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Rockford Fosgate SSC-500, Installation Manual

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INSTALLATION MANUAL FOR 

SSC-500 CONTROL SYSTEMS 

ON HYDRAULIC PRESSES

IMPORTANT:

 PLEASE REVIEW THIS ENTIRE 

PUBLICATION BEFORE INSTALLING, OPERATING OR 

MAINTAINING THE SOLID-STATE HYDRAULIC PRESS 

ELECTRICAL CONTROL SYSTEM.

SSC-500 Control Box

(Not Shown)

Operator Interface 

Keypad/Display

5795 Logistics Parkway • Rockford, Illinois 61109 • Toll Free 1-800-922-7533 (USA only) • Phone (815) 874-7891

Fax (815) 874-6144 • Web Site:  www.rockfordsystems.com • E-Mail:  [email protected]

Manual No. KSL-249

Program/Run 

Selector Switch

Remote Operator 
Station (Optional)

Summary of Contents for SSC-500

Page 1: ...ATE HYDRAULIC PRESS ELECTRICAL CONTROL SYSTEM SSC 500 Control Box Not Shown Operator Interface Keypad Display 5795 Logistics Parkway Rockford Illinois 61109 Toll Free 1 800 922 7533 USA only Phone 815...

Page 2: ...T SKETCH 42 SE CTION 11 RETURN AUTHORIZATION FORM 43 SE CTION 12 ORDER FORM 44 FIGURES PHOTOS AND TABLES Figure 2 1 Block Diagram 12 Figure 4 1 Initial Setup Procedure Flowchart 24 Figure 4 2 Initial...

Page 3: ...top management to operators since only as a group can any operational problems be identified and resolved It is everyone s responsibility to implement and communicate the information and material cont...

Page 4: ...1151 www mfgtech org Safety References OSHA S ACT AND FEDERAL REGULATIONS Since the enclosed equipment can never overcome a mechanical defi ciency defect or malfunction in the machine itself OSHA Occu...

Page 5: ...king 12304 0335 Drills Portable Reamer 12304 0497 Drop Hammers Steam 12304 0720 Electrical Controls for Mechanical Power Presses 12304 0624 Forging Hammer Dies Setup and Removal of 12304 0716 Forging...

Page 6: ...is precau tion pamphlet is provided for attaching pur poses Additional copies of this precaution are available Please call e mail write fax or use the order form found on a later page in this manual W...

Page 7: ...de Part No KSC 055 Danger Sign Foot Standard Part No KSC 055S Spanish Part No KSC 055F French See page 6 for details on this pamphlet OPERATOR SAFETY PRECAUTIONS Handout for Anyone Operating This Mach...

Page 8: ...l boxes provided All personnel operating or working around the machine where this control box is installed must be required to read understand and adhere to all dangers and warnings If any of these la...

Page 9: ...ENT SIGNS CALL FAX E MAIL OR FACTORY OR USE ORDER FORM ON A LATER PAGE OF THIS MANUAL Rockford Systems LLC 5795 Logistics Parkway Rockford Illinois 61109 Toll Free 1 800 922 7533 USA only Phone 815 87...

Page 10: ...r prevent a mechanical defect or failure of a machine part These controls cannot prevent a repeat or unintended stroke cycle resulting from a mechanical or hydraulic component malfunction defect or fa...

Page 11: ...l machine operation during operator cycling modes Examples of these types of interlocks are barrier guard interlocks and gate device interlocks When a mechanical guard or device nonelectrically interl...

Page 12: ...OS bottom of stroke and speed change limit switch inputs can be either N O or N C as required See OPTIONS EDIT programming on page 33 OFF The machine is inoperable in this mode of operation To initiat...

Page 13: ...connected to the return selector switch to facilitate pressure pressure distance or distance return on machines with BOS limit and pressure switches The BOS limit switch input can be either N O or N C...

Page 14: ...eration is desired but the press is faster than the material feeding equipment When this mode of operation is ON each press cycle can be initiated by the material or material feeding equipment This mo...

Page 15: ...gn becomes destroyed or unreadable it must be replaced immediately Contact factory for replacement and do not operate the machine until the danger sign is in place Foot Switch Danger Sign Part No KSC...

Page 16: ...ove the module from the shock vibration mounts turn power off to the control Remove all terminal blocks from the left and right sides of the printed circuit board Loosen the four Allen head bolts and...

Page 17: ...box on the proper wiring connection Mounting the Control Box Solidly mount the control box in an accessible location either on or near the machine to be controlled A convenient location will keep con...

Page 18: ...ngle hub Optionally available are the Touchdown or chrome light push palm buttons These may be furnished in place of the standard black run inch palm buttons The palm buttons can be assembled as shown...

Page 19: ...l time allowed for the stopping performance monitor to compensate for variations in the normal stopping time When applying the two palm run buttons to meet the requirements for a point of operation sa...

Page 20: ...to depressing the two palm buttons These buttons may be mounted as part of the operator s control station After releasing the button the operator has a 5 second time period in which to depress the ru...

Page 21: ...re occurs Please refer to the enclosed wiring schematics for proper wiring of this starter If an existing starter is used a 120 VAC coil is required ANSI Standard B11 2 requires that 1 The motor start...

Page 22: ...ment Tc the response time of the press control Note Ts Tc are usually measured by a portable or built in stop time measuring device Tr response time of the presence sensing device and its interface if...

Page 23: ...ted near or in the same conduit or raceway with conductors for main power feeds or motor leads 25 of cable is supplied as standard and can be cut to length if required Do not splice or interrupt signa...

Page 24: ...the control box or remote operator station Power Up Control Program User Inputs Program Standard Settings Ready for Production See Pages 29 30 Step Completed Step See Pages 26 29 See Page 24 Program...

Page 25: ...rogram options that can be modified When the program option you want to edit is displayed press ENTER Once the required information is entered and the ENTER key is pressed again the display returns to...

Page 26: ...button to abort the clear and return to the main menu level The LCD again displays CLEAR STROKE Function The 7 digit stroke counter is used to count strokes in the single or automatic modes of operati...

Page 27: ...RUN position BATCH PRESET Select the PROG position on the Program Run selector switch Press the t and s buttons on the keypad to scroll through the pro gram options Press ENTER when the LCD displays B...

Page 28: ...l energize returning the ram to the TOS limit switch DECOMPRESS TIMER Select the PROG position on the Program Run selector switch Press the t and s buttons on the keypad to scroll through the program...

Page 29: ...ect the PROG position on the Program Run selector switch Press the t and s buttons on the keypad to scroll through the program options Press ENTER when the LCD displays SING RETURN MODE The display no...

Page 30: ...o reactivate the PSDI mode of operation depress the PSDI prior action push button ASINGLE MODE Automatic Single Stroke Select the PROG position on the Program Run selector switch Press the t and s but...

Page 31: ...0 has four 4 programmable user inputs These inputs are 24VDC sinking NPN type There are three 3 parameters that can be programmed for each input Programmable Parameters 1 FAULT MESSAGE When the input...

Page 32: ...ng is the same for all four inputs The display now reads X FLT Where X FLT is a fault message from the list in Figure 4 8 on page 28 Press the t and s buttons on the keypad to scroll through the list...

Page 33: ...O and N C Press the t and s buttons to scroll to the next option The display now reads BOS LS N O Press the ENTER key to toggle between N O and N C Press the t and s buttons to scroll to the next opti...

Page 34: ...The operator must break the light curtain sensing field a second time and remove hand s and arm s from the sensing field to initiate a stroke before the timer expires If the timer expires the display...

Page 35: ...ydraulic control systems In all cases please refer to the individual control wiring schematic for particular test points and terminal numbers 2 Each control system may be slightly different depending...

Page 36: ...ents may be defective Contact factory for technical support SSR 1 K1 OFF FLT The processor did inot detect through feedback that the SSR 1 Solid State Relay turned OFF or that K1 relay contacts did no...

Page 37: ...s of the UP solenoid valve coming on Check the status LED on the TOS limit switch input Check all wiring to the switch Check 24 VDC power supply Make sure the UP solenoid valve is energizing and that...

Page 38: ...ipment and safeguarding are in safe operating condition and adjustment E7 3 The employer should consider the manufacturer s instructions and recommendations in determining maintenance programs The emp...

Page 39: ...e cover straight off over the relays and transformers 2 Locate the U4 main EPROM see Photo 3 4 on page 16 and Photo 8 1 below It is located below the K2 Solenoid Relay on the dual CPU Control Processi...

Page 40: ...e safeguard This protection may also be accomplished by the use of a combination of guards and devices When updating a power press the most important decision is the selection of the proper guard or d...

Page 41: ...PS page 13 4 Hand feeding tools Hand feeding tools are intended for placing and removing material in and from the press Hand feeding tools are not a point of operation guard or protection device and s...

Page 42: ...SECTION 10 LAYOUT SKETCH SSC 500 Hydraulic Press Solid State Control Rockford Systems LLC 42 Call 1 800 922 7533 Continued on next page...

Page 43: ...at 1 800 922 7533 for an R M A Number All returned materials shipments must be prepaid Complete this form and send with material to 5795 Logistics Parkway Rockford IL 61109 Make sure the R M A Number...

Page 44: ...x 6 English KSC 055S Danger Sign Foot Switch 5 x 6 Spanish KSC 055F Danger Sign Foot Switch 5 x 6 French KSL 051 Booklet Mechanical Power Press Safety MPPS FAB Catalog Safeguarding Fabricating Machine...

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