTING Because Filter Unit can be installed on many different types of machines; the following mounting instructions are ONLY offered as a suggestion.
Check Pump Motor rotation; if necessary, reverse rotation by exchanging any two of three leads.
PLUMBING
A user-supplied or made Mounting Bracket will be required to mount PF-401 Filter Unit.
NOTES: Both Inlet and Outlet Fittings have 3/4" NPT pipe thread. When installing Inlet and Outlet lines, use thread sealant.
1. Make Mounting Bracket to attach to four (4) 7/16" (11mm) holes in Filter Unit Bracket. The hole pattern on Filter Unit Bracket are shown in following illustration.
1. The Inlet Hose MUST have a screen attached to keep large particles from entering system. And the end of Inlet Hose MUST be submerged at least 6" (152mm) into fluid.
2. Mount Filter Unit high enough off floor to get a container under Draincocks, for servicing unit.
FLOW DIAGRAMS For illustration of Filter System on Other Machines see Figure 6 on page 11.
2. Outlet Hose can be routed to a Flow Control Valve. Filter Unit can safely run while user-supplied Flow Control Valve is SHUT OFF.
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INSTRUCTIONS FOR MACHINES OTHER THEN SUNNEN TUBE HONES The PF-401 Filter Unit can deliver filtered or unfiltered fluid by adjusting the two valve handles on the system, as shown below.
FIGURE 8, Flow Diagrams For Filter System on Other Machines
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NOTES
“SUNNEN® AND THE SUNNEN LOGO 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. PRINTED IN U.S.A.
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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:1-800-325-3670 International Division Fax: 314-781-6128
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