M-vss-861: Vss86 Specs Sheet (sn1044 Up)

Transcript

I-VSS-861A Installation, Setup and Operation INSTRUCTIONS for SUNNEN® VERTICAL SINGLE STROKE HONING® MACHINE Models: VSS®86 & VSS®86-200 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE SUNNEN® VERTICAL SINGLE STROKE HONING® SYSTEM. “VSS, SINGLE STROKE HONING, 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: [email protected] 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. TABLE OF CONTENTS Page TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v LIST OF APPENDIXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v GENERAL INFORMATION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii NUMBERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii FLOOR PLAN LAYOUT (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii INSTALLATION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools & Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 3 PREPARING FOR OPERATION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Workholding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Single Stroke Honing® Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Small Diameter Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Large Diameter Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 High-Helix Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Door Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SETUP & OPERATION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup - Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup - Indexing Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup - Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup - Tool Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 13 14 14 15 17 ROUTINE MAINTENANCE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Line Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Screw Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball Screw Shear Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Separator (Opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant System (Opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 22 22 22 23 23 24 25 TROUBLESHOOTING General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 LIST OF APPENDIXES A Checklist - Setup & Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 B Single Stroke Honing® Tools - Tooling Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 “VSS, SINGLE STROKE HONING, SUNNEN, AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OR TRADEMARKS OF SUNNEN PRODUCTS COMPANY.” © Copyright 2008 by Sunnen® Products Company • Printed in U.S.A. v GENERAL INFORMATION & SPECIFICATIONS Sunnen® Vertical Single Stroke Honing® System Diameter Range (ID):1 5,92-19,00 mm (0.233-0.748 in) For diameters above or below stated range, call Sunnen in St. Louis. Workpiece2 Maximum Height (VSS64): 150 mm (5.9 in) (VSS64-200): 300 mm (11.8 in) Maximum Weight: (See Indexing Table below) Maximum Size: 150 x150 x 150 mm (6 x 6 x 6 in) For larger sizes, call Sunnen in St. Louis. Spindle Spindle Speed Range: 100 to 2500 rpm Spindle Motor: 10 Hp Stroking (Ball Screw Drive) Speed Range: 250 to 6350 mm/min (10 to 250 IPM) Vertical Travel: 400 mm (15.7 in) Indexing Table Workpiece & Fixture Weight: Maximum total workpiece & fixture weight that may be used on the index table is 113 kg (250 lbs). Coolant System Connection3 Supply Port: Hose Barb for 25mm (1in.) ID Hose Return Port: Hose Barb for 51mm (2in.) ID Hose Electrical System Electrical Requirements: 440/460 V, 50/60 Hz, 35/30 A Control: Industrial Embedded PC Temperature Range: 0° to 35° C (32° - 95° F) (Optional cooling unit is available). Floor Requirement (Concrete): 150 mm (6 in.) minimum thickness Floorspace4 VSS®86: 2348H x 2248W x 1886D mm ( 92 x 89 x 74 in.) VSS®86-200: 2548H x 2248W x 1886D mm (100 x 89 x 74 in.) 1 2 3 4 Diameter range, length range, and workpiece weight are contingent on workpiece and application. Stroke length & workpiece weight is contingent on machine configuration and application. Machine not supplied with Coolant System. Call Sunnen Product Co. in St. Louis. Machine Height indicates maximum operating height clearance. VSS®86 & VSS®86-200 8 STATIONS - 6 SPINDLES vi INTRODUCTION These Instructions provide information required to install, operate, and maintain Sunnen® Vertical Single Stroke Honing® System. When ordering parts for, or requesting information about your Machine, include the model and serial numbers of your Machine. READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING SUNNEN VERTICAL SINGLE STROKE HONING SYSTEM. IMPORTANT NOTE The temperature requirements of the Sunnen® VSS® Vertical Single Stroke Honing® Machine have been established as 35 degrees C (95 degrees F). Above this temperature, an optional cooler will be available to handle temperatures from 35º to 46º C (95º to 115º F). IT IS NOT recommended that the Machine be operated at temperatures above 46º C (115º F). Sunnen Products Company warrants the VSS® Vertical Single Stroke Honing® Machine for operating environments up to 35º C (95º F). For operating environments of 35º to 46º C (95º to 115º F) the warranty only applies if the optional cooler is installed on the Machine. No warranty coverage is offered for operating environments above 46º C (115º F). NUMBERING V S S - 8 6 X - 000 NUMBER - Column Height Extension (millimeters) LETTER - Voltage & CE Declaration of Conformity E - 460V G - 400V CE - 460V & Carries Mark CG - 400V & Carries Mark NUMBER - Number of S/S Spindles (6) NUMBER - Number of Stations (8) Vertical Single Stroke Honing® System EXAMPLE V S S - 8 6 E - 200 200mm 460V 6 Single Stroke Honing Spindles (1 Column) 8 Stations (Workholding Fixtures) Vertical Single Stroke Honing® System vii 71.5 in. (1816 mm) 74 in. (1886 mm) WORK AREA OUTLINE LAYOUT 53 in. (1340 mm) 89 in. (2248 mm) 34 in. (868 mm) Weight Installed: VSS86: Approximately 1610 kg. (3550 lbs.) including coolant. VSS86-200: Approximately 1655 kg. (3650 lbs.) including coolant. Floor Loading: Less than 675 kg/sm (180 lbs/sf). TOP VIEW VSS86-200 20 in. (508 mm) 100 in. (2548 mm) 34 in. (870 mm) 13 in. (333 mm) 61 in. (1544 mm) 80 in. (2040 mm) 92 in. (2348 mm) VSS86 12 in. (308 mm) 18.5 in. (470 mm) 53 in. (1340 mm) 74 in. (1877 mm) SIDE VIEW FRONT VIEW FIGURE 1-A, Floor Plan Layout (System Configuration) viii SECTION 1 INSTALLATION GENERAL 1. Move Machine to staging/unpacking area. Consult this section when unpacking, inspecting, and installing Sunnen® VSS®-86 Vertical Single Stroke Honing® System. Hereafter referred to as the Machine. 2. Remove plastic wrap. TOOLS & MATERIALS 5. Check all components against packing list. 3. Remove top and sides from packing crate. 4. Remove all loose components from crate. The following tools and materials are required for unpacking and installation of your Machine: Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips Slip Joint Pliers Forklift Screwdriver (Std) 6. Inspect Machine and components for dents, scratches, or damage resulting from improper handling, by carrier. If damage is evident, immediately file a claim with carrier. CAUTION Base is made of a polymer composite and may be chipped if not handled with care. Machine Base may be forked from any side. DO NOT support weight of machine on bottom of Electrical Enclosure when lifting or moving.. 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 operator as one looks at Machine or assembly being described (see Figure 1-1). 7. Move Machine to desired location and lower into place. NOTE: Machine should be located on a leveled concrete floor away from heavy traffic. Allow at least 1 m (3 ft) around enclosure to any adjacent equipment and walls. Refer to Floor Plan Layout for your particular machine configuration. NOTE: When ordering parts for, or requesting information about your Machine, include Model and Serial Numbers printed on Nameplate. 8. Adjust Leveling Bolt in left rear foot as required. Tighten Jam Nuts to lock bolt in place (see Figure 1-2). CABLE TRACK LEFT RIGHT JAM NUT FOOT FRONT FIGURE 1-1, VSS® Honing System FIGURE 1-2, Leveling 1 9. ATTENTION - The Cable Track has been disconnected from column for shipping purposes. Reattach Cable Track to top of column using bolt and washer supplied (see Figure 1-3). CABLE TRACK 10. Wipe all protective shipping oil and grease from Machine. BOLT & WASHER ELECTRICAL All wiring is to be performed by a competent, Licensed Electrician in accordance with all local, state, and federal codes and regulations (see Figure 1-4). WARNING Electrical Equipment service should performed by authorized personnel ONLY. be 1. Unlock Door to Electrical Control Enclosure. 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. FIGURE 1-3, Cable Track BLK GROUND WIRE: GRN RED WARNING Residual Voltage exists for 2-3 minutes after Master ON/OFF Switch is turned OFF. Before working inside Enclosure, wait for all fans to stop running to allow drives to discharge. WHT ELECTRICAL DISCONNECT BLOCK 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. TB23 WARNING You must use the hole provided. Drilling any new holes in the electrical enclosure may void the warranty. 4M 4. Remove hole plug located on top, right side of the enclosure. Then install an oil tight fitting. 5. Insert Electrical Supply Cord through oil tight fitting, and route to Electrical Disconnect Block. MAIN POWER DISCONNECT 6. Strip 254 mm (10 in) off cable's outer jacket. 7. Strip 6 mm (1/4 in) of insulation off each wire. 8. Connect Green Wire (GRN) to Terminal PE on Electrical Disconnect Switch (Earth Ground). 9. Connect other three wires to Block as noted on Block. 10. Route and secure Cord inside of Enclosure. 11. Tighten Oil Tight Fitting. CONDUIT PLATE 12. Close and lock Door(s) to Enclosure. 13. Route and connect Electrical Supply Cord to factory main power source. FIGURE 1-4, Electrical Control Enclosure 2 1. Route and connect coolant Supply and Return Hoses to corresponding supply and return connections on your coolant system (see Figure 1-5). Attach hoses to hose barbs using hose clamps RETURN HOSE CAUTION Be sure voltage of coolant system matches supply voltage of the machine. The pressure/flow switch control voltage is 24V. 2. Route coolant system Electrical Supply Cord from machine enclosure through Conduit Plate to coolant system (refer to Figure 1-3). Connect power cord to Contactor 4M and pressure or flow switch (if supplied) to Terminal Block #23 (-87 & -24Vac). SUPPLY HOSE FIGURE 1-5, Coolant Lines Connection COOLANT SYSTEM 3. Fill Coolant Reservoir with either Sunnen Industrial Honing Oil or Sunnen Water-Based Coolant. Refer to Section 4. Placement and system requirements will vary with coolant system used. Sunnen provides several standard coolant systems. Check with your local Sunnen Field Service Engineer or Sunnen Products Company Technical Services before installing another manufacturers coolant system. OPERATIONAL CHECK Read Sections 2 and 3 thoroughly and carefully before performing the Operational Check. IMPORTANT Operating Instructions and Repair Parts Manuals for the optional Paperbed Filter Coolant System are supplied by the systems manufacturer. 1. Release E-STOP and press POWER ON Button. Screen will display "Column Initialization Menu." 2. Power up Machine and check that motors and spindles are operating properly. NOTE: Two Hoses (Supply and Return) are provided for attaching the machine to your coolant system supply and return connections. 3. Turn OFF power to Machine. 4. After unpacking and installing Machine, clean and lubricate. Refer to Section 4. 3 NOTES 4 SECTION 2 PREPARING FOR OPERATION GENERAL mounted at each station and parts are indexed (rotated) around the table to each of the operating stations. Single Stroke Honing® Column: Ball Screw Stroker Assembly is located inside of Column. It provides stroking power to the Spindle Carriage. It consists of Ball Screw Motor and Ball Screw for variable stroke speed motion. Spindle Carriage is located on front of Column. It provides the means for stroking and rotating Tool(s). Six Spindle Assemblies are mounted on Carriage in Single Stroke Honing Column configuration. Spindle System consists of Spindle Drive Motor, and six Spindle Assemblies. Spindle Drive Motor is mounted on carriage and provides power through pulley sets. Pulley sets in turn transfers power to Spindle Assemblies mounted on Spindle Carriage. Single Stroke Honing® Tools mount directly into precision spindles for quick and easy setup on most jobs. Some applications may require optional Adjustable Spindle Noses (VSS-9110) or optional Floating Tool Holders (VSS-9115). Consult this section when preparing the Machine for operation. MAJOR COMPONENTS Machine Base: Machine Base consists of Base, and one of three (3) fixturing options (see Figure 2-1). Base is equipped with a Leveling Bolt in one of its rear feet for stabilizing the Machine. Rotary Indexer: These Machines are equipped with a Rotating Indexing Table, which is available with three, four, six, or eight stations. Fixtures are Coolant System Interface Machine is equipped with two (2) ports for coolant incoming supply and out-going return lines (see Figure 2-2). The incoming port is a hose barb for 25mm (1in.) ID hose and the return port is a hose barb for a 51mm (2in.) ID hose. Use hoses that are lined with nitrile. An optional VSS-2070 2 meter Hose Module is available for connecting the machine to a coolant system. Individual control valves are located at each spindle operating station on table. They provide independent regulation of coolant flow at each spindle station. Operator interface controls power supplied from machine to coolant system. Machine can be wired to a pressure switch or flow switch that will prevent machine operation when low pressure or low flow is detected in coolant supply line. FIGURE 2-1, Machine Base RETURN LINE COOLANT VALVE Operator Control Console Operator Control Console is mounted on Side of Electrical Enclosure (refer to Figure 2-1). Operator can control all Machine functions from Controls mounted on face of Console. Also, on face of console is a display screen, which displays operating information and guides the operator through setup and operation of machine via machine's operating program. SUPPLY LINE FIGURE 2-2, Coolant System Interface 5 Electrical Enclosure Master ON/OFF Disconnect Switch is located on door to Electrical Enclosure. Enclosure houses most of components for the control of all the electrical power to the machine (see Figure 2-3). It also houses the CPU drive and interface for the machine's operating program. Tooling These machines use Sunnen Single Stroke Honing® Tools (see Figure 2-4). For more information on Tooling, refer to procedures on Single Stroke Honing Tools later in this section. Coolant System (optional) The optional Coolant Systems are normally along side or in back of Machine. The basic Systems consist of a Settlement Tank with or without a Magnetic Separator or a Paperbed Filter with or without a Magnetic Separator. All systems come with a Coolant Reservoir for storage of the coolant fluid, a Motor/Pump Assembly to circulate coolant from the reservoir to the machine, and a Pressure Switch to monitor coolant system operation (see Figure 2-5). Settlement Tank which is the storage unit for the coolant fluid. Paperbed Filter consists of a roll of filter paper that is fed across the reservoir to filter returning coolant. Paper (filter media) advances automatically as needed. Motor & Pump Assembly circulates coolant from the reservoir, through system, and delivers it to the Machine. An optional Magnetic Separator can be incorporated into the system to filter out metal particles from the coolant as it is returned to the reservoir. Coolant Maintenance Kit (optional) Because it is recommended that Sunnen Water-Based Coolant Concentrate be used in this Machine, Sunnen has available the optional SCC-900 Coolant Maintenance Kit for checking and maintaining water-based coolant (see Figure 2-6). FIGURE 2-3, Electrical Enclosure FIGURE 2-4, Tooling NOTE: Maintaining proper pH levels is important when using water-based coolants, both for fluid life and cutting performance. Workholding Fixture (optional) Because each part and parts handler will need specific fixturing design requirements, your Machine does not come equipped with any Workholding Fixture. Consult your local Sunnen Field Service Engineer or contact Sunnen Technical Services Dept., about your particular part and/or application. FIGURE 2-5, Coolant System OPERATOR CONTROLS For the location and function of the operator controls refer to Figure 2-7 and Table 2-1. FIGURE 2-6, Coolant Maintenance Kit 6 DISPLAY CONTROL CONSOLE CYCLE STOP SELECTOR SWITCH R KEYPAD ENT POWER ON 7 8 9 4 5 6 1 2 3 . 0 +/- PALM BUTTONS F1 F2 F3 E-STOP E-STOP “F” KEYS FIGURE 2-7, Operator Control Console TABLE 2-1, Operator Controls SYMBOL DESCRIPTION FUNCTION E-STOP (Pushbutton, Red) Stops all Machine movements. POWER ON (Pushbutton, White) Turns ON all electrical power to the Machine. CYCLE STOP (Pushbutton, Red) Turns OFF power to machine spindle, column motors and index table. SELECTOR SWITCH Used in Engineering Function. DISPLAY Colored display screen, used to prompt operator for information, during the setup and operation of the machine. Used in conjunction with “F” keys and alpha-numeric keypad. “F” KEYS These keys are used for a variety of functions, as indicated across the bottom of the display screen. KEYPAD Numeric keypad is used to enter information into the display screen. (Palm Buttons) Located on the front of the Machine. These buttons are used to index the table to its various work stations. They are also used for various functions during the setup and operation of the machine. Buttons MUST be activated together, with both hands, to ensure operator hands are clear of any moving parts. 7 TABLE 2-2, Safety Symbols SYMBOL ! 200 kg ! DESCRIPTION 2 FUNCTION Warning Label Warns that an electrical hazard exists. Warning Label Warns maintenance personnel to block carriage before removal of brake cover to prevent carriage from falling. Warning Label Warns that no drilling is allowed. Drilling any new holes may void warranty. CE Label Designates this machine is “CE” compliant. 1 SAFETY SYMBOLS For a description of safety symbols used on this machine, refer to Table 2-2. WORKHOLDING FIXTURE Install and align Workholding Fixtures according to instructions packaged with fixtures supplied for your particular application. NOTE: Fixtures used on these machines are custom made for each job. Follow installation and alignment procedures packaged with your fixture. FIGURE 2-8, Single Stroke Honing® Tool FLOATING TOOL HOLDER SINGLE STROKE HONING® TOOL The SINGLE STROKE HONING® Tool (A-Series or DPT-Series Tool) used on this Machine is an adjustable (diamond) superabrasive plated tool (see Figure 2-8). It comes in a variety of sizes and grits to accommodate a wide range of bore diameters and finishes. It can be installed in either a floating or a rigid Tool Holder. ADJUSTABLE SPINDLE NOSE Tool Holders For most applications, no special tool holder is required. Sunnen Single Stroke Honing Tool with its Adapter Sleeve will fit directly in precision spindles with no need for runout adjustment. Some demanding applications may require more precise adjustment. For those applications an Adjustable Spindle Nose (VSS-9110) or Floating Tool Holder (VSS-9115) are available as an option (see Figure 2-9). A Floating Tool Holder is available for use when parts are mounted in a rigid Fixture, which allows Tool to center itself in rigidly mounted part. A Rigid Tool Holder is used when parts are mounted in a floating Fixture, which allows a floating part to center itself on rigidly mounted tool. FIGURE 2-9, Optional Spindle Noses ADAPTER SLEEVE PILOT MANDREL FIGURE 2-10, Small Diameter Tool 8 SMALL DIAMETER TOOLS TABLE 2-3, Single Stroke Honing® Tools TOOL SERIES A8 A10 A12 A14 A16 A18 A20 A22 A24 A26 A28 A30 A32 Consult the following procedure when assembling and presizing A8 and A10 series Single Stroke Honing Tools (see Figure 2-10). MAX. STK RMVL. PER PASS* IN. mm DIAMETER RANGE IN. mm .233 - .298 .298 - .368 .368 - .429 .429 - .491 .491 - .553 .553 - .613 .613 - .676 .676 - .721 .721 - .799 .799 - .858 .858 - .922 .922 - .981 .981 - 1.039 5,91 - 7,67 7,67 - 9,35 9,35 - 10,90 10,90 - 12,47 12,47 - 14,05 14,05 - 15,57 15,57 - 17,17 17,17 - 18,31 18,31 - 20,29 20,29 - 21,79 21,79 - 23,42 23,42 - 24,92 24,92 - 26,39 .0008 .0008 .0008 .0009 .0010 .0011 .0013 .0014 .0015 .0016 .0018 .0020 .0020 0,020 0,020 0,020 0,023 0,025 0,028 0,033 0,036 0,038 0,041 0,046 0,051 0,051 1. Obtain proper diameter Tool according to Table 2-3. (Or, refer to Sunnen Single Stroke Honing Tool Catalog X-DPT-1000; or consult your local Sunnen Field Service Engineer; or contact Sunnen Technical Services Dept. for the Tool best suited for your particular application and/or operation.) 2. Wipe tapered Mandrel and ID of Abrasive Sleeve to remove any oil, dust and grime. 3. Coat Mandrel with light oil and slide Abrasive Sleeve and Pilot on tapered end of Mandrel. 4. Remove Turret from Sleeve Adjusting & Removal Tool by turning Handle clockwise (see Figure 2-11). *Rough grit Sleeves ONLY; D8 Sleeve require less Stock Removal. S/R is based on cast iron; S/R will vary with other materials. 5. Rotate Turret until side with corresponding Tool Number is face up; then reinstall in Removal Tool. 6. Turn Handle on Sleeve Adjusting & Removal Tool as required until Single Stroke Honing Tool can be placed into Removal Tool (see Figure 2-12). Pilot and Abrasive Sleeve should rest in Turret and Undercut in Mandrel Shaft should rest in slot in opposite end of Removal Tool as shown. 7. With Locking Screw engaging Undercut in Mandrel, tighten Locking Screw. 8. Turn Handle clockwise until Pilot and Abrasive Sleeve are snug on Mandrel. (So, Pilot and Sleeve can no longer rotates on Mandrel.) IL-129 8 9. Remove Tool. FIGURE 2-11, Sleeve Adjusting & Removal Tool CAUTION Use extreme care when using micrometer to measure diameter of Abrasive Sleeve. Diamond abrasive used on Abrasive Sleeve can damage contact pads of a micrometer. 10. Measure outside diameter of Tool's Abrasive Sleeve (see Figure 2-13). IL-1299 11. Reinstall Tool in Removal Tool. CAUTION DO NOT exceed desired diameter; check diameter frequently while setting. If Sleeve becomes over expanded, remove Sleeve from Mandrel and readjust Tool. FIGURE 2-12, Adjust Tool MEASURE DIA. HERE 12. Turn Handle until diameter of Sleeve is approximately 0,03 mm (.001 in) smaller than desired size or at minimum diameter setting for Tool, whichever is larger. 1.5 in. 38 mm SLEEVE NOTE: After Turret engages Tool Pilot, moving one numbered graduation on the Handle will increase diameter of Abrasive Sleeve by approximately 0,003 mm (.0001 in). PILOT FIGURE 2-13, Checking OD of Tool 9 13. When Tool is approximately 0,03 mm (.001 in) smaller than desired size, remove Tool from Removal Tool and install in the Machine. TABLE 2-4, Single Stroke Honing® Tools TOOL LARGER DIAMETER TOOLS A8 A10 A12 A14 A16 A18 A20 A22 A24 A26 A28 A30 A32 Consult the following procedure when assembling and presizing A12 through A32 series Single Stroke Honing Tools (see Figure 2-14): 1. Obtain proper diameter Tool, according to Table 2-4. (Or, refer to Sunnen Single Stroke Honing Tool Catalog X-DPT-1000; or consult your local Sunnen Field Service Engineer; or contact Sunnen Technical Services Dept., for the Tool best suited for your particular application and/or operation.) 2. Wipe tapered Mandrel and ID of Abrasive Sleeve to remove any oil, dust and grime. 3. Coat Mandrel with light oil and slide Abrasive Sleeve on tapered end of Mandrel. MAX. STK RMVL. PER PASS* IN. mm DIAMETER RANGE SERIES IN. mm .233 - .298 .298 - .368 .368 - .429 .429 - .491 .491 - .553 .553 - .613 .613 - .676 .676 - .721 .721 - .799 .799 - .858 .858 - .922 .922 - .981 .981 - 1.039 5,91 - 7,67 7,67 - 9,35 9,35 - 10,90 10,90 - 12,47 12,47 - 14,05 14,05 - 15,57 15,57 - 17,17 17,17 - 18,31 18,31 - 20,29 20,29 - 21,79 21,79 - 23,42 23,42 - 24,92 24,92 - 26,39 .0008 .0008 .0008 .0009 .0010 .0011 .0013 .0014 .0015 .0016 .0018 .0020 .0020 0,020 0,020 0,020 0,023 0,025 0,028 0,033 0,036 0,038 0,041 0,046 0,051 0,051 *Rough grit Sleeves ONLY; D8 Sleeve require less Stock Removal. S/R is based on cast iron; S/R will vary with other materials. 4. Insert Key in Mandrel with long offset toward Sleeve as illustrated. 5. Slide Pilot on end of Mandrel. ADAPTER 6. Install Tip and Regulating Screw on end of Mandrel. SLEEVE PILOT IL-1297 7. Turn Regulating Screw clockwise until Pilot and Abrasive Sleeve are snug on Mandrel. (So, Pilot and Sleeve can no longer rotate on Mandrel.) MANDREL CAUTION Use extreme care when using a micrometer to measure diameter of Abrasive Sleeve. The diamond abrasive used on Abrasive Sleeve can damage the contact pads of a micrometer. KEY TIP REGULATING SCREW FIGURE 2-14, Large Diameter Tool 8. Measure outside diameter of Tool's Abrasive Sleeve (see Figure 2-15). CAUTION DO NOT exceed desired diameter; check diameter frequently while setting. If Sleeve becomes over expanded, remove Sleeve from Mandrel and readjust Tool. 5/8 in. 16 mm REGULATING SCREW 9. Turn Regulating Screw until diameter of Sleeve is approximately 0,03 mm (.001 in) smaller than desired size or at minimum diameter setting for the Tool, whichever is larger. MEASURE DIA. HERE FIGURE 2-15, Checking OD of Tool NOTE: Turning Regulating Screw clockwise one notch (graduation) on Tip increases diameter of Abrasive Sleeve by approximately 0,003 mm (.0001 in). 10. When Tool is approximately 0,03 mm (.001 in) smaller than desired size, install in the Machine. HIGH-HELIC TOOLS Consult the following procedure when assembling High-Helix Plated Diamond Single Stroke Honing Tools (see Figure 2-17): FIGURE 2-16, High-Helix Tool 10 NOTE: If using a Micrometer: Use extreme care when measuring outside diameter of Tool's Abrasive Sleeve. The diamond abrasive used on Abrasive Sleeve can damage the contact pads of a micrometer. MEASURE DIA. HERE 8. Remove part from Sleeve and turn Pilot 1/4 turn. NOTE: Turning Pilot clockwise 1/4 turn increases diameter of Abrasive Sleeve by approximately 0,003 mm (.0001 in). 9. Remove Tool from vise and install in Machine. PILOT 10. Repeat for remaining tools. FIGURE 2-17, Sizing Tool NOTE: Finishing Tools can not be adjusted to final sized until part is properly hone using roughing Tool. DOOR MODIFICATION When a VSS is assembled at the factory, the plastic pane in front guard door covers the full opening above index table. If you purchased your VSS machine with Sunnen fixtures installed at the factory, then plastic pane in front door will have been modified to clear those fixtures. However, if you are building and installing your own fixtures, then you may have to modify pane to clear those fixtures. Adjust as follows (see Figure 2-18): MEASURE HERE FIGURE 2-18, Plastic Pane NOTE: High-Helix Tools are specially design for around your specific application. Contact your local Sunnen Field Service Engineer; or Sunnen Technical Services Dept., for Tool best suited for your particular application and/or operation. 1. Install fixtures on machine or measure fixtures carefully. Mark on pane the region to be removed. 2. Lift front door off its hinges and lay it down carefully with door handle down. 1. Obtain proper diameter Tools (roughing & finishing) and unhone sample part. 3. Remove gasket material between rim of door and pane. 2. Wipe tapered Mandrel and ID of Abrasive Sleeve to remove any oil, dust and grime. 4. Lift up on pane and slide it out bottom of door. 3. Coat Mandrel with light oil and slide Abrasive Sleeve on tapered end of Mandrel. 5. Cut out marked region. 4. Screw Pilot on end of Mandrel. 7. Install door on its hinges; making sure it clears fixtures. 6. Replace pane and gasket. 5. Mount Tool securely in soft face vise. NOTE: Door must clear fixtures and workpieces as it closes AND fixtures and workpieces must clear door as index table rotates. Make sure all handles, levers, fittings, hoses, and other fixture protrusions will clear door. Keep all air hose runs on index table short and tied down to minimize chance of them catching door. If more than one fixture is to be used on this machine, then make opening fit largest fixture setup. 6. Turn Pilot clockwise until Pilot contact Abrasive Sleeve are snug on Mandrel. (So, Pilot and Sleeve can no longer rotate on Mandrel.) CAUTION Use extreme care when turning (tightening) Pilot against Abrasive Sleeve. Pilot can damage the Sleeve if too much pressure is applied. DO NOT exceed desired diameter; check diameter frequently while setting WARNING Do not make opening in plastic pane any larger than necessary. Pane protects operator and keeps coolant contained in work area. If this machine uses more than one set of fixtures and one set is unusually large, then it is recommended that you buy a second door (or pane) and use that door just for large fixtures. 7. While sliding sample part over tool, continue to turn Pilot to expand Sleeve (see Figure 2-17). When stiff resistant is felt continue to tighten Pilot only back-off Pilot slightly after each 1/2 turn to allow Sleeve to relack. Continue this procedure until resistant is felt while sliding part over sleeve. The largest diagram of the sleeve is approximately 2/3 the way up the Sleeve. 11 NOTES 12 SECTION 3 SETUP & OPERATION GENERAL • 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. • Be sure to work in a well lit area to avoid dangerous unseen conditions which may exist otherwise. • Use ONLY factory authorized or recommended parts or replacement accessories. Using parts or accessories other than those approved by Sunnen could result in damage to machine and loss of warranty. • Electrostatic discharge can damage the circuitry of the electronic components used in this Machine. Use proper electrostatic controls when working with or around electronic components. Ground Machine and use wrist strap to reduce the chances of static discharge. • Residual Voltage exists for 2-3 minutes after Master ON/OFF Switch is turned OFF. Before working inside Enclosure, wait for all fans to stop running to allow drives to drain. This section gives a step-by-step overview of the setup & operation procedures for this machine. The machine's operating system software will walk you through the setup procedure step-by-step on the display screen. Follow all instructions carefully. (Also, refer to related topics in these Instructions, the Addendum which most closely matches your machine configuration, and to any Instructions packaged with optional equipment ordered with your machine.) SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around your Machine. • Wear proper Safety Items (such as safety glasses and other personal safety equipment as necessary or required). • Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tear-away type. • DO NOT wear loose fitting clothes or jewelry while working on or around Machine. • Keep area around Machine free of paper, oil, water and other debris at all times. • Keep Machine and area around machine cleaned of excessive lubricant and lubricant spills. • Keep tools and other foreign objects clear of Machine while in operation. • Keep tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life. • Inspect Tools before using. Check for cracks, burrs or bent parts that might effect operation. • DO NOT force tools when operating. Tools will do a better and safer job when operated at the rate for which they were designed. • Turn OFF electrical power when performing service on your machine, which does not require power. • Disconnect Machine from main power supply and allow drives to drain before any work is performed inside of Electrical Enclosure. • Ensure all Guards are in place and are in proper working order. • DO NOT override safety switches or lockouts. 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. SETUP - INITIAL To set up your machine for operation select "SETUP" from main menu. The machine's operating system software will walk you through the setup procedure step by step on the display screen. Follow all instructions carefully. Special Topics Controls: See Section 2, Operator Controls Single Stroke Honing Tool Adjustment: See Section 2, Small or Large Diameter Tools Tool Runout, Single Stroke Honing Tool: See Section 2, Install Single Stroke Honing Tool Table Setup: See separate instructions package with table Fixture Setup: See separate instructions package with fixtures Tool & Fixture Alignment: See separate instructions package with fixtures Setting Stroke Position: See Section 3, Setup Stroke Position In preparation for going through the setup sequence, the following preliminary steps can be helpful: • Install and align any fixturing. • Install Single Stroke Honing Tools. 13 SETUP - INDEXING TABLE All Machines are equipped with a Rotary Indexing Table (see Figure 3-1). The table is bolted and pinned to the machine base. The dowel pins provide precise repeatability of location if the table is ever removed for service. On top of the table is a round Tooling Plate. This plate is the mounting surface for the workpiece holding fixtures. If your fixtures were purchased as part of a complete Honing System, it is likely that the tooling plate was machined specially to mount the unique fixtures for your application. If you are making your own fixtures, you will probably have to machine the tooling plate to accept the fixtures you provide. If your Sunnen fixtures arrive assembled to the tooling plate, then they have also been accurately aligned to the spindles for best honing performance. No other alignment should be necessary, but be sure to read any special instructions that come with your unique fixtures. If you are providing the fixtures or if they are taken off the tooling plate for any reason, they must be aligned to the spindles when they are reinstalled. The tooling plate is bolted and pinned to the rotary indexing table. The dowel pins provide precise repeatability of location if the tooling plate is ever removed. If you will be running more than one application on the same machine, and if those applications use different fixtures, it is recommended that each set of fixtures be assembled permanently to a tooling plate. In that way, the plate can be changed as the setup is changed and you can avoid the time consuming fixture to spindle alignment process. The rotary indexing table can be made to index only through simultaneously touching Palm Buttons on front work shelf of the machine (see Figure 3-2). The control program will only allow this indexing motion at points in the Setup or in Diagnostics Modes where it is safe and pertinent to the instructions displayed on the operator control console screen. FIGURE 3-1, Rotary Indexing Table PALM BUTTONS FIGURE 3-2, Palm Buttons SETUP - FIXTURE INSTALLATION If your Sunnen fixtures arrive assembled to tooling plate, then they have also been accurately aligned to the spindles for best honing performance. No other alignment should be necessary, but be sure to read any special instructions that come with your unique fixtures. If you are providing fixtures or if they are taken off tooling plate (table) for any reason, they must be aligned to spindles when they are reinstalled. On machine equipped rotary indexing tables; tooling plate is bolted and pinned to the table. Dowel pins provide precise repeatability of location if the tooling plate is ever removed. If you will be running more than one application on the same machine, and if those applications use different fixtures, it is recommended that each set of fixtures be assembled permanently to a tooling plate. In that way, the plate can be changed as setup is changed and you can avoid time consuming fixture to spindle alignment process. This procedure is provided as an overview aligning fixture base with spindle. For detailed instructions; refer to instructions packaged with your fixture. To initially align Spindle and Fixture, proceed as follows: CAUTION Never attempt to activate the Palm Buttons without first reading the display screen. These buttons perform different functions at different stages of the setup. At some points during the setup and operation, the indexing table will only move one station at a time (or two at a time, if you are setup for double indexing). At other points during setup, the table may continue to move until the required position is reached. 1. Install Fixture bases at each station on table. Roughly align fixtures with hole in table and secure with mounting bolts. Snug, DO NOT tighten bolts at this time (refer to Figure 3-1). SAFETY NOTE: Any time the Palm Buttons are used to index the table, the table will stop at next station. 14 15. Repeat with each fixture in turn, until all fixture bases are aligned. ALIGNMENT TOOL 16. Route and attach airlines to fixtures as needed. 17. Attach and position coolant lines at each column (operating station). FIXTURE SETUP - TOOL INSTALLATION To set up your machine for operation select “SETUP” from main menu. The machine’s control software will walk you through the setup procedure step by step on the display screen. Follow all instructions carefully. If additional information is needed at any time during set up, refer to the related setup overview, which follows. FIGURE 3-3, Fixture Installation NOTE: The following is provided for general reference. Specific steps on your machine may be different. 2. Turn ON power at Master ON/OFF Switch, located on Electrical Enclosure. SYSTEM INITIALIZATION To install a New Single Stroke Honing® Tool (A-Series, DPT-Series, or High-Helix Tools), proceed as follows: 3. Close all Guards. 4. Release Emergency STOP Button on Operator Control Console. 1. Select Tool (refer to Section 2). 2. Turn ON power to the Machine at Master ON/OFF Switch, located on Electrical Enclosure. 3. Close all Safety Guards. 5. Press POWER-ON Button. Display will read: COLUMN INITIALIZATION WARNING Tool MUST be retracted from part. Retract Tool if machine shut down due to power outage or other reason with tool in part. 4. Release Emergency STOP Button on Operator Control Console. 5. Press POWER-ON Button. 6. Verify all Guards are in place. WARNING Tool MUST be retracted from part. Retract Tools if machine shut down due to power outage or other reason with tool in part. Check tools to ensure they turn freely in part before using power to remove tools. 7. Press Palm Buttons to HOME the machine. Revised MENU will appear after all drives have been initialized. COLUMN INITIALIZATION 8. Press F1, and follow steps as displayed on screen. 6. Verify all Guards are in place. 9. Install workpiece in fixtures. RUN SCREEN CARRIAGE POSITION 9.25 10. Select any one spindle, preferably the last, and mount a dial indicator that can sweep a hole or other cylindrical surface on your fixture. INDEX 7.50 FEED 10.50 REVERSAL 13.75 SPINDLE LOAD l 10 l 0 l 20 SPINDLE SPEED: H O N I N G F E E D R AT E : CYCLE TIME: C Y C L E C O U N T: 11. Use Palm Buttons to position fixture #1 under spindle. l 30 l 40 l 50 l 60 l 70 l 80 l 90 l 100 1250 10 2 SEC 3 USE THE SELECT SWITCH TO CHANGE THE HIGHLIGHTED SELECTION. PRESS THE +/- TO CHANGE THE SELECTION THESE WILL ALLOW A 25% CHANGE. 12. Turn the spindle by hand (with Power OFF) and read the indicator. Adjust fixture location until precise alignment is achieved (see Figure 3-3). The allowable amount of misalignment depends on your application and the type of fixturing used. 7. Press Palm Buttons to HOME Carriage. NOTE: To retrieve a previously saved setup, refer to system utilities. 8. Press F1, SETUP MENU. 13. Then, tighten mounting bolts. MAIN MENU NOTE: An alternate method is to mount a special close fitting alignment bar in the spindle, adjust its runout to nearly zero (see runout adjustment), and then use this bar to locate fixture on tooling plate. VSS 14. When first fixture is aligned, advance table to next fixture and align next fixture. 1.01.01 1/03/01 F1: SETUP MENU 15 F2: SYSTEM UTILITIES F3: RUN MENU 9. Use Arrows to select option; press enter; key in value; then press enter. • Use Arrows to select Final Diameter - Press Enter - Enter value using key pad - Press Enter to accept. TOOL FINAL DIAMETER: 0.750000 • Use Arrows to select Bore Length - Press Enter Enter value using key pad - Press Enter to accept. LETTERED SETSCREW BORE LENGTH: 2.000 • Use Arrows to select Abrasive Length - Press Enter - Enter value using key pad - Press Enter to accept. TOOL HOLDER TOOL ALIGNMENT INDICATOR ABRASIVE LENGTH: 2.500 10. Press Down Arrow to accept the following options. NUMBERED SETSCREW NOTE: Machine calculates following parameters. These values can be edited, but should only be changed after observing honing performance. • • • • • Press Down Arrow to accept Spindle Speed. Press Down Arrow to accept Rapid Feed Rate. Press Down Arrow to accept Honing Feed Rate. Press Down Arrow to accept Reverse Feed Rate. Press Down Arrow to accept Maximum Spindle Load. FIGURE 3-4, Tool Alignment Stand INDEX 11. Use +/- along with Palm Buttons, to raise or lower Carriage so tool can be installed at a comfortable height. 12. Open Guards. TOP OF BORE RAPID STOP 13. Install Single Stroke Tools with Adapter Sleeves in spindles and tighten set screws in spindles. SPINDLE START) SPINDLE STOP REVERSE FEED NOTE: If using Sunnen® Adjustable Spindle Nose, adjust for runout using Sunnen® MVH-9120 Tool Alignment Stand before installing tool in Spindle (see Figure 3-4). Refer to instructions packaged with MVH-9120 Tool Alignment Stand. FIGURE 3-5, Set Bore Position 14. Install workpiece in Station #1 (Load Position) and press ↵ (ENTER). 15. Press and hold Touch Buttons to move workpiece to desire Station. 16. Use Arrows to select Top of Bore Position. 17. Set Top of Bore Position (see Figure 3-5): • Use - (DOWN) and + (UP) keys to change "Palm Button Function." • Use Palm Buttons, to raise or lower Carriage until leading edge of abrasive sleeve is at Top Of Bore. • Then press F2 to accept. MEASURE BETWEEN BOTTOM OF HOLDER AND TOP OF ABRASIVE NOTE: Continue to use - (DOWN) and + (UP) Keys along with Palm Buttons to adjust Carriage height. 18. Press F3 for recommended value for Rapid Stop Position. Then press F2 to accept. 19. Press F3 for recommended value for Spindle Start Position. Then press F2 to accept. FIGURE 3-6, Install Tool 16 3. Press POWER-ON Button. 20. Press F3 for recommended value for Reverse Feed Position. Then press F2 to accept. 4. Verify all Guards are in place. 21. Press F3 for recommended value for Spindle Stop Position. Then press F2 to accept. RUN SCREEN CARRIAGE POSITION 9.25 INDEX 7.50 22. Use Palm Buttons to raise carriage until tools are safely above all fixtures. Everything on index table must clear tools when index table rotates. Be sure that tools are not set too low. Then press F2 to accept. FEED 10.50 REVERSAL 13.75 SPINDLE LOAD l 10 l 0 l 20 SPINDLE SPEED: H O N I N G F E E D R AT E : CYCLE TIME: C Y C L E C O U N T: l 30 l 40 l 50 l 60 l 70 l 80 l 90 l 100 1250 10 2 SEC 3 USE THE SELECT SWITCH TO CHANGE THE HIGHLIGHTED SELECTION. PRESS THE +/- TO CHANGE THE SELECTION THESE WILL ALLOW A 25% CHANGE. 23. Press F1 to return to Main Menu when complete. 5. Press Palm Buttons to HOME Carriage. NOTE: To retrieve a previously saved setup, refer to system utilities. NOTE: Both the two and four spindle machines’ Table can be double indexed so two parts can be honed at one time. This setting can be changed under the Engineering Menu, which can be accessed through System Utilities. 6. Press F1, SETUP MENU. Display will read: 24. Press F3, Run Menu. Display will read: MAIN MENU 25. Press 2, Hone Part. VSS 26. Press F2, to turn Coolant System ON. • Open Guards. • Position Coolant Lines. • Close Guards. 1.01.01 1/03/01 F1: SETUP MENU 27. Press Palm Buttons to start cycle. F2: SYSTEM UTILITIES F3: RUN MENU 7. Use Arrows to select option; press enter; key in value; then press enter. • Use Arrows to select Final Diameter - Press Enter - Enter value using key pad - Press Enter to accept. 28. Open Guards. 29. Remove and check (gage) part. • To edit: Press F1 Main Menu. Then F1, Setup Menu. Press F1 to return to Main Menu when complete. FINAL DIAMETER: 0.750000 • Use Arrows to select Bore Length - Press Enter Enter value using key pad - Press Enter to accept. 30. Adjust tool as required and repeat operation until part is to size. BORE LENGTH: 2.000 • Use Arrows to select Abrasive Length - Press Enter - Enter value using key pad - Press Enter to accept. 31. Install next tool. Tools should all be installed at the same height (see Figure 3-6). ABRASIVE LENGTH: 2.500 32. Repeat for remaining tools. 8. Press Down Arrow to accept the following options. NOTE: Finishing Tools will need to be adjusted to final sized using rough hone part that is hone to properly size using roughing Tool. NOTE: Machine calculates following parameters. These values can be edited, but should only be changed after observing honing performance. SETUP & OPERATION • • • • • Consult the following procedure when setting up your machine for operation. (Machine's control software will walk you through the setup procedure step-by-step on the view screen. Follow all instructions carefully.) • Install and align fixtures, as required. • Install tools, as required. • Install properly sized workpieces at each station. Press Down Arrow to accept Spindle Speed. Press Down Arrow to accept Rapid Feed Rate. Press Down Arrow to accept Honing Feed Rate. Press Down Arrow to accept Reverse Feed Rate. Press Down Arrow to accept Maximum Spindle Load. 9. Use Down Arrow to select Top Of Bore: • Use - (DOWN) and + (UP) keys to change "Palm Button Function." • Use Palm Buttons, to raise or lower Carriage until leading edge of abrasive sleeve is at Top Of Bore (see Figure 3-7). • Press F2 to accept. 1. Turn ON power to Machine at Master ON/OFF Switch, located on Electrical Enclosure. 2. Release Emergency STOP Button on Operator Control Console. 17 NOTE: The following setup processes require interaction with various machine movements. Start with recommended positions. These values can be edited, but should only be changed after observing the honing performance. The positions can be entered three different ways. The first way is to press enter and then type the desired position. The second is to move the column to the desired position and press F2. This will place the current column position in the highlighted selection. The last is to press F3. This will place the recommended value in the highlighted selection. INDEX 10. Press Down Arrow to accept the following options. • Press Down Arrow to accept Rapid Stop Position. • Press Down Arrow to accept Spindle Start Position. • Press Down Arrow to accept Reverse Feed Position. • Press Down Arrow to accept Spindle Stop Position. TOP OF BORE RAPID STOP SPINDLE START SPINDLE STOP REVERSE FEED 11. Press Down Arrow to select Index Position. • Use - (DOWN) and + (UP) keys to change "Palm Button Function." • Use Palm Buttons, to raise Carriage until tool is clear of workpiece and workholding fixture. • Press F2 to accept. FIGURE 3-4, Top of Bore ENGINEERING MENU C L E A R C Y C L E C O U N T: C H E C K F O R C O O L A N T FA U LT S : A L L O W I N D E X TA B L E M O V E M E N T: ALLOW SKIP HONING: I N D E X TA B L E A L L O W E D : SPINDLE SPEED: CURRENT POSITION: 12. Press F1 to return to Main Menu when complete. NO NO YES NO YES 100 0.75 MACHINE FUNCTION: NONE P R E S S T H E + / - K E Y TO C H A N G E F U N C T I O N ! ! ! WA R N I N G ! ! ! T H E S E S VA L U E S W I L L B E R E TA I N E D W H E N P O W E R I S R E M O V E D . PRESS ENTER TO EDIT HIGHLIGHTED SELECTION. CLEAR THE CURRENT CYCLE COUNT. MACHINE PARAMETERS MACHINE TYPE: S TAT I O N S P E R I N D E X : PULSES PER INDEX: C O L U M N L O W E R L I M I T: C O L U M N S E T U P R AT E : VSS86 1 1 12.500 25 F1: SYSTEM UTILITIES 8.0: 15.75 10.0: 60.0 17. Open Guards. 18. Remove and check (gage) workpiece(s). • To edit: Press F1 Main Menu. Then F1, Setup Menu. ! ! ! WA R N I N G ! ! ! T H E S E S VA L U E S W I L L B E R E TA I N E D W H E N P O W E R I S R E M O V E D . PRESS ENTER TO EDIT HIGHLIGHTED SELECTION. MACHINE TYPE: DEFINES NUMBER OF STATIONS AND SPINDLES. F1: ENGINEERING MENU F2: MACHINE PARAMETERS F2: MACHINE FAULT LIST 19. Press F1 to return to Main Menu when complete. 20. Load parts. RUN SCREEN 21. Press F3, Run Menu. 22. Press Palm Buttons to Start Cycle. P R E S S PA L M BU T TO N S TO S TA RT C Y C L E NOTE: The machines’ table can be double indexed so two parts can be honed at one time. This setting can be changed under the Engineering Menu, which can be accessed through System Utilities. E NTER: COOLANT ON/OFF L AST CYCLE TIME: 0 SEC C YCLE COUNT: 0 F1: MAIN MENU F2: REPEAT HONING F3: 13. Press F3, Run Menu. Display will read: 14. Press 2, Hone Part. Display will read: 15. Press F2, to turn Coolant System ON. • Open Guards. • Position Coolant Lines. • Close Guards. 16. Press Palm Buttons to start cycle. Display will read: 18 NOTES 19 SPINDLE MOTOR COOLING FAN SPINDLE MOTOR BEARING GREASE FITTINGS RUNNER BLOCK LUBE UNITS (BOTTOM TWO NOT SHOWN) BALL NUT GREASE FITTING FIGURE 4-1, Column Maintenance Locations OIL FILL LOCATIONS OIL LEVEL SIGHT GAGE INDEXER DRAIN PLUG FIGURE 4-2, Indexer Maintenance Locations 20 SECTION 4 ROUTINE MAINTENANCE GENERAL • Fill to middle of oil level sight gauge. Oil capacity of Camco model 601RDM index drive is 1.2 liters (1.25 quarts). The 180SM gear reducer supplied with indexer is a sealed unit and requires no lubrication maintenance. • Inspect ball screw and spindle drive belts; replace belts as required. • Wipe down and relubricate carriage ways. To relub wipe rails with a clean cloth containing a light gage oil. DO NOT allow oil to stand on rails. Note it is important to visual inspect for possible lubrication breakdown and/or bearing contamination that may cause premature failure. Every 5,000 hrs. or 2 years, whichever comes first. • Replace Ball Screw Drive Belt. Consult this section for routine maintenance procedures and suggested service periods for your Machine. MAINTENANCE SCHEDULE The following procedures and suggested maintenance periods are given as guides only, and are not to be construed as absolute or invariable. Local conditions must always be considered. Each machine must be maintained individually. (Refer to Figures 4-1 & 4-2.) Daily • Check coolant level in coolant reservoir. If water based coolant is used, check for proper concentration and add water or concentrate as necessary. Every 100 hrs. • Check that spindle motor cooling fan is turning when power to machine is on. Every 200 hrs. • Apply two pumps of Sunnen SML-160 (Mobilith AW-3 Grease or equivalent) to Ball Nut. To access Ball Nut remove screw holding upper Way Cover to Spindle Carriage and lift upper Way Cover to expose fitting on Ball Nut. • Inspect condition of Way Covers. Replace at first sign of a tear or a hole. • Index drive is furnished with a "bulls-eye" type oil level sight gauge on right side of indexer. Oil level should be checked monthly and oil added as required to maintain proper level. Use Sunnen SML-150 (MobilGear 630 or equivalent). The oil level should be checked when indexer is stopped at which time oil level should reach the center of sight glass. WARNING Removing Belt Guard from top of Column will disengage Ball Screw from Brake. Carriage will fall violently if it is not properly supported. Place a wood block or some other sturdy prop under Carriage before attempting to service Brake, Belt, or Ball Screw Motor. • Check air gap on Ball Screw Brake. It should be 0.15 - 0.25 mm. Adjust if necessary. If gap is larger, also inspect brake rotor for sufficient lining thickness. NOTE: The brake is used primarily as a holding device. It only stops a moving Ball Screw in an Emergency Stop situation. If rotor lining shows significant wear, it is an indication of a recurring machine malfunction. • If supplied motor has grease fittings for this purpose: Grease Spindle Motor Bearings (top & bottom) with Sunnen SML-170 (Exxon Polyrex EM or equivalent). Every 30,000 hrs. or 5 years, whichever comes first • Recharge Runner Blocks with Grease. Use a grease made to specification KP2K according to DIN51825. (Mobil Mobilux EP2, Kluber Centoplex 2, or equivalent). Every 2000 hrs. or 6 months, whichever comes first. • Drain and replace oil in index table. Use Sunnen SML-150 (MobilGear 630 or equivalent). Index drive is furnished with a "bulls-eye" type oil level sight gauge on right side of indexer. During oil changes this "bulls-eye" can be removed for cleaning. Remove breather vent cover and breather vent on front of indexer to expose a ½ NPT port or remove pipe plug in T-Fitting behind sight glass for use in filling indexer with oil. Remove drain plug in front bottom of indexer for draining. NOTE: Sunnen supplied workpiece fixtures may also require some routine preventative maintenance. Refer to documentation supplied with your fixtures. NOTE: Magnetic drain plug should be visually inspected at this time for metallic chips that might indicate failure of one of internal components. CLEANING Daily • After use, wipe exterior of the Machine with a clean, dry cloth to remove any coolant, dust and grime. Empty Pail (Magnetic Separator) as required. 21 7. Re-install Brake & Belt Guard Assembly and secure with Screws. Monthly • Wipe with a clean dry cloth. Then clean exterior of Machine with warm water and a mild detergent or mild industrial solvent. Rinse thoroughly with clean hot water and wipe dry. Lightly lubricate following lubrication instructions. SPINDLE DRIVE BELT REPLACEMENT COOLANT LINES CHECK NOTE: For complete parts breakdown, refer to Repair Parts Catalog. To replace the spindle and intermediate drive belts, proceed as follows: Inspect Coolant Lines and Fittings monthly for leaks or damaged parts. Replace parts as required. 1. Block up Spindle Carriage with a wood block, or other suitable material.Block should be between machine base and Carriage. IMPORTANT Operating Instructions and Repair Parts Manuals for the optional Paperbed Filter Coolant System are supplied by the systems manufacturer. WARNING Failure to adequately support Carriage will result in a violent fall of Carriage when Brake is removed. NOTE: The Coolant System does not come standard with your machine. Refer to general coolant maintenance procedures later in this section and to manuals packaged with your coolant system. 2. Remove screws holding Top and Front Belt Covers in place (see Figure 4-5): • On front cover, remove only the lower row of screws. This will allow top and front covers to be removed together. Coolant Level Check • Daily, check level of Coolant in Coolant Reservoir; do not allow Coolant to drop below minimum recommended level (approx. a 19 L/5 Gal drop in level). Fill as required (see Figure 4-3). 3. Remove tension from both Belts: • The Intermediate Belt adjustment is located directly under the Spindle Motor (see Figure 4-6). Loosen Belt Tensioning Screw Jam Nut and four Screws securing Spacer to Motor Plate. Loosen Belt Tensioning Screw, and slide Motor toward rear of machine. BALL SCREW BELT REPLACEMENT To replace Ball Screw Belt, proceed as follows (see Figure 4-4): NOTE: For complete parts breakdown, refer to Repair Parts Catalog X-VSS-8601. 1. Block up Spindle Carriage with a wood block, or other suitable material.Block should be between machine base and cast iron of Carriage. WARNING Failure to adequately support Carriage will result in a violent fall of Carriage when Brake is removed. 2. Remove two screws holding Belt Guard to Column. Leave brake fastened to Belt Guard. 3. Lift Assembly off Ball Screw. Set Assembly aside, but be careful not to leave them hanging by Electrical Cord. 4. Loosen four screws holding Ball Screw Motor Bracket to top of column. Slide motor forward to remove old belt. 5. Install new belt. 6. While pulling motor with your hand to tension belt, tighten four screws holding the Ball Screw Motor Bracket to top of column. NOTE: Pulling motor by hand is sufficient tension for belt. Too much tension can cause motor stalling, bearing failure, and short belt life. Check belt tension by feel to be sure that it cannot come off pulleys. FIGURE 4-3, Coolant Line Check BALL SCREW PULLEY MOTOR PULLEY SCREW DEFLECTION BRAKE & BELT GUARD ASSEMBLY BELT FIGURE 4-4, Ball Screw Belt 22 • The Spindle Belt adjustment is the Idler Pulley on the right as you face the machine (see Figure 4-7). Loosen 30mm Locknut under Spindle Carriage. Loosen Jam Nut on Belt Tensioning Screw. TOP COVER SCREWS SCREWS FRONT COVER DO NOT REMOVE UPPER SCREWS 4. Remove Intermediate Shaft and Bearing Plate Assembly located behind Spindle Motor (see Figure 4-8): • Remove four (4) Bolts securing Bearing Plate to Motor Plate. • Remove four (4) Screws securing Lower Bearing Housing. These are located under the Carriage. • Lift Intermediate Shaft and Bearings out of the Machine. SCREWS SCREWS NOTE: There is an L-Shaped Alignment Bracket next to Bearing Plate. This Bracket MUST NOT be loosened or removed (refer to Figure 4-8). FIGURE 4-5, Belt Covers 5. Remove Belt: • Guide Intermediate Drive Belt off Motor Sprocket and remove (refer to Figure 4-6). • Remove two Screws from Idler Strap and rotate Strap so Spindle Drive Belt can be removed from Idler Pulley. Then remove belt from remaining Sprockets (refer to Figure 4-7). DEFLECTION MOTOR TENSION SCREW MOTOR PLATE SCREW SPACER JAM NUT TOP BEARING HOUSING SHAFT PULLEY MOTOR PULLEY BELT BOLTS BEARING PLATE FIGURE 4-6, Intermediate Shaft Drive Belt INTERMEDIATE SHAFT 6 1 ALIGNMENT BRACKET DEFLECTION IDLER SHAFT MOTOR PLATE BELT IDLER STRAP 2 3 1 4 TENSION SCREW 6 JAM NUT SCREW 5 LOWER BEARING HOUSING LOCKNUT TENSIONING IDLER FIGURE 4-8, Spindle Drive Belt FIGURE 4-7, Spindle Drive Belt 23 6. Install new Spindle Drive Belt, rotate Idler Strap back into position over Tension Block and reinstall two Screws removed in step 5. SCREW 7. Install new Intermediate Drive Belt. BRAKE 8. Reinstall Intermediate Shaft and Bearing Plate Assembly (refer to Figure 4-8): • Place Intermediate Shaft and Bearings back into position in machine. Assure that Lower Bearing Housing Iis seated flat in location on Carriage. • Position Belts on the correct Pulleys. Tighten the four Screws securing Lower Bearing Housing in position. • Position Bearing Plate over Top Falnge Bearing. With Bearing Plate flat against Motor Plate, tighten Bolts securing Bearing Plate to Motor Plate. BELT GUARD BELT SHEAR PIN MOTOR PULLEY NOTE: Be certain that screws are located on shaft flats. 9. Adjust Spindle Drive Belt tension by turning Spindle Belt Tensioning Screw. Torque Tensioning Screw to 1011 lbf (44,5-49 N) to achieve .28in. (7,2mm) deflection at center of span between sprockets 1 & 6 (refer to Figure 4-7). Then secure Spindle Belt Tensioning Screw Jam Nut. FIGURE 4-9, Ball Screw Shear Pin 5. Note the shear pin cross-hole in the pulley. The shear pin is a press fit through one wall. The hole on the opposite side is clearance. Place the pulley on the motor shaft so that this clearance side is aligned with the motor keyway. Slip a 3mm-dowel pin in this clearance side to engage the hole in the bottom of the keyway. This will hold the pulley and motor shaft in alignment while the new shear pin is being installed. 6. Press a new shear pin (VSS-4273) into the tight side of the pulley cross-hole and into the motor shaft. Press the pin in until it is flush with the flat on the pulley hub. Use a C-clamp or some similar device to press in the pin. Hammer blows are not recommended as they can potentially damage the motor bearings. NOTE: If a new shear pin is not available the old pin may be reused once. A new pin is long enough that if sheared once the long remnant may be reused. However, in this case the pin is not to be pressed in flush but to be pressed in 4mm below flush. If you are doing this, be sure to order a new VSS-4273 from Sunnen Products immediately. This pin will not be reusable if it shears again. The motor pulley has two set screw holes but setscrews are not used in this application. If set screws are added after the delivery of the machine or if the shear pin is replaced with a pin that is not from Sunnen Products, the warranty coverage will be voided for the ball screw, ball nut, linear way bearings, and spindle bearings. 10. Adjust Intermediate Drive Belt tension by sliding Spindle Motor forward and adjusting Belt Tensioning Screw. Torque Tensioning Screw to 11-12 lbf (49-53 N) to achieve .10in. (2,5mm) deflection at center of span between motor sprocket & pulley on intermediate shaft (refer to Figure 4-6). Tighten Screws that secure Spindle Motor. Then secure Jam Nut. 13.Reinstall Belt Covers (refer to Figure 4-5). BALL SCREW SHEAR PIN REPLACEMENT The Ball Screw Motor Pulley is connected to the Ball Screw Motor by means of a brass shear pin. This pin is designed to shear in severe crash situations. This protects the ball screw, ball nut, linear way bearings, and the spindle bearings from damage. NOTE: For complete parts breakdown, refer to Repair Parts Catalog X-VSS-8601. 1. Block up Spindle Carriage with a wood block, or other suitable material.Block should be between machine base and cast iron of Carriage. WARNING Failure to adequately support Carriage will result in a violent fall of Carriage when Brake is removed. 2. Remove two screws holding Belt Guard to Column. Leave brake fastened to Belt Guard (refer to Figure 4-4). 3. Lift Assembly off Ball Screw. Set Assembly aside, but be careful not to leave them hanging by Electrical Cord (see Figure 4-9). 4. Press the broken pin pieces out of the pulley (VSS-4270) and the motor shaft (PMO-438). 24 COOLANT SYSTEM (Optional) Daily, check level of Coolant in Coolant Reservoir; do not allow Coolant to drop below minimum recommended level. Replace Coolant as follows using only Sunnen Industrial Honing Oil or Sunnen Water-Based Coolant (see Figure 4-11). CAUTION For instructions on inspecting and servicing waterbased coolant, refer to Instructions packaged with Sunnen SCC-900 Coolant Maintenance Kit. (The SCC-900 Coolant Kit IS REQUIRED, when servicing a Machine which is using a water-based coolant. Use only approved Sunnen Water-Based Coolant Concentrate.) FIGURE 4-10, Magnetic Separator IMPORTANT Operating Instructions and Repair Parts Manuals for the optional Paperbed Filter Coolant System are supplied by the systems manufacturer. 1. Turn OFF all power to Machine at Master ON/OFF Switch. 2. Close Coolant Control Valves. 3. Unplug Coolant System's electrical cords from power source. 4. Pump coolant from reservoir into an approved waste container. 5. Dip or siphon out any remaining coolant from the reservoir. 6. Clean Sludge from Reservoir and wipe clean. 7. Fill Reservoir by pumping or pouring ONLY approved Sunnen Industrial Honing Oil (or Sunnen Water-Based Coolant) into Coolant Reservoir. 8. Plug Coolant System's electrical cords into power source. FIGURE 4-11, Coolant Reservoir MAGNETIC SEPARATOR (Optional) The magnetic separator should be checked, cleaned, and adjusted as follows (see Figure 4-10): NOTE: For complete maintenance instructions, refer to instructions packaged with Magnetic Separator. • Water-Based Coolant: Clean discharge chute daily. When using water-based coolant, the sludge that builds up in the chute often hardens if the machine is turned off for 8 hours or more. Therefore, the sludge should be cleaned off the chute at the start of each shift. When using honing oil as a coolant, the sludge rarely if ever hardens in the chute and will not have to be checked as often. NOTE: A certain amount of coolant will be carried into the sludge bucket along with the sludge. After gravity separates the coolant from the sludge, there is normally an inch or more of coolant that collects in the bucket. This coolant can be dipped out and returned to the reservoir. • Periodically: Drain Inlet Hopper, wipe clean, and adjust Gap Plate as required. Proper Gap setting is 4,5 mm ±1 mm (3/16 in ±1/16 in). 25 NOTES 26 SECTION 5 TROUBLESHOOTING GENERAL TROUBLESHOOTING This section contains Troubleshooting information which should be used when problems occur with machine. The following recommendations are provided as a guide. TROUBLESHOOTING Problem – Control System believes the Spindle Carriage is in an Overtravel position. Solutions – If Spindle Carriage is really at extreme top or bottom of its travel, then follow instructions on the screen. – If Spindle Carriage is not at the ends of its travel then the Proximity Switch Target (VSS-4267) may be hung up causing control system to think Carriage is already at home position. Corrective Action - Lift upper Way Cover and check for free movement of Target. Lubricate pivot point with a light oil such as WD-40. – Proximity Switch, Cable or wiring may be defective. Problem – Carriage won't move and there is an error message saying "No column movement detected. Shear pin may have failed due to crash." Solutions – If there has been a recent crash, the Shear Pin in the Ball Screw Motor Pulley probably sheared to protect bearings and ball screw from damage. See section on Ball Screw Motor Shear Pin Replacement. – If the shear pin has not failed, check the operation of the proximity switch (PES-641) attached to the Belt Guard. This should switch on and off repeatedly as the motor turns. – If the shear pin has failed and there has not been a recent crash and this failure has occurred more than once, then contact Sunnen Service to determine the cause and corrective action. Problem – One or more spindles are too hot after running. Solution – At high speeds the spindles are generally very warm. To see if the temperature is excessive, run the spindle continuously at 2500 rpm. (To do this, from the main menu select System Utilities, then Engineering Menu. Set speed to 2500 and press the hand buttons to start.) Measure the temperature of the carriage casting in locations that are close to the lower spindle bearings and upper spindle bearings. If the temperature at any location exceeds 50°C over room temperature then the bearings at that location are running too hot and should be replaced. (Consult Sunnen Service for replacement.) If after one hour of continuous running, no location exceeds 50°C over room temperature then the spindle bearings are operating normally. 27 NOTES 28 APPENDIX A CHECKLIST SETUP & OPERATION SEQUENCE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Install Workholding Fixtures. Install and align tools, as required. Install properly sized workpiece at each workstation. Turn ON power. Release Emergency STOP. Press POWER-ON Button. Verify all Guards are in place. Press Palm Buttons to HOME Carriage Press F1, Setup Menu. Enter values for following options: Final Diameter: Select - ENTER - Key in Value - ENTER. Bore Length: Select - ENTER - Key in Value - ENTER. Abrasive Length: Select - ENTER - Key in Value - ENTER. Spindle Speed: Select - ENTER - Key in Value - ENTER. Use Down Arrow to accept values for following options: Rapid Feed Rate: Down Arrow. Honing Feed Rate: Down Arrow. Reverse Feed Rate: Down Arrow. Maximum Spindle Load: Down Arrow. Set Top Of Bore, then press F2. Use Down Arrow to accept values for following options: Rapid Stop Position: Down Arrow. Spindle Start Position: Down Arrow. Reverse Feed Position: Down Arrow. Spindle Stop Position: Down Arrow. Set Index Position, then press F2. Press F1 when setup is complete. Press F3, Run Menu. Press 2, Hone Part - Run Menu. Press F2, to turn Coolant System ON. Open Guards. Position Coolant Lines. Close Guards. Press Palm Buttons to start cycle Open Guards, when cycle is ended. Remove and check (gage) workpiece. Edit settings, as required. Press F1 when complete. Load parts. Press F3, Run Menu. Press Palm Buttons to Start Cycle. Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment. 29 NOTES 30 APPENDIX B SINGLE STROKE HONING ® TOOLS TOOLING SELECTIONS Tool Dimensions The Sunnen® Single Stroke Honing® Tools are recommended for use in selected materials, where speed and accuracy are important. To aid in adapting your machine(s) for use of the Sunnen Single Stroke Honing Tool, the following Tool Dimensions Table is provided. Mandrel dimensions may be altered using common metal cutting tools. Letters across the top of the table refer to the Lettered Dimensions on Figures A & B. D2 D2 D1 L2 S NOTE: For bore diameter sizes below 5,92 mm (.233") and above 52,20 mm (2.055"), or for special designed high production tools, consult your local Sunnen Field Service Engineer. D1 P L2 P S L1 L1 FIGURE A FIGURE B Single Stroke Honing® Tool Dimensions DIAMETER RANGE† OF TOOL mm in. 05,92-06,68 06,68-07,57 07,57-08,46 08,46-09,35 09,35-09,88 09,88-10,39 10,39-10,90 10,90-11,53 11,53-11,99 11,99-12,47 12,47-13,18 13,18-14,05 14,05-14,78 14,78-15,57 15,57-16,48 16,48-17,17 17,17-18,31 18,31-18,82 18,82-19,76 19,76-20,29 20,29-21,31 21,31-21,79 21,79-23,42 23,42-24,92 24,92-26,39 26,39-27,91 27,91-29,67 29,62-31,14 31,14-32,66 32,66-34,47 34,47-35,89 35,89-37,64 37,62-39,14 39,14-40,67 40,67-42,19 42,19-43,99 43,99-45,49 45,49-47,02 47,02-48,54 48,54-50,37 50,37-52,20 †Diameter 0.233-0.263 0.263-0.298 0.298-0.333 0.333-0.368 0.368-0.389 0.389-0.409 0.409-0.429 0.429-0,454 0.454-0.472 0.472-0.491 0.491-0.519 0.519-0.553 0.553-0.582 0.582-0.613 0.613-0.649 0.649-0.676 0.676-0.721 0.721-0.741 0.741-0.778 0.778-0.799 0.799-0.839 0.839-0.858 0.858-0.922 0.922-0.981 0.981-1.039 1.039-1.099 1.099-1.168 1.166-1.226 1.226-1.286 1.286-1.357 1.357-1.413 1.413-1.482 1.481-1.541 1.541-1.601 1.601-1.661 1.661-1.732 1.732-1.791 1.791-1.851 1.851-1.911 1.911-1.983 1.983-2.055 SERIES NO. FIG. L1 mm A8A A813 A10A A1013 A12A A12B A12C A14A A14B A14C A16A A16B A18A A18B A20A A20B A22A A24A A24B A24C A26A A26B A28A A30A A32A LH9X---1062 LH9X--- 1125 LH9X--- 1188 LH9X---1250 LH9X---1312 LH9X---1375 LH9X---1438 LH9X- -1500 LH9X---1562 LH9X---1625 LH9X---1688 LH9X---1750 LH9X---1812 LH9X---1875 LH9X---1938 LH9X---2000 A A A B A B B A B B A B A B A B A A A B A B A A A B B B B B B B B B B B B B B B B 230,171 23,017 23,017 23,017 30,444 30,444 30,444 33,714 33,714 33,714 36,297 36,297 39,969 399,691 431,671 43,167 46,340 50,023 50,023 50,023 53,198 53,198 56,055 59,352 62,525 * * * * * * * * * * * * * * * * L2 in. 9.062 9.062 9.062 9.062 11.986 11.986 11.986 13.273 13.273 13.273 14.187 14.187 15.736 15.736 16,995 16.995 18.244 19.694 19.694 19.694 20.944 20.944 22.069 23.367 24.616 * * * * * * * * * * * * * * * * mm 34,93 34,93 34,93 34,93 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 54,76 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 57,15 D1 D2 in. mm in. 1.375 1.375 1.375 1.375 2.156 2.156 2.156 2.156 2.156 2,156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.156 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 2.250 05,79 06,55 07,44 08,33 09,25 09,78 10,29 10,79 11,43 11,88 12,36 13,08 13,92 14,66 15,47 16,38 17,04 18,14 18,64 19,58 20,14 21,16 21,64 23,27 24,77 26,24 27,76 29,46 30,99 32,51 34,32 35,74 37,47 38,99 40,51 42,04 43,84 45,34 46,86 48,39 50,22 0.228 0.258 0.293 0.328 0.364 0.385 0.405 0.425 0.450 0.468 0.487 0.515 0.548 0.577 0.609 0.645 0.671 0.714 0.734 0.771 0.793 0.833 0.852 0.916 0.975 1.033 1.093 1.160 1.220 1.280 1.351 1.407 1.475 1.535 1.595 1.655 1.726 1.785 1.845 1.905 1.977 mm 07,54 07,54 07,54 07,54 09,36 09,36 09,36 10,93 10,93 10,93 12,53 12,53 14,08 14,08 15,68 15,68 17,26 18,78 18,78 18,78 20,38 20,38 21,96 23,53 25,11 25,10 25,10 25,10 25,10 31,37 31,37 31,37 31,37 31,37 31,37 31,37 31,37 31,37 31,37 31,37 31,37 range refers to a group (Series No.) of tools having a common mandrel. *Refers to Sunnen Bore Sizing &Finishing Supplies Catalog for overall length dimensions of LH9X Single Stroke Honing® Tools. 31 S in. 0.2970 0.2970 0.2970 2,970 0.3685 0.3685 0.3685 0.4305 0.4305 0.4305 0.4935 0.4935 0.5545 0.5545 0.6175 0.6175 0.6795 0.7395 0.7395 0.7395 0.8025 0.8025 0.8645 0.9265 0.9885 0.9885 0.9885 0.9885 0.9885 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 1.2350 mm 47,631 4,763 4,763 4,763 5,715 5,715 5,715 6,668 6,668 6,668 7,620 7,620 8,573 85,731 9,525 9,525 10,478 11,430 11,430 11,430 12,383 12,383 13,335 14,288 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 15,240 P in. 1.875 1.875 1.875 1.875 2.250 2.250 2.250 2.625 2.625 2.625 3.000 3.000 3.375 3.375 3.750 3.750 4.125 4.500 4.500 4.500 4.875 4.875 5.250 5.625 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 6.000 mm 2,9,13 29,13 29,13 29,13 25,25 25,25 25,25 29,41 29,41 29,41 33,27 33,27 36,45 36,45 39,90 39,90 43,08 49,83 49,83 49,83 53,01 53,01 54,61 59,06 62,23 62,23 63,83 63,83 63,83 65,41 65,41 65,41 65,41 65,41 65,41 65,41 65,41 65,41 65,41 67,44 67,44 in. 1.147 1.147 1.147 1.147 0.994 0.994 0.994 1.158 1.158 1.158 1.310 1.310 1.435 1.435 1.571 1.571 1.696 1.962 1.962 1.962 2.087 2.087 2.150 2.325 2.450 2.450 2.513 2.513 2.513 2.575 2.575 2.575 2,575 2.575 2.575 2.575 2.575 2,575 2.575 2.655 2.655 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 .... .019685 0,5000 11/32 .343750 8,7313 .... .708661 18,0000 .... .023622 0,6000 .... .354331 9,0000 23/32 .718750 18,2563 .... .027559 0,7000 23/64 .359375 9,1281 47/64 .734375 18,6531 1/32 .031250 0,7938 3/8 .375000 9,5250 .... .748031 19,0000 .... .031496 0,8000 25/64 .390625 9,9219 3/4 .750000 19,0500 .... .035433 0,9000 .... .393701 10,0000 49/64 .765625 19,4469 .... .039370 1,0000 13/32 .406250 10,3188 25/32 .781250 19,8438 3/64 .046875 1,1906 27/64 .421875 10,7156 .... .787402 20,0000 1/16 .062500 1,5875 .... .433071 11,0000 51/64 .796875 20,2406 5/64 .078125 1,9844 7/16 .437500 11,1125 13/16 .812500 20,6375 .... .078740 2,0000 29/64 .453125 11,5094 .... .826772 21,0000 3/32 .093750 2,3813 15/32 .468750 11,9063 53/64 .828125 21,0344 7/64 .109375 2,7781 .... .472441 12,0000 27/32 .843750 21,4313 .... .118110 3,0000 31/64 .484375 12,3031 55/64 .859375 21,8281 1/8 .125000 3,1750 1/2 .500000 12,7000 .... .866142 22,0000 9/64 .140625 3,5719 .... .511811 13,0000 7/8 .875000 22,2250 5/32 .156250 3,9688 33/64 .515625 13,0969 57/64 .890625 22,6219 .... .157480 4,0000 17/32 .531250 13,4938 .... .905512 23,0000 11/64 .171875 4,3656 35/64 .546875 13,8906 29/32 .906250 23,0188 3/16 .187500 4,7625 .... .551181 14,0000 59/64 .921875 23,4156 .... .196850 5,0000 9/16 .562500 14,2875 15/16 .937500 23,8125 13/64 .203125 5,1594 37/64 .578125 14,6844 .... .944882 24,0000 7/32 .218750 5,5563 .... .590551 15,0000 61/64 .953125 24,2094 15/64 .234375 5,9531 19/32 .593750 15,0813 31/32 .968750 24,6063 .... .236220 6,0000 39/64 .609375 15,4781 .... .984252 25,0000 1/4 .250000 6,3500 5/8 .625000 15,8750 63/64 .984375 25,0031 17/64 .265625 6,7469 .... .629921 16,0000 1 1.000000 25,4000 .... .275591 7,0000 41/64 .640625 16,2719 1-1/16 1.062500 26,9880 FORMULAS: MULTIPLY INCHES (in) FEET (ft) x x BY 25.4 0.3048 = = TO GET MILLIMETERS (mm) METERS (m) MULTIPLY MILLIMETERS (mm) METERS (m) x x BY 0.03937 3.281 = = TO GET INCHES (in) FEET (ft) “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. 0804 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: [email protected] SUNNEN AG SUNNEN PRODUCTS COMPANY 7910 Manchester Road, St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. 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