Sunrise IW-45M User manual
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Fax: 886-4-2359-3409
www.sunriseiw.com.tw
SUNRISE
HYDRAULIC IRONWORKER
SINGLE CYLINDER MODELS
IW-45M, IW-50A, IW-60H
OPERATION &
MAINTENANCE MANUAL
Original Instructions
632EG013
12-2012
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Fax: 886-4-2359-3409
www.sunriseiw.com.tw
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TABLE OF CONTENTS
Introduction ……………………………………………….…… 1
Safety Precautions ……………………………………………… 2
Transport …………………………………………..…………… 6
Installation ………………………………………………………7
Lubrication …………………………………………………..… 9
Standard Equipment ………………………………..……….… 10
Control Switches …………………………………………….… 11
Low pressure tool alignment with JOG mode……...…………. ..14
Foot Switch …………………………………………………… 15
Optional Electric BackGauge ……………..………………..… 16
Stroke Adjustment …………………………………..………… 17
Adust the Main Central Shear Slide ………….……..………… 19
Adjust the Punch Ram (IW-50A Only) ……………..………… 19
Punching Station …………………………………….………… 20
Standard Equipment ……………………………………… 20
Alignment of Punch and Die ………………..…………… 20
Punch and Die Clearance ………………..……………… 21
Adjusting Stripper ………………………….…………… 21
Actual Punching Force ………………………..………… 22
Precaution ……………………………………….……… 22
Punch and Die Lubricant ………………………….…… 22
Punch Operation ……………………......…………….… 23
Punching Station Assembly ……………………………. 26
Flat Bar Shearing Station ………………..…………….……… 27
Blades ……………………………………….………..… 27
Cutting Clearance ………………………………………. 27
Precaution ……………………….……………………… 28
Flat bar Shear Operation ………….….………………… 29
Angle Flange Shear Operation ……….………………… 29
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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Angle Shearing Station ………………..……………………… 30
Blades …………………………………...……………… 30
Cutting Clearance ……………………………………… 30
90 Degree Shear Operation …………………..………… 31
45 Degree Internal Miter Shear Operation
(on IW-45M and IW-50A) ……………………..… 32
45 Degree Internal/External Miter Shear Operation
(on IW-60H only) ………………..…….………… 32
Square/Round Bar Shear Station …………….……..………… 34
Cutting Clearance ……………………….…..…………. 34
Precaution …………………………………...…………. 34
Bar Shear Operation ………………………….………… 34
Notching Station (On IW-50A and IW-60H) ………..………… 36
Blades ………………………………………..……………36
Bolster Adjustment …………………………..………… 36
Notching Operation ……………………….….………… 37
Maintenance …………………………………………………… 38
Trouble Shooting ………………………………..…….……… 40
Hydraulic Circuit Diagram ……………………..……………… 42
Hydraulic Parts List …….…………………………………….… 43
Electrical Circuit Diagram IW-45M ………………………….… 44
Electrical Parts List IW-45M…………………………………… 45
Electrical Circuit Diagram IW-50A, IW-60H…………..…….… 46
Electrical Parts List IW-50A, IW-60H………………………… 47
Electrical Circuit Diagram IW-50A, IW-60H with sensor…...… 48
Electrical Parts List IW-50A, IW-60H with sensor .…………… 49
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Fax: 886-4-2359-3409
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INTRODUCTION
The Sunrise Ironworker is a hydraulically powered punching and metal
shearing machine. The machine is equipped with Punching, Flat Bar
Shearing, Angle Shearing, Round Bar / Square Bar Shearing, and Notching
stations (on IW-45M, the notcher is an optional tooling installed at the
punching station). This multi-function aspect allows the Sunrise
Ironworker to meet the diversified needs of the metal forming industry.
There are many optional accessories that will further increase the versatility
of the machine, contact our dealer for details.
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 ironworker 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.
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 either the foot switch or by the optional
electric backgauge. The operator should be familiar with the control and
function of the switch/backgauge 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 all safety guards and hold-downs are
in place. Use of optional attachments/tooling should also have proper
hold-downs and guards installed. If any guards are damaged or worn
out, replace immediately with new guards.
2. On the single cylinder models, only one operator is allowed to operate
the machine. Before each operation, make sure no other person is near
the machine.
3. Operator must wear Protective Glasses during operation to protect
the eyes.
4. Keep hands clear of all moving parts at all times. Fingers must not
go under or inside the danger zone established by the safety guards,
stripper, and/or holddowns.
5. On IW-50A and IW-60H which has a notcher, the nature of the station
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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requires opening the notcher safety cover during notching operation for
processing different shape and sizes of materials. This creates a
potential risk to the operator. The notcher safety cover is interlocked
by the SHEAR/NOTCH selection switch. Notcher safety cover must
be closed when not using the notching station. During notching
operation, keep fingers away from moving parts. Do not notch material
that operator cannot hold firmly during notching. Exercise caution and
be alert to potential risks.
6. Any maintenance/repair of electrical/hydraulic circuit; change/adjust of
blade/tooling; and alignment of punch-die should be done only by
qualified engineers or personnel.
7. Always turn off power and disconnect electric supply before doing any
tool change or maintenance work.
8. After tool changes, always check punch & die alignment and blade
clearances before operation.
9. Do not punch, shear, or notch parts that are too small to fit under the
safety hold downs.
10. 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.
11. The machine should never be left under power when not in operation or
unattended. Always isolate the machine after turned the power off.
12. After completion of operation, all slugs and waste materials must be
cleaned away from the machine.
13. Regularly check all stations and tooling for defects and wear to ensure
safety and maintain good condition.
14. Heavy materials should be supported.
15. Use handling equipment when lifting heavy tooling and materials.
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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16. 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.
17. Do not punch material thicker than the diameter of the punch.
Doing so can overload and break the punch and create a hazard.
18. 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 or other consequences to machine, material, and persons
caused by the non-compliance of the above safety precaution
procedures, in particular for the following situations:
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 danger zone established
by the safety guards, stripper, and/or holddowns.
3. Did not wear protective glasses for the eyes.
4. Did not close the stripper during operation.
5. Did not close the notcher safety cover when using other workstations.
6. Did not properly adjustment the clearance resulting the
punch/die/blades hitting each other.
7. Did not interrupt the main electric power supply before any
maintenance work.
8. Damage of electric parts or risk of fire due to incorrect electric
power supply.
9. 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
Fax: 886-4-2359-3409
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DANGER
zKEEP HANDS CLEAR OF ALL MOVING PARTS.
zALL GUARDS AND HOLD-DOWNS MUST BE IN POSITION
BEFORE OPERATING THE MACHINE.
zALWAYS POSITION MATERIAL UNDER A CORRECTLY SET
HOLD-DOWN. NEVER ALLOW THE MATERIAL TO FEED
BEYOND THE HOLD-DOWN.
CAUTION
zTHOROUGHLY READ THE OPERATION MANUAL BEFORE
OPERATION.
zTURN OFF POWER AND ISOLATE THE MACHINE WHEN
CHANGING TOOLING OR DOING MAINTENANCE.
zALL MAINTENANCE/REPAIR WORK MUST BE DONE BY
QUALIFIED PERSONNEL.
zIF ANY PROBLEM OR ABNORMAL CONDITION OCCURS,
STOP THE MACHINE IMMEDIATELY. DO NOT OPERATE
THE MACHINE AGAIN UNTIL THE PROBLEM IS FIXED.
Opertators’s working positions:
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Fax: 886-4-2359-3409
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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
Fax: 886-4-2359-3409
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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:
zMaintain a spacious working area around the machine for safety.
zHave the work area well illuminated with proper lighting.
zClean the scraps and waste materials regularly, and make sure the work
area is free of obstructing objects.
zKeep the ground free of oil and make sure it is not slippery.
zIf 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.
zRemove the back cover.
zBriefly 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.
zTo 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
Fax: 886-4-2359-3409
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- 9 -
LUBRICATION
Lubricate the machine with recommended grease every 8 working
hours. Use the grease gun provided to supply grease to all lubrication
points, which are located on both sides of the machine as shown in the
figure.
A: Lubrication Points
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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RECOMMENDED GREASE
Lubricant Grease (or equivalent):
Esso Beacon 2
Shell Alvania Grease R-2
Kraff KL2
STANDARD EQUIPMENT SUPPLIED WITH MACHINE
(including items pre-installed on the machine)
Flat Bar Shear Blades 1 set
Angle Shear Blades 1 set
Round & Square Bar Shear Blades 1 set
Rectangular Notch Blades 1 set*
Punch and Die (20mm) 1 set
Punch Support Table 1 pc
Notch Support Table 1 pc*
Punch Retaining Nut / Sleeve 1 set
Die Holder 1 pc
Punch Stripper Unit 1 pc
Spotting Light 1 pc*
1 Meter backgague 1 pc
Work station Safety Guards 1 set
Lifting Eye Bolt 1 pc
* : Not supplied on IW-45M
TOOL BOX 1 pc
Grease Gun 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
Fax: 886-4-2359-3409
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- 11 -
CONTROL SWITCHES
EMERGENCY STOPS – Use the EMERGENCY STOP buttons to stop
the machine in an emergency. The emergency buttons must be released
before the PUMP ON button will function. To release the emergency stop
buttons, 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.
PUNCH/SHEAR/NOTCH Switch (for IW-50A and IW-60H) - Use this
switch to select between punching, shearing or notching operations. In
PUNCH and SHEAR mode, the slide travels in full distance set by the
upper and lower stroke limit switches. In the NOTCH mode, the slide
travels at a shorter distance set by middle and lower stroke limit switches.
Note: The PUNCH/SHEAR/NOTCH switch is electrically interlocked with
the Notch Safety Guard. When in PUNCH and SHEAR mode, the machine
is IMMOBILIZED if the Notch Safety Guard is lifted. Please also refer to
the section on stroke adjustment.
Note for IW-60H only: Because of the design of the location of the
square/round bar shear station, the operation of the bar shear station on IW-
60H is in the same selection as the punching operation. In other words,
when shearing square/round bars, turn to PUNCH mode instead of Shear
mode. Use SHEAR mode for flat shear and angle shear.
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
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PUNCH/SHEAR Switch (for IW-45M) - Use this switch to select punch or
shearing operations.
NORMAL/JOG 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.
AUTO/MANUAL Switch (for machines equipped with the optional
electric backgauge only) - Turn to AUTO to use the backgauge, and turn to
MANUAL to use the foot switch. Also refer to the section on electric
backgauge.
IMPORTANT WARNING:
On IW-45M, IW-50A, and IW-60H models, in PUNCH mode the
cylinder/slide moves in opposite direction as to the SHEAR/NOTCH mode.
Therefore, when switching from Shear or Notch mode to PUNCH mode, the
cylinder starts moving and the Shear/Notch Blades will come down.
Similarly when switching from Punch mode to SHEAR or NOTCH mode,
the cylinder starts moving and the Punch will come down. This has the
potential of body injury. Before turning the PUNCH/SHEAR/NOTCH
switch, be very careful and make sure that the punching stripper and
notcher cover are closed, that no materials are in any of the
workstations, and that all fingers and body parts are away from all
moving parts. ONLY for the supervisor and his trained authorized
operator of the machine who understands the potential risk of the
machine and is authorized to use the notching station.
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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- 14 -
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.
The JOG mode works for all working stations. The safety cover of other
stations MUST be closed for the machine to move.
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.
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ELECTRIC BACKGAUGE
Optional electric touch-and-cut back gauge is available to control the
movement of the machine (instead of using the foot paddle). To use the
electric back gauge, turn the Auto/Manual switch to AUTO. To use the
foot switch, turn the switch to MANUAL.
To use the electric backgauge:
1) Install the two pipes of the backgauge.
2) Connect the sensor wire to the socket on the back of the machine with
the key way correctly aligned.
3) Turn the switch to AUTO.
4) Adjust the back gauge to the desired length.
5) Position the sensor on the back gauge so that the working piece will
touch the sensor during operation.
6) To operate, simply push in the work piece. When the sensor is touched
by the work piece, the blade will start moving down after a short delay.
The delayed time can be adjusted by a timer inside the electrical box.
After the shear, the cut piece falls out and the blade automatically
returns to the up position for the next shear.
7) If the length of the sheared piece is not the same as the reading on the
backgauge, there is an adjustment nut on the backgauge to set the zero-
position of the backgauge reading.
NOTE: Once the sensor is touched and the shearing operation has started,
the machine will complete the whole shearing cycle. The machine cannot
be stopped halfway unless the emergency stop button is pushed. Although
the electric backgauge increases the working efficiency, special care is
required when using this function. Carelessness often causes accidents.
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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 adjusting the limit switches and actuators
on a drive bar installed on the back of machine.
For IW-45M:
There are two limit switches, one for the upper limit and one for the lower
limit. The role of the limit switches changes from Shear mode to Punch
mode. In other words, the upper limit in Shear mode becomes the lower
limit when switched to Punch mode, and vise versa.
For IW-50A and IW-60H:
There are three limit switches, one for the upper limit, one for the lower limit,
and one for the notch upper limit (short stroke). At SHEAR and PUNCH
mode, the slide moves in full length between the right limit switch and the
left limit switch. The role of the limit switches changes from Shear mode to
Punch mode. In other words, the upper limit in Shear mode becomes the
lower limit when switched to Punch mode, and vise versa. In NOTCH mode,
the center limit switch functions as the upper limit (short stroke), and the
slide moves between the center and left limit switches.
Note: the center actuator for the center limit switch must be adjusted to stay
at the left side of the limit switch. This enables the stroke movement
between the center and left limit switch in the Notch mode. Fail to do so
will result in the machine not function properly.
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 damage the pump. If the pump is not in
unloading position at either upper or lower limit, a loud noise can be heard
from the pump. Immediately turn the machine off and adjust the limit
switch actuators to set the proper stroke movement.
Other manuals for IW-45M
2
This manual suits for next models
3
Table of contents
