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Rockford Systems SSC-1500, Installation Manual

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Rockford Systems SSC-1500 Installation Manual Download Page 1

IMPORTANT:

 

PLEASE REVIEW THIS ENTIRE PUBLICATION 

BEFORE INSTALLING, OPERATING OR MAINTAINING THE SOLID-
STATE CLUTCH/BRAKE CONTROL SYSTEM.

4620 Hydraulic Road • 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-276

INSTALLATION MANUAL FOR  

SSC-1500 CONTROL SYSTEMS ON

PART REVOLUTION CLUTCH MACHINES

Plain-Door Custom 
Control Box

Resolver/Pulser 
Assembly

Remote 
Operator 
Station

Light 
Curtains

Palm Button 
Assembly

Summary of Contents for SSC-1500

Page 1: ...linois 61109 Toll Free 1 800 922 7533 USA only Phone 815 874 7891 Fax 815 874 6144 Web Site www rockfordsystems com E Mail sales rockfordsystems com Manual No KSL 276 INSTALLATION MANUAL FOR SSC 1500...

Page 2: ...3 36 Other Installation Considerations 36 38 SECTION 4 PROGRAMMING 39 64 User Inputs 42 45 Brake Monitor 46 48 Counters 49 System Setup 50 53 Angle Settings 54 55 Timed Settings 56 57 Optional Modes 5...

Page 3: ...ement 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 contained in...

Page 4: ...S ACT AND FEDERAL REGULATIONS Since the enclosed equipment can never overcome a mechanical deficiency defect or malfunction in the machine itself OSHA Occupational Safety and Health Administration has...

Page 5: ...S Other good references for safety on machine tools are the National Safety Council s Safety Manuals These manuals are written by various committees including the Power Press Forging and Fabricating E...

Page 6: ...ary for the machine See packing list for details Individual packages may vary in contents However a packing list is always enclosed showing exactly what material was shipped on this order Please check...

Page 7: ...utches an air cylinder is not required Safeguard Interlocks and Other Types Of Interlocks SAFEGUARD INTERLOCKS The machine will not operate or must not be operated until you either 1 electrically inte...

Page 8: ...essors Redundant Microprocessor Logic Power Supplies Triple Redundant Solid State Solenoid Relays 4 Line x 20 Character LCD Liquid Crystal Display with 20 Key Operator Interface Absolute Resolver Puls...

Page 9: ...INGLE INPUT K2 PLS 1 PLS 1A PLS 1B USER INPUT 4 MCR SHIELD COSINE COM SINE K3 PLS 2 PLS 2A PLS 2B SSR 1 SOLENOID 2 USER INPUT 5 USER INPUT 6 24 COM AUX OUT 2A AUX OUT 2B SSR 2 NEUTRAL SAFE GRD INT 2 1...

Page 10: ...noperable in this mode of operation The OFF position cannot be used solely as the lockout tagout means To use any of the following modes of operation turn the mode selector switch from OFF to the appr...

Page 11: ...ows the press to operate continuously after initiation without the operator present To initiate this mode press the prior action push button then depress the palm buttons The press will run in the con...

Page 12: ...rake Control Panel with Starter and Disconnect Switch Air Counterbalance Cylinders Emergency Stop Button Bolster Rear Guard Side Guard Air Surge Tank Resolver Pulser Assembly Belts Sheave Lifting Bolt...

Page 13: ...any retrofit installation begins Please notify Rockford Systems immediately if there are any questions about the components received MECHANICAL POWER PRESS SAFETY BOOKLET A copy of Booklet No MPPS Me...

Page 14: ...operate this machine until you test the machine with its guard or safety device before you start or restart production Do not begin operating the machine unless you are sure the safeguarding is adjust...

Page 15: ...igns Part No KSC 000 Part No KSC 000 Control Box DANGER AND WARNING LABELS PROVIDED The illustrated danger and warning labels are affixed to all control boxes provided All personnel operating or worki...

Page 16: ...elay with force guided contacts and two solid state relays These output relays are independently controlled and cross checked by the microprocessors This allows control reliable operation of the outpu...

Page 17: ...mer Master Control Relay CUSTOM CONTROL BOX A custom control box contains the standard control module and components described above plus the following main power disconnect switch main drive motor st...

Page 18: ...ndard SSC 1500 control box without the control transformer but with an e stop top stop and prior action push button and two 2 guarded run inch buttons on the sides of the enclosure CONTROL MODULE KIT...

Page 19: ...n mounts and four 1 4 20 x 1 2 Allen head bolts The module case has four keyhole mounting slots that allow for easy removal without taking off the Allen head mounting bolts Red and green LEDs allow fo...

Page 20: ...P4 Fuse F2 Fuse F1 Fuse F3 Fuse F4 Fuse F5 Fuse F6 Auxiliary Output Terminal P7 Core Module Resolver Terminal P5 User serviceable parts on the dual CPU board are the core module the battery and the fu...

Page 21: ...n 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 conduit runs to a minimum length Note...

Page 22: ...to the connector provided therefore no wiring is necessary The resolver pulser is factory arranged for clockwise CW rotation when facing the end of the shaft A wiring change is required for counterclo...

Page 23: ...y is approximately parallel with each other when the chain is installed The spring is normally positioned between the two plates when the chain is pulling down see Photo 3 21 When the chain is pulling...

Page 24: ...control to indicate when one valve may have failed Filter Regulator Lubricator FRL Assembly If furnished See enclosed Manual KSL 208 The filter cleans air that goes to the dual solenoid air valve The...

Page 25: ...lutch engaging period The minimum setting for the air counterbalance pressure may be in the 20 to 30 PSI range see machine manufacturer s recommendations Check Valves for Counterbalance Systems If fur...

Page 26: ...l from ANSI B11 1 These sections cover two hand control as an initiating means and two hand control as a point of operation safeguard for part revolution clutch presses Please read and make sure you u...

Page 27: ...agraph b 7 v of this section See paragraph b 7 v on page 24 c The safety distance Ds between the two hand control device and the point of operation shall be greater than the distance determined by the...

Page 28: ...ormulas Simply stated safety distance is the mounting location of the palm buttons at a distance where the operator cannot reach into the point of operation hazard before the ram has stopped or comple...

Page 29: ...must be depressed and released by the operator before depressing the actuating means in order to initiate the Continuous automatic RUN type of press operation This is sometimes referred to as Walk Aw...

Page 30: ...have a timer to prevent successive automatic single strokes if the time expires between the initiating signals Shall require a setup and reset action or decision by the operator prior to stroke initi...

Page 31: ...e press to finish the stroke Repeat this test while releasing the other palm button The press should not finish the stroke Both palm buttons must be released and reactuated in order for the press to f...

Page 32: ...rnished When two or more palm button or foot switch operating stations are required on one machine one supervisory control station is required at each operator station This remote control station cons...

Page 33: ...y sources Know the hazards of the energy to be controlled Determine the methods or means to control energy 5 Hazardous energy sources associated with machinery are Electrical Pneumatic Hydraulic Fluid...

Page 34: ...ir in the line the handle is pushed in This valve is available in port sizes 3 4 and 1 Manual Pilot Valve This valve is used for air systems that are larger than those that can be used with the manual...

Page 35: ...The main purpose of this starter is to start and stop the main motor and to drop out the main motor when a power failure occurs Please refer to the enclosed wiring schematics for proper wiring of thi...

Page 36: ...n an appropriate pipe size throughout for proper air flow Connect the piping to the ports using teflon tape on the male threads only Do not allow tape to enter the interior of the filter regulator lub...

Page 37: ...perate the machine unless the muffler is clean KEYPAD DISPLAY See page 21 The keypad display can be furnished in a remote enclosure which is connected to the control module with a seven conductor shie...

Page 38: ...d a wire from the other side of each contact to the appropriate control module input terminal If multiple foot switches are used the COM connection may be split up Refer to the multiple operator drawi...

Page 39: ...am Timed Settings Program Batch Counter Program Var Speed Top Stop Settings See Pages 42 45 If required See Page 63 If required See Page 49 If required See Pages 61 62 If required See Pages 58 60 If r...

Page 40: ...ress YES on the keypad and proceed Main Run Screen Overview The MAIN RUN SCREEN displays the crankshaft angle in degrees speed of the press in SPM batch counter total counter mode of operation and sto...

Page 41: ...ss when the pound symbol is next to SYSTEM SETUP the second MAIN PROGRAM SCREEN will be displayed See Figure 4 6 If you press when the pound symbol is next to VAR SPD SETTINGS the third MAIN PROGRAM S...

Page 42: ...t is activated or goes true the press cycle will stop in one of two ways E STOP emergency stop will immediately stop the cycle in progress T STOP top stop will stop the cycle in progress at TDC top de...

Page 43: ...program A screen similar to the one shown in Figure 4 12 will be displayed Once you are in the programming screen of the parameter you want to program use and on the keypad to reach the setting you d...

Page 44: ...ndow during which the control will look for a change of state of the input The setting ranges from 0 to 359 If this setting and the OPEN angle are both set to 0 the input will be a static input HOW TO...

Page 45: ...gram A screen similar to the one shown in Figure 4 18 will be displayed Once you are in the programming screen of the parameter you want to program use and on the keypad to reach the setting you desir...

Page 46: ...ime may also increase if you use a heavier die for the same reason If you have a counterbalance system the stopping time may increase if the air pressure is not adjusted properly based on the upper di...

Page 47: ...e on the downstroke See Figure 4 22 Press ESC to exit and select the OFF position of the program OFF ON selector switch Then either inch or single stroke the press to return to TDC To run more than on...

Page 48: ...angle setting and your press is stopping at TDC you are ready to calculate the warning and fault setpoints for the brake monitor Take and record several readings at least ten of the stopping time usi...

Page 49: ...to the COUNTERS PROGRAM SCREEN To clear the Batch Counter Use and on the keypad to scroll up and down Press ENTER when the arrow symbol is next to Batch Clear You will see the CLEAR BATCH SCREEN See...

Page 50: ...resolver When the press setup is run the control measures the amount of time the press takes to go from 0 to 4 SPM strokes per minute This is because any speed less than 4 SPM is not considered as no...

Page 51: ...will be prompted to enter the security code Press ESC to stop and return to the MAIN PROGRAM SCREEN Press BKSP to backspace or press CLR to delete the entry and start over Press ENTER when finished A...

Page 52: ...s BKSP to backspace or press CLR to delete the entry and start over Press ENTER when finished After the correct security code has been entered the SYSTEM SETUP SCREEN will be displayed See Figure 4 38...

Page 53: ...program options Press ENTER when the pound symbol is next to SYSTEM SETUP The security code screen will be displayed See Figure 4 40 You will be prompted to enter the security code Press ESC to stop a...

Page 54: ...od angle to start with is 270 If the press stops before TDC a higher continuous top stop setting is required Add the number of degrees the machine stopped short of TDC to the continuous top stop setti...

Page 55: ...oll through the angle settings Press ENTER when the arrow symbol is next to the angle setting you want to program A screen similar to the one shown in Figure 4 45 will be displayed Use the numeric key...

Page 56: ...control will allow is approximately 220 SIGNAL TIME OUT SETTING The signal time out setting is the amount of time within which a signal from an automatic feeding mechanism or other auxiliary equipment...

Page 57: ...ad to scroll through the timed settings Press ENTER when the arrow symbol is next to the timed setting you want to program A screen similar to the one shown in Figure 4 48 will be displayed Use the nu...

Page 58: ...If the signal is received within the programmed amount of time the press will cycle and the signal time out setting will reset and start over Initially the timer is started before the first continuous...

Page 59: ...This timed setting is called signal time out For directions on how to program this setting refer to the timed settings section on pages 56 57 The programmed time must be longer than the entire Automat...

Page 60: ...displayed See Figure 4 51 Press ENTER when the arrow symbol is next to the optional mode you want to turn on or off A screen similar to the one shown in Figure 4 52 will be displayed Once in the progr...

Page 61: ...DC top dead center when the top stop palm button is pressed while in the Continuous mode of operation This will ensure the press will stop at top regardless of the speed at which it is run These setti...

Page 62: ...ress ENTER when the double arrow symbol is next to the variable speed setting to be programmed A programming screen similar to Figures 4 59 and 4 60 will be displayed Use the numeric keypad to enter t...

Page 63: ...uired every three cycles the counter setting is set to 3 strokes When the counter reaches 3 strokes the PLS output turns on and the oil mist is given The counter is then reset and the cycle starts ove...

Page 64: ...acts will change state when a fault occurs The programming choices are OFF or ON 3 Aux Out Stop With this function turned on the auxiliary output contacts will change state when the machine stops The...

Page 65: ...gure 4 66 Press ENTER when the arrow symbol is next to the parameter you want to program A screen similar to the one shown in Figure 4 67 will be displayed Once you are in the programming screen of th...

Page 66: ...or Off Two Hand Maintained Continuous On or Off One Hand Foot Trip On or Off Auto Single Stroke On or Off Speed 4 500 SPM Angle 0 359 On Angle 0 359 Off Angle 0 359 Counter 0 999 strokes Timed Off 0 9...

Page 67: ...wer switch off for 5 to 10 seconds Turn it back on and proceed as normal If the message persists the module may need to be replaced Consult factory SSR1 or K1 OFF FLT SSR1 solid state relay and or K1...

Page 68: ...ithin the given reference time allotted Check that the press is running at full speed and the air pressure hasn t dropped If this message persists rerun the press setup from TDC and note the reference...

Page 69: ...uation that can be used HAND OFF The actuating means selector switch was changed from HAND to FOOT while the machine was running in Continuous CONT MODE OFF An attempt was made to switch to Single Str...

Page 70: ...Y or N Note The shaft extension of the resolver must have the keyway up and perpendicular to the base of the assembly when setting the resolver 8 The resolver pulser assembly was shipped with the pri...

Page 71: ...ated to prevent machine operation when open Please refer to the schematic for the location of the various interlocks 2 Motor starter does not energize Motor starter operating coil may not be 120 V AC...

Page 72: ...e date of inspection the signature of the person who performed the inspection and the serial number or other identifier of the power press that was inspected ii Each press shall be inspected and teste...

Page 73: ...l 3 Be sure to check the lubricator for proper oil level and oil delivery adjustment See Installation Manual No KSL 208 4 The monitored dual solenoid air valve that operates the clutch and releases th...

Page 74: ...the circuit board Photo 8 5 and lift the circuit board straight up 6 Locate the core module in the center of the circuit board Remove the small screw and lift the core module out by gently wiggling it...

Page 75: ...ower cord and insert all terminal strips Be careful when placing the cover back onto the module The op amp must remain in its original 45 position see Photo 8 9 All power to the machine must be off be...

Page 76: ...e battery 4 Insert the new battery 5 Put the cover plate back onto the control module and secure it with the four screws 6 Put the control module back in place tighten the Allen head bolts plug in the...

Page 77: ...safeguarding for the operator by at least one type of guard or a device This protection may also be accomplished by the use of a combination of guards and devices When updating a power press the most...

Page 78: ...to items such as a main power disconnect switch which must be provided for each machine and a magnetic type motor starter for the main drive motor All mechanical power transmission apparatus of the m...

Page 79: ...533 for an RMA Number All return materials shipments must be prepaid Complete this form and send with material to Rockford Systems LLC 4620 Hydraulic Road Rockford IL 61109 2695 Make sure the RMA Numb...

Page 80: ...S Precaution Pamphlet Spanish KSC 000F Precaution Pamphlet French KST 134 Danger Closing Ram and Die Label KSC 054 Danger Sign 5 x 6 English KSC 054S Danger Sign 5 x 6 Spanish KSC 054F Danger Sign 5 x...

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