Sunrise IW-60 Manual
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Sunrise IW-60 Manual

Hydraulic ironworker , single cylinder models
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HYDRAULIC IRONWORKER
SINGLE CYLINDER MODELS
IW-45M, IW-50A, IW-60H
OPERATION &
MAINTENANCE MANUAL
No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan
Tel: 886-4-2359-1190
Fax: 886-4-2359-3409
SUNRISE
sales@sunriseiw.com.tw
www.sunriseiw.com.tw
Original Instructions
632EG013
12-2012

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  • Page 1 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw 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...

  • Page 2: Table Of Contents

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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……...………….
  • Page 3 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 ……………………….…..………….

  • Page 4: Introduction

    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.

  • Page 5: Safety Precautions

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 6 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 7 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 8 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw DANGER KEEP HANDS CLEAR OF ALL MOVING PARTS. ALL GUARDS AND HOLD-DOWNS MUST BE IN POSITION BEFORE OPERATING THE MACHINE. ALWAYS POSITION MATERIAL UNDER A CORRECTLY SET HOLD-DOWN.

  • Page 9: Transport

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 10: Installation

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 11 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 12: Lubrication

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 13: Standard Equipment

    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 (+)

  • Page 14: Control Switches

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 15 Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.
  • Page 16 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 13 -...

  • Page 17: Low Pressure Tool Alignment With Jog Mode

    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.

  • Page 18: Foot Switch

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 19: Optional Electric Backgauge

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 20: Stroke Adjustment

    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.
  • Page 21 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw IW-45M IW-50A, IW-60H - 18 -...

  • Page 22: Adust The Main Central Shear Slide

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw ADJUST THE MAIN CENTRAL SLIDE The main central slide (holding the moving shear/notch blades) should be pushed against the back of the machine body. Adjustment of the central slide is carried out by setting the "Pressure Pads".

  • Page 23: Punching Station

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 24: Punch And Die Clearance

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 25: Actual Punching Force

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 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.

  • Page 26: Punch Operation

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Punch Operation Punching on Flat Plates: 1) Make sure the notcher safety cover and punching stripper are closed. Turn the Punch/Shear/Notch switch to PUNCH. 2) Check again that the stripper, punch/die alignment is properly adjusted, and the height of the stripper is adjusted to about only 2 to 3mm above the work material.
  • Page 27 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 2) If punching the channel web, use the single-hole die holder with the table removed. If punching the channel flange, use the optional overhang two-hole die holder with the lower support portion and the front piece of the 2-piece table removed.
  • Page 28 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 25 -...

  • Page 29: Punching Station Assembly

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Punching Station Assembly - 26 -...

  • Page 30: Flat Bar Shearing Station

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw FLAT BAR SHEAR STATION This station is equipped with a hold down suitable for shearing of various material thickness. The machine also comes with a feed table with guides for material support and positioning.

  • Page 31: Precaution

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 8) Tighten the locking nut of the adjust screws to prevent loosening. 9) Tighten the fixing bolts to fix the position of lower blade. 10) Reinstall the table and holddown.

  • Page 32: Flat Bar Shear Operation

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Flat bar Shear Operation 1) Make sure the notcher safety cover and punching stripper are closed. Turn the Punch/Shear/Notch switch to SHEAR. 2) Push the material under the hold-down to the desired length. Use the backgauge for getting the precise length.

  • Page 33: Angle Shearing Station

    On IW-60H, external miter shear is also possible. Feed the material through the central slot on the hold-down for 90-degree shear. On IW-45M and IW-50A, feed the material through the slots on the top and side of the hold-down for different directions of 45-degree internal shear.

  • Page 34: 90 Degree Shear Operation

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw 1) In JOG mode, move down the moving blades to lower position so that the opening between the blades are closed. 2) Turn power OFF and isolate the machine. 3) Remove the hold-down.

  • Page 35: Degree Internal Miter Shear Operation (On Iw-45M And Iw-50A)

    Fax: 886-4-2359-3409 www.sunriseiw.com.tw 45 Degree Internal Miter Shear Operation (on IW-45M and IW-50A) 1) Make sure the notcher safety cover and punching stripper are closed. Turn the Punch/Shear/Notch switch to SHEAR. 2) Insert the Angle through the guide slot on the side of the hold down to shear the flanges of angle at 45 degree.
  • Page 36 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 33 -...

  • Page 37: Square/Round Bar Shear Station

    Bar Shear Operation 1) Make sure the notcher cover and punching stripper are closed. 2) On IW-45M and IW-50A, turn Punch/Shear/Notch switch to SHEAR to use this station. On IW-60H, turn Punch/Shear/Notch switch to PUNCH to use this station.
  • Page 38 Alternatively the electric backgauge can be used. See section on Electric Backgauge for details. Note: On IW-45M the holddown for this station is the same as the holddown for the flat shear station. - 35 -...

  • Page 39: Notching Station (On Iw-50A And Iw-60H)

    The rectangular notcher is very useful to notch the edges and corners of flat plates, as well as to notch the flanges of Angles. The triangular Vee- notcher is also available as an optional tooling. On IW-45M, the notcher is optional tooling to be installed at the punching station. Blades The three lower blades each has four cutting edges.

  • Page 40: Notching Operation

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw WARNING The nature of the notch station 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 at the SHEAR/NOTCH selection switch.

  • Page 41: Maintenance

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw MAINTENANCE 1. Before operating the machine: Routinely check the electrical power cable and the foot switch cable for any loosening or damage. Inspect all the blades, punch, die, and safety guards to ensure they are in good condition.
  • Page 42 It is better to keep the oil level close to the high mark indicated on the gauge. Model Capacity (liter) Oil Required (liter) IW-45M IW-50A IW-60H 5. Oil temperature: The oil temperature should be under 50 degrees Celsius. If the upper/lower limit switches are not set correctly for unloading of the pump, the oil temperature can raise quickly.

  • Page 43: Trouble Shooting

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw TROUBLE SHOOTING Problem Probable cause Solution Motor cannot start 1. No power. Check the power source. 2. Isolator switch not turn Turn the switch to ON position.
  • Page 44 No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Problem Probable cause Solution (cont.) 7. Interlocked safety Close covers/stripper. covers not closed. 8. Limit switch not set at Adjust the limit switch for correct position.

  • Page 45: Hydraulic Circuit Diagram

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Hydraulic Circuit IW-45M-50A,60H (with low pressure JOG) - 42 -...

  • Page 46: Hydraulic Parts List

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Hydraulic Circuit Parts IW-45M, IW-50A, IW-60H (with low pressure JOG) Description Qty Specification / Part No. IW-45M: 211702940 (JOG) Tank IW-50A: 211802920 (JOG) IW-60H: 211902920 (JOG) Breather &...

  • Page 47: Electrical Circuit Diagram Iw-45M

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 44 -...

  • Page 48: Electrical Parts List Iw-45M

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Electrical Parts IW-45M (CE) (with low pressure JOG) Code Description Quantity Function Motor Circuit Breaker Motor Protection FU1,FU2,FU3 Fuse Control Circuit Protection Isolator Switch...

  • Page 49: Electrical Circuit Diagram Iw-50A, Iw-60H

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 46 -...

  • Page 50: Electrical Parts List Iw-50A, Iw-60H

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Electrical Parts IW -50A, IW-60H (CE) (with low pressure JOG, working light) Code Description Quantity Function Motor Circuit Breaker Motor Protection FU1,FU2,FU3 Fuse Control Circuit Protection Fuse Spot Light Protection Isolator Switch...

  • Page 51: Electrical Circuit Diagram Iw-50A, Iw-60H With Sensor

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw - 48 -...

  • Page 52: Electrical Parts List Iw-50A, Iw-60H With Sensor

    No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan Tel: 886-4-2359-1190 sales@sunriseiw.com.tw Fax: 886-4-2359-3409 www.sunriseiw.com.tw Electrical Parts IW-50A, IW-60H (CE) (with low pressure JOG, Electric backgauge, working light) Code Description Quantity Function Motor Circuit Breaker Motor Protection FU1,FU2,FU3 Fuse Control Circuit Protection Fuse Spot Light Protection...

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