CK-21 Vertical Honing Machine

Problem Checks
Air pressure Fault Check air pressure to main regulator. Adjust between .45 - .60 mpa.
Verify LED is on at end of the pressure switch. Light will be on if air pressure range is met.
Verify 24 VDC output to switch. Measure wire 7 to wire 5 going to pressure switch is 24VDC.
Verify input from switch to the control board. Measure wire 60 to wire 5 at TB3 is 0VDC.
Verify LED D23 is on at the control board. Light will be on if pressure range is met.
Check for broken wires or loose connections from pressure switch to terminal block to control board.
Replace pressure switch if return signal is not present.
Replace control board if above checks are found to be in working order.
 
AC Drive Fault Spindle or Stroker Check both VFD drives in lower left corner of main electric panel for fault messages.
Reset drives. Turn main power off and back on. Press power on button and initialize machine.
Check fault history in VFD drives. See drive manual for instructions.
Verify door switch and head safety switch is functioning properly.
Check three phase power to VFD drives. Insure voltage within 10 % tolerance range.
Check hold in circuit to power up contactor for VFD drives.
Reduce the Spindle Torque Preload value in set up screen by 10.
Contact Sunnen Field Service Dept for assistance.
 
Feed Error 20 Fault  Remove top cover and check for damage between bevel gears.
Verify feed motor encoder connections at motor and control board.
Verify feed motor power leads connections at motor and control board.
Disconnect all tooling from upper drive tube assembly. Run feed system again.
Remove feed motor from transmission and try moving.
Switch motor power leads and check if motor turns in opposite direction. (Fault will be generated)
Replace control board.
Replace feed motor and encoder.
   
Door or Head safety Fault  Switches are wired in series. Check for loose connections at control board TB3.
Check the head is in the down position and the switch is toggled.
Check the door is raised in the up position and the switch is toggled.
Check 24VDC supply going to both switches. See wire diagram and measure at control board.
Check 24VDC return coming from both switches. See wire diagram and measure at control board.
Contact Sunnen Field Service Dept for instructions for checking LED’s on control board.
Verify that no VFD faults are occurring at the same time.
 
Screen is dark/hard to see Make sure power on button is turned on and the hold in circuit is activated.
Adjust CONTRAST potentiometer on center of control board.
Verify two wire connections for back light is seated properly and tight.
Replace control board. Defective power supply on board.
Replace LCD display. Rarely needs replacing or is defective.
   
Sizing Issues
Undersize parts
Verify set-up parameters are correct for application.
Increase Spindle Torque Preload value by 4 numbers. Check size after honing.
Check stones for contact area and true them if necessary. Verify stone grit size and hardness.
Lower Spindle Torque Preload value if using vitrified bonded stones by 8 numbers.
Remove tooling from upper drive tube and inspect hone head. (Thrust bearing area).
Check coolant concentration level using a refract meter for proper level.
Check u-joint in upper feed tube assembly for wear. Replace if necessary.
   
Oversize parts Verify set-up parameters are correct for application.
Decrease Spindle Torque Preload value by 4 numbers. Check size after honing.
Check stones for contact area and true them if necessary. Verify stone grit size and hardness.
Lower Spindle Torque Preload value if using metal bonded stones by 8 numbers.
Remove tooling from upper drive tube and inspect hone head. (Thrust bearing area).
 
Rough reversals Check stroke positions to insure hone head is not contacting fixturing or bottom of part (blindhole). Slow down stroking speed. Listen and look for loose machine components.
Check rocker arm adjustment. See Installation, Setup and Operation Instructions manual for settings.



Print
Find A Sales Rep
Select your state to find a rep near you.
Ask The Expert
Select a category from the dropdown list and then click the "ask" button to continue.