CGM - Horizontal Honing Machine

Problem Checks
Air pressure Fault Check air pressure to main regulator. Adjust between 70 - 85 psi.
Verify 24 VDC output to switch. Measure wire U2405 to wire U2400 going to pressure switch is 24VDC. Verify wire numbers on wiring diagram.
Verify input from switch to the mother board. Measure wire U2431 to wire U2400 at TB1-3. 4-20MA return to mother board. Verify wire numbers on wiring diagram.
Verify analog reading in Diagnostics>Analog Inputs>Air pressure.
Check for broken wires or loose connections from pressure switch to mother board.
Replace pressure switch if return signal is not present.
 
Drive Fault Spindle or Stroker Check drives in lower right corner of main electric panel for blinking fault lights.See manual for codes. Reset drives. Turn main power off and back on. Press power on button and initialize machine.
Check for loose electrical connections on both drives.
Verify cover interlocks are functioning properly.
Check three phase power to drives. Insure voltage within 10 % tolerance range.
Check hold in circuit to power up contactor for VFD drives.
Reduce the Spindle or Stroker speed and cycle the machine again.
Contact Sunnen Field Service Dept for assistance.
 
Feed Fault  Check electrical connections on the feed motor and encoder.
Verify feed motor encoder connections at feed drive and SBX Counter board in card rack (ribbon cable).
Verify feed motor power leads connections at motor and control board.
Disconnect all tooling from spindle nose. Run feed system again.
Remove feed motor and gear box from feed motor adaptor and try moving feed motor using expand/retract switch.
Switch motor power leads and check if motor turns in opposite direction. (Fault will be generated)
Replace feed motor and encoder.
Contact Field Service Dept for assistance
   
Interlock Fault  Switches are wired in series. Check for loose connections at mother board TB3-5.
Check the machine cover door interlock has the key inserted completely.
Check the work station is lowered and the proximity switch is toggled (light on).
Check 24VDC supply going to both switches. See wire diagram and measure at mother board.
Check 24VDC return coming from both switches. See wire diagram and measure at mother board.
 
Nematron Touch Screen dark and not responding Make sure power on button is turned on and E-stop has been released.
Check single phase power going to back of Nematron.
Check ribbon cable connection to primary port of display. Also check connection at CPU unit.
Turn off main power and turn back on. Reinitialize machine.
Send unit back to Nematron for repairs. Contact Sunnen Field Service Dept for loaner unit and instructions for reconfiguring the repaired unit.
   
Sizing Issues
Undersize parts
Verify set-up parameters are correct for application.
Check tool for worn areas of missing diamonds.
Check tool alignment and re-indicate if necessary. Verify grit size and tool life.
Remove tooling from spindle nose and inspect feed rod u-joint area for wear.
Check coolant concentration level using a refract meter for proper level.
   
Oversize parts Verify set-up parameters are correct for application.
Use diamond condition sleeve to remove sharp edges from new tool.
Check tool alignment and re-indicate if necessary. Verify grit size and tool life.
Remove tooling from spindle nose and inspect feed rod u-joint area for wear.
Check coolant concentration level using a refract meter for proper level.
 
Machine will not power on. Check three phase power inside main electrical panel. Phase to phase.
Check single phase power from transformer inside main panel.
Check all power supplies – 5, 12, 24 VDC unregulated and 24 VDC regulated.
Check all fuses for 3 phase, 1 phase and DC volts. See repair parts manual.
Check all circuit breakers and over loads. See repair parts manual.
Check status of lights on CPU, cards in rack and mother board.



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