Sunrise PM Manual

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [e-mail]
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SUNRISE
HYDRAULIC PUNCHING MACHINE
PM MODELS
OPERATION &
MAINTENANCE MANUAL
Original Instructions
632EG043
12-2012

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: [phone] [e-mail]
Fax: [phone] www.sunriseiw.com.tw
i
TABLE OF CONTENTS
Introduction ……………………………………………….…… 1
Safety Precautions ……………………………………………… 2
Transport …………………………………………..…………… 6
Installation ………………………………………………………7
Standard Equipment ………………………………..……….… 9
Control Switches………...…………………………………….… 10
Low pressure tool alignment with JOG mode……...………….… 12
Foot Switch …………………………………………………… 13
Stroke Adjustment …………………………………..………… 14
Adjust the Punch Cylinder Ram ……………………………… 15
Punching Station …………………………………….………… 16
Standard Equipment ……………………………………… 16
Alignment of Punch and Die ………………..…………… 16
Punch and Die Clearance ………………..……………… 17
Adjusting Stripper ………………………….…………… 17
Actual Punching Force ………………………..………… 18
Precaution ……………………………………….……… 18
Punch and Die Lubricant ………………………….…… 18
Punch Operation ……………………......…………….… 19
Punching Station Assembly ……………………………. 21
Optional Tooling
I. Press Brake ……………………….…….……..…… 22
II. Duplicating Table …………………..……………… 23
III. Hydraulic Punching Stripper ………….…………… 25
Maintenance …………………………………………………… 26
Trouble Shooting ………………………………..…….……… 28
Hydraulic Circuit Diagram PM-35 ………………..…………… 30
Hydraulic Parts PM-35 ……………………………………….… 31
Hydraulic Circuit Diagram PM-55, PM-80 …………..……….. 32
Hydraulic Parts PM-55, PM-80 ………………………………… 33
Hydraulic Circuit Diagram PM-120, PM-160, PM-200 ……..… 34
Hydraulic Parts PM-120, PM-160, PM-200………………….…. 35
Electrical Circuit Diagram ………………………………….… 36
Electrical Parts List …………………………………………… 37

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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INTRODUCTION
The Sunrise Punching Machine is a hydraulically powered machine for
punching holes on metals. There are many optional accessories that can be
used on the punching machine and turns it into an universal machine. Some
example of optional tooling include Press Brake, Bar Shear Tooling, Flat
Bar Shear Tooling, Channel or Sectional Bar Shear Tooling, Angle Shear
Tooling, Notching Tooling, Pipe Notching, Pipe Punching, and punches
and dies of various shapes and sizes.
Each machine has been individually tested in the factory and under-gone an
extensive pre-delivery check to ensure that the machines meet the highest
quality standard. The punching machine has been designed to be a reliable
and dependable machine with excellent performance. We know the
working quality of the machine will confirm that you have made a good
choice by selecting Sunrise products for your facility.
In order to have a better understanding of the operating procedures, to
obtain maximum benefits from the machine, and to minimize the
maintenance cost of the equipment, please have the operators and engineers
read this Manual thoroughly and carefully before operating the machine.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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SAFETY PRECAUTIONS
IMPORTANT:
It is the duty of both employer and employees to acquaint themselves
with the safe working practices contained in this manual and ensure
that all operators adopt these practices.
To ensure safe operation, guards are provided for the work stations.
NEVER REMOVE THESE GUARDS. If any guards are damaged or
worn out, replace immediately with new guards.
While every effort has been made to furnish sufficient safe guards, this
equipment, if not operated and maintained properly, has the potential to
cause serious injury or death. A thorough knowledge of the machine and
operating with carefulness is the best protection against accidents.
All operations are controlled by the foot switch. The operator should be
familiar with the control and function of the switch before perform the
operation.
Many warning labels are fixed on the machine. NEVER REMOVE
THESE LABELS. Be sure to follow these warnings to avoid injury.
Please also pay attention to the following general rules:
1. Do not operate the machine unless the stripper is in place. Use of
optional attachments/tooling should also have proper hold-downs and
guards installed.
2. All operators must wear Protective Glasses during operation ot
protect the eyes.
3. Before each operation, make sure no other person is near the machine.
Only the operator should be near the machine during operation.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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4. Any maintenance/repair of electrical/hydraulic circuit; change/adjust of
tooling; and alignment of punch-die should be done only by qualified
engineers or personnel.
5. Always turn off power and disconnect electric supply before doing any
tool change or maintenance work.
6. After tool changes, always check punch & die alignment before
operation.
7. Keep hands clear of all moving parts at all times. Fingers must
not go under or inside the stripper.
8. If any problem or abnormal condition arises during operation, stop
the machine immediately and report to a supervisor. Do not turn on
the machine again until the problem is rectified by qualified personnel.
9. The machine should never be left under power when not in operation
or unattended. Always isolate the machine after turned the power off.
10. After completion of operation, all slugs and waste materials must be
cleaned away from the machine.
11. Regularly check all stations and tooling for defects and wear to
ensure safety and maintain good condition.
12. Heavy materials should be supported.
13. Use handling equipment when lifting heavy tooling and materials.
14. Do not punch partial holes as this creates a side load force on the
punch and can result in tool breakage. Special tooling may be
available for this purpose.
15. Do not punch material thicker than the diameter of the punch.
Doing so can overload and break the punch and create a hazard.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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16. Never exceed the rated capacity of the machine. Refer to the
specification chart for details for each model.
The manufacturer shall not be held for any liability for damages, body
injuries and other consequences to machine, material, and/or persons
caused by the non-compliance of the above safety precaution
procedures, in particular for the following situation:
1. Removing or disabling any guards or hold-downs is a violation and
will result in the termination of your warranty.
2. Place of any body part under or inside the safety guards/stripper.
3. Did not wear protective glasses for the eyes.
4. Did not close the stripper during operation.
5. Did not properly adjusted the clearance resulting the tooling
hitting each other.
6. Did not interrupt the main electric power supply before any
maintenance or repair work.
7. Damage of electric parts or risk of fire due to incorrect electric
power supply.
8. Damage of pump or other hydraulic parts due to incorrect setting
of the limit switches.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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DANGER
 KEEP HANDS CLEAR OF ALL MOVING PARTS.
 ALL GUARDS MUST BE IN POSITION BEFORE OPERATING
THE MACHINE.
 ALWAYS POSITION MATERIAL UNDER A CORRECTLY
SET STRIPPER/HOLD-DOWN. NEVER ALLOW THE
MATERIAL TO FEED BEYOND THE HOLD-DOWN.
CAUTION
 THOROUGHLY READ THE OPERATION MANUAL BEFORE
OPERATION.
 TURN OFF POWER AND ISOLATE THE MACHINE WHEN
CHANGING TOOLING OR DOING MAINTENANCE.
 ALL MAINTENANCE/REPAIR WORK MUST BE DONE BY
QUALIFIED PERSONNEL.
 IF ANY PROBLEM OR ABNORMAL CONDITION OCCURS,
STOP THE MACHINE IMMEDIATELY. DO NOT OPERATE
THE MACHINE AGAIN UNTIL THE PROBLEM IS FIXED.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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TRANSPORT
When transporting the machine by a crane, hook the crane to the eye bolt
on top of the machine. Do not use slings under the machine. Pay special
care if lifting / transporting the machine with forklifts. The forks should
extend fully to cover the width of the machine. Do not put the forks from
either end.
NOTE: As the top of the machine is heavy, the high center of gravity can
cause the machine to tip over if machine is not in good balance.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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INSTALLATION
The machine only requires the normal industrial concrete foundation. If the
ground is uneven and the machine vibrates during operation, use foundation
bolts to tighten the machine firmly to the ground or alternatively mount the
machine on anti-vibration pads.
IMPORTANT:
 Maintain a spacious working area around the machine for safety.
 Have the work area well illuminated with proper lighting.
 Clean the scraps and waste materials regularly, and make sure the work
area is free of obstructing objects.
 Keep the ground free of oil and make sure it is not slippery.
 If long lengths of material are to be fed into the machine, make sure
that they will not extend into any gangways.
Crowded, poorly illuminated or slippery area are often causes for
accidents.
Remove all anti-corrosion grease after installing the machine. Check that
the oil reservoir, located in the machine base, has been properly filled.
When refilling oil, use recommended oil and fill the reservoir to the upper
level of the oil level gauge.
Connecting Power Supply
Electrical wiring must be done by a qualified electrician. Before
connecting the electrical supply, make sure the voltage and current is
compatible to the electrical components in the machine. Check the data
shown in the electrical control box.
IMPORTANT: Turn off Supply Electricity at your facility's circuit
breaker before making electrical connections to the machine.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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To connect the power cord:
1) Open the electric box.
2) Remove the small panel under the electric box.
3) Insert the power cord through the entrance hole on the base of machine,
and then through the base of electric box.
4) Connect the three phase wires to the power terminal strip in the
electric box.
5) Also make sure to ground the machine properly.
6) Check that the power cord surface is not damaged, scratched or cut
during installation.
7) Reinstall the panel and close the electric box.
To check the correct rotation of the motor.
 Remove the back cover.
 Briefly start and stop the motor and check that the motor rotates in the
same direction as the arrow indicated on motor. Improper rotation
can severely damage the pump.
 To change the motor rotation, first make sure the power is disconnected,
then reverse any two of the three phases of the electrical power supply.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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STANDARD EQUIPMENT SUPPLIED WITH MACHINE
(including items pre-installed on the machine)
Punch and Die (20mm) 1 set
Punch Support Tables 1 set
Punch Retaining Nut / Sleeve 1 set
Die Holder 1 pc
Punch Stripper Unit 1 pc
Lifting Eye Bolt 1 pc
TOOL BOX 1 pc
Adjustable Spanner (250mm) 1 pc
Screw Drivers (+) 1 pc
Screw Driver (-) 1 pc
Hex Key Wrench Set 1 set
Hex Wrench (12mm) 1 pc
Hex Wrench (14mm) 1 pc
SPA Spanner 1 pc

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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CONTROL SWITCHES
EMERGENCY STOPS – Use the EMERGENCY STOP buttons to stop
the machine in an emergency. The Emergency button must be released
before the PUMP ON button will function. To release the emergency stop
button, turn knob slightly to the right.
ISOLATOR Switch - This switch controls the main electric source. It
also functions as a lock for the electric box. At the ON position the switch
locks the electric box and enables you to start the machine. At the OFF
position, the power is cut off and the electric box can be opened.
PUMP ON - Push this button to turn on the machine. All EMERGENCY
STOP buttons must be released before the PUMP ON button will function.
The green POWER LIGHT stays on when the machine is turned on.
PUMP OFF - Push this button to turn off the machine.
NORMAL/JOG keyed Switch - This switch allows selection between the
normal (automatic return) mode and the jog (low pressure, slow speed,
non- return) mode. Use the normal mode to operate the machine. Use the
jog mode to align punch/die, to set blade clearance, and to set the strokes.
In NORMAL mode, the ram/slide move in both up and down directions. In
JOG mode, the hydraulic system is in low pressure setting and the
ram/slide move only in downward direction at slower speed. Also refer to
the section on Low Pressure Tool Alignment in JOG mode.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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Low pressure tool alignment with JOG mode
Sunrise Fluid Power Inc. is the market leader in providing low pressure tool
alignment setting on its products. When the NORMAL/JOG switch is
turned to JOG mode, the machine provides a low pressure and low speed
setting for safer tool alignment operation. This will reduce tool damages
due to miss-alignment of tools and increase the operator safety. If a
material is placed under the punch in JOG mode, the punch will only make
a dent on the material without punching through. In addition, the punch
cylinder will only move downward when the foot paddle is pressed, and
will not retract backup when the foot paddle is released. Turn the
NORMAL/JOG switch to NORMAL to move the cylinder upward.
WARNING: for ease of tool alignment, the stripper cover is allowed to
open in JOG mode. Even with the low pressure setting, be sure to
keep all body parts away from moving parts, wear appropriate eye
protection goggles and gloves for eye and hand protection. The JOG
mode is a keyed switch, and only properly trained and authorized
personnel should have access to the key and use the machine with JOG
mode.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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FOOT SWITCH
The machine uses a foot switch for easy and fast operation control. The
foot switch enables the operator to use the machine while holding the work
piece with both hands. NEVER has one operator hold the material and
another operator press the foot switch.
The foot switch has three positions: UP, HALFWAY and DOWN.
UP position is when you release the foot switch completely.
HALFWAY position is when you press or release the foot switch halfway.
DOWN position is when you press the foot switch all the way down.
When not pressed, an internal spring pushes the switch to the UP position.
The foot switch functions differently in the NORMAL and the JOG modes.
In NORMAL mode, press the foot switch to DOWN position for the
downward motion of the slide. Release the foot switch to HALFWAY
position will cause the slide to stop. This is very useful in position the
work piece without using the gauge stoppers. Press the foot switch again
to Down position and the slide will continue moving downward until
reaching the lowest position set by the limit switches. Releasing the foot
switch completely (UP position) will cause the slide to return to its up
position.
In JOG mode, press the foot switch to the DOWN position for the
downward motion of the slide. The slide stops moving when the foot
switch is released to either HALFWAY position or UP position. The slide
does not move back up even when foot switch is completely released. This
allows the operator to make necessary adjustment / alignment. In other
words, the slide moves only in one direction in JOG mode. To move the
slide back to the up position, switch the Normal/Jog switch to NORMAL.

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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STROKE ADJUSTMENT
Certain working operations do not require a full working stroke. For large
quantities of the same operation, merely execute the required working
stroke distance to save operating time. The position and length of the
cylinder strokes are controlled by limit switches and actuators on a drive
bar installed inside the back panel of machine. There are two limit
switches, one for the upper limit and one for the lower limit. Adjust the
length of stroke by shifting the position of the actuator mount on the drive
bar. See Figure.
IMPORTANT: The limit switch must be actuated before the Cylinder
reaches the full extend or full extract position. In other words, the pump
should be unloaded in upper or lower limit of the slide travel. Fail to do so
can overload the motor and damaging the pump. If the pump is not in
unloading position at either upper or lower limit, a loud noise is heard from
the pump. Immediately turn the machine off and adjust the limit switch
actuators to set the proper stroke movement.

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ADJUST THE PUNCH CYLINDER RAM
The alignment of the punch cylinder ram is guided by a "bronze guide pad"
inside the cylinder cast. When the ram is loose and starts to swivel or
when the ram is misaligned (not square with the die base), the punch ram
should be adjusted.
To adjust the punch ram, follow these steps:
1) Remove the two locking nuts located on the left side of the cylinder
cast.
2) Adjust the two adjusting screws to lightly press the guide pad onto the
ram.
3) Check the adjustment by moving the ram up and down with non-round
(oblong or square) punches and dies. The ram should be moving
smoothly and without any gaps.
4) Retighten the lock nuts to prevent loosening.

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PUNCHING STATION
Standard Equipment
The machine is equipped with one set of Ø20mm round punch and die.
Many other punching tools of different sizes are also available upon request.
In addition, a large 2-piece support table with gauges is installed as
standard equipment. Measuring scales on the table enable accurate
positioning.
IMPORTANT: The punch stripper must be closed properly during
operation. On some models with an interlock limit switch inside the
stripper back cover, the punching station is IMMOBILIZED if the stripper
is open.
Alignment of Punch and Die
The punch and the die may have previously been centered. However, you
should check the tools regularly for proper alignment. To center the die,
follow these steps:
1) Insert Punch into Retaining Nut, then tighten the nut onto the Retaining
Thread.
2) Insert the Die into the Holder and secure the set screw.
3) Loosen all of the die holder fixing bolts
4) Lower the punch gradually (by using the JOG mode).
WARNING: Be very careful that the punch does not hit the die
which can break the punch and create a hazard.
5) After the punch is inside the die, turn power off and isolate the machine.
6) Adjust the position of the Die Holder until the Clearance around the
punch and die is even all the way around.
7) Tighten the die holder bolts to fix the die position.
8) Adjust the limit switches to change the stroke length if necessary.
When setting up square or oblong punches and dies, be sure to properly
locate the key on top of the punch in the keyway of the punch retaining
thread. Check carefully the alignment (both position and direction) of the
die with the punch. Incorrect set up will damage the punch and die, and
may cause danger.

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IMPORTANT: Be sure to check the alignment of the punch and die
whenever tools are changed.
Punch and Die Clearance
Punch size is the same as the desired hole size. Die size is bigger by the
clearance. The clearance depends on the thickness of the material. The
clearance is usually about 10% of the material thickness. Please also refer
to the following chart for recommend clearance.
Material Thickness mm up to 4 4 - 9 9 – 14 14 - 20
Die Clearance mm 0.2 0.7 1.2 1.7
Adjusting Stripper
 The distance between the stripper and the material should be adjusted
to about 2~3mm. Adjust the stripper height each time when changing
to material of different thickness.
 Adjust the stripper height by turning the large knurled screws at both
sides of the stripper.
 If the stripper tend to fall down at the right side, tighten the spring at
the left side of stripper.
 Make sure the stripper is at even height for left and right sides. The
stripper should be adjusted so that the work-piece contact the stripper
evenly when the punch retracts out of the material. Unbalanced
stripping may break the punch and cause hazard.
 If the material cannot have adequate contact with the stripper when
stripping, such as asymmetrical material, material too small, or punched
hole too close to the edge of material, do not proceed with the punching
operation.
The stripper has exchangeable plates with various opening sizes to match
the size of the hole. Select the plate with the smallest suitable opening.
Keeping the opening close to the size of punch will greatly reduce
deformation, especially on thinner materials.

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Actual Punching Force
The actual force required in a punching operation is calculated by the
circumference of the hole multiplied by the thickness of material multiplied
by tensile strength of material.
Max. Capacity = circumference x thickness x tensile strength
The capacity chart is based on material with 45 kg/mm2 tensile. Do not
attempt a punching operation that requires force over the maximum
capacity of the machine.
Precaution
1) Always use die with the proper clearance.
2) Always check the alignment after each tool change.
3) To prevent overloading and breakage of the punch, do not punch
material which is thicker than the hole diameter,
4) Do not punch partial holes. Punching incomplete holes will cause the
punch and die to bend and break.
5) Applying some lubricant oil on the punch will prolong the life of the
punch and reduce the stripping load.
6) Regrinding of punching tools is not recommended.
Punch and Die Lubricant
SHELL - GARIA 927
B. P. - SERVORA 68
CASTROL - ILOBROACH 219
DUCKHAMS - ADFORNOL EP7
JOSEPH BATSON - LB 733