Sunnen HTA-2000 (2M) User manual
SUNNEN PRODUCTS COMPANY • 7910 MANCHESTER ROAD • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100
Operating Display
SCREENS
for
SUNNEN®HTA-SERIES TUBE HONES
Models: HTA-2000 (2M) & HTA-4000 (4M)
I‐HTA‐247
NOTE: This manual was written for a Standard HTA-2000, screens for different
machine configurations will be slightly different.
GENERALINFORMATION
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
OPERATING 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:
NOTE:Sunnenreservesrighttochangeorrevisespecificationsandproductdesigninconnection
withanyfeatureofourproductscontainedherein.Suchchangesdonotentitlebuyerto
correspondingchanges,improvements,additions,orreplacementsforequipment,suppliesor
accessoriespreviouslysold.Informationcontainedhereinisconsideredtobeaccuratebasedon
availableinformationattimeofprinting.Shouldanydiscrepancyofinformationarise,Sunnen
recommendsthatuserverifydiscrepancywithSunnenbeforeproceeding.
1
TABLEOFCONTENTS
PAGE
Main Menu ............................................................................................................. 2
Important Note ........................................................................................................ 3
Part Specifications .................................................................................................. 4
Setup Menu ............................................................................................................ 5
Run Menu ............................................................................................................... 6
Diagnostic Menu ..................................................................................................... 8
PLC Home .............................................................................................................. 9
PLC Tuning .......................................................................................................... 10
Diagnostic Digital I/O ............................................................................................ 11
Diagnostic Stroker ................................................................................................ 12
Diagnostic Spindle ................................................................................................ 13
Diagnostic Feed ................................................................................................... 14
System Menu ....................................................................................................... 15
System Settings ................................................................................................... 16
Stroker Settings .................................................................................................... 17
Spindle Settings ................................................................................................... 18
Feed Settings ....................................................................................................... 19
Utilities .................................................................................................................. 20
Fault History ......................................................................................................... 21
2
MAIN MENU
This screen presents options; to enter a new setup, go directly to run menu, go to diagnostic
menu or the system/utilities menu.
Sequence to Creative a Setup
Press Setup (Go to Page 5).
Function Keys
Setup: For entering or editing setups (Go to Page 5).
Run: To hone workpiece bore in a production mode (Go to Page 6).
Diagnostic:Entering this mode allows actuation of individual machine functions for diagnosing
machine problems or for other special circumstances (Go to Page 8).
System: To enter / alter special machine functions (Go to Page 15).
Home Machine: This button will initiate the machine homing process. During the process the
stroker is sent to the back of the machine, once in position the stroker position is set to zero.
NOTE: Once the Home Machine button is pressed the stroker will automatically start to move
towards the home position. Drive shafts must be disconnected before homing the machine.
3
IMPORTANT NOTE
This screen is displayed after the machine has been powered up. It is a reminder to double
check stroke positions before running a cycle, right after the machine has been powered up.
Press OK to acknowledge the important note and return the Main Menu (Go to Page 2).
NOTE: Starting a cycle with incorrect stroke positions could cause damage to the machine, tool
and/or workpiece, and could cause serious personal injury.
4
PART SPECIFICATIONS
This screen presents options for entering a new setup. This information will be found on
workpiece blueprint or by measuring workpieces
Entry in this screen is not require, but when used will provide default values in the setup menu.
Start Diameter – Enter the start diameter of the workpiece.
Bore Length – Enter the bore length of the workpiece.
Roughing – Select this option if stock must be removed to clean up the workpiece.
Finishing – Select this option if not much stock needs to be removed from the workpiece.
Enable Crosshatch Entry – Select this option if a specific crosshatch angle is desired in the
workpiece.
Actual Crosshatch – Displays the honing crosshatch angle, once the Calculate Defaults is
pressed.
Desired Crosshatch – Enter the desired crosshatch angle, only available when Enable
Crosshatch Entry is selected.
Calculate Defaults – Press this button to have the software calculate the default honing
parameters based on the part specifications provided.
Function Keys
Main: To return to the main menu (Go to Page 2).
Setup: For entering or editing honing parameters (Go to Page 5).
5
SETUP MENU
This screen is used for entering or editing of honing parameters for the workpiece.
Spindle Speed – This value is recommended from part specs screen and can be edited here.
Stroke Speed – This value is recommended from part specs screen and can be edited here.
Spindle Load – This value is recommended from part specs screen and can be edited here.
Honing Time – Enter desired honing time.
Teach Start Of Stroke – Press this button to set start of stroke at current stroker position.
Teach End Of Stroke – Press this button to set end of stroke at current stroker position.
Stroker Position – Displays current stroker position.
Function Keys
Part Specifications: Return to Part Specifications (Go to Page 4).
Main: Return to Main Menu Screen (Go to Page 2).
Stroker (Enabled/Disabled): Toggle between stroker enabled or disabled. When enabled
stroker can be moved by joystick control. When disabled stroker can be moved manually by
hand.
Jog Spindle: Press and hold to slowly rotate spindle.
Run: Go directly to Run Menu (Go to Page 6).
6
RUN MENU
This screen allows you to start a honing cycle.
Coolant (Off/On) – Toggle coolant on or off.
Stroker (Enabled/Disabled) – Toggle between stroker enabled or disabled. When enabled
stroker can be moved by joystick control. When disabled stroker can be moved manually by
hand.
Jog Spindle – Press and hold to slowly rotate spindle.
Dwell – Press and hold to dwell at any location in workpiece while honing.
Bump Feed – Press to advance feed while honing.
Feed Active – Visual indication that feed is active.
Stroker Position – Displays current stroker position.
Honing Time – Displays remaining honing time.
Feed Clutch – Use up and down arrow keys to increase or decrease feed clutch setting. The
higher the setting the fast the feed will advance. Start lower with setting to avoid overshooting
desired spindle load. Then increase value so that desired spindle load can be maintained. Once
value is set for a specific application and desired spindle load it will not need to be changed.
7
Function Keys
Main: To return to the main menu (Go to Page 2).
Setup: For entering or editing honing parameters (Go to Page 5).
Coolant (Auto/Manual): Toggle between coolant automatic or manual mode. In automatic
mode coolant will be automatically turned on and off for honing cycle. In manual mode coolant
must be turned on and off manually, with the Coolant (On/Off) button.
Feed (Auto/Manual): Toggle between feed automatic or manual mode. In automatic mode
feed will be automatically fed for honing cycle. In manual mode feed must be fed by hand wheel
or Bump Feed button.
Stroker (Auto/Manual): Toggle between stroker automatic or manual mode. Stroker must be
in automatic mode to start honing cycle. In manual mode stroker can be moved by joystick
control or by hand if stroker is disabled.
8
DIAGNOSTIC MENU
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 not change
parameters that pertain to your setup.
Function Keys
Main: Return to main menu (Go to Page 2).
PLC: Allows monitoring and modifying of PLC (Go to Page 9).
I/O: Displays status of machine inputs and outputs (Go to Page 11).
Stroker: Allows testing of stroker system (Go to Page 12).
Spindle: Allows testing of spindle (Go to Page 13).
Feed: Allows testing of feed system (Go to Page 14).
9
PLC - HOME
This screen allows monitoring and modifying of PLC.
NOTE: All of the buttons have been password protected and should only be used with the
assistance of or by Sunnen personnel. Incorrect changes in this screen can render the machine
inoperative.
Indicators
ON – PLC is on.
INTF – PLC has an internal fault.
EXTF – PLC has an external fault.
BUSF – There is an active Profibus fault.
RUN – PLC is in run mode.
STOP – PLC is in stop mode.
Autostart – After startup PLC will be set to same mode (RUN/STOP) as it was prior to closing.
StartAtBoot – HMI will automatically start machine software after bootup.
Function Keys
Exit: Return to diagnostic menu (Go to Page 8).
Tuning: Go to PLC tuning screen (Go to Page 10).
10
PLC - TUNING
This screen allows monitoring of PLC scan time.
NOTE: This screen has been password protected and should only be used with the assistance
of or by Sunnen personnel. Incorrect changes in this screen can render the machine
inoperative.
Function Keys
Exit: Return to diagnostic menu (Go to Page 8).
Home: Go to PLC home screen (Go to Page 9).
11
DIAGNOSTIC DIGITAL I/O SCREEN
This screen allows viewing of machine input and output functions.
First Column – Terminal numbering and green indicates function is turned ON.
Second Column – Function description.
Function Keys
Back: Return to diagnostic menu (Go to Page 8).
Hide Faults/Show Faults: Allows the fault display to be toggle on/off (not shown).
12
DIAGNOSTIC STROKER
This screen allows for testing the stroke system.
Enable/Disable Drive – Allows enabling/disabling the stroker motor from servoing.
Reset Fault – Allows reset of any current stroker drive faults.
Toggle Limits – Turns the stroker position limits on/off (password protected).
Teach Start Of Stroke – Press this button to set start of stroke at current stroker position.
Teach End Of Stroke – Press this button to set end of stroke at current stroker position.
Jog – Enables joystick to allow jogging of stroker.
Jog Speed – Allows entry of desired jog speed.
Stroke – Enters stroking mode which allows testing of stroking function.
Stroke Speed – Allows entry of desired stroke speed.
Function Keys
Back: Return to diagnostic menu (Go to Page 8).
Hide Faults/Show Faults: Allows the fault display to be toggle on/off (not shown).
13
DIAGNOSTIC SPINDLE
This screen allows for testing the spindle system.
Speed (RPM) – Allows entry of desired spindle speed.
Direction – Allows selecting the spindle direction of rotation, fwd/rev.
Run Spindle – Press this button to run the spindle.
Function Keys
Back: Return to diagnostic menu (Go to Page 8).
Hide Faults/Show Faults: Allows the fault display to be toggle on/off (not shown).
14
DIAGNOSTIC FEED
This screen allows for testing the feed system.
Output Voltage (V) – Allows entry of desired control system output voltage to the feed clutch
controller. (0-10V)
Apply – Press this button to transfer the desired voltage to the feed clutch controller.
Function Keys
Back: Return to diagnostic menu (Go to Page 8).
Hide Faults/Show Faults: Allows the fault display to be toggle on/off (not shown).
15
SYSTEM MENU
This screen allows for viewing of the machine run hours and software version. And allows entry
into the system settings, utilities menu and the fault history.
Function Keys
Main: Return to main menu (Go to Page 2).
Settings: For editing system settings (Go to Page 16).
Utilities: To run system utilities (Go to Page 20).
Fault History: To view the machine fault history (Go to Page 21).
16
SYSTEM SETTINGS
This screen allows editing of machine display language and unit system. It also allows entry into
the settings for each axis on the machine.
NOTE: Changing password level is not required to setup, run or diagnose problems with the
machine. Password levels are only to be used with the assistance of or by Sunnen personnel.
Language – Select language to be used (Defaults to English).
Password Level – Displays password level and password entry dialog.
Units – Select Inch or Millimeter.
Passwords – Allows editing of passwords.
Function Keys
Back: Return to system menu (Go to Page 15).
Stroker: For editing stroker settings (Go to Page 17).
Spindle: For editing spindle settings (Go to Page 18).
Feed: For editing feed settings (Go to Page 19).
17
STROKER SETTINGS
This screen allows editing stroker settings.
Stroker Jog Speed – This is the speed used for the joystick in the setup and run screens.
Machine Length – Displays software stroke limit of the machine.
Homing Torque Limit – This value can only be seen by Sunnen personnel.
Function Keys
Back: Return to system settings screen (Go to Page 16).
18
SPINDLE SETTINGS
This screen allows editing spindle settings.
Spindle Jog Speed – This is the speed used to jog the spindle in the setup and run screens.
Rough Spindle Load – The default value of spindle load suggested when roughing is selected.
Finish Spindle Load – The default value of spindle load suggested when finishing is selected.
Function Keys
Back: Return to system settings screen (Go to Page 16).
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