Operating Display SCREENS - Sunnen Menu (Edit Tool Parameters) ..... 110 Utilities Menu (Backup/Restore) ..... 111 ... diameter of set up workpiece. Final Diameter – Desired diameter

SUNNEN® PRODUCTS COMPANY • 7910 MANCHESTER ROAD • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100

Operating Display SCREENS

for SUNNEN® VERTICAL HONING SYSTEMS

Models: SV210/215, SV310, SV500, SV1000/1005, & SV1010/1015 Series

I-SV-213

“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”

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GENERAL INFORMATION Sunnen® equipment has been designed and engineered for a wide variety of parts within capacity and limitation of equipment. With proper care and maintenance this equipment will give years of service. READ FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE OPEARTING THIS EQUIPMENT. IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with 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. Emergency breakdown support is available on a 24 hour / 7 day basis. 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 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 literature packaged with your equipment. Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please has following information available: • Have ALL MANUALS on hand. 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 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 USA, contact your local authorized Sunnen Distributor. Additional information available at: http://www.sunnen.com or e-mail: [email protected] NOTE: Sunnen reserves right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle 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 time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

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TABLE OF CONTENTS

PAGE

Initialization Screen (Waiting for Power ON) .......................................................... 1 Initialization Screen (Waiting for Palm Buttons or Cycle Start) .............................. 2 Main Menu ............................................................................................................. 3 Setup Menu ............................................................................................................ 4 Setup Menu (Part Specification) ............................................................................ 5 Setup Menu (Diameters) ........................................................................................ 7 Setup Menu (Index Table) ...................................................................................... 8 Setup Menu (Airlines, Fixtures) ............................................................................ 10 Setup Menu (Interlocks, Fixtures) ........................................................................ 11 Setup Menu (Column A Tool Selection) ............................................................... 12 Setup Menu (Column A Tool Selection - 2-Stage Setup) ..................................... 14 Setup Menu (Column A Honing Parameters) ....................................................... 15 Setup Menu (Column A Pre Honing Feed Parameters) ....................................... 18 Setup Menu (Column A Honing Feed Parameters) ............................................. 20 Setup Menu (Column A Honing Feed Parameters – Spindle Reversal) .............. 22 Setup Menu (Column A Post Honing Feed Parameters) ..................................... 23 Setup Menu (Zero Shutoff Parameters) ............................................................... 25 Setup Menu (Column A Air Lines Setup) ............................................................. 27 Setup Menu (Column A Fixture Interlock Setup) .................................................. 29 Setup Menu (Column A Tool Options) ................................................................. 31 Setup Menu (Column A Tool Preparation) ........................................................... 33 Setup Menu (Column A Remove Tool) ................................................................ 34 Setup Menu (Column A Remove Adapter) ........................................................... 35 Setup Menu (Column A Install Adapter) ............................................................... 36 Setup Menu (Column A Install Tool) .................................................................... 37 Setup Menu (Column A Snug Tool) ..................................................................... 38 Setup Menu (Column A Align Tool) ...................................................................... 40 Setup Menu (Column A Set Stroke) ..................................................................... 42 Setup Menu (Column A Set Load Position) ......................................................... 44 Setup Menu (Column A Set Transition Position) .................................................. 45 Setup Menu (Column A Single Stroke Honing® Parameters) .............................. 46 Setup Menu (Column A Single Stroke Honing® Return Parameters) ................... 48 Setup Menu (Column A Guide Pot) ...................................................................... 49 Setup Menu (Column A Step & Repeat) .............................................................. 50 Setup Menu (Gage a Position) ............................................................................. 52

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TABLE OF CONTENTS (cont’d)

PAGE

Setup Menu (Gage a Mastering) ........................................................................... 54 Setup Menu (Automation Setting 1) ...................................................................... 55 Setup Menu (Setup Complete) ............................................................................. 56 Setup Menu (Save As) .......................................................................................... 57 Setup Menu (Base Setup) ..................................................................................... 58 Setup Menu (Column A Setup) ............................................................................. 59 Setup Menu (Gage Setup) .................................................................................... 61 Automation Menu (Automation Setup) .................................................................. 62 Run Menu (Main Run Menu Setup Screen) .......................................................... 63 Run Menu (Run Settings - Column A) .................................................................. 64 Run Menu (Run Settings - Machine) ..................................................................... 66 Run Menu (Run Settings - Controls) ..................................................................... 67 Run Menu (Run Settings - Controls - Gas Gage) ................................................. 68 Run Menu (Run Settings - Controls - Oversize Bore) ........................................... 69 Run Menu (Run Settings - Controls - Multipass Honing Setup) ............................ 70 Run Menu (Run Settings - Controls – Column A Bore Profile 1) .......................... 72 Run Menu (Run Settings - Controls – Column A Load Graph 1) .......................... 73 Run Menu (Run Settings - Controls – Debug Setup) ............................................ 74 Run Menu (Run Settings – Adjustment Page - Column A) ................................... 75 Run Menu (Run Settings - Handwheel) ................................................................ 77 Run Menu (Run Settings - Cleanup Cycle Settings) ............................................. 78 Run Menu (Geometry Adjustment – Column A) ................................................... 79 Run Menu (Geometry Adjustment – Column A Settings) ..................................... 80 Run Menu (2-Stage Settings) ............................................................................... 81 Run Menu (Step & Repeat Movement) ................................................................. 82 Run Menu (Check Parts) ...................................................................................... 83 Diagnostic Menu (Main Diagnostic Menu Screen) ................................................ 84 Diagnostic Menu (Faults & Warnings History) ...................................................... 85 Diagnostic Menu (Machine Diagnostics - Machine I/O) ........................................ 86 Diagnostic Menu (Machine Diagnostics - Lube System) ...................................... 87 Diagnostic Menu (Machine Diagnostics - Spindle Breakin) .................................. 88 Diagnostic Menu (Machine Diagnostics - Index Table) ......................................... 89 Diagnostic Menu (Machine Diagnostics – Fixture I/O) .......................................... 90 Diagnostic Menu (Column A Diagnostics - Spindle) ............................................. 91 Diagnostic Menu (Column A Diagnostics - Feed) ................................................. 92

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TABLE OF CONTENTS (cont’d)

PAGE

Diagnostic Menu (Column A Diagnostics - Stroker) ............................................. 93 Diagnostic Menu (Column A Diagnostics - Column Motion) ................................ 95 Diagnostic Menu (Column A Diagnostics - Column I/O) ...................................... 96 Diagnostic Menu (Automation Diagnostics - Automation I/O) .............................. 97 Diagnostic Menu (Gage Automation – Gage a) ................................................... 98 Diagnostic Menu (Gage Automation – Gage I/O) ................................................ 99 System Settings (System Settings - Settings) .................................................... 100 System Settings (System Settings - Rates) ....................................................... 101 System Settings (System Settings - Index Settings) .......................................... 102 System Settings (System Settings - Machine Settings) ..................................... 103 System Settings (System Settings - Gage Settings) .......................................... 104 System Settings (System Settings - Gage a Limits) .......................................... 105 System Settings (System Settings - Machine Limits) ......................................... 106 System Settings (System Settings - Column A Limits) ...................................... 107 Utilities Menu (Main Utilities Menu Screen) ....................................................... 108 Utilities Menu (Select Tool Operation) ............................................................... 109 Utilities Menu (Edit Tool Parameters) ................................................................ 110 Utilities Menu (Backup/Restore) ......................................................................... 111 Utilities Menu (Select Adapter Operation) .......................................................... 112 Utilities Menu (Select Adapter Parameters) ....................................................... 113 Utilities Menu (Tool Part Count) ......................................................................... 114

NOTE: This manual combines the standard SV200, SV300, SV500 & SV1000 Series Machine Screens. Screens for different machine configurations will be slightly different.

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NOTES

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INITIALIZATION SCREEN (Waiting for Power ON) This is the first screen seen after the machine is powered up and logged into Windows.

Pressing Power On Button will start the initialization process of all the motor drives.

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INITIALIZATION SCREEN (Waiting for Palm Buttons or Cycle Start) Pressing the Cycle Start Button (SV200/300) or Palm Buttons (SV500/1000/1010) will complete the initialization process.

During the initialization process all the machine motor drives are verified.

CAUTION: It is important that machine be in a safe state before proceeding.

IF POWER WAS SHUT DOWN DUE TO AN EMERGENCY STOP DURING HONING: Honing tool(s) may still be tight in workpiece bores. If so, it is essential that tools be retracted first. Also, if any tool is stuck in its workpiece, workpiece must be freed from its fixture or tool must be uncoupled from spindle before sending carriage to home position.

Function Keys F5 – Go To Diagnostics Menu: Entering this mode allows actuation of individual machine functions for diagnosing machine problems or for other special circumstances. (Go to Page 84.)

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MAIN MENU This screen presents options; to enter a new setup, go directly to run menu, go to diagnostic menu, system settings, or utilities menu. Sequence to Retrieve a Setup F1: Setup Menu F3: Retrieve Setup Sequence to Creative a Setup Press F1, Setup Menu. (Go to Page 4.)

Function Keys F1 – Setup Menu: For entering, editing, saving, or retrieving setups. (Go to Page 4.) F2 – Run Menu: To hone workpiece bore in a production mode. This will show as depressed (unavailable) if no setup has been entered. (Go to Page 63.) F3 – Diagnostic Menu: Entering this mode allows actuation of individual machine functions for diagnosing machine problems or for other special circumstances. (Go to Page 84.) F4 – System Settings: To enter / alter special machine functions. (Go to Page 100.) F5 – Utilities Menu: Entering this mode allows adding or editing tool and backing up or restoring a setup. (Go to Page 108.) F10 – Safe Shutdown: This puts the machine computer in a safe state so that the machine disconnect can be turned off. For rotary feed machines this also allows current feed position to be saved. Then when powered back up there is no need to re-snug. NOTE: The machine computer can be damaged if the computer is not put in a safe state before the machine disconnect is turned off.

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SETUP MENU This screen presents options to enter a new setup or retrieving a saved setup. From this screen you can also change stored information regarding workpiece specifications and column setup. Press F2, New Setup. (Go to Page 5.)

Function Keys F1 – Main Menu: Return to Main Menu Screen. (Go to Page 3.) F2 – New Setup: Begin a new setup. (Go to Page 5.) F3 – Retrieve Setup: Retrieve a previous saved setup. (F3) F4 – Part Specifications: Go directly to Part Specification to edit present setup. (Go to Page 5.) F5 – Column A Setup: Go directly to column to edit present setup. (Go to Page 59.) F10 – Run Menu: Go directly to Run Menu. Begin honing operation of currently loaded setup. (Go to Page 63.) INSERT – The insert depicts the change of the F4 button for machines with base items installed. These include index table, fixture airlines and fixture interlocks. And on multi-column machines the column diameters. Also shown are the automation and gage setup buttons. These buttons are displayed if they are installed on the machine. F4 – Base Setup: Go directly to Base Setup to edit present setup. (Go to Page 58.) F9 – Automation Setup: Go directly to Automation Setup to edit present setup. (Go to Page 62.) F14 – Gage Setup: Go directly to Gage Setup to edit present setup. (Go to Page 61.)

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SETUP MENU (Part Specification) This screen presents options for entering a new setup. This information will be found on workpiece blueprint or by measuring workpieces. You cannot proceed to next step until all these parameters have been entered.

Step-by-Step: This procedure is used to take you through this part of process step by step. It is important to read and follow all instructions that are displayed on screen. Instructions are displayed on right side of screen. The steps you have already completed are shown in green.

Start Diameter – Workpiece bores created by some other manufacturing process, before they arrive at SV, can produce a variation in bore size. It is important to enter smallest diameter that you expect to encounter during entire production run not just starting diameter of set up workpiece.

Final Diameter – Desired diameter for finished bore.

Bore Length – When entering bore length, be sure to exclude length of any countersinks or counterbores. For tandem bores the bore length will include the open area between bores.

Material – If material you are honing is not on selection list, select a material that is close in to it in machinability. It may also be wise to initially reduce any feed rates that SV recommends until process can be tested.

Hardness – Choose from a table a value 1 through 6 that most accurately represents hardness of workpieces to be honed. If unsure of exact hardness, it is always safer to enter a higher hardness number.

Blind Bore Relief (Blind Bores ONLY) – Length (Depth) of relief in a blind bore.

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Front Bore Length (Tandem Bores ONLY) – Length of honed area at front (top) of bore.

Rear Bore Length (Tandem Bores ONLY) – Length of honed area at Rear (bottom) of bore.

Special Bore Types (Blind or Tandem Bores) – Select either or both only if the part has these features.

Enter START DIAMETER and press NEXT to go to next screen. (System will walk you through the complete setup procedure.) Pressing BACK again will return you to Setup Menu. (Go to Page 4.) Pressing NEXT will ask you to press OK and enter the Final Diameter. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.)

NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5).

Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Diameters) Only available for multi-column machines. This page allows for setup of the amount of material honed by each column. The machine can be setup to hone sequentially from one column to the next. Or have all columns hone the same amount. Other variations are possible as well.

Range Selection Entire Amount – Column will hone the entire amount entered in the part specifications page.

Beginning/Intermediate/Ending – The part specifications amount will be divided between the columns.

Manual – Allows for a custom range independent of amount entered in part specifications.

Final Diameter – Allows changing the amount of material each column hones from part.

Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Index Table) Only on machines equipped with an index table.

Number Of Indexes – Allows for changing the number of index positions. For instance it might be desired to index between only 2 positions on a 4 position table. NOTE: The number of table positions is entered in System Settings page (Go to Page 102).

Index Rate – The speed the index table indexes at.

First Index – In the example of 2 index positions on a 4 position table, enter table position for one of the 2 desired index positions.

Manual Position Setup – Allows for non-equally spaced table positions, see insert.

Table Position Part Status – Allows for setting the part status at each active table position.

NOTE: When set to Bad, Unknown, No Part or Faulty Fixture spindle column will not hone at that table position.

At Index – Indicates when the table is at a valid index position.

Index To All Positions – Allows table to index to all table positions not just the number of index positions.

Direction – Allows changing the direction of rotation for the index table.

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INSERT – The insert depicts the manual table position entry dialog.

The manual table position feature allows manual entry of up to 12 table positions.

NOTE: Entering improper positions may cause some machine stations to be inaccessible.

Enable Manual Table Positions – Used to enable the manual table position feature.

Number Of Table Positions – Enter the number of desired table positions (2-12).

NOTE: The number of table positions, in system settings, and the number of indexes are not used for this feature.

Angle – Press the desired table position angle to edit the value.


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SETUP MENU (Airlines, Fixtures) Only available for machines with fixture I/O. Station Position Control – Enables feature that allows setting airlines to have different states depending on machine station. NOTE: A machine station is a location on the machine base where spindle columns, gage columns, etc. is located. Airlines Per Fixture – The number of airlines used per index table fixture. NOTE: Any airlines that are not used for fixtures are called “Discrete” airlines. Air Line Settings – Use these tabs to set the desired airline states for discrete airlines as well as fixture airlines depending on station position. NOTE: To test an airline press the “Airline #” button for the desired airline. Press once to toggle on then again to toggle off. Edit Headings – Depress this button to change the action of the “Airline #” button. Now the button will allow changing the “Airline #” text. For instance Airline 1 could be changed to “Clamping” and “Airline 2” could be changed to “Centering”. INSERT – The insert depicts the fixture airline layout tab. NOTE: The layout tab displays how the airlines need to be connected to the fixtures for the station position control feature to work properly. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys – Inactive

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SETUP MENU (Interlocks, Fixtures) Only available for machines with fixture I/O. Interlock Settings – If required, for fixturing, set the desired type of interlock action and set the value by pressing the “Interlock X” heading. Disabled – The interlock is not needed and will not be used. Before Indexing – The interlock will monitor the input for the specified time out, once the cycle has been initiated. If the input has not become active before the specified time out an error will be generated and the cycle will be aborted. Before Honing – This option is the same as “Before Indexing” except the time out period is not started until after the table has been indexed into position. Percent of Cycle – The interlock will monitor the input for the specified percent of cycle. If the input has not become active before the specified percent of cycle an error will be generated and the cycle will be aborted. Torque Pin Detection – option is the same as “Percent of Cycle” except the machine cycle is not started until after successful torque pin detection. During torque pin detection the tool is moved into the part and the spindle is rotated slowly while the tool is expanded. The percent of cycle is the percent of total honing feed travel. NOTE: When using interlocks the machine cycle is started and will proceed until either the cycle has completed or an interlock error has occurred. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys – Inactive

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SETUP MENU (Column A Tool Selection) Select Tool Adapter from List. Select Tool Family from List.

INSERT – The insert depicts selection of number of stones for P mandrel tool.

Then select a tool from Bottom Left List. And if applicable select Grit Size from Bottom Right List.

Abrasive Length – Overall length of abrasive.

Tool Protection Force (Rotary Feed) – Percentage of maximum allowed tool force from 5 to 100%.

Tool Protection Force (Linear Feed) – The force in pounds that the system will generate a fault if exceeded.

Number of Stones – This is used to change the number of stones loaded in a selection P mandrel type tool.

2-Stage Settings – Only available when a tool equipped with a 2-stage hone head is available for use. (Go to Page 14.)

Manual Stroker Setup – Enable this feature to allow for manual setup for top and bottom of stroke for honing.

NOTE: Caution should be used when enabling manual stroker setup. All stroker limits are removed. Improper use can cause extreme damage to part, tooling and/or machine.

NOTE: The following buttons are not available until a setup has been completed.

Install Tool – Press this button to install a new tool into the machine.

Snug Tool – Press this button to re-snug the current tool in the machine.

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Align Tool – Press this button to re-align the current tool in the machine, if required.


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SETUP MENU (Column A Tool Selection – 2-Stage Setup) 2-Stage Tools – Only available when a tool equipped with a two stage hone head is available for use.

User will be asked to select the type of hone head and honing cycle.

Hone Head: Stone-Brush – Hone head equipped with a set of stones and a set of brushes. Stone-Stone – Hone head equipped with two grades of stones.

Honing Cycle: Roughing Only – Hone using only the roughing stage. Finishing Only – Hone using only the finishing stage. Roughing-Finishing – Hone using both stages, roughing then finishing.

NOTE: When a Two-Stage hone head is used, regardless of honing cycle setting, both stages MUST be setup. This requires entering parameters for roughing stage by pressing the Roughing Button on the top of each setup page. And entering finishing stage parameters by pressing the Finishing Button on the top of each setup page.

Press OK will return you to previous screen. Pressing CANCEL will return you to previous screen.


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SETUP MENU (Column A Honing Parameters) The Honing Parameters are calculated by the information you have inputted into the system during setup.

INSERT – The insert depicts screen for two-stage applications.

Select any of the items to change. Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.)

NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 54).

Spindle Speed – The SV recommends a spindle speed based on diameter. This can be edited. However for safety, there is an upper limit based on diameter. Speed can also be reduced, but a common mistake is to slow spindle down for “safety” without changing any other parameter. When spindle is slowed and feed rate is unchanged torque load on tool increases and actually makes a crash of tool or fixture more likely. If spindle is slowed significantly, feed rate should be reduced by same percentage. Stroke Length – The SV program calculates stroke length for application based on bore length and abrasive length from a previous screen. In general, this value should only be changed to correct a honing problem such as bellmouth or barrel shaped bores. In some applications it may be necessary to change stroker length from value calculated. Stroke Speed – Stroke speed is calculated by the SV based on stroke length. This can be edited to a slightly faster value, but the SV limits this to protect internal stroker mechanism. Stroke speed can be slowed, but there is usually an increase in spindle load when stroker is slowed down. Spindle Load Limit – The SV calculates a safe spindle torque limit based on tool selected for operation. 100% rating is 100% of this tool limit, not 100% of spindle motor torque available. This value can be reduced to further safeguard tools and fixtures from

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damage due to high torque. However, by their nature, Krossgrinding® Tools require increasing more torque as they wear. Therefore, reducing spindle torque limit will effectively reduce tool life at feed rate selected. Therefore, 100% setting is recommended except where long running applications have demonstrated a history of tools or fixtures failing before Spindle Load Limit function can warn operator of a worn tool. (NOTE: Spindle Load Limit cannot protect tools, especially small tools, from significant, abrupt increases in torque. For example if a tool rapidly feeds into a bore that is significantly undersized, the SV system cannot stop spindle quickly enough to save tool. Spindle load display and limit function is primarily useful as an indicator of tool wear which gradually increases torque over time. Stroker Load Limit – The limit is set to default value. This value is associated with the pre and post hone position rates. This value can be set to protect tooling and fixturing, when the tool enters and exits the bore. Honing Options – Selecting one of the Honing Options will active one or more of the Inactive Honing Parameters Tabs at bottom left of list. Pre-Hone Position Rate – In some applications the operator may want to either increase or decrease the rate at which the stroker carriage moves. This option controls the speed of the carriage as it moves from the loading position to the honing position. Pre-Hone Spindle Rotation – Selecting Pre-Hone Spindle Rotation actives Pre-Hone Spindle Speed. Pre-Hone Spindle Speed – In some applications it may be useful if the tool is rotating at a very slow RPM as it enters the workpiece bore. This allows you to edit speed of rotation within range from 20 to 100 RPM. Post-Hone Position Rate – In some applications the operator may want to either increase or decrease the rate at which the stroker carriage moves. This option controls the speed of the carriage as it moves from the honing position to the unloading position. Post-Hone Spindle Rotation – Selecting Post-Hone Spindle Rotation actives Post-Hone Spindle Speed. Post-Hone Spindle Speed – In some applications it may be useful if the tool is rotating at a very slow RPM as it withdraws from the workpiece bore. This allows you to edit speed of rotation within range from 20 to 100 RPM. Low Torque Sensitivity – In applications with very light tool load the rapid until load feature does not work well. Select this option to set the load range lower, so the load sensitivity is increased, to help make rapid until load work properly. This feature is not suitable for applications with spindle loads above 40%. Manual Stroker Setup – Enable is feature to allow for manual setup for top and bottom of stroke for honing. NOTE: Caution should be used when enabling manual stroker setup. All stroker limits are removed. Improper use can cause extreme damage to part, tooling and/or machine. Offset Stroke – This feature is only available for blind bore parts. Normally when the stroke position (center of stroke) is set the tool abrasive is stroked equally above and below the center of the part. Sometimes, in blind bore parts, it is desired to have the center of stroke to be offset from the center of the part. That way the bottom of stroke could be with the abrasive at the bottom of the part but the top of stroke could be with half the abrasive out of the part. Simply put this option allows for much wider stroke lengths and stroke adjustments.

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Select HONING OPTION. Then select tab, key in information and press OK to go to return to this screen. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Pre Honing Feed Parameters) The Pre-Honing Feed Parameters are calculated by the information you have inputted into the system during setup.


Select any of the items to change. Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.)

NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5.) Retract Amount – This is the Tool Load Clearance. Between cycles tool will retract to a diameter that is smaller than start diameter by amount of this clearance. Default is 0.05 mm (.002 in). More clearance will reduce possibility of tool not entering workpiece bore and damaging tool or fixture. Rapid Feed Rate - This is rate at which the tool expands at beginning of a cycle from retracted diameter to diameter at which honing will begin. Decreasing this rate will reduce possibility of a serious failure if an undersized hole should reach this tool. However, cycle time will be longer. Accepting default maximum rapid rate will keep cycle time to a minimum but it increases chance for a major failure if an undersized workpiece reaches tool. However, other measures may be taken to reduce chance of such a failure, see Amount Before Start. Preload Amount - This setting will allow the tool to partially expand prior to starting the spindle. This is the amount that the tool will expand prior to starting the spindle. It has been found generally with the smaller CGT tools, that when the tool is retracted, the tip of the tool tends to drop. When it starts to expand, the tool rises back to its running position. If the spindle starts to rotate and the tip of the tool has dropped, it will have quite a bit of runout. Running a tool in this way, particularly the smaller tools may cause tool damage.

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Amount Before Start - In theory it should be possible to rapidly feed a tool right up to “start” diameter for workpiece at that station. However, in practice, this can cause problems. For example, if operation in question is preceded by a previous operation, there is likely to be some tool wear in previous operation. Until this wear is detected and tool size compensated, previous tool will create progressively smaller bores (slightly). At next operation, a tool that is fed at rapid feed rate up to theoretical start diameter will expand into slightly undersized bore at full speed. A tool failure or at least a torque impact, which is detrimental to tool, is likely. By setting some Amount Before Start, rapid feed will cease at this position prior to start and much slower honing feed rate will begin. The proper amount varies with application. If previous operation is a process controlled directly by feedback from an air gage, then Amount Before Start can be very small or even zero. But if previous process is monitored by infrequent manual checks from operator, then Amount Before Start should be at least amount that you expect prior tool to wear before it is measured and compensated. Conditioning Amount – The amount of material to take out before the normal honing cycle begins. Conditioning Rate – The rate to take the material out before the normal honing cycle begins. Auto Bore Detection Force (ABD) – (Linear Feed) The feed force at which the bore is detected. This is used at beginning of cycle and automatic bore snugging. ABD Upper Offset Position – Only available for Multiple ABD. The top most position in the bore for ABD to be performed. This value is relative to the center of bore. ABD Offset Position – Available for both ABD and Multiple ABD. The middle position in the bore for ABD to be performed. This value is relative to the center of bore. ABD Lower Offset Position – Only available for Multiple ABD. The bottom most position in the bore for ABD to be performed. This value is relative to the center of bore. Feed Options – Selecting one of the Feed Options will active one or more of the Inactive Honing Parameters Buttons. Bore Conditioning – This feature allows for correcting slight geometry issues before honing. It will take out the specified amount of material at the specified rate before the normal honing cycle begins. Rapid Until Load - This option is available when selected. This allows the tool to feed up until it sees a certain amount of load instead of a rapid advancing to a particular position. This function cannot be used with Automatic Bore Detection. Auto Bore Detection – (Linear Feed) This feature runs the feed out until the bore is detected. Then the feed is slightly retracted and the normal honing cycle starts. Multiple ABD Detection – (Linear Feed) This feature is the same as ABD except rather than detecting the bore at 1 location the bore is detected at 3 locations (top, middle, and bottom). This is helpful on tapered parts when the taper can change location from part to part. Honing Info – This information is calculated by the information you have inputted into the system during setup. Select FEED OPTION. Then select button, key in information and press OK to return to previous screen. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Honing Feed Parameters) The Honing Feed Parameters are calculated by the information you have inputted into the system during setup.


Select any of the items to change. Honing Feed Rate [ ] - Only one Honing Feed Rate is required. The SV calculates a single recommended honing feed rate based on workpiece parameters entered during setup. This can be edited, but any increase in feed rate should be tried in small increments under careful observation to avoid any tool or fixture damage. In some applications there may be a benefit to initially feeding faster or slower than rest of cycle. There may also be a benefit to feeding faster or slower toward end of honing cycle. For this reason the SV provides option to use two additional feed rates. Feed rates are numbered 1, 2, and 3. If more than one is used, they will occur in that order during honing. Clicking appropriate check box activates additional feed rates. NOTE: After activating step 2 or 3 you will then have to input a starting diameter and a rate for additional feed rates selected. Step [ ] Stop Diameter – If you have activated Step 2 or 3 then you will have to input diameter at which this feed rates ends. Default values that show for stop diameter are merely a guess by the SV program and should not be taken as “recommended” values.

Feed Options – Selecting one of the Feed Options will active step 2 and/or step 3 of the Inactive Honing Parameters Tabs at bottom left of list.

Spindle Reverse – Allows you to select direction of spindle rotation during each feed rate.

Honing Info – This information is calculated by the information you have inputted into the system during setup.

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Cycle Time - At bottom of this screen is an estimate of honing cycle time. If you are making a new set up and have not yet been in all of the Feed Parameters screen, cycle time shown here is based on some recommended feed rate. It is displayed on this screen because some of parameters on this screen also have an effect on cycle time. As you edit these parameters, you can see how estimated cycle time changes. This can help you to optimize cycle time as well as honing performance. NOTE: Cycle time shown is an estimate for honing cycle. Actual part to part cycle time depends on loading and unloading time which usually depends on several factors that cannot be controlled by machine. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Honing Feed Parameters – Spindle Reversal) Feed Options – Selecting spindle reverse will active Spindle Direction Button.

Spindle Reverse – Allows you to select direction of spindle rotation during each feed rate.

Selecting Spindle Reversal under Feed Options and than pressing Spindle Direction Button will open the following screen.

WARNING: Misuse of this feature could damage tooling, fixturing, and/or machine system.

Select direction of rotation and press OK. Then press NEXT to go to next screen. Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.)

CAUTION: Feed Rate is outside of range.


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SETUP MENU (Column A Post Honing Feed Parameters) The Post Honing Feed Parameters are calculated by the information you have inputted into the system during setup.

INSERT – The insert depicts screen for two-stage applications. Sizing Amount - “Sizing” process is feeding honing tool very slowly for a very small amount of stock removal right up to final size at end of honing cycle. This has been shown to improve bore size repeatability, bore geometry, and to a small degree, surface finish. But there is a slight penalty of longer cycle time. Sizing Feed Rate - Typically the Sizing feed rate will be much slower than Feed rates 1, 2, and 3. However, the available range for the Sizing feed rate is the same as that for Feed rates 1, 2, and 3. Sparkout Time - Sparkout is allowing honing tool to rotate and stroke in workpiece bore for a period of time after feeding stops. Beneficial effects are similar to Sizing process (see Sizing). Whether sparkout should be used instead of sizing and, if so, amount of sparkout should be determined experimentally. Default value of 2 seconds is usually a good starting point. As with sizing, there will be a longer cycle time when sparkout is used. Backlash Amount – The feed system has almost negligible amount of backlash. However, some of the tooling couplings have a large amount of backlash. Use this variable to ensure the tooling is retracted enough to compensate for this. NOTE: Backlash can be entered either as diametrical tool expansion or as linear feed travel. Choose the entry method you prefer. Tool Withdraw – Under normal operation, at the end of a cycle, the spindle and stroker come to a complete stop at the same time the feed reaches the retract diameter. With super fine stones this can cause cosmetic scuff marks in the bore. With this feature enabled, at the end of a cycle, the feed is retracted the withdraw amount. Then the stroker and spindle are stopped and then the feed is sent to the retract diameter.

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Select FEED OPTIONS.

Feed Options – Selecting one of the Feed Options will active one or more of the Inactive Honing Parameters Tabs at bottom left of list.

Honing Info – This information is calculated by the information you have inputted into the system during setup.

Cycle Time - At bottom of this screen is an estimate of honing cycle time. If you are making a new set up and have not yet been in Feed Parameters screen, cycle time shown here is based on some recommended feed rate. It is displayed on this screen because some of parameters on this screen also have an effect on cycle time. As you edit these parameters, you can see how estimated cycle time changes. This can help you to optimize cycle time as well as honing performance. NOTE: Cycle time shown is an estimate for honing cycle. Actual part to part cycle time depends on loading and unloading time which usually depends on several factors that cannot be controlled by machine. Crosshatch Angle - Crosshatch angle shown is a value calculated from spindle and stroke speed. For most applications crosshatch angle is unimportant and default should be accepted. If an application requires a certain crosshatch in finished bore, then this can be accomplished two ways. First is to alter spindle speed or stroke rate in this screen until desired crosshatch value is displayed. However, changing spindle speed or stroke rate for entire honing cycle can adversely affect honing performance. Since crosshatch angle that will be permanent is really only generated in last brief moments of honing cycle, a special crosshatch is more efficiently produced during a sizing or sparkout process on last operation. This can be set directly to desire value after activating sizing or sparkout options.

Crosshatch Options: Default – Use the crosshatch achieved from the honing spindle and stroke speeds. Simple – Use the entered crosshatch. Crosshatch angle is achieved by increasing or decreasing the spindle speed to generate the desired crosshatch. Constant – Use the entered crosshatch. Crosshatch angle is achieved by adjusting the spindle speed profile to match the stroke profile to generate a constant crosshatch through out the bore. Crosshatch Angle – Enter the desired crosshatch angle.

Select any of the items to active:

Sizing – Selecting sizing allows you to set Sizing Amount and Feed Rate; it also actives Crosshatch Options.

Sparkout – Selecting sparkout allows you to set Sparkout Time; it also actives Crosshatch Options.

Spindle Reverse – Selecting spindle reverse will active Spindle Direction Button.


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SETUP MENU (Zero Shutoff Parameters) Only available if option is installed on machine.

INSERT - Shows the options available for air gage zero shutoff.

Disabled – For this setup you do not want to use a zero shutoff device.

Plug Gage – This selection is available only if installed. For this setup you want to use the size plug as the zero shutoff device.

Air Gage – This selection is available only if installed. For this setup you want to use the integrated air gage as the zero shutoff device.

Start Probing Cycle Time – Enter how long you want the cycle to run before the size plug starts being stroked into the part.

Maximum Elevator In Position Delay – The machine knows the state of the size plug elevator, up or down. If the mechanism for the elevator gets sticky it may not go down into place. Enter the amount of time before the machine faults because the elevator is not in the down position.

Maximum Cycle Time Fault – Enter the maximum allowed cycle time. Once the cycle time has exceeded this value a machine fault will occur. Use this to safeguard from greatly over sizing a part do to an alignment issue with the size plug.

Minimum Consecutive At Size Strokes – Enter the number of times the size plug must drop into the part, before the part is considered to be at size.

Extra Strokes After Part At Size – Enter the number of desired extra strokes, after it is determined the part is at size. This is used to compensate for size plug wear.

Enable Size Plug Saver – This option is used if a size plug elevator is installed. It enables the size plug from being stroked into the part for the entered time. For long cycles this can greatly reduce size plug wear.

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Turn Off Air Between Cycles – Turns off air to the Air Gage when the machine is not running cycles. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Air Lines Setup) Only available on Machines equipped with column I/O. Actuation of some fixturing or automation components must be synchronized with certain machine operations. This screen allows you to “program” timing of four solenoid valves. On the left is a list of machine operations that cover the entire honing cycle. To change the state of an airline at any operation, use the arrow keys to highlight the entry and then press the ENTER key.

When programming these airlines, if you are unsure which fixture motions are controller by a specific airline or if you want to be sure that the airlines are attached correctly, you can test each valve. As you press "Test Air Line" to change states, the machine will actuate the valve accordingly.

Load Position - This period starts when all tools have withdrawn from their workpiece bores and returned to index position. This is end of honing cycle. This period ends when next honing cycle is started by touching cycle start button (or by automation signal). State of airlines shown here will be their states before honing has started or when honing process is stopped.

Load Position +0.5 Sec. – Same as Load Position.

While Indexing - This period starts when honing cycle is started by touching cycle start buttons (or by automation signal). This period ends when index table (or other part transfer mechanism) has completed its move.

Moving To Honing - This period starts when index table (or other part transfer mechanism) has completed it move and tools begin to move down into workpieces. This period ends when all tools are in workpiece bores.

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Honing Part - This period starts when spindles begin to turn and honing begins. This period ends when honing stops (spindles stop).

Honing Complete - This period starts when honing has stopped (spindles stop.). This period ends when tools begin to withdraw from workpiece bores.

Unload Position – This period starts when tool have withdrawn from the workpiece bore and returned to unload position.

Unload Position +0.5 Sec. – Same as Unload Position.

Test Airline - This is not a portion of honing cycle. This is used only in this screen to test actuation of airlines. When you press Test, airline states will actually switch on the machine. This is used to be sure that airlines are connected correctly or to determine which airline is responsible for each motion. NOTE: Do not press enter here if fixtures are in a state where they would be harmed by actuating airlines.

Select condition and fixture airlines then press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Fixture Interlock Setup) Only available on Machines equipped with column I/O. For some fixturing certain actions need to happen before the machine honing cycle can run safely. These may include verifying a gate is closed or a part torque pin has dropped in place. The machine is supplied with 4 independent inputs to monitor desired actions. Each interlock can be set to any one of four possible modes, Disabled, Continuous, Percent of Cycle, or Torque Pin Detection. Disabled – The interlock is not needed and will not be used. Continuous – The interlock will monitor the input for the specified time out. If the input has not become active before the specified time out an error will be generated and the cycle will be aborted. When using this option the machine cycle is started and will proceed until either the cycle has completed or an interlock error has occurred. Percent of Cycle – The interlock will monitor the input for the specified percent of cycle. If the input has not become active before the specified percent of cycle an error will be generated and the cycle will be aborted. When using this option the machine cycle is started and will proceed until either the cycle has completed or an interlock error has occurred.

Torque Pin Detection – The interlock will monitor the input for the specified percent of cycle. If the input has not become active before the specified percent of cycle an error will be generated and the cycle will be aborted. When using this option the machine cycle is not started until after successful torque pin detection. During torque pin detection the part is moved on the tool and the spindle is rotated slowly while the tool is expanded. The percent of cycle is the percent of total honing feed travel

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Select options then press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Tool Options) To install a tool and an adapter, if required, follow the steps in the subsequent pages. This page allows selecting the desired options for tool installation.

Install New Tool – Select this option to either install a new tool or a different tool from the last tool used in this setup. Install Last Tool Used – Select this option if you have the same tool that was used in this setup the last time the setup was run and the tool has not been used since the last time this setup was run. Teach Tool Size (Snug) – With this option the machine will be taught physical diameter. And then will be able to hone to a size. Non-Sizeloc Mode – With this option the machine is in a relative mode. Only being able to take out an amount of material. Align Tool – For some adapter and tool combinations it can be possible to align the tool but not required. If that is the case, chose this to go ahead and align the tool. Do Not Align – If you do not want to align the tool and it is not required, make this choice. INSERT – Displays the feed system condition choice for machines with rotary feed. Feed System Has Moved – Between the time that the machine was powered down and now that it has been powered up again the feed system has been moved. When this option is selected you will be taken to the snug page before you are allowed to run cycles. Feed System Has Not Moved – Between the time that the machine was powered down and now that it has been powered up again the feed system has not been moved. When this option is selected you are not required to snug before running cycles.

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SETUP MENU (Column A Tool Preparation) Follow the instructions on the screen to prepare the machine for tool removal/installation.

NOTE: On linear feed machines pressing the Next button may cause the feed system to move automatically. Make sure to follow the instructions about removing bolted on adapter caps or loosening screwed on adapter caps. Failure to do this can result in damage to the tool, adapter and machine.


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SETUP MENU (Column A Remove Tool) Follow the instructions on the screen to remove the tool from the machine.

INSERT – The page that is displayed, while the feed system is moving to the tool removal position, prior to the above page.

NOTE: This page will only be displayed if the tool in the machine is different than the tool in the setup.


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SETUP MENU (Column A Remove Adapter) Follow the instructions on the screen to remove the adapter from the machine.

INSERT – The page that is displayed, while the feed system is moving to the adapter removal position, prior to the above page.

NOTE: This page will only be displayed if the adapter in the machine is different than the adapter in the setup.


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SETUP MENU (Column A Install Adapter) Follow the instructions on the screen to install the adapter in the machine.

INSERT – The page that is displayed, while the feed system is moving to the adapter install position, prior to the above page.

NOTE: This page will only be displayed if the adapter in the machine is different than the adapter in the setup.


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SETUP MENU (Column A Install Tool) Follow the instructions on the screen to install the tool in the machine.

INSERT – The page that is displayed, while the feed system is moving to the tool install position, prior to the above page.

NOTE: This page will only be displayed if the tool in the machine is different than the tool in the setup.


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SETUP MENU (Column A Snug Tool) Snug Diameter – The feed system needs a reference point from which it will determine encoder positions that correspond to critical diameters. The process of setting this reference point is called “Snugging” because you will expand tool inside a workpiece until the workpiece is “snug” on tool. You will first tell the machine the exact diameter of workpiece that you will use for this process (Snugging Part Size). Any diameter within range of tool will work but for best results, use a workpiece that is close to finish size for that operation.

Auto Bore Detection Force (ABD) – (Linear Feed Only) The feed force at which the bore is detected. This is used at the beginning of a cycle and for automatic snugging.

Manual – Select this option to manually teach the part size. You will need to expand the tool with the hand wheel until the workpiece is snug on the tool. It is a good practice to either slide the workpiece back and forth on the tool or giggle the tool while in the workpiece to assist in feeling when the workpiece is getting snug. As a safe rule of thumb, a workpiece is considered “snug” when the abrasive just starts to grab the part. However, there are exceptions to this rule. An “accurate” snugging feel will come with experience. However, accurate snugging is not a requirement because after the first workpiece is honed and measured an adjustment can be made to compensate for the snugging inaccuracy.

NOTE: Expanding the tool too tightly in the workpiece can cause damage to the tool.

Automatic – (Linear Feed Only) Select this option, if available, to have the machine automatically snug the part. You will need to use the hand wheel to move the tool’s abrasive to approximately the center of the bore. Then the machine will do the rest.

Teach – Press this button when either the workpiece is snug, for manual, or you want to initiate automatic snugging.

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Snug Status – Will display red when the tool has not been snugged, green when the tool has been snugged.

Sizeloc – Turn Sizeloc on to run the machine in absolute feed mode, turn it off to run the machine in relative feed mode.


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SETUP MENU (Column A Align Tool) This page will only be displayed if alignment is required or you have chosen to align the tool.

Tool Alignment (Expandable Tools) - Use following procedure: 1. Install a concentric alignment bushing on tool using same snugging process used to set tool diameter. Many standard sizes of alignment bushings are available from Sunnen. If you prefer you may use or make any bushing with I.D. concentric to OD and a length that is at least equivalent to 4 x I.D. NOTE: For best results use an alignment bushing with an I.D. that is inside range that tool will be honing. Using an I.D. that is close to final size for that operation will be best for very tight tolerance honing. NOTE: Do not snug too tightly or too loosely. On some tools, tool runout is altered by axial load of tool’s wedge. It will be best to adjust runout when tool’s wedge is loaded as it will be when honing. 2. Attach Sunnen runout indicator to spindle housing and adjust it so that indicator points will contact alignment bushing. For best results, spread points as far away from each other as possible. 3. Turn Runout Knob on indicator counterclockwise until it stops. Then turn knob clockwise one turn. 4. Loosen Indicator Clamp Knob and rotate indicator assembly on its post until Reference Gage Point comes in contact with tool arbor. Then tighten Clamp Knob. 5. Turn Runout Knob counterclockwise, toward conical symbol, until it stops. This brings reference point and indicating point in contact with arbor for measuring conical runout.

6. Rotate spindle by hand, taking note of location of highest reading.

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Align tool and press NEXT to go to next screen. Pressing BACK will return you to the Previous Screen. Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.)

NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5.)


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SETUP MENU (Column A Set Stroke) The first position that the machine must learn is the center of stroke position. This is accomplished by moving the carriage until the front of the abrasive is aligned to the front of the bore. It is important to read and follow instructions on screen for this step. By aligning the front of abrasive to front of bore, the machine calculates the center of stroke position. Loading Method:

Manual – The operator will move the column such that the tool is within the stroking range before each cycle is started. Auto Load – If Auto Load is selected the operator will be prompted to move the carriage to the position where the fixture will be loaded. This position is such that the tool will be out of the way from fixtures and workpieces indexing underneath.

Handwheel Mode: Positioning – This mode is used to move the stroker until the top of the abrasive is at top of workpiece. When finished press SET STROKE button. Check Stroke – This mode is used to move the stroker to the extents of the stroke length to verify stroking motion.

NOTE: The Top and Bottom of stroke MUST be checked before proceeding. Column Information:

Column Position – Current position of column. Set Stroke – Press this button when the top of the abrasive is at the top of stroke.

Position Adjustment – This is used to change the stroking position. A negative number will move the column upwards.

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Set Top Of Stroke – (Manual Stroker Setup Only) After the stroker has been moved to the desired top of stroke press this button to set the top of stroke.

Set Bottom Of Stroke – (Manual Stroker Setup Only) After the stroker has been moved to the desired bottom of stroke press this button to set the bottom of stroke.

Press SET STROKE, Key in information, then press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Set Load Position) This position is where the part to be honed will be loaded into the fixture. Follow the screen instructions on how to move the carriage.

Guide Pot: Floating Adapter ONLY. If a guide pot is installed on the machine select the “Installed” option. NOTE: When a Floating Adapter is used a Guide Pot is required for the machine to automatically move the tool into the part. Otherwise, the stroker will need to be manually moved. Enable Transition Position – Enabling this will allow setting another position between the load position and the center of stroke. This might be used, for instance, to move the stroker quickly down to the part and then have it slowly enter the part.

Press SET POSITION and then press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

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SETUP MENU (Column A Set Transition Position) This is a position between the load position and the center of stroke.

Set Position – Press this button when the stroker is at the desired location.

Position Rate – Enter the desired rate for this position. Just to clarify, this rate will be used when the stroker moves from this position to the center of stroke and then back to this position after the part is honed.


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SETUP MENU (Column A Single Stroke Honing® Parameters) This page will only be displayed if a single stroke tool was selected.

Top Of Bore – The stroker position where the tip of the tool abrasive is at the top of the part. This value can be manually entered or taught.

Load Position – The stroker position where the stroker is up and out of the way so parts can be loaded and unloaded.

Rapid Feed Rate – Stroker speed from the load position to the rapid stop position.

Rapid Stop Position – Stroker position between the load position and the top of bore where the stroker can be moved rapidly.

Feed Rate [ ] – The stroker speed during the move to feed [] stop position, or reverse position for the last move.

Spindle Speed [ ] – The spindle speed during the move to feed [] stop position, or reverse position for the last move.

Feed [ ] Stop Position – The stroker position associated with a particular stroke speed and spindle speed.

Reverse Position – The last stroker position associated a particular stroke speed and spindle speed, before the stroker starts moving back up.

INSERT – The insert depicts the buttons available when pecking is selected.

Forward Distance – Used for pecking, the forward movement of the pecking move.

Reverse Distance – Used for pecking, the reverse movement of the pecking move.

NOTE: You must have more forward movement than reverse movement so that the stroker will move down to the reversal point.

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Reverse Rate – Used for pecking, the stroker speed during the reverse movement.

2nd Honing Rate – Enables using the 2nd stroker rate.

Pecking – Enables using pecking. This movement moves the stroker forward and reverse during the stroker move.

Spindle Direction – Allow setting forward or reverse rotation of the spindle.

Manual – Allows manual entry of stroker positions.

Current Position – Allows stroker positions to be set at the current stroker position, used with hand wheel.


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SETUP MENU (Column A Single Stroke Honing® Return Parameters) This page will only be displayed if a single stroke tool was selected. Reverse Position – Bottom stroker position where stroker reverses and starts to move back up. Return Rate [ ] – The stroker speed during the move to return [ ] stop position, or spindle stop position for the last move. Spindle Speed [ ] – The spindle speed during the move to return [ ] stop position, or spindle stop position for the last move. Return [ ] Stop Position – The stroker position associated with a particular stroke speed and spindle speed. Rapid Return Rate – Stroker speed from the spindle stop position to the load position. Load Position – The stroker position where the stroker is up and out of the way so parts can be loaded and unloaded. 2nd Honing Rate – Enables using the 2nd stroker rate. Spindle Direction – Allow setting forward or reverse rotation of the spindle. Manual – Allows manual entry of stroker positions. Current Position – Allows stroker positions to be set at the current stroker position, used with hand wheel. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys – Inactive

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SETUP MENU (Column A Guide Pot) This page is displayed if the guide pot installed selection is made in the set load position page (Go to Page 44).

Guide Pot Diameter – Enter the guide pot diameter. If the guide is larger than the maximum range, just enter the maximum range. When the machine column is moved (left/right), and the tool is in the guide pot, the tool is set to this diameter. This keeps the drive shaft from flopping back and forth.

Guide Pot Retract Amount – This is the amount the tool is retracted, below the guide pot diameter, before the tool is moved in to and out of the guide pot.

Set Guide Pot Position – This is the up/down position of the stroker where the guide pot is just engaged with the stroker. Use the hand wheel to move the stroker to the desired position and press this button.

Guide Pot Carriage Rate – The rate at which the stroker moves when the guide pot is engaged and being moved with the stroker.

Tool Carriage Rate – This is the rate at which the stroker moves when the guide pot is not engaged and is not being moving with the stroker.


50

SETUP MENU (Column A Step & Repeat) Follows steps as shown on display screen.

Enable Step & Repeat – Enables Step & Repeat feature, which can automatically hone each bore without user intervention.

Bores Per Bank – Number of bores, per bank of a part. For example a V8 block would have 4 bores per bank.

Bore Spacing – The hole to hole spacing between bores.

Banks Per Part – Number of banks of a part. For example a V8 block would have 2 banks. Up to 5 banks are allowed.

Bank Offsets – Allow entry of the hole to hole offset between the first bore in bank 1 and the first bore in bank 2. This is the left to right distance, as viewed in the machine. A positive offset means that the first bore in bank 2 is offset to the right of the first bore in bank 1. The offset for banks 3, 4, and 5 is the same, based off of the first bore in bank 1.

Number Of Parts – Number of identical parts fixtured in the machine.

Part Spacing – The hole to hole distance from the first bore in part 1 to the first bore in part 2. This is the left right distance, as viewed in the machine.

Bore Positioning Rate – The rate at which the column servo moves the column from one bore to the next.

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Set Part Load Position – This is the left to right position of the column, where the column is out of the way and a part can be loaded into the machine. It is also the up / down position of the stroker, where the stroker is out of the way and a part can be loaded into the machine. Use the hand wheel to move the column to the desired position and press the button.

Set First Bore Position – This is the left to right position of the first bore to be honed. Use the hand wheel to move the column to the desired position and press the button.

Set Bank Switch Position – This is the up to down position of the stroker where the part can be rotated from bank to bank without hitting the stroker. Use the hand wheel to move the stroker to the desired position and press the button.

Single Step – Use this button to single step through the Step & Repeat process to verify all positions are set properly. The Step & Repeat setup is complete only after single stepping through completely.

Press SET POSITION and then press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

52

SETUP MENU (Gage a Position) This page will only be displayed if post-process gaging is installed on the machine.

Measurements Per Part – Enter the desired number of measurements per part.

Probe Airjet Offset – Enter the distance from the tip of the air probe to the airjet on the air probe.

Set Position – Use this button to set the position selected in the position list. The top of part and the top of bore must be set before any measurement positions can be set. The machine will default to set the measurement positions equally spaced from the top to the bottom of the bore.

Extend Master Bracket – Use this to lower the master bracket so that the master ring can be measured by the gage.

Gage Part – When the gage setup is complete press this button to run a measurement cycle on a part.

Zero Master – Press this button to zero/re-zero the master ring for the gage.

Manual Entry – Allows the measurement position to be entered when the set position button is pressed.

Current Position – When the set position button is pressed the measurement position is set to the current position.

Relative To Bore – Use this to display the measurement value relative to the top of bore rather than absolute.

53


54

SETUP MENU (Gage a Mastering) This page will only be displayed if in-process gaging is installed on the machine. Minimum/Maximum/Mean Ring Size – Enter the minimum, maximum and mean ring sizes. Zero Offset Amount – After the gage is calibrated and parts have been honed, if the honed part size is not exactly at the final diameter, enter a value here to adjust the it to be correct. Toggle Air – Press this button to toggle the air to the air gage on and off. Zero Master – Press this button to zero/re-zero the mean ring for the gage. Gage Part – When the gage setup is complete press this button to measure a part. Disabled – You are not currently in gage calibration mode. Master Selected Ring Size – Press this button to master the selected ring size, Minimum/Maximum/Mean. NOTE: For gage calibration follow the instructions on the screen, for best results. Press NEXT to go to next screen. (System will walk you through setup.) Pressing BACK will return you to previous screen. Pressing NEXT will ask you to press OK to go to next screen. Pressing CANCEL will return you to the Part Specification Screen. (Go to Page 5.) Pressing CANCEL again will return you to Setup Menu. (Go to Page 4.) NOTE: If you cancel you will have to manual select each specification, system will not walk you through it. See Part Specifications (Go to Page 5). Function Keys F1 – Previous Screen: Inactive

55

SETUP MENU (Automation Settings 1) This page(s) will only be displayed if automation is installed on the machine.

INSERT – Displays the automation single step page.

For automation setup instructions refer to the documentation specific to your machine.


56

SETUP MENU (Setup Complete) Setup Complete – When all the parameters have been entered; the Setup Complete screen will appear.

Press YES to go to next screen. Pressing NO will return you to the Part Specification Screen and make changes.

Function Keys – Inactive

57

SETUP MENU (Save As) Save Setup – In the Save As dialog, enter the file name for this setup and press Save. Key in file name and press Save when complete. (Go to Page 4.)


58

SETUP MENU (Base Setup) This screen allows you to change previously entered base settings. Not all pages may be present. You will only see those for the base items installed on your machine.

INSERT – Displays the Part Specification page. For machines without base devices only this page will be displayed when the F4 button is pressed.

Part – This screen allows you to edit part specifications. (Go to Page 5).

Index Table – This screen allows you to edit index table settings. (Go to Page 8).

Airlines – This screen allows you to edit the fixture airline settings. (Go to Page 10).

Interlocks – This screen allows you to edit the fixture interlock settings. (Go to Page 11).

Click on Tab to select. Then press APPLY to apply change. Then press OK to return to Setup Menu. (Go to Page 4.) Then press Cancel to return to Setup Menu. (Go to Page 4.)


59

SETUP MENU (Column A Setup Screen) This screen allows you to change previously entered column settings. Not all pages may be present. You will only see those pages corresponding to selections made in the Setup

Tool – This screen allows you to edit Tool Selection and settings. (Go to Page 12.)

Honing – This screen allows you to edit Honing Parameters. (Go to Page 15.)

Feed Prehone – This screen allows you to edit Pre Hone Feed Parameters. (Go to Page 18.) Feed Honing – This screen allows you to edit Honing Feed Parameters. (Go to Page 20.)

Feed Posthone – This screen allows you to edit Post Hone Feed Parameters. (Go to Page 23.)

Zero Shutoff – This screen allows you to edit Zero Shut-Off Parameters. (Go to Page 25.)

Air Lines Settings – This screen allows you to edit Air Lines settings. (Go to Page 27.)

Fixture Interlock Settings – This screen allows you to edit Interlock settings. (Go to Page 29.)

Stroke Position – This screen allows you to edit Stroke Position settings. (Go to Page 42.)

Load Position – This screen allows you to edit Load Position settings. (Go to Page 44.)

Transition Position – This screen allows you to edit the Transition Position settings. (Go to Page 45.)

Single Stroke Honing – This screen allow you to edit the Single Stroke Honing Parameters. (Go to Page 46.)

Single Stroke Return – This screen allow you to edit the Single Stroke Return Parameters. (Go to Page 48.)

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Guide Pot – This screen allows you to edit Guide Pot Parameters. (Go to Page 49.)

Step & Repeat – This screen allows you to edit Step & Repeat settings. (Go to Page 50.)



61

SETUP MENU (Gage Setup) This screen allows you to change previously entered gage settings. This screen is only available if post process gaging is installed.

Gage a Positions – This screen allows you to edit Gage Positions. (Go to Page 52.)

Index Table – This screen allows you to index the table so parts can be checked. (Go to Page 83.)

INSERT – Shows gage setup screen for in-process gaging.

Gage a Mastering – This screen allows you to edit the Gage Calibration. (Go to Page 54.)



62

AUTOMATION MENU (Automation Setup) This screen allows you to change previously entered automation settings. This screen is only available if automation is installed. For automation setup instructions refer to the documentation specific to your machine.



63

RUN MENU (Main Run Menu Screen) This screen allows you to start at honing cycle or edit machine settings.

Select one of the Functions Keys.

Function Keys F1 – Main Menu: Return to main menu. (Go to Page 3.) F2 – Run Settings: Edit run settings. (Go to Page 64.) F3 – Cycle Adjustment: Make cycle adjustment. (Go to Page 75.) F4 – Edit Setup: Edit current loaded setup. (Go to Page 4.) F5 – Handwheel Setup: Displays present handwheel settings. (Go to Page 77.) F6 – Cleanup Cycle: Setup and run a clean cycle. (Go to Page 78.) F7 – Geometry Adjustment: Make and/or edit geometry adjustments. (Go to Page 79.) F8 – Two Stage Cycle: Setup and run a two stage cycle. (Go to Page 81.) F9 – Step & Repeat: (With step & repeat enabled) Change part banks and move carriage to unload parts. (Go to Page 82.) F11 thru F14 – Used defined Macro Buttons. F20 – Check Parts: (Index Table only) Use to index table and check parts. (Go to Page 83.)

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RUN MENU (Run Settings – Column A) This screen allows you to review and edit settings for Column A.

Coolant – (If Available) Toggle the coolant on and off. LED will be green when on.

Airlines – (If Available) Toggle the fixture airlines on and off. LED will be green when on.

Stone Wear Compensation – Allows for adjustment of stone wear.

Amount – Enter amount of stone feed up.

Frequency – Enter frequency at which amount is added.

Stock Removal Amount – This is only available when Sizeloc is disabled. Enter the amount of stock to be honed out of bore.

Sizeloc – When enabled the honing cycle is completed when part is honed to final size. When disable the honing cycle is completed when the amount of stock entered is removed.

NOTE: Rapid Until Load must be enabled when Sizeloc is disabled.

Dwell – The dwell settings can be individually set for each enabled feed rate.

Normal Strokes – Number of normal honing strokes.

Short Strokes – Number of short honing strokes (Short Stroke Only).

Short Stroke Length – The desired length for short strokes (Short Stroke Only).

Dwell Time – The time, in seconds, to dwell (Time and Auto Only).

Load Threshold – The differential in spindle load percentage for auto dwell to be triggered. (Auto Only).

None – No dwelling enabled for this feed rate.

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Short Stroke – Hone part for number of normal strokes followed by number of short strokes, repeating this sequence for entire feed rate.

Time – Dwell at the desired location, for the specified time, each stroke of entire feed rate.

Auto – Dwell at the tight spot in the bore for the specified time or number of short strokes, repeating as needed for entire feed rate.

Dwell Location – The desired dwell location for timed dwell. If the bore profile is enabled the dwell location can be selected by the arrow in the bore profile. If the bore profile is not enabled selected the desired dwell location.

Front – Dwell at the front of bore for the specified time, each cycle.

Rear – Dwell at the rear of bore for the specified time, each cycle.

Press OK to return to Run Menu. (Go to Page 63.) Select MACHINE Tab. Press CANCEL to return to Run Menu. (Go to Page 63.)


66

RUN MENU (Run Settings – Machine) This screen allows you to review and edit Machine settings.

Coolant – Toggle Coolant ON or OFF. LED will display Green when ON.

Part Counter: Parts – Indicates number of parts run.

Clear – Select to reset.

Cycle Mode – Select either single or automatic.

Macros: Button – Select Button then select Assignment to assign button to a new function.

Press OK to return to Run Menu. (Go to Page 63.) Select CONTROLS Tab. Press CANCEL to return to Run Menu. (Go to Page 63.)


67

RUN MENU (Run Settings – Controls) This screen allows you to review and edit Control settings.

Select Controls to Display: Controls – Select Control to be Displayed then select Add to display.

Displayed – Select item in display to Remove or double click to edit.

Press OK to return to Run Menu. (Go to Page 63.) Add Controls. Press CANCEL to return to Run Menu. (Go to Page 63.) Press APPLY to accept changes and return to Run Menu. (Go to Page 63.)


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RUN MENU (Run Settings – Controls – Gas Gage) Each run control that is displayed can be double clicked to open a setup dialog for that control.

Double click the control in the displayed control list to edit the control settings.

Edit setting and press OK to return to Run Setting - Controls. (Go to Page 63.) Press CANCEL to return to Run Setting - Controls. (Go to Page 63.)


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RUN MENU (Run Settings – Controls – Column A Oversized Bore) The oversized bore control allows a part to be honed to the nominal final diameter in the setup. Or to any one of six users defined oversized diameters. This control is useful if you hone parts to a nominal diameter and then find that the bore has not cleaned up. Then you can press the next oversized button and hone again. If the bore has still not cleaned up you can continue this process until the bore has cleaned up.

INSERT – The insert depicts the oversized bore control.

Oversized Bore Adder 1-6 – Enter the additional amount of desired stock removal, above the nominal final diameter.

In the oversize bore control (insert) press the button for the desired final bore diameter and press cycle start to hone to that diameter.

Edit setting and press OK to return to Run Setting - Controls. (Go to Page 63.) Press CANCEL to return to Run Setting - Controls. (Go to Page 63.) Function Keys – Inactive

70

RUN MENU (Run Settings – Controls – Multipass Honing Setup) The multipass honing control allows multiple setups, all using the same tool, to be run sequentially all in one honing cycle. This control is useful if you have a part with multiple lands that will all be honing by the same tool, separately. You can enter a setup for each land separately and get each to hone properly. Then you can add each setup into a multipass setup, which allows each setup to be run one after another to completely hone the part.

INSERT – The insert depicts the multipass honing control.

Enable Multipass Honing – Enables the Multipass Honing feature that will run multiple setup files all in one honing cycle.

Open – Press this button to open a previously saved Multipass setup.

Save – Press this button to save changes to the current Multipass setup.

Save As – Press this button to save the current Multipass setup under a different name.

Select sequentially run setup files: Saved Setup Files – Select a setup file and press the Add button to add it to the list of setup files to be run.

Selected Setup Files – Select a setup file and press the Remove button to remove it from the list of setup files to be run.

Up – Select a selected setup file and press the Up button to move the setup upwards in the list.

Down – Select a selected setup file and press the Down button to move the setup downwards in the list.

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Change Directory – Press this button if you save your setup files to a different directory than the default in the machine software.

Multipass Honing Control This control displays the currently active setup and allows for some modification of the Multipass setup. The checkboxes can be used to enable or disable a particular setup from being run, the next time a cycle is started. The arrow buttons can be used to change the currently active setup to either a setup above or below the currently active setup.

NOTE: When a honing cycle is started the currently active setup will be the first setup run and then all setups lower in the list will be run sequentially after.



72

RUN MENU (Run Settings – Controls – Column A Bore Profile 1) Double click the control in the displayed control list to edit the control settings.



73

RUN MENU (Run Settings – Controls – Column A Load Graph 1) Double click the control in the displayed control list to edit the control settings.



74

RUN MENU (Run Settings – Controls – Debug Setup) Double click the control in the displayed control list to edit the control settings.

The debug control is only displayed when in debug mode. In addition to displaying the control the “RxtServer” window is displayed, for troubleshooting machine issues. This control is typically only used for troubleshooting and should not be used during normal operation. Also, because of the overhead with the text being displayed cycle time will be increased as well as overall system load.



75

RUN MENU (Adjustment Page – Column A) This screen allows you to make cycle adjustment.

Bore Size: Accumulated Bore Size Adjustment – Total adjustments to this point. Last Bore Size Adjustment – Amount of last adjustment. Desired Bore Size Adjustment – New bore size adjustment to be inputted.

Stroke Positions: Accumulated Stroke Position Adjustment – Total adjustments to this point. Last Stroke Position Adjustment – Amount of last adjustment. Desired Stroke Position Adjustment – New stroke position adjustment to be inputted.

NOTE: A negative value will move column upwards.

Stroke Length: Accumulated Stroke Length Adjustment – Total adjustments to this point. Last Stroke Length Adjustment – Amount of last adjustment. Original Stroke Length – Stroke length original inputted. Current Stroke Length – Presently set stroke length. Desired Stroke Length Adjustment – New stroke length adjustment to be inputted.

Do Automatic Blind Bore Stroke Position Adjustment – This is only available for blind bores. Under normal operation, when a stroke length adjustment is made, the limits usually are limited to the tool abrasive reaching the bottom of the blind bore relief. If this option is selected, once the tool abrasive is at the bottom of the blind bore relief, additional stroke length adjustment is allowed because the machine will automatically do a stroke position adjustment to keep the abrasive just at the bottom of the relief.

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Check Stroke – Press this button down to use the hand wheel to move the stroker to the extents of the stroke length to verify stroking motion.

Press OK to return to Run Setting. (Go to Page 63.) Press CANCEL to return to Run Setting. (Go to Page 63.)


77

RUN MENU (Handwheel) This screen displays present handwheel settings

AXIS – Set Handwheel for spindle, stroker, feed, or column (if installed).

MULTIPLIER – Set Handwheel power.

INFORMATION – Display current information.

Press CLOSE to return to Run Menu. (Go to Page 63.)


78

RUN MENU (Cleanup Cycle Settings) This screen is used for the setup and running of a cleanup cycle.

Feed Rate – This is the feed rate for the cleanup cycle only. Rapid Until Load – This is the percentage of load for the cleanup cycle only. Stock Removal Amount – This is the stock removal rate for the cleanup cycle only.

Cycle Time – This is the cycle time in seconds for the cleanup cycle ONLY. Cycle Type – The cleanup cycle can be set by size or time.

Run Cleanup Cycle for Next Cycle – Checking this box will allow cleanup cycle to be run on the very next cycle of the machine.

Do Bore Size Adjustment For Stock Removal Amount – Checking this box will enter a bore size adjustment for the stock removed.

Press OK to return to Run Menu. (Go to Page 63.) Press CANCEL to return to Run Menu. (Go to Page 63.)


79

RUN MENU (Geometry Adjustments – Column A) Geometry Adjustment: Make and/or edit geometry adjustments. Pressing one of these buttons will adjust the system by the amount entered on the Column A Settings on Page 80. This is not an additive feature. That is, pressing the button multiple times will only make one adjustment per cycle.

Column A: Used in conjunction with Column A Settings on Page 80.

Size: This is the amount the final size will be adjusted Over or Under the present diameter.

Shape: Correcting for Barrel condition will increase stroke length and correcting for Bell Mouth will shorten stroke length.

Taper: Correcting for Taper at Top will lower top of stroke position and correcting for Taper at Bottom will raise stroke position.

Column A Settings – For editing of Column A setting go to Page 80.

Select item to be corrected; press APPLY; then go to Column A Setup. (Go to Page 80.)

Press OK to return to Run Menu. (Go to Page 63.) Press CANCEL to return to Run Menu. (Go to Page 63.) Press APPLY to apply changes.


80

RUN MENU (Geometry Adjustments – Column A Settings) Geometry Adjustment: Make and/or edit geometry adjustments.

Column A Settings: Used in conjunction with Column A on Page 79.

Size: This is the amount the final size will be adjusted Over or Under the present diameter.

Shape: Correcting for Barrel condition will increase stroke length and correcting for Bell Mouth will shorten stroke length.

Taper: Correcting for Taper at Top will lower top of stroke position and correcting for Taper at Bottom will raise stroke position.

Select item to be corrected; press APPLY; then press OK to return to Run Menu.



81

RUN MENU (2-Stage Setup) 2-Stage Tools ONLY – Two Stage Cycle Roughing ONLY – Runs a honing cycle on the roughing stage ONLY.

Finishing ONLY – Runs a honing cycle on the finishing stage ONLY.

Roughing-Finishing – Runs a two-stage honing cycle, roughing first followed by finishing.

Switch Stone Set – Press this button to toggle the currently active stone set, between roughing and finishing.

Apply Bore Size Adjustments to Both Stages – Select this option to only be required to enter a bore size adjustment in one stage, for it to be used in both. This option is not available when using brushes.



82

RUN MENU (Step & Repeat Movement) Step & Repeat Setup ONLY – Bank Change Dialog Bank – Select the desired bank to hone.

Move to Bank Switch Position – Press to have the column and carriage moved to the bank switch position.

Move to Part Load Position – Press to have the column and carriage moved to the part removal/load position.

Bore – Move column to selected bore.

Move To First Bore Position – Press button to have the column move to the first bore position.

Move To Next Bore – Press button to have the column move to the next bore position. Follow the instructions in the dialog.



83

RUN MENU (Check Parts) Displayed for machines with index table. Allows table to be indexed and part status to be set. Follow instructions in screen.



84

DIAGNOSTIC MENU (Main Diagnostic Menu Screen) With this screen you have entered Diagnostic Mode. In this mode you can independently actuate a variety of machine functions and view state of inputs and outputs of machine control system. This is helpful for diagnosing or repairing machine problems.

NOTE: Because machine functions can be actuated independently, great care should be taken when in Diagnostic Mode. Fixtures or tools can be damaged. Before leaving Diagnostic Mode, it is a good practice to return machine to same state it was in before entering Diagnostic Mode.

NOTE: Any speeds or positions set while you are in Diagnostic Mode is only for Diagnostic Mode and will not be retained when you exit that mode. Diagnostic Mode will change parameters that pertain to your setup.

Function Keys F1 – Main Menu: Return to main menu. (Go to Page 3.) F2 – Faults & Warnings History: Displays fault history. (Go to Page 85.) F3 – Machine: Go to machine diagnostics. (Go to Page 86.) F4 – Column A: Go to Column A diagnostics. (Go to Page 91.) F8 – Automation: Go to automation diagnostics. (Go to Page 97.) Only if automation is installed on machine.

F9 – Gage: Go to gage diagnostics. (Go to Page 98.) Only if gaging is installed on machine.

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DIAGNOSTIC MENU (Faults & Warnings History) Faults History – Select this tab to display any faults that have occurred during the operation of the machine.

Warnings – Select this tab to display any warnings that have occurred during the operation of the machine.

Press CLOSE to return to Diagnostic Menu. (Go to Page 84.)


86

DIAGNOSTIC MENU (Machine Diagnostics – Machine I/O) MACHINE I/O: This screen allows viewing of machine input and output functions.

Status – Green LED indicates function is turned ON.

Input & Output Functions – These columns shows functions related to status.

Press OK to return to Diagnostic Menu. (Go to Page 84.) Press CANCEL to return to Diagnostic Menu. (Go to Page 84.) Press APPLY to apply changes.


87

DIAGNOSTIC MENU (Machine Diagnostics – Lube System) This screen allows cycling of machine Lube System settings.

Pulse Count – Refers to the number of pulses to give the lube system.

Pulse Frequency – Refers to the intervals between pulses.

Lube System – Toggle between Starting and Stopping of Lube System.

NOTE: Exiting this screen will stop Lube System.



88

DIAGNOSTIC MENU (Machine Diagnostics – Spindle Breakin) This screen is used to break in the spindle bearings. This only needs to be done once after the bearings have been replaced.



89

DIAGNOSTIC MENU (Machine Diagnostics – Index Table) Only displayed if index table is installed on machine. This screen allows for checking the index table function.

Index Table Position – Displays the current index table encoder position.

Index Table Torque – Displays the current index table motor torque.

Index Table Torque Limit – Allows editing the index table motor torque limit.

Index Table Speed – Allows editing the index table index speed.

Direction – Allows changing the index table direction of rotation.



90

DIAGNOSTIC MENU (Machine Diagnostics – Fixture I/O) Only displayed if fixture I/O is installed on machine. This screen allows viewing of fixture input and output functions.



91

DIAGNOSTIC MENU (Column A Diagnostics – Spindle) This screen allows for checking the Spindle System.

Spindle Speed – The speed the spindle will rotate while palm buttons or cycle start is pressed.

Spindle Torque – The current spindle torque in percentage (%).

Spindle Torque Limit – The value the system is limiting the spindle torque too



92

DIAGNOSTIC MENU (Column A Diagnostics – Feed) This screen allows for testing the Feed System.

Feed System Torque – The current feed system torque.

Feed System Torque Limit – The value that the feed system is limited too.

Feed Position – Feed position in encoder counts.

Tool Diameter – Tool diameter size. This is only relevant if a complete setup is in the machine.

Handwheel – Pressing SETUP will activate Handwheel screen insert. This screen displays present handwheel settings.

Axis – Set Handwheel for Feed. Multplier – Set Handwheel power. Information– Display current information regarding Position, Count, & Last Move. Close – Close Handwheel screen insert.



93

DIAGNOSTIC MENU (Column A Diagnostics – Stroker) This screen allows for testing the Stroke System.

Fast Stroker Speed – The speed of the stroker will move while palm buttons or cycle start is pressed.

Stroke Length – Displays the current value that the stroke length is set too.

Stroker Torque – Displays the current stroker torque in percentage (%).

Stroker Torque Limit – The value at which the system is limiting the stroke.

Stroke Position Encoder – Displays the current stroker position encoder counts

Stroke Position – Displays the current stroker position in inches/millimeters.

Column Position: Set Stroke Offset – The following information will be displayed under instructions on Diagnostic Menu: Use start button to start fast stroker. Remove hand from button to stop motion. Cancel Stroke Offset – The following information will be displayed under instructions on Diagnostic Menu: Press cycle start to proceed.

Stroke Movement: Positioning – Use handwheel to move stroker up (CW) or down (CCW). Fast Stroker – Use cycle start or palm buttons to fast stroke carriage up or down for the desired stroke speed and stroke length.

NOTE: When going from positioning to fast stroker mode the current position of the stroker carriage is set as the bottom of the stroke.

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Axis – Set Handwheel for spindle or stroke. Multiplier – Set Handwheel power. Information – Display current information regarding Position, Count, & Last Move. Close – Close Handwheel screen insert.



95

DIAGNOSTIC MENU (Column A Diagnostics – Column Motion) This screen allows for testing the column movement (X-axis), if installed.

Column Torque – Displays the current column torque in percentage (%).

Column Torque Limit – The value at which the system is limiting the column.

Column Position – Displays the current column position in inches/millimeters.

Column Position Encoder – Displays the current column position encoder counts.

Set Column Offset – This button is used to set the column motor zero position. This button should only be used if the column motor, ball screw or coupler have been replaced. Before pressing the button make sure the column is over to the left side of the machine, close to actuating the left limit switch.





96

DIAGNOSTIC MENU (Column A Diagnostics – Column I/O) This screen allows for viewing of the column input and output functions, if installed. Handwheel – Pressing SETUP will activate Handwheel screen insert. This screen displays present handwheel settings.



V

97

DIAGNOSTIC MENU (Automation Diagnostics – Automation I/O) Only displayed if automation is installed on machine. This screen allows viewing of automation input and output functions.



98

DIAGNOSTIC MENU (Gage Diagnostics – Gage a) Only displayed if post process gaging is installed on machine. This screen allows testing of gage functions.

Extend Master Bracket – Allows the master bracket to be extended so that the master ring can be measured.

Take Reading – Allows taking single or continuous gage measurements.

CMZ Control – Under normal operation all gage functions are performed in the Sunnen software. This option allows you to use the CMZ32 application to take measurements and master the gage.



99

DIAGNOSTIC MENU (Gage Diagnostics – Gage I/O) Only displayed if post process gaging is installed on machine. This screen allows viewing of gage input and output functions.



100

SYSTEM SETTINGS (System Settings – Settings) This screen allows editing of machine display language and password level.

Language – Select language to be used. (Defaults to English.)

Password – Select password level. Setup Advanced

Password Level – Select password level and press PASSWORDS. Operator Setup Advanced Master

Units – Select Inch or Millimeter.

Change Setup/Advanced Level Password – Key in new password, then press OK.

NOTE: By default no password are entered.

Press OK to return to System Settings. (Go to Page 100.) Press CANCEL to return to System Settings. (Go to Page 100.) Press APPLY to apply changes.

Function Keys F1 – Main Menu: Inactive

101

SYSTEM SETTINGS (System Settings – Rates) These screens allow for the editing of settings of machine rates.

Sump Time Out – The amount of time the Sump Pump is on after a honing cycle.



102

SYSTEM SETTINGS (System Settings – Index Settings) This screen allows editing index table settings and will only be displayed if an index table is installed on the machine.

Table Positions – The number of table positions used in the software.

Run Cycle Table Direction – Allows setting the index table rotation direction while running cycles.

Enable External OK to Index Feature – This feature inhibits the table from indexing if the machine input associated with this feature is not active.



103

SYSTEM SETTINGS (System Settings – Machine Settings) This screen allows editing machine settings.

Loading Station – Allows setting the loading station for the machine. Will only be displayed on machines with a base having more than 1 station.

Unloading Station – Allows setting the unloading station for the machine. Will only be displayed on machines with a base having more than 1 station.



104

SYSTEM SETTINGS (System Settings – Gage Settings) This screen allows editing gage settings and will only be displayed if post process gaging is installed. Index Position Rate – The gage column movement rate when moving to or from the unlock position. Unlock Position Rate – The gage column movement rate when moving to or from the measurement position. Measurement Rate – The gage column movement rate while taking measurements. Diagnostic Rate – The gage column movement rate in diagnostic screens. Attempts per Part – How many times the gage probe is tried but unable to enter the part before a fault occurs. Bad Parts in Succession – How many bad parts measured in a row before a fault occurs. Successive Failures per Fixture – How many faults on any given fixture before a fixture fault occurs. Enable Reverse Measurement Direction – Enables measurements to be taken from bottom to top rather than top to bottom. Enable Automatic Adjustments – Enables automatic size, taper and straightness compensation from the gage. Press OK to return to System Settings. (Go to Page 100.) Press CANCEL to return to System Settings. (Go to Page 100.) Press APPLY to apply changes.


105

SYSTEM SETTINGS (System Settings – Gage a Limits) This screen allows editing gage limits and will only be displayed if post process gaging is installed.

Column Position:

Top Limit – The highest allowed gage column position.

Bottom Limit – The lowest allowed gage column position.



106

SYSTEM SETTINGS (System Settings – Machine Limits) This screen allows editing machine limits.

Cradle (if installed):

Clockwise Limit – The most clockwise allowed cradle position.

Counter Clockwise Limit – The most counter clockwise allowed cradle position.



107

SYSTEM SETTINGS (System Settings – Column A Limits) This screen allows editing the absolute minimum and maximum travel limits for all installed servo axes.

Stroker: Top Limit – The highest allowed stroker position. Bottom Limit – The lowest allowed stroker position.

Feed: Inner Limit – The most inner allowed feed rod position. Outer Limit – The most outer allowed feed rod position.

Column (X-axis): Left Limit – The farthest left allowed column position. Right Limit – The farthest right allowed column position.



108

UTILITIES MENU (Main Utilities Menu Screen) This screen allows tool adjustment and file backup or restoring.

Function Keys F1 – Main Menu: Return to main menu. (Go to Page 3.) F2 – Tool Wizard: Start tool entry wizard. (Go to Page 109.) F3 – Backup: Run backup/restore utility. (Go to Page 111.) F4 – Adapter Wizard: Start adapter entry wizard. (Go to Page 112.) F5 – Part Counter: View and reset the machine tool part counters. (Go to Page 114.)

109

UTILITIES MENU (Select Tool Operation) This screen allows you to perform various tool operations.

Tool List – Select the desired tool or tool family.

Add – Allows adding a new tool.

Merge – Allows merging (adding) a single tool file into the user tool file.

Edit – Allows editing an existing tool.

Remove – Allows removing an existing tool.

Extract – Allows extracting an existing tool into a single tool file.

New Tool Based on Standard Tool – Allows adding a new tool that has all of the same parameters as an existing tool. This is helpful if you are adding a tool that is almost the same as another tool.

Press NEXT to proceed with entering Basic Tool Parameters Press BACK to return to Utilities Menu main screen. (Go to Page 108.) Press NEXT to proceed with entering Edit Tool Parameters. (Go to Page 110.) Press CANCEL to return to Utilities Menu main screen. (Go to Page 108.) Function Keys – Inactive

110

UTILITIES MENU (Edit Tool Parameters) This screen allows you to edit the parameters of the tool you are working with.

Tool Parameters – Select each parameter to see and edit the current value.

Edit Value – Press the button to edit the selected parameter.

All Parameters – Press this button to display all of the tool parameters.

Press NEXT to proceed with entering Basic Tool Parameters Press BACK to return to Utilities Menu main screen. (Go to Page 108.) Press FINISH to return to Utilities Menu main screen. (Go to Page 108.) Press CANCEL to return to Utilities Menu main screen. (Go to Page 108.)


111

UTILITIES MENU (Backup/Restore) This screen allows for full or partial backing up or restoring of file settings.

Backup – Pressing this box will display Backup options. Full Backup – Checking this box will deactivate Partial Backup settings. Partial Backup – This box allows you to select which items to backup.

Restore – Pressing this box will display Restore options. Full Restore – Checking this box will deactivate Partial Restore settings. Partial Restore – This box allows you to select which items to restore.

Browse – Select backup/restore destination.

Press OK to return to Utilities Menu main screen. (Go to Page 108.) Press CANCEL to return to Utilities Menu main screen. (Go to Page 108.) Press START is only activated once a destination is selected.


112

UTILITIES MENU (Select Adapter Operation) This screen allows you to perform various adapter operations.

Adapter List – Select the desired adapter or adapter family.

Add – Allows adding a new adapter.

Merge – Allows merging (adding) a single adapter file into the user adapter file.

Edit – Allows editing an existing adapter.

Remove – Allows removing an existing adapter.

Extract – Allows extracting an existing adapter into a single adapter file.



113

UTILITIES MENU (Edit Adapter Parameters) This screen allows you to edit the parameters of the adapter you are working with.

Adapter Parameters – Select each parameter to see and edit the current value.

Edit Value – Press the button to edit the selected parameter.

All Parameters – Press this button to display all of the adapter parameters.



114

UTILITIES MENU (Tool Part Count) Every time a tool used to hone a part is added to the tool part counter. The tool part counter keeps track of how many times a particular tool has been used. When used properly you can determine how many parts have been run on a particular tool.

Press CLOSE to return to Utilities Menu main screen. (Go to Page 108.) Press CLEAR to zero the count for the selected tool.


115

NOTES

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NOTES

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NOTES

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Like any machinery, this equipment may be dangerous is used improperly. Be sure to read and follow instructions for operation of equipment.

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 the user verify the discrepancy with Sunnen before proceeding.

PRINTED IN U.S.A. 0706 © COPYRIGHT SUNNEN® PRODUCTS COMPANY 2007, ALL RIGHTS RESERVED

SUNNEN PRODUCTS COMPANY 7910 Manchester Road • St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. Toll-Free Sales and Service - Auto: 1-800-772-2878 • Ind: 1-800-325-3670 International Division - Telex: 4312052 SUNNEN PRODSTL http://www.sunnen.com e-mail: [email protected]

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 Fabrikstrasse 1 8586 Ennetaach-Erien, Switzerland Phone: ++ 41 71 648 16 16 Fax: ++ 41 71 648 31 31 www.sunnen.ch e-mail: [email protected] SHANGHAI SUNNEN MECHANICAL CO., LTD. 889 Kang Qiao East Road, PuDong Shanghai 201319, P.R. China Phone: 86 21 5 813 3322 Fax: 86 21 5 813 2299 www.sunnensh.com e-mail: [email protected] SUNNEN ITALIA S.R.L. Viale Stelvio 12/15 20021 Ospiate di Bollate (MI) Phone: 39 02 383 417 44 Fax: 39 02 383 417 50 www.sunnenitalia.com e-mail: [email protected]

Documents

Operating Display SCREENS - Sunnen Menu (Edit Tool Parameters) ..... 110 Utilities Menu (Backup/Restore) ..... 111 ... diameter of set up workpiece. Final Diameter – Desired diameter