MHS - Vertical Honing Machine

Problem Checks
Air pressure Fault Check air pressure to main regulator. Adjust between .50 - .60 mpa.
Verify 24 VDC supply to switch. Verify wire numbers on wiring diagram.
Verify output from switch to the input module on I/O rack. Verify wire numbers on wiring diagram.
Verify input signal in Diagnostics>Digital I/O>Air pressure.
Check for broken wires or loose connections from pressure switch to Input module on I/O rack.
Replace pressure switch if return signal is not present.
Replace Input module.
 
AC Drive Fault Check drives in lower right corner of main electric panel for blinking fault lights or messages. See drive manual for codes.
 
Spindle or Stroker  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.
   
Brushless Drive Fault Column, Feed and Stroke Length Check electrical connections between drive and motor. Both power and encoder cable connections.
Determine which drive has faulted by the status light color. Green is ok, Yellow is warning, red is fault.
Connect laptop to drive to view faults using Bru Master software supplied with machine.
Reset drives. Turn main power off and back on. Press power on button and initialize machine.
Operate motor in Diagnostic menu. Select which motor to operate in manual mode.
Disconnect load from motor by removing belts or remove motor from transmission.
Replace motor/encoder assembly.
Contact Field Service Dept for assistance.
 
Interlock Fault Switches are wired in series. Check for loose connections at switches and relays in panel.
Check the machine door interlocks has the key inserted completely.
Check 24VDC supply going to switches. See wire diagram. and measure at relays and I/O rack..
Check 24VDC return coming from switches. See wire diagram and measure at relays and I/O rack..
Display Screen is dark and
not responding
Make sure power on button is turned on and E-stop has been released.
Check cable connections at display and video card in main panel. See Repair Parts Manual.
Check both fuses on 12VDC power supply. Check supply at display on J4 connection.
Check connections from video card to first card in card rack. This is the computer card.
With main power turned off to machine, reseat computer card in rack. Power up machine.
Contact Sunnen Field Service Dept for assistance.
Sizing Issues
Undersize parts
Verify set-up parameters are correct for application.
Check tool for worn areas of missing diamonds/stones.
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
 
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 and Ziatech power supply in card rack.
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 computer, cards in rack and digital I/O racks.
Check all hooded connectors at bottom on main electrical panel.
   
Stroke position is
changing often 
Check incoming air pressure to main regulator. Must be at least .55 mpa.
Check stroker clamp adjustment. See troubleshooting in Installation, Setup and Operation manual.
Disassemble stroker clamp and look for wear items. See repair parts manual.
Check stroker drive shaft for loose bolts on pivot beam.
Contact Field Service Dept. for assistance.
Turn off auto compensation feature on gage system if applicable.
Check solenoid valve on side of column for leaks and electrical connection issues.
 
Stroke length is
changing often
Check incoming air pressure to main regulator. Must be at least .55 mpa.
Check stroker pivot adjustment. See troubleshooting in Installation, Setup and Operation manual.
Disassemble stroker pivot assembly and look for wear items. See repair parts manual.
Check stroker clamp screw for loose bolts on cylinder.
Contact Field Service Dept. for assistance.
Turn off auto compensation feature on gage system if applicable.
Carriage drops at end
of cycle before moving up

Check mounting bolts and clamp bracket of the counter balance cylinder. See Repair Parts Manual
Check for piston position by sliding screw driver across length of counter balance cylinder. If magnetic
tension is felt outside of the bracket assembly on the cylinder, piston has decoupled and cylinder must be
replaced.
Check stroker clamp adjustment. See troubleshooting in Installation, Setup and Operation manual.
   
Noise from carriage area
when stopping at index
position (end of cycle).
Check adjustment/position of damper mounted on stroker clamp assembly. See repair parts manual.
Replace damper on stroker clamp assembly. Be sure new damper can not bottom out against carriage.
   
Brushless Drive Faults
when changing stroke
length or stroke position .
Check electrical connections between drive and motor. Both power and encoder cable connections.
Check motor for mechanical binding or obstruction.
Replace all three 24VDC (Finder brand) relays for encoder signals. See repair parts manual.



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