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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 • Phone (815) 874-7891

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

Manual No. KSL-277

INSTALLATION MANUAL

 FOR  

SSC-1500 GEN II CONTROL SYSTEMS ON 
PART-REVOLUTION-CLUTCH PRESS BRAKES

Plain-Door 

Control Box

Palm Button 

Assembly

Light Curtain

Remote Operator 

Station

Resolver/Pulser 

Assembly

(Not Shown)

Содержание SSC-1500 GEN II

Страница 1: ...is 61109 Toll Free 1 800 922 7533 Phone 815 874 7891 Fax 815 874 6144 Web Site www rockfordsystems com E Mail sales rockfordsystems com Manual No KSL 277 INSTALLATION MANUAL FOR SSC 1500 GEN II CONTRO...

Страница 2: ...Operator Junction Box 36 Other Components 37 40 Other Installation Considerations 40 42 SECTION 4 PROGRAMMING 43 73 User Inputs 46 49 Brake Monitor 50 52 Counters 53 54 System Setup 55 64 Angle Setti...

Страница 3: ...mpany s safety program must involve everyone in the company from top management to operators since only as a group can any operational problems be identified and resolved It is everyone s responsibili...

Страница 4: ...02 Phone 703 893 2900 Toll Free 1 800 524 0475 Fax 703 893 1151 E Mail AMT amtonline org www amtonline org Safety References OSH ACT AND FEDERAL REGULATIONS Since the enclosed equipment can never over...

Страница 5: ...luding the Power Press Forging and Fabricating Executive Committee Copies of the following publications are available from their library Power Press Safety Manual 5th Edition Safeguarding Concepts Ill...

Страница 6: ...SER INPUT 6 27 USER INPUT 7 CYCLIC 28 USER INPUT 8 CYCLIC 5 R PB NC 6 L R PB NO 7 HAND 8 FOOT 9 INCH 10 SINGLE 11 SEQUENCE STOP 12 13 LC OFF 14 LC CT 1 15 LC CT 2 16 MTR FWD 17 SAFEGRD 18 SAFEGRD 19 2...

Страница 7: ...OTOR RED COSINE BLACK COSINE WHITE SINE BLACK SINE GREEN CABLE 7 CONDUCTOR WITH SHIELD KEYPAD DISPLAY UNIT FTL 062 RS 422 150 MAX CUT TO LENGTH IF REQUIRED BUT DO NOT SPLICE 150 MAX CUT TO LENGTH IF R...

Страница 8: ...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 the...

Страница 9: ...disengage the clutch Install the air cylinder in the most logical place to actuate the clutch Please see the enclosed Installation Manual No KSL 096 if an air cylinder was ordered Note On machines eq...

Страница 10: ...sor Logic Power Supplies Triple Redundant Solid State Solenoid Relays 4 Line x 20 Character LCD Liquid Crystal Display With 20 Key Keypad Absolute Resolver Pulser With Sync Sensor for Timing and Motio...

Страница 11: ...tagout means To use any of the following modes of operation turn the mode selector switch from OFF to the appropriate position Two Hand Inch is a mode of operation in which the ram travels as long as...

Страница 12: ...HAND HAND FOOT SEQUENCE STOP Hand Foot Sequence Stop is a mode of operation in which the palm buttons are held depressed until the slide automatically stops at the programmed sequence stop point usua...

Страница 13: ...w speed until the programmed speed change off angle is reached usually at the bottom of the stroke or slightly after and then it returns to the top of the stroke in high speed To use High Low Speed Ch...

Страница 14: ...anical protection for the wires Most of the electrical products supplied have an oil tight construction 4 Miscellaneous wiring components such as electrical tape wire connectors and terminals as requi...

Страница 15: ...to the person Make sure the person understands the information To order this sign in Spanish use Part No KSC 000S in French use Part No KSC 000F These precautions must be reviewed daily DANGER SIGNS...

Страница 16: ...destroyed or unreadable they MUST be replaced Contact the factory immediately for replacement labels and do not operate the equipment until danger and warning labels are all in place Photo 3 5 SSC 150...

Страница 17: ...dual solenoid air valve is provided by one safety relay with force guided contacts and two solid state relays These output relays are independently controlled and cross checked by the microprocessors...

Страница 18: ...onents described above plus the following main power disconnect switch main drive motor starter ram adjust motor starter if furnished This NEMA 12 enclosure will vary in size based on the size of the...

Страница 19: ...enclosure CONTROL MODULE KIT When a control module kit is furnished it is supplied without the control enclosure panel control transformer control fuse terminal strips wire duct and wiring This contro...

Страница 20: ...s four keyhole mounting slots that allow for easy removal without taking off the Allen head mounting bolts Red and green LEDs allow for visual indication of control operation and the status of inputs...

Страница 21: ...y Keypad Display Terminal Strip P4 Fuse F2 Fuse F1 Fuse F3 Fuse F4 Fuse F5 Fuse F6 Auxiliary Output Terminal Strip P7 Core Module Resolver Terminal Strip P5 User serviceable parts on the dual CPU boar...

Страница 22: ...ntrols this will have to be done during installation Twenty five feet of cable is supplied as standard if the keypad display is remote and can be cut to length if required Do not splice the cable or i...

Страница 23: ...nkshaft angle display wires to Terminal Strip P4 on the SSC 1500 Gen II control module please follow the wiring schematics included with the crankshaft angle display and see Photos 3 19 and 3 20 Strip...

Страница 24: ...each wire Match each wire with the appropriate terminal in accordance with the wiring schematics and the color coding Make sure each wire is tight and is making good contact with the metal part of th...

Страница 25: ...er is monitored by the control logic to verify proper resolver position Position changes can occur either mechanically or electrically A mechanical failure can result if the resolver slips and an elec...

Страница 26: ...he factory A special crimping tool is required to properly crimp the ferrules on the wires If you do not have one it is available from Weidmuller Inc 821 Southlake Boulevard Richmond Virginia 23236 To...

Страница 27: ...drive chain it will be necessary to adjust the length of the chain in order to obtain proper action of the spring loaded base of the resolver assembly The normal position of the two hinged plates on...

Страница 28: ...s clean The muffler must be removed and cleaned on a regular basis If the machine has a split clutch and brake two valves may be required Both valves must be monitored dual valves with an electrical o...

Страница 29: ...talling any air cylinder The purpose of the spring on the cylinder is to help the return action of the linkage to disengage the clutch and apply the brake All existing spring action must remain in the...

Страница 30: ...may be in the 20 to 30 PSI range see machine manufacturer s recommendations Check Valve for Counterbalance System If furnished See enclosed Manual KSL 038 If the machine is equipped with an air count...

Страница 31: ...ontrol as an initiating means and two hand control as a point of operation safeguard for part revolution clutch press brakes Please read and make sure you understand the following sections before proc...

Страница 32: ...and from being initiated or shall cause an immediate stop command In the event of a failure re initiation of the press brake shall be prevented until the failure is corrected or the system or device i...

Страница 33: ...the point of operation is chosen connect the interlock to the safeguard interlock terminals P8 17 and P8 18 in the control box and as shown on the control wiring schematic wire numbers 86 and 87 If a...

Страница 34: ...utton and the multiple operator supervisory selector switch and indicator light See the control bar wiring schematics for proper wiring A palm button assembly or control bar can be mounted on a floor...

Страница 35: ...n that was just released The machine should not begin another stroke Repeat this step with the other palm button The machine should not begin another stroke This verifies the control has antirepeat c...

Страница 36: ...e optional foot switch be sure the wiring schematics are referenced for proper connections Be sure to maintain the foot switch in first class condition It must always be wired properly and the protect...

Страница 37: ...shutdown Identify all energy 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 Electrica...

Страница 38: ...is pushed in This valve is available in port sizes 3 4 and 1 Slide Operated Valve This three way valve is opened with the manual movement of a slide that opens and closes the valve This valve shuts o...

Страница 39: ...arter 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 this starter If an existing sta...

Страница 40: ...tion safeguards for power press brakes Other Installation Considerations PIPING 1 An air lockout valve must be installed in the air line usually just before the filter regulator lubricator assembly to...

Страница 41: ...wo black wires to the proper terminals on the control transformer see electrical schematic or transformer nameplate for proper connections for different primary voltages Note If a custom control box w...

Страница 42: ...on may be split up Refer to the multiple operator drawing for wiring details Be sure to connect the ground in the foot switch to the GND terminal in the control box with a green wire SUPERVISORY CONTR...

Страница 43: ...Program Angle Settings Run Power Up Procedure Program Timed Settings Program Counters Program Var Speed Top Stop Settings Program Auxiliary Output Setup of Control System The flowchart in Figure 4 1...

Страница 44: ...f safeguards are in place press YES on the keypad and proceed Main Run Screen Overview The MAIN RUN SCREEN displays the crankshaft angle in degrees speed of the machine in SPM batch counter stroke cou...

Страница 45: ...ypad to scroll through the program options If you press 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...

Страница 46: ...PN inputs PROGRAMMABLE PARAMETERS FOR USER INPUTS 1 6 1 Logic This setting is used to change the logic that activates the input The programming choices are N O normally open N C normally closed and OF...

Страница 47: ...st be wired into so they correspond to the assigned fault messages If the order of the messages is changed or if other fault messages are assigned the connections to the terminal strip must also be re...

Страница 48: ...l look for a change of state of the input The setting ranges from 0 to 359 If this setting and the Close angle are both set to 0 the input will be a static input 5 Close Angle This angle setting is us...

Страница 49: ...yed See Figure 4 17 Press ENTER when the double arrow symbol is next to the parameter you want to program A screen similar to the one shown in Figure 4 18 will be displayed Once you are in the program...

Страница 50: ...the increased inertia The stopping time 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 ad...

Страница 51: ...in inches if the test was done 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 machine to re...

Страница 52: ...ct STM angle setting and your machine 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...

Страница 53: ...d to scroll through the program options Press ENTER when the pound symbol is next to COUNTERS The first COUNTER PROGRAM SCREEN will be displayed See Figure 4 25 If you press when the arrow symbol is n...

Страница 54: ...to scroll up and down Press ENTER when the arrow symbol is next to Total Clear The Security Code Screen will be displayed See Figure 4 31 You will be prompted to enter the security code Press ESC to s...

Страница 55: ...elation to the resolver s physical 0 point mounted with the keyway up perpendicular to the base The sync switch should not come on between 330 and 30 If it does the reference cycle will fail and a fau...

Страница 56: ...d of the machine in SPM strokes per minute The three choices are low 0 30 medium 31 150 and high 151 This will allow the control to react and process information appropriately in relation to the speed...

Страница 57: ...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 After the correct security code has been entered th...

Страница 58: ...e security code screen will be displayed See Figure 4 37 You 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...

Страница 59: ...ress 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 first SYSTEM SETUP SCREEN will be displayed See Fi...

Страница 60: ...ROGRAM SCREEN Press 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 first SYSTEM SETUP SCREEN will be d...

Страница 61: ...d see MODE below this parameter does not need to be programmed 5 MODE This setting is used to select the type of IP address that is used The programming choices are STATIC and DHCP Static is a permane...

Страница 62: ...er letters when programming the Name and Work Group see Figure 4 52 If an underscore is needed use the blank key above the YES key Use and on the keypad for setting the Mode Press ENTER to finish Pres...

Страница 63: ...ion of the program off on selector switch One of the MAIN PROGRAM SCREENS will be displayed On the MAIN PROGRAM SCREEN use and on the keypad to scroll through the program options Press ENTER when the...

Страница 64: ...of the MAIN PROGRAM SCREENS will be displayed On the MAIN PROGRAM SCREEN use and on the keypad to scroll through the program options Press ENTER when the pound symbol is next to SYSTEM SETUP The secu...

Страница 65: ...C a higher sequence stop top stop setting is required If the machine stops beyond TDC a lower sequence stop top stop setting is required Subtract the number of degrees the machine went over TDC from t...

Страница 66: ...le SEQ Stop Angle Speed Change ON Angle PROGRAMMING SS T Stop Angle 330_ Degrees ENTER SECURITY CODE _ CODE Speed Change OFF Angle Auto Up Angle LC Mute Angle Figure 4 65 First Angle Settings Screen F...

Страница 67: ...h the palm buttons may be held activated If timed inch is not required the programmed setting should be at 0 ms which will disable this feature When timed inch is disabled the normal Inch mode of oper...

Страница 68: ...nch OFF Figure 4 71 Security Code Screen ENTER SECURITY CODE _ CODE OPTIONAL MODES The SSC 1500 Gen II press brake control has two 2 optional modes screens that are used to turn on or off Top Stop Inc...

Страница 69: ...he 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 over HOW TO PROGRAM THE PLS O...

Страница 70: ...turned on the auxiliary output contacts 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 chang...

Страница 71: ...isplayed See Figure 4 78 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 79 will be displayed Once you are in the programmi...

Страница 72: ...Fault Open Angle 0 359 Open Angle 0 Close Angle 0 359 Close Angle 0 Brake Monitor Warming Setpoint 0 999 ms Warming Setpoint 50 ms Fault Setpoint 0 999 ms Fault Setpoint 50 ms STM Angle 20 340 STM Ang...

Страница 73: ...999 ms Timed Inch 0 ms Off Optional Modes Top Stop Inch On or Off Top Stop Inch Off Inch with Fault On or Off Inch with Fault Off PLS Outputs 1 3 On Angle 0 359 On Angle 0 Off Angle 0 359 Off Angle 0...

Страница 74: ...rcuit failed Turn the module power 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 Possible circuit failure consult the...

Страница 75: ...Verify that the resolver cable is not run near high voltage lines motor leads Check the resolver chain or coupling for tightness and make sure there is no backlash or slop Check the resolver cable an...

Страница 76: ...rove the stop time See pages 50 52 for a detailed description of the brake monitor DO REFERENCE CYCLE A valid reference cycle has not been done Perform a reference cycle See page 57 for detailed instr...

Страница 77: ...ETECTED PRESS ESC TO EXIT The sync switch in the resolver housing did not come on during the reference cycle The sync switch can only come on between 30 and 330 The ideal location is around 90 for mos...

Страница 78: ...when looking at the shaft extension where the sprocket is attached If this assembly is mounted to operate in a counterclockwise CCW rotation the resolver wiring must be reset for counterclockwise rot...

Страница 79: ...egically located 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...

Страница 80: ...point of operation safeguarding is in place adjusted and operating properly for the job and for the operator ANSI Requirements for Inspections ANSI B11 3 INSPECTION AND MAINTENANCE RECORDS It is the u...

Страница 81: ...e 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 air cylinder or operates th...

Страница 82: ...8 4 and lift the cover straight up 5 Remove the eight small screws from 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 R...

Страница 83: ...rews 6 Put the control module back in place tighten the Allen head bolts plug in the main power cord and insert all terminal strips All power to the machine must be off before replacing the battery or...

Страница 84: ...s 3 Locate the battery on the control module See Photo 8 10 Carefully lift the battery clip up and remove the battery 4 Insert the new battery 5 Put the cover plate back onto the control module and se...

Страница 85: ...TROL ON PRESS BRAKES ANSI B11 3 Please refer to the ANSI B11 3 standard for the requirements for point of operation safeguarding on press brakes When updating a press brake the most important decision...

Страница 86: ...OOLS Hand tools do not provide point of operation safeguarding they are intended only for placing and removing materials in and from the press brake They should be made of material that does not shatt...

Страница 87: ...7533 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 Illinois 61109 2695 Make sure the R...

Страница 88: ...ns Sign English KSC 000S Operator Safety Precautions Sign Spanish KSC 000F Operator Safety Precautions Sign French KST 134 Danger Closing Ram and Die Label KSC 054 Danger Sign 5 x 6 English KSC 054S D...

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