SUNRISE P157C, P159C Instruction Manual

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan

Tel: [phone] Fax: [phone]
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SUNRISE

HYDRAULIC BENDING MACHINE

HBM-40NC
HBM-75NC

OPERATION &

MAINTENANCE MANUAL

Original Instructions

OMEG072

2011/12

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan

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[e-mail] www.sunriseiw.com.tw

TABLE OF CONTENTS

Introduction ……………………………………………….…… 1
Safety Precautions ………………………………………………2
Transport …………………………………………..……………5
Installation ………………………………………………………6
Control Panel ……………………………………………….…8
Operating Modes …………………………….……………...…… 9
Two Hand Switch / Foot Paddle …………….………………..… 10
Programming Instructions ….……………………………….…11
Optional Tooling …………………………….……………….… 18
Maintenance ………………………………………………….…19
Hydraulic Circuit Diagram ……………………..…………….…21
Hydraulic Circuit Parts …………………………………….…22

Electrical Circuit Diagram ………………………………….…24

Electrical Parts List ……………………………………………26

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No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan

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INTRODUCTION

The Sunrise Bending Machine is a hydraulically powered metal bender for thick
material. There are many bending tooling available for a wide range of bending
operation. Furthermore, optional accessories such as Plate Shearing, Punching and
Profile Strengthening tool can increase the versatility of the machine. This multi­function aspect allows the Sunrise Bending Machine to meet the diversified needs
of the metal forming industry.

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 bending 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.

The machine is only suitable for bending material under 1 meter in length.

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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, two-hands switch should be used to avoid accidents of
hand/finger injury. The foot paddle is also provided as an option to be used only by
authorize personnel and with safety guards installed.

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.

The operator should be familiar with the control and function of the switches before
perform the operation.

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. Only one operator is allowed to operate on the HBM bending machines. Before
each operation, make sure no other person is near the machine.

2. Operator must wear Protective Glasses during operation to protect the eyes.

3. Use of optional attachments/tooling should have proper guards installed.

4. Any maintenance/repair of electrical/hydraulic circuit; change/adjust of tooling
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. Keep hands clear of all moving parts at all times.

7. Do not bend, punch, or shear parts that are too small for safe operation.

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8. If any problem or abnormal condition arises during operation, stop the machine
immediately(push the emergency button) 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. After completing of work, always isolate the machine power supply
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 tooling for defects and wear to ensure safety and maintain good
condition.

12. Use handling equipment when lifting heavy tooling and materials.

13. Never exceed the rated capacity of the machine. Refer to the specification chart
for details.

The manufacturer shall not be held any liability for damages/body injuries or
other consequences to machine, material, and persons caused by the non­compliance of the above safety precaution procedures, in particular for the
following situations:

1. Non-use of the two-hand switches or use of foot switch without safety

protections.

2. Did not wear protective glasses for the eyes.

3. Did not interrupt the main electric power supply before any maintenance

work.

4. Damage of electric parts due to incorrect electric power supply.

5. Warning sign as follows

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6. Proper environment condition

a.Ambient temperature: 0~50℃
b.Relative humidity: 20~85%
c.The required space around the machine is at least 1000 mm.

DANGER

KEEP HANDS CLEAR OF ALL MOVING PARTS.

z

ALL GUARDS AND HOLD-DOWNS MUST BE IN POSITION BEFORE

z

OPERATING THE MACHINE.

ALL SAFETY PROTECTION MUST BE IN POSITION BEFORE

z

OPERATING THE MACHINE.

CAUTION

THOROUGHLY READ THE OPERATION MANUAL BEFORE

z

OPERATION.

TURN OFF POWER AND ISOLATE THE MACHINE WHEN

z

CHANGING TOOLING OR DOING MAINTENANCE.

ALL MAINTENANCE/REPAIR WORK MUST BE DONE BY

z

QUALIFIED PERSONNEL.

IF ANY PROBLEM OR ABNORMAL CONDITION OCCURS, STOP

z

THE MACHINE IMMEDIATELY. DO NOT OPERATE THE
MACHINE AGAIN UNTIL THE PROBLEM IS FIXED.

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TRANSPORT

When transporting the machine by a crane, hook the crane to the two eye bolts
provided for the machine.

Do not use slings under the machine.

if lifting / transporting the machine with forklifts. The forks should extend fully to
cover the width of the machine.

Pay special care

Model HBM-40NC HBM-75NC NC backgauge

Machine Weight (kg) 1030 2080 170

Crane/Forklift (kg)

＞

1030

＞

2080

5

＞

170

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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 anti­vibration pads.

IMPORTANT:

Maintain a spacious working area around the machine for safety.

z

Have the work area well illuminated with proper lighting.

z

Clean the scraps and waste materials regularly, and make sure the work area is

z

free of obstructing objects.
Keep the ground free of oil and make sure it is not slippery.

z

If long lengths of material are to be fed into the machine, make sure that they

z

will not extend into any gangways.

Crowded, poorly illuminated or slippery areas 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.

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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.

z

Briefly start and stop the motor and check that the motor rotates in the same

z

direction as the arrow indicated on motor.

damage the pump.

To change the motor rotation, first make sure the power is disconnected, then

z

Improper rotation can severely

reverse any two of the three phases of the electrical power supply.

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CONTROL PANEL

ISOLATOR Switch

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.

- This switch controls the main electric source. It also

EMERGENCY STOP

- Use the EMERGENCY STOP button to stop the machine
in an emergency. The Emergency button must be released before the PUMP ON
button will function. To release it, turn knob slightly to the right.

I (PUMP ON)

- Push this button to turn on the machine. The EMERGENCY
STOP button must be released before the PUMP ON button will function. The green
POWER LIGHT stays on when the machine is turned on.

O (PUMP OFF)

- Push this button to turn off the machine.

FORWARD (TWO-HAND SWITCHES)

– Use these switches to operate the
machine cylinder movement. Both switches must be pressed at the same time for
the cylinder movement.

NEVER has one operator hold the material and

another operator operating the machine.

BACK

– Use these switches to move the cylinder backward in JOG mode.

HAND/PADDLE -

Use this switch for choosing operation by the two-hand

switches or with foot paddle.

8

Manual/Continue/JOG –

Use this switch to choose the three operating modes.

Opertators’s working positions:

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OPERATING MODES

In MANUAL mode

the cylinder. The cylinder slows down at the Slow position and stops at the
Forward position. Releasing the switches and the cylinder retract to the Back
position, and the controller moves to the next Step in the Program. After finish the
last Step set by the End parameter, the controller moves back to the first Step in the
Program. Place the next work piece and start from the first step(bend).

In AUTO mode

move back and forth between the Back and Forward position. Releasing the
switches and the cylinder retract to the Back position. The controller does not move
to the next Step in this mode.

In JOG mode,

press the two-hand switch together for the forward motion of the
cylinder. The cylinder goes only forward and does not retract. Press the BACK
button for the backward movement of the cylinder. This mode is useful to set the
required cylinder stroke length for the required bend.

PRESSURE SETTING

In certain work job, the pressure of the cylinder need to be adjusted to a lower level,
the pressure can be adjusted by the pressure value in the machine base. A pressure
gauge is included to indicate the pressure.

, press the two-hand switch together for the forward motion of

, press the two-hand switch together and hold. The cylinder will

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TWO HAND SWITCH / FOOT PADDLE

The machine uses two-hand switches for operation.

hold the material and another operator operating the machine.

paddle is only by authorized personnel. It is provided as an option only for the
cases when the operator cannot use the hand switches.

The key of the Hand/Paddle selector switch must never be left on the machine. The
key should be kept in a safe place by the authorized officer of the company.

When using the foot switch mode, the operator understands and accepts the
potential risk of body injuries, and should use extra caution when use the foot
switch.

tool.

NEVER has hands/fingers in between the top(left) tool and lower(right)

Hence the manufacturer should not be held responsibility and liability of
damages and/or body injuries by the non-compliance of the operator to the safety
warnings stated in this manual.

NEVER has one operator

The use of foot

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CONTROLLER OPERATION

1) Turn on power. Be sure the emergency button is released. Screen will be on

after a brief self-check.

2) Press Pump ON to start the motor

3) If the current cylinder position is in the back, the scren will ask you to press the

FWD button (both button simultaneously) to move the cylinder forward. Note:
if the cylinder position is already at an extended position, the screen may just
show press BACK as in next step.

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4) When the screen shows press the BACK button, press BACK to move the

cylinder back for completing the calibration.

5) After the cylinder calibration is done, the controller will ask you to calibrate the

NC stopper:

Press the NC START for 2 seconds to do the NC stopper calibration.

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6) After the cylinder and NC stopper calibrations, the screen switches to the

program mode.

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The Programming Screen

The top of the screen show the current Cylinder position and the NC stopper
position.

The bottom of the screen are the Function Keys:

PROGRAM: program mode (the current screen)
SAVE: save the current program
MANUAL: go to the manual mode to manually move the NC gauge.
SETUP: go to the Setting screen

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The controller can store 50 programs, and each program can have up to 10 steps. A
program can be consider as a working job, and a step is one bending operation. The
END inform the controller the last step of the program. Example, if END=2, then
only step 1 and 2 in the program will be executed.

For each STEP, there are 4 parameters:

BACK: the back position of the cylinder when retracted.
SLOW: when moving forward, the cylinder first move at fast speed and low

pressure. When SLOW is reached, the cylinder turns to slow speed and high
pressure. The cylinder should be in slow speed before the bending started.
The SLOW position is also the reference point for the NC stopper to retract
right before the bend start (refer to NC stopper section for more detail).

FORWARD: The cylinder stopps at the FORWARD position. Adjust this position

for the angle of bend.

GAUGE: This is position of the NC stopper when the NC gauge function is turned

ON.

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The NC stopper function can be turned off. By press the NC gauge button for 2
seconds, the NC function is turned to OFF and the stopper moves back to the origin
position. Press for another 2 seconds to turn the NC function back ON, but the
stopper stay at origin position.

If the NC Gauge function is turned ON, press the NC start button 2 seconds and
moves the NC stopper to the position set by STEP 1 GAUGE. Then press the two
forward buttons or the foot paddle to execute the STEP 1 bend. After STEP 1 is
completed, if there is more steps, the NC stopper will move automatically to the
position set by STEP 2 GAUGE. The NC START is only for the first STEP.

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This is the counter function. Each time a program is executed and completed, the
PCS number increase by one. Press the field and enter zero to reset the counter, or
any other number if desired.

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MANUAL mode for the NC stopper:

Press the Manual button under program screen will go to the manual screen to move
the NC stopper manually:

In this mode, you can either use the cursor keys (arrows or the function buttons
BACK/FORWARD to move the NC stopper, or enter a value at the SINGLE field
and press START to move the NC stopper to a specific position.

The SPEED field adjusts the speed the NC stopper travels. Either enter a % value,
or use the + and – button to change by increment of 10%.

The NC value at the upper right corner of screen shows the current position of the
NC stopper.

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Settting Screens:

In the setting screen, the Function key allows switching between the NC SET (NC
backgauge setting parameters) and CY SET (cylinder setting parameter). Press the
PROGRAM button goes to the program screen.

CY SET SCREEN

HOLD TIME: In CONTINUOUS mode, the cylinder moves back and forth between

the FWD and BACK positions. At the FWD position, the cylinder can hold
for a while before moving back. The hold time set this temporary pause time
at the FWD position. If set to zero, the cylinder moves back immediately.

ORIGIN SET: the origin position of the cylinder after calibration. Adjust this

parameter if the cylinder position is off.

Δ FORWARD: If the Forward position is off from the set value, use this field to

fine adjust the difference.

Δ BACK: If the BACK position is off from the set value, use this field to fine adjust

the difference.

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NC RETRACT: Right before the bend, the NC stopper retract slightly to protect the

stopper from damaged by the bended material. The timing of the retract is a
referenced by the SLOW value. If the NC RETRACT is set at zero, thn
retract happens at the same time the cylinder reach SLOW position. Enter a
positive or negative value here to have the NC stopper retract earlier or later
than the SLOW position.

Retract should happen before the bending

started.

NC SET SCREEN

ORIGIN SET: the origin position of the NC stopper after calibration. Adjust this

parameter if the NC stopper position is off.

STROKE MIN: the MIN position of the NC stopper travel. Be sure not to enter a

number too small that the NC stopper can be damaged by the bending tool.

STROKE MAX: the MAX position of the NC stopper. This should be smaller than

the hardware limit of the machine to provide software limit protection.
NC SPEED: Set the speed the NC stopper travels
NC BACK AMT: Right before the bend, the NC stopper retract slightly to protect

the stopper from damaged by the bended material. Set the amount of the

retract in this field.

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EURROR MESSAGE

OVER SOFTWARE MAX. TRAVEL

The NC gauges has reached the maximum travel range set by the software max.
limit. Use the manual mode to move the NC gauge forward.

OVER SOFTWARE MIN TRAVEL

The NC gauges has reached the minimum travel range set by the software min. limit.
Use the manual mode to move the NC gauge backward.

SERVO MOTOR ERROR

The Servo motor driver sense an error at the servo motor. This may be caused by
torque exceeding the motor limit, or a hardware error. Check the motor for cause of
problem. If unable to solve the problem, contact Sunrise dealer for service.

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※Input Layout List:

INPUT Description Memo

X00 Servo Motor Z value
X01

X02

X03 Optical gauge A value

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Optical gauge Z value

X04 Optical gauge B value

X05

X06

X07

X10

X11

X12

X13

X14

X15

X16

X17

X20

X21

X22

X23

NC origin sensor

Servo Motor Ready

CYLINDER BACKWARD

CYLINDER FORWARD BUTTON 1

CYLINDER FORWARD BUTTON 2

CYLINDER FORWARD FOOT SWITCH

PUMP ON

CONTINUOUS mode

JOG mode

MANUAL mode

NC Max. limit switch

NC Min. limit switch

FOOT operation mode

HAND operation mode

X24

X25

X26

X27

Cylinder origin position sensor

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※Output Layout List:

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OUTPUT

Description Relay

Y00 Servo motor turn

Y01

Y02 Servo motor turn

Y03

Y04 Cylinder foward SSR1

Y05 Cylinder backward SSR2

Y06 Cylinder fast mode SSR3

Y07 Pump ON KA1

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OPTIONAL TOOLING

The bending machine can be used with a variety of optional tooling including
various bending tool, punching, shearing, profile strengthening, and well as many
custom made tooling.

Depend on the tooling, the upper die set is fixed at the cylinder head block, and the
lower die set is fixed using one or combination of the ø83mm and ø58mm fixing
holes. The ø83mm fixing hole has a handle on the backside of the machine for lock
up the tool. After install the tooling, turn the handle to right to lock the tool. Lose
the handle to left before uninstall the tool.

Because this manual cannot cover all the possibility of the optional tooling, the user
should refer to the appropriate instruction for the specific tooling for installation,
operation, and maintenance.

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MAINTENANCE

1.

Before operating the machine

Routinely check the electrical power cable and the foot switch cable for any

loosening or damage.

Clean all slugs, cut off pieces, and other waste material from and around the

machine.

2.

Filter and Oil Change

:

Take off and clean the suction filter inside the oil tank every time when
changing oil. The first oil change should be performed after approximately
600 operating hours. Further oil change is needed for every 1200 operating
hours. A drain outlet is located at the base of the oil tank.

Screw back the cleaned suction filter after the draining the oil. If the suction

filter is damaged or clogged, replace the suction filter. Do not mix different
brands of oil.

Hydraulic Fluid (or equivalent)

Mobil DTE 46

Esso Nuto H46

Shell Tellus 46 or Hydraulic oil 46
B.P. Energol HLP 46
Castrol Hyspin AWS 46 6018

3.

Oil level

:

Make sure the hydraulic oil level is in the range indicated on the oil level gauge.

It is better to keep the oil level close to the high mark indicated on the gauge.

:

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4.

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. Adjust the limit switches so the pump will be in
the unloading condition.

5.

Hydraulic pressure

:

The working pressure of the hydraulic system is pre-set in the factory. There is

a pressure gauge to indicate the working pressure of the machine. The pressure
gauge should normally be closed and be used only during service/maintenance
work.

Model

Max Pressure

HBM-40NC

210

Kg/cm

2

HBM-75NC

210

Kg/cm

2

AIRBORNE NOISE

The continuous airborne noise level of the machine under normal condition is
approximately 75 dB ± 5 dB.

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Hydraulic Circuit

HBM-40NC , HBM-75NC

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Hydraulic Circuit Parts

HBM-40NC

No. Description Qty Specification / Part No.

1
2
3
4
5
6
7
8

9
10
11
12

Tank 1 6102910B

Breather & Filter 1 OLHW-HY-08A

Oil Level Gauge 1 OLHW-LG-4

Suction Oil Filter 1 OLFL-MF-086

Motor 1 5 HP (3.75 kW)

Pump 1 Gear Pump

Pressure Gauge 1 OLOV-35DSK

Relief Valve 1 OLOV-DG-02-H-22

Relief Valve 1 OLOV-RPEC-FAN

Solenoid Valve 1 OLSV-DFA-02-3C60

Solenoid Valve 1 OLSV-DFA-03-2B3

Cylinder 1 6103900C

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Hydraulic Circuit Parts

HBM-75NC

No. Description Qty Specification / Part No.

1

2

3

4

5

6

7

8

9
10
11
12

Tank 1 6202910

Breather & Filter 1 OLHW-HY-08A

Oil Level Gauge 1 OLHW-LG-4

Suction Oil Filter 1 OLFL-MF-086

Motor 1 7.5 HP (5.625 kW)

Pump 1 Gear Pump

Pressure Gauge 1 OLOV-35DSK

Relief Valve 1 OLOV-DG-02-H-22

Relief Valve 1 OLOV-RPEC-FAN

Solenoid Valve 1 OLSV-DFA-02-3C60

Solenoid Valve 1 OLSV-DFA-03-2B3

Cylinder 1 6203900B

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PLC I/O layout

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Electrical Parts

HBM-40NC, HBM-75NC

Code Description

QF Motor Circuit Breaker
FU1,FU2,FU3

FU4
FU5 Fuses

QS Isolator Switch

SB1 Push-Lock Push Bottom

SB2 Flush Push Bottom (Green)

SB3+SB4 Two-hand Push Bottoms

SB5 Push Bottom

SA1 Selector Switch

SA2 Selector Switch

FS Foot Switch

KM1

VC Bridge Rectifiers

TC Transformer

SSR1 Solid Relay

Fuses

Magnetic Switch
(Contactors)

Maker

Bussmann FUSE-2A 2A

Bussmann FUSE-6A 6A

SSUPOU YC-135N/1A1B(BNA) Foot Switch Control

SUENN

LIANG

FOTEK SSR-10DD Forward

TE GV2-ME14 6-10A

ABB OT16F3 Circuit Interrupter

TE XB5AS542 Emergency Stop

TE TEXB5AL42 Pump On

TE ZB5-AA3 Forward

TE ZB5-AA2 backward

TE ZB5-AD3 MANUAL/CONT/JOG

TE ZB5-AG2 HAND/FOOT

TE TENLC1D25B7 25A/ AC24V

FY KBPC2506 KBPC2506

SP-TBSW-1025D

Model

(CE)350VA secondary
instrument:110V(1.5A)24V(6A)
24V(1A)

Specifications

SSR2 Solid Relay

SSR3 Solid Relay

YV1 / YV2 Solenoid Valves Coil

YV3 Solenoid Valves Coil

SQ1 Photo Meter

PLC PLC

U1 Human Machine Interface

GS1 Switching Power Supply

SB6 Flush Push Bottom (Red)

SQ2 SENSOR

SQ3 SENSOR

SQ4 SENSOR

SQ5 SENSOR

SM Servo motor

SMD Servo motor driver

8EX PLC expander

FOTEK SSR-10DD Backward

FOTEK SSR-10DD Slow

Dofluid DFA-02-3C60-DC24V-35 Forward / Backward

Dofluid DFA-03-2B3-DC24V-35 Slow

Mitutoyo

LIYAN EX1N24MT PLC controller

DELTA DOP-B05S100 Interface Screen

MW 52201NED35B For Photo Meter and Interface

TE XB5-AL42 Pump Off

OMRON TL-Q5MC1-Z (NO)

OMRON TL-Q5MC1-Z (NO)

OMRON TL-Q5MC2-Z (NC)

OMRON TL-Q5MC2-Z (NC)

Mitsubishi 52305HFKP43K

Mitsubishi 52501MRJ340A

LIYAN EX1S08EX EX1S08EX

AT216-250T /
AT216-350T

Stroke gauging meter

Cylinder origin position
sensor

NC origin sensor

NC Max. limit switch

NC Min. limit switch

Servo motor

Servo motor driver

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Annex 1

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan

Tel: [phone] Fax: [phone]
[e-mail] www.sunriseiw.com.tw

34

No. 7, Road 12, Industrial Zone, Taichung City 407, Taiwan

Tel: [phone] Fax: [phone]
[e-mail] www.sunriseiw.com.tw

35