INTRODUCTIONSunnen® Optional VSS29040 Lube System Kit isdesigned for used on Sunnen VSS2 Series VerticalSingle Stroke Honing® Machines.

TOOLS & MATERIALSThe following tools and materials are required forunpacking and installing of your Machine:

Knife Hex Wrenches Crow Bar Open End Wrenches Tin Snips Cleaning Solvent

MECHANICAL INSTALLATIONRead the following instructions carefully andthoroughly before unpacking, inspecting andinstalling the Kit. To install Kit, proceed as follows:

1. Check nameplate on Brake Motor to be sure itagrees with supply line voltage and frequency.

2. Turn off main electrical power switch.

3. Remove power from the machine.

4. Assemble Lubrication Unit and Manifold asshown (see Figure 1).5. Remove Carrage Guarding (see Figure 2).6. Assemble Lubrication components as identified

(see Figures 3 & 4).• Remove manual Grease Fittings from two UpperLinear Rail Assemblies. Replace with Reducer(VSS24251) and Elbow (PPPM422).• Remove manual Grease Fittings (#42) from frontof Carriage (for 2 Lower Linear Rail Assembliesfittings and for 1 Ballscrew Nut fitting). Replacewith Elbow (PPPM615).• Install Panel Bushings to protect lubrication linesin top and bottom of Carriage and in center Gusset.

7. Prefill lube lines with Mobilux EP2 prior toinstallation, leaving a few centimeters of lube lineunfilled, and mark position of lubrication in eachline. A total of 5 lube lines will be installed.

1 for Ballscrew Nut and1 for each of 4 Linear Rail Assemblies (2 upper &

2 lower) on carriage.

8. Route 5 lube lines as follows (refer to Figure 4):• Route lines between electrical cabinet and back ofcolumn, through Cable Carrier, down the side of theMotor to Strain Relief Plate.

9. Route 2 lube lines to two Upper Linear RailAssemblies (refer to Figures 3 & 4).

10. Route remaining 3 lube lines through upper andlower Panel Bushing in Carriage Assembly (refer toFigures 3 & 4).11. Leave lube lines disconnected at this time.

ELECTRICAL INSTALLATIONAll wiring is to be performed by a competent,Licensed Electrician in accordance with all local,state, and federal codes and regulations To installelectrical portion of your Kit, proceed as follows:

WARNINGElectrical Equipment service should beperformed by authorized personnel ONLY.

1. Unlock Door to Electrical Control Enclosure.

CAUTIONDoor is equipped with lockable Safety Door Latch.Door should be closed and latched during operationto prevent accidental interruption of operation fromdoors being opened. Door Latch should be Locked-Out and Tagged during servicing to prevent machinefrom being powered up.

WARNINGResidual Voltage exists for 2-3 minutes afterMaster ON/OFF Switch is turned OFF. Beforeworking inside Enclosure, wait for all fans to stoprunning to allow drives to discharge.

2. Turn Master ON/OFF Switch to OFF positionand open Door. (Door WILL NOT open unlessMaster ON/OFF Switch is in OFF position.)

3. Open Door to enclosure.

4. Install Control Relay (9CR) and Diode on DinRail as shown (see Figure 5 & your machine’swiring diagram). Wire Control Relay (9CR) asshown (see Figure 5).5. Wire CBL-673 Cable to Pressure Switch as

shown.

6. Wire CBL-674 Cable to Lube Pump as shown.

7. When all wiring matches your machine’s wiringdiagram, turn on power to machine.

8. On Machine Settings Screen, System Menu, setOptional Lubrication Option to Active.

I-VSS-294B

FIELD INSTALLATION INSTRUCTIONSfor

SUNNEN® VSS29040 LUBE SYSTEM KITFor Use on Sunnen® VSS2 Series Vertical Single Stroke Honing® Machines

http://www.sunnen.com

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

2

FIGURE 1, Base Assembly Module (VSS22000 op40)

ITEMNO.

ORDER BYPART

NUMBER QTY.DESCRIPTION

- - VSS22000-40 Ref. .......Base Assembly Module Option includes1 CL26 2 ...........Nut, Hex (#8-32)2 DRB0325 1 ...........Din Rail (325mm)3 EC2693 2 ...........Spacer4 EC3004 2 ...........Spacer5 MVH7120 1 ...........Air Preparation Unit6 PES786 1 ...........Air Pressure Switch7 PFC148 1 ...........Pressure Gage8 PFC175 5 ...........Metering Valve9 PFC218 1 ...........Solenoid Valve Stack

10 PG459 2 ...........Screw (#8-32 x 1/4 PRHMS)11 PHNM467 4 ...........Nut, Insert (M8 x1,8)12 PHSM427 2 ...........Screw (M5 x 0,8 x 40mm SHCS)13 PHSM495 4 ...........Screw (M8 x 1,25 x 20mm HHCS)14 PHWM407 4 ...........Lockwasher (M8)15 PPPM430 1 ...........Nipple16 PPPM449 3 ...........Hex Socket Pipe Plug17 PPPM464 8 ...........Plug18 PPPM468 16 ...........Reducer Elbow19 PPPM470 5 ...........Compression Bushing20 PPPM471 5 ...........Compression Sleeve21 PPPM472 5 ...........Tubing Insert22 PPPM501 1 ...........Male Run Tee23 PPPM505 1 ...........Pipe Hex Nipple24 PPPM587 1 ...........Reducer Bushing25 PPPM588 1 ...........Tee26 PPPM589 1 ...........Reducer Bushing27 SV02202 1 ...........Pressure Switch Assembly28 SV31201 1 ...........Grease Pump29 SV31209 1 ...........Grease Distribution Block

PARTS LIST

LUBRICATION UNITAND MANIFOLD

AIR PRESSURESWITCH

CABLE(CBL674)

CABLE(CBL673)

3

FIGURE 2, Spindle Carriage Assembly (VSS24300 op20)

ITEMNO.

ORDER BYPART

NUMBER QTY.DESCRIPTION

- - VSS24300-20 Ref. .......Spindle Carriage Assembly, VSS264 includes1 PEM712 2 ...........Tie Mount2 PHNM425 1 ...........Nut, Insert (M4 x 1,8)3 PHNM436 23 ...........Nut, Self Clinching (M6 x 1,0)4 PHNM483 8 ...........Insert, Knurled Rivet Nut (M6 x 1,0)5 PHNM499 2 ...........Knurled Rivet Nut (M6 x 10)6 PHSM534 8 ...........Screw (M6 x 1,0 x 20mm SHCS)7 PHSM505 1 ...........Screw (M4 x 0,7 x 12mm BSHCS)8 PHSM510 21 ...........Screw (M6 x 1,0 x 12mm BSHCS)9 PHSM535 2 ...........Screw (M6 x 1,0 x 12mm SHCS)

10 PHWM509 13 ...........Lockwasher (M6)11 PHWM518 11 ...........Flatwasher (M6)12 PHW169 23 ...........Flatwasher13 PHWM570 23 ...........Lockwasher (M6)14 VSS28016 1 ...........Motor Cover15 VSS28021 1 ...........Carriage Guard - Top16 VSS28022 1 ...........Carriage Guard - Center17 VSS28023 1 ...........Carriage Guard - Bottom18 VSS28024 1 ...........Guard19 VSS29001 1 ...........Strain Relief Plate20 PHSM405 5 ...........Screw (M6 x 1,0 x 16mm SHCS)

PARTS LIST

MOTOR STRAINRELIEF PLATE

4

FIGURE 3, Spindle Carriage Assembly (VSS24300 op10)

ITEMNO.

ORDER BYPART

NUMBER QTY.DESCRIPTION

- - VSS24300-10 Ref. .......Spindle Carriage Assembly, VSS264 includes1 PBR325 2 ...........Ball Bearing, Double Row Angular Contact2 PDB220 1 ...........Timing Belt3 PEM712 2 ...........Tie Mount4 PEM1202 3 ...........Panel Bushing5 PHNM200 1 ...........Nut, Hex Jam (M6 x 1.0)6 PHNM436 2 ...........Nut, Self Clinching (M6 x 1.0)7 PHRM109 4 ...........Retaining Ring 8 PHRM321 2 ...........Retaining Ring 9 PHSM453 1 ...........Screw (M12 x 1,75 x 45mm SHCS)

10 PHSM480 1 ...........Screw (M12 x 1,75 x 65mm SHCS)11 PHSM505 2 ...........Screw (M4 x 0,7 x 12mm BSHCS)12 PHSM510 2 ...........Screw (M6 x 1,0 x 12mm BSHCS)13 PHSM513 1 ...........Screw (M6 x 1,0 x 50mm SHCS)14 PHSM515 16 ...........Screw (M8 x 1,25 x 25mm SHCS)15 PHSM535 7 ...........Screw (M6 x 1,0 x 12mm SHCS)16 PHSM548 8 ...........Setscrew (M8 x 1,25 x 16mm SHSS)17 PHSM553 4 ...........Setscrew (M12 x 1,75 x 25mm SHSS)18 PHSM607 2 ...........Screw (M6 x 1,0 x 30mm SHCS)19 PHSM512 3 ...........Screw (M6 x 1,00 x 16mm FHMS)20 PHSM534 16 ...........Screw (M6 x 1,0 x 20mm SHCS)21 PHSM971 24 ...........Screw (M6 x 1,0 x 16mm, BSHCS)22 PHSM978 3 ...........Screw (M10 x 1,5 x 110mm HHCS)23 PHWM509 6 ...........Lockwasher (M6)24 PHWM518 3 ...........Flatwasher (M6)25 PHWM521 3 ...........Lockwasher (M10, Din 127, Plain

PARTS LIST

ITEMNO.

ORDER BYPART

NUMBER QTY.DESCRIPTION

- - VSS24300-10 Ref. .......Spindle Carriage Assembly, VSS264 includes26 PHWM531 3 ...........Flatwasher (M10, Din 125, Zinc27 PHWM570 23 ...........Lockwasher (M6)28 PHWM571 16 ...........Lockwasher (M8)29 PPPM411 3 ...........Grease Fitting (M6 x 1,0 x 5mm)30 PPPM571 1 ...........Male Connector31 PPPM615 2 ...........Elbow (90 Degree)32 VSS24010 4 ...........Spindle Assembly Module33 VSS24011 2 ...........Idler Pulley34 VSS24012 1 ...........Idler Post35 VSS24013 8 ...........Jack Screw Block36 VSS24023 1 ...........Idler Post37 VSS24024 1 ...........T-Slot Housing38 VSS24026 1 ...........T-Slot Key39 VSS240552 1 ...........Linear Rail Assembly40 VSS240553 1 ...........Linear Rail Assembly41 VSS240554 2 ...........Linear Rail Assembly42 VSS24156 1 ...........Tension Block43 VSS24159 1 ...........Bellows Bracket44 VSS24218 4 ...........End Cap45 VSS24220 1 ...........Carriage Assembly, VSS26446 VSS24232 3 ...........Motor Riser47 VSS26200 1 ...........Spindle Motor Assembly - 10Hp, VSS264 (48 VSS28001 2 ...........Linear Rail Cover49 PPPM422 2 ...........Elbow50 VSS24251 2 ...........Reducer

5

FIGURE 4, Lube Lines

CABLE CARRIER

CABLE CARRIER

UPPER LINEARRAIL ASSEMBLIESFITTING

MOTOR CABLECARRIER BASE

UPPER PANELBUSHING

LOWER PANELBUSHING

BALLSCREWNUT FITTING

LOWER LINEARRAIL ASSEMBLIESFITTING

MOTOR STRAINRELIEF PLATE

SPINDLE MOTORCOOLING FAN

RUNNER BLOCK LUBE FITTINGS

(BOTTOM - 2X )

SPINDLE MOTORBEARING GREASEFITTINGS (2X)

BALL NUTGREASE FITTING

RUNNER BLOCK LUBE FITTINGS(TOP - 2X )

6

FIGURE 5, Wiring Diagram

LUBEOPT

TB-24COM:9TB-9009CR 9SOLTB-24V4:11 900

LUBE OPT1413

413Q H N

AIR PRESSURESWITCH

GREASE (LUBE)PUMP

CABLE(CBL674)

CABLE(CBL674)

FINAL INSTALLATIONRead the following calibration instructions carefullyand thoroughly, then proceed as follows: (Refer toIOM Instructions and Display Screens Manualspackaged with your machine for details.)1. Turn on power if you have not done so already.

2. On Lube System Screen, Diagnostic Menu, pressStart Button. This will manually cycle lubricationsystem so that air can be bled from system.

The lubrication cycle functions by pumping greaseuntil Pressure Switch is made. When Switch ismade, pump shuts down and will not run anothercycle for a preprogrammed amount of time. Thistime allows pressure in the system to reduce andactually deliver grease to the appropriate points.

During the air bleeding process, the manual pulsewill probably “time out”. This is a preprogrammed2 minute interval that prevents pump from runningindefinitely. If this happens, reset alarm on AlarmsScreen. Then Start Button can be pressed again.View “Lube State” box on screen to determinestatus of lubricator.

3. After pressing Manual Pulse Button, bleed thesystem (see Figure 6): (Also refer to IOMInstructions packaged with your machine fordetails.)• Slowly open Port on front of Grease Pump tobleed air from pump.

• Slowly loosen Setscrew in Manifold until grease isdispensed.

• Loosen Compression Bushing (#19) on eachgrease line. Grease should be ejected from eachinjector. When grease is present, tightenCompression Bushing .

• Observe marking you placed on each Lube Lineearlier (Mechanical Installation, step 7). Greaseshould be moving past this mark.

4. Cut Lube Lines to length and verify that they arefilled with grease. Attach all Lines to appropriateFitting (refer to Figure 3 & 4).5. Verify that all grease lines are not rubbing on

any adjacent components.

6. Replace all guarding (refer to Figure 2)7. Place machine in service by running the machine

for 10 manual cycles.

• This can be automatically set using the LubeSystem Screen, Diagnostic Menu.

• This process assures that each component isproperly greased

• When complete, machine will automaticallylubricate machine based upon cycle data.

7

FIGURE 6, Lube Unit

PORT

PORT

SETSCREW

SETSCREW

COMPRESSIONBUSHING

COMPRESSIONBUSHING

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Sunnen® reserves the right to change orrevise specifications and product designin connection with any feature of ourproducts contained herein. Such changesdo not entitle the buyer to correspondingchanges, improvements, additions, orreplacements for equipment, supplies oraccessories previously sold. Informationcontained herein is considered to beaccurate based on available informationat the time of printing. Should any discrepancy of information arise, Sunnenrecommends that user verify discrepancywith Sunnen before proceeding.

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