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Rockford Systems, LLC

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Call: 1-800-922-7533

SSC-1500 Part Revolution Solid-State Control

SECTION 3—INSTALLATION OF COMPONENTS

Front

Part No. KSC-000

Part No. KSC-000

Attachment of Precaution Pamphlet
1.  

Locate the Operator Safety Precaution Pamphlet.

2.  

Attach the pamphlet to the machine with a nylon tie through the hole 
provided. See Photo 3.2.

Attach it to the machine where it is readily 
accessible and visible to the operator. Additional 
copies of this precaution are available. Please 
call, write, fax, e-mail or use the order form 
found on a later page in this manual.
When a language barrier or insufficient 

education prevents a person from reading or 
understanding the contents of this pamphlet, 
you should either translate this information or 
have it read or interpreted to the person. Make 
sure the person understands the information. 
To order this pamphlet in Spanish, use Part No. 
KSC-000S; in French, use Part No. KSC-000F.
This precaution pamphlet must be reviewed 
daily.

DANGER SIGNS

1. 

Locate the furnished danger sign(s).

2.  

Determine the mounting location for the danger sign(s) on the machine.

It must be permanently mounted in a prominent 
location on the machine where it is readily 
accessible and visible to the operator, setup 
person, or other personnel who work on or 
around this machine.

3.  

Drill a hole(s) in the sign and the machine at the mounting location. 
See Photo 3.3.

4.  

Attach the sign(s) to the machine with screws or rivets. 

    See Photo 3.4.

Never operate this machine unless the danger 
sign(s) is in place. Also make sure the sign(s) is 
read and understood before operating the machine.

Photo 3.1 -  Part No. KSC-000 Operator Safety Precaution 

Pamphlet

Back

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NOTICE TO EMPLOYER:

 A copy of this “Operator Safety Precautions” must be given to all operators

(including set-up people, maintenance personnel and supervisors) of this machine. A copy should

also be hung on the machine readily accessible and visible to the operator. Additional copies

of this precaution are available upon request. Just call or write.

IMPORTANT:

 Where a language barrier or insufficient schooling would prevent  a person from reading

and understanding the contents of this Operator Safety Precaution, you should either translate

this information or have it read or interpreted to the person, with assurance that it is understood.

THIS PRECAUTION MUST BE REVIEWED DAILY.

Never  operate  this  machine  until  you  understand   

that this machine is dangerous and never place your 

hands or any part of your body in this machine which 

could  result  in  the  loss  of  fingers,  limbs  or  even 

death.
Never  operate  this  machine  without  the  use  of  a 

point-of-operation*  guard  or  safety  device  that  will 

always protect you from bodily injury.
Never  use  a  foot  switch  to  operate  this  machine 

unless  a  point-of-operation  guard  or  device  is 

provided and properly maintained.
Never "ride" the foot pedal or foot switch. Never rest 

your foot on top of the foot pedal or inside the foot 

switch. Always remove your foot completely from the 

foot  pedal  or  foot  switch  after  each  cycle  and  any 

time you are not intending to trip the machine.
Always  use  hand  tools  for  feeding  or  retrieving 

material  from  the  point  of  operation  or  any  other 

hazardous part of the machine. Never reach through 

or into point of operation for any reason.
Never  operate  this  machine  unless  you  feel  you 

have  been  fully  trained  and  have  received  and 

understand all operating instructions. Make sure you 

know  how  the  machine  works  and  how  it  is 

controlled.
Never  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 

adjusted  properly  and  working  correctly.  If  you  are 

not sure call your supervisor.
Never  operate  this  machine  if  it  is  not  working 

properly  or  if  you  notice  any  unusual  noise  or 

change  in  the  performance  of  the  machine.  Stop 

operating the machine immediately and advise your 

supervisor.
Never  operate  this  machine  with  pullbacks  (if 

furnished) unless they are adjusted properly for you. 

Have  your  supervisor  demonstrate  that  when  the 

ram descends, the pullbacks will pull fingers clear of 

any pinch points. Always wear your wristlets properly 

and securely.
Never  operate  this  machine  with  pullbacks  (if 

furnished)  without  reading  and  understanding  the 

instructions.  Instructions  must  be  kept  with  the 

pullback  device  at  all  times  and  made  available  to 

you. Obtain, read and follow these instructions.

Never  operate  this  machine  unless  two-hand  trip, 

two-hand  control  or  presence  sensing  device  (if 

furnished)  is  installed  correctly  and  at  the  proper 

safety distance. Consult your supervisor should you 

have  any  questions  regarding  the  proper  safety 

distance.
Never operate this machine unless the light curtain 

(if  furnished)  is  interfaced  into  the  machine  control 

system  properly.  Only  mute  during  the  non-

hazardous  part  of  the  machine  cycle;  blanking 

should be discouraged.
Never  tamper  with,  rewire  or  bypass  any  control, 

component or safeguard on this machine.
Always wear safety glasses, hearing protection and 

any  other  personal  protection  equipment  needed 

when operating this machine.
Never  operate  this  machine  with  long  hair,  loose 

clothing or jewelry. It could become caught in part of 

the machine or auxiliary equipment.
Be sure all persons are clear of the machine before 

it  is  cycled,  especially  when  multiple  operators  or 

helpers are present. Do not operate machine unless 

you and every operator and/or helper are protected 

from injury by a guard or safety device.
Always  stay  alert  (don't  daydream)  and  never 

operate  this  machine  while  under  the  influence  of 

alcohol  or  any  drug,  including  prescription 

medications.
Maintenance  and  Die  Set-Up  Personnel:  Never 

work on this machine unless power is off and locked 

out,  flywheel  is  at  rest,  safety  blocks  are  used 

between  dies,  and  all  energy  (electrical,  air, 

hydraulic, etc.) are in a zero state.
Always  be  prepared  if  an  emergency  situation 

should arise. You should know how to stop and shut 

down the machine should there be a need.
Never  operate  this  machine  unless  all  mechanical 

power-transmission  apparatus  (flywheels,  gears, 

etc.) and auxiliary equipment are free from hazards.

Do Not Operate This Machine 

Until You Read and Understand the 

Following Safety Precautions.

* Point of Operation - “The location in the machine tool where material is positioned and a process is performed.” (ANSI B11.19)

NOTICE  TO  EMPLOYER:  A  copy  of  this  “Operator  Safety  Precautions”  must  be  given  to  all  operators 

(including  set-up  people,  maintenance  personnel  and  supervisors)  of  this  machine.  This  pamphlet     

should also be hung on the machine readily accessible and visible to the operator.  Additional precaution 

pamphlets are available upon request.

IMPORTANT: Where a language barrier or insufficient schooling would prevent a person from reading and 

understanding  the  contents  of  this  Operator  Safety  Precaution,  you  should  either  translate  this 

information or have it read or interpreted to the person, with assurance that it is understood. If Spanish or 

French operator safety precaution pamphlets are required, please consult factory.

Photo 3.2

Photo 3.3

Photo 3.4

OPERATOR SAFETY PRECAUTION PAMPHLET

(Continued on next page.)

Содержание SSC-1500

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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