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Rockford Systems SSC-1500 Installation Manual

Control systems on part revolution clutch machines
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INSTALLATION MANUAL FOR
SSC-1500 CONTROL SYSTEMS ON
PART REVOLUTION CLUTCH MACHINES
Plain-Door Custom
Control Box
IMPORTANT:
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 sales@rockfordsystems.com
PLEASE REVIEW THIS ENTIRE PUBLICATION
Manual No. KSL-276
Resolver/Pulser
Assembly
Remote
Operator
Station
Light
Curtains
Palm Button
Assembly

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  • Page 1 INSTALLATION MANUAL FOR SSC-1500 CONTROL SYSTEMS ON PART REVOLUTION CLUTCH MACHINES Resolver/Pulser Assembly Remote Operator Station Plain-Door Custom Control Box Light Curtains Palm Button Assembly IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION BEFORE INSTALLING, OPERATING OR MAINTAINING THE SOLID- STATE CLUTCH/BRAKE CONTROL SYSTEM.

  • Page 2: Table Of Contents

    SECTION 11—ORDER FORM FOR SIGNS AND LITERATURE ........................80 (Continued on next page.) © 2017 Rockford Systems, LLC. All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A. Rockford Systems, LLC Call: 1-800-922-7533...

  • Page 3: Section 1-In General

    SECTION 1—IN GENERAL SSC-1500 Part Revolution Solid-State Control Safety Precautions “ ” Danger is used to indicate the presence of a hazard which WILL cause SEVERE DANGER personal injury if the warning is ignored. “ ” THIS SAFETY ALERT SYMBOL IDENTIFIES IMPORTANT SAFETY MESSAGES IN THIS MANUAL.
  • Page 4 SECTION 1—IN GENERAL SSC-1500 Part Revolution Solid-State Control Safety References ANSI SAFETY STANDARDS FOR MACHINES The most complete safety standards for machine tools are published OSHA’S ACT AND FEDERAL REGULATIONS in the ANSI (American National Standards Institute) B11 series. The...

  • Page 5: Section 1—In General

    WARRANTY Rockford Systems, LLC. warrants that this product will be free from defects in material and workmanship for a period of 12 months from the date of shipment thereof. ROCKFORD SYSTEMS LLC’S OBLIGATION UNDER THIS WARRANTY IS EXPRESSLY AND EXCLUSIVELY LIMITED to repairing or replacing such products which are returned to it within the warranty period with shipping charges prepaid and which will be disclosed as defective upon examination by Rockford Systems, LLC.

  • Page 6: Section 2-Introduction

    SECTION 2—INTRODUCTION SSC-1500 Part Revolution Solid-State Control General Description of Components in the System A complete control package for part revolution clutch machines includes the following: 1. Literature folder (see page 13) containing installation manuals, “Operator Safety Precaution” Pamphlet, danger sign(s), electrical control schematics, and a “Mechanical Power Press Safety”...
  • Page 7 SECTION 2—INTRODUCTION SSC-1500 Part Revolution Solid-State Control Preliminary Steps Before Installation (continued) 4. Please make sure the machine is in first-class condition. Before starting any installation, it is essential that the machine is thoroughly inspected. Be sure all mechanical components and all collateral equipment are in first-class operating condition. Your inspection should be done according to the machine manufacturer’s installation and maintenance instruction manual.
  • Page 8 There is an additional charge for this service. General Features of the SSC-1500 Control • Redundant/Cross-Checking Microprocessors • Redundant Microprocessor Logic Power Supplies •...
  • Page 9 SSC-1500 Part Revolution Solid-State Control Theory of Operation The SSC-1500 press control consists of three major components: the control module, the keypad/display module, and the resolver/pulser assembly which provides all press timing and motion detection. See the block diagram in Figure 2.1 below.
  • Page 10 Sequence of Operation This sequence of operation applies to all standard modes provided with the SSC-1500 Press Control. The press is inoperable 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 appropriate position.
  • Page 11 Continuous-On-Demand, Foot-Maintained Continuous, Two-Hand-Maintained Continuous, One-Hand or Foot Trip Single Stroke, and Automatic Single Stroke are optional modes of operation also provided with the SSC-1500 press control. These modes of operation are accessed through the optional modes program screen. See pages 58 - 60 of this installation manual for programming information.

  • Page 12: Se Ction 2—Introduction

    SECTION 2—INTRODUCTION SSC-1500 Part Revolution Solid-State Control Press Components Identification Part Revolution OBI Press Motor Resolver/Pulser Counterbalance Motor Assembly Belts Starter Dual Sheave Air- Solenoid Releasing Valve Lifting Bolt Brake Crankshaft Disconnect Flywheel Switch Knockout Air Friction Clutch Connection Knockout...

  • Page 13: Section 3-Installation Of Components

    Mechanical Power Press Safety (Part No. KSL-051). These publications must be available and fully understood by all appropriate personnel, before any retrofit installation begins. Please notify Rockford Systems immediately if there are any questions about the components received.
  • Page 14 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control OPERATOR SAFETY PRECAUTION PAMPHLET Attachment of Precaution Pamphlet 1. Locate the Operator Safety Precaution Pamphlet. Photo 3.1 - Part No. KSC-000 Operator Safety Precaution Pamphlet 2. Attach the pamphlet to the machine with a nylon tie through the hole Part No.

  • Page 15: Control Box

    MUST be replaced. Contact factory immediately for replacement labels and do not operate the equipment until danger and warning labels are all in place. Photo 3.5 SSC-1500 Standard Control Box Outside View Label No. KST-152 Label No.
  • Page 16 When the control box is wired to an existing main motor starter, the starter must have a 120-V coil and in most cases, an auxiliary contact. If the starter does not have these components and they are not readily available, please contact Rockford Systems for a replacement magnetic motor starter.
  • Page 17 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control STANDARD CONTROL BOX The standard control box (20” x 20” x 8”) is furnished with the keypad/display, program OFF/ON selector switch, and other selector switches on the front of the enclosure door. This NEMA 12 enclosure contains the control module assembly, master control relay, primary multi-tap transformer, and terminal strips.
  • Page 18 Style X— Standard SSC-1500 control box without the control transformer Style Y— Standard SSC-1500 control box without the control transformer, but with an e-stop, top-stop, and prior-action push button in the enclosure Style Z— Standard SSC-1500 control box without the control transformer, but with an...
  • Page 19 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control CONTROL MODULE ASSEMBLY The solid-state control module assembly below, Part No. FTL-046, measures 8 ⁄ ” W x 8 ⁄ ” H x 3 ⁄ ” D. It is mounted to the panel with four shock/ vibration mounts and four 1/4-20 x 1/2”...
  • Page 20 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control CONTROL MODULE ASSEMBLY (continued) If necessary, the cover of the module can be taken off by removing the screws on the corners and pulling the top straight off. The dual CPU circuit board is then exposed as shown in the photo below.
  • Page 21 The keypad/display can be furnished in a remote enclosure up to a maximum of 150’ from the SSC-1500 control module. Information displayed during the machine run cycle are Angle, Speed, Batch Counter, Total Counter, Mode, and Stop Time. All programming is accessed by a program OFF/ON keyed selector switch.

  • Page 22: Resolver/Pulser Assembly

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Resolver/Pulser Assembly Cable The absolute resolver/pulser assembly with spring-tension base is used to provide position and velocity/motion information of the machine crankshaft to the control. The resolver is a highly accurate and repeatable timing device. The resolver/pulser is contained in a rugged, heavy- duty housing with a spring-tension base.

  • Page 23: Sprocket Assembly

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Sprocket Assembly (If furnished) Existing sprockets may be reused, or two sprockets with an identical number of teeth (usually 48) may be supplied. They are used to drive the resolver/pulser assembly. The standard set consists of one sprocket with the proper bore, keyway and setscrews to mount directly on the shaft extension of the resolver.

  • Page 24: Monitored Dual Solenoid Air Valve

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Monitored Dual Solenoid Air Valve (If furnished—See enclosed Manual KSL-036 or KSL-037) A minimum of 30 to 40 PSI must be maintained at the valve for proper operation. Use pipe size at least as large as the valve ports. An accumulator (air surge tank) is recommended.

  • Page 25: Air Pressure Switch

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Air Pressure Switch (If furnished—See enclosed Manual KSL-165) The clutch/brake air supply must be monitored by an air pressure switch on all part revolution power presses. If an air counterbalance is used, it must also be monitored by a separate air pressure switch. Please check the machine owner’s manual for the minimum suggested air pressure for these switches.
  • Page 26 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Palm Button Assembly (continued) 1. When the modes of operation of Off, Inch, Single Stroke, Foot Switch Single Stroke, Two-Hand Walk-Away Continuous, Automatic Single Stroke, Continuous-On-Demand, and One-Hand/Foot Trip are furnished, a palm button assembly will consist of four buttons (two black run/inch buttons with ring guards, one red emergency-stop button, and one yellow top-stop button).
  • Page 27 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Palm Button Assembly (continued) OS HA 1910.217 for two-hand control used as a method of safeguarding the point of operation as follows: (c)(3) Point-of-Operation Devices (i) Point-of-Operation devices shall protect the operator by: (e) Requiring the application of both of the operator’s hands to machine operating controls and locating such controls at such a safety distance...
  • Page 28 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control 3. According to ANSI B11.1 - 1988, the total stopping time of the press (for two-hand control) should include the total response time of the control system and the time it takes the press to cease slide motion. The following formula should be used when calculating the safety distance: = K (T s + T c + T bm );...
  • Page 29 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Palm Button Assembly (continued) RED EMERGENCY-STOP BUTTON (Required) The red emergency-stop button is used to stop the machine anywhere in its cycle. When the operator depresses the button, it should stop the hazardous motion of the machine immediately. This palm button assembly requires either a double-hub mounting box Part No.
  • Page 30 Function Tests of Two-Hand Control Two-hand control is furnished with the SSC-1500 press control and can be used as a point-of-operation device. If it is going to be used as a point- of-operation device, the following function tests should be run before operating the press. These tests should be done at every operator, die, or shift change, and every time maintenance is performed.

  • Page 31: Foot Switch

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Function Tests of Two-Hand Control (continued) 2. With the main motor drive on, the flywheel rotating, the actuating means selector switch set to HAND, and the mode selector switch set to SINGLE, perform the following tests.

  • Page 32: Multiple Operator Station

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Foot Switch ( continued) Install either the electrically interlocked method of safeguarding or the mechanical guard or device. 1. When an electrically interlocked method of safeguarding 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).

  • Page 33: Other Components

    Lubrication System* Bar/Run Station Reel Cradle for Coil * The electrical or electronic schematics are required if Rockford Systems is to interface this equipment to the control. Other Components That May Be Required AIR LOCKOUT VALVE (If furnished—See enclosed Manual KSL-098) OSHA 29 CFR 1910.147 requires that all employers develop a complete hazardous energy control program.
  • Page 34 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control Figure 3.6 Illustration of where an air lockout valve could be located in the air line on part revolution power press Filter- Clutch/ Lock- Dual Valve Tank Regulator- Brake Supply Lubricator...
  • Page 35 If this is not possible, or an electrical disconnect switch is not provided, then you must obtain and install a proper disconnect switch. (For a proper disconnect switch, please contact Rockford Systems.)

  • Page 36: Other Installation Considerations

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control FLYWHEEL AND GEAR COVERS According to OSHA 1910.219 and ANSI B15.1 for Mechanical Power-Transmission Apparatus, all rotating components including flywheels, gears, sprockets and chains, sheaves and belts, shaft ends, etc., must be covered if at or below a seven-foot level from the floor or platform. Note: ANSI states it should be a nine-foot level.
  • Page 37 The cable connects from the resolver/pulser to the drive assembly, and should be wired directly in to the control module terminal strip P5 as shown in the schematic prints that were sent with the control box. Do not splice or interrupt signals. Please contact Rockford Systems if a longer cable is required.
  • Page 38 SECTION 3—INSTALLATION OF COMPONENTS SSC-1500 Part Revolution Solid-State Control WIRING (continued) PALM BUTTON ASSEMBLY (See page 25) These are normally wired as an assembly with the blue wires routed from the control box to the nearest palm button and then the others, as required.

  • Page 39: Section 4-Programming

    Setup of Control System The flowchart in Figure 4.1 outlines the order and method of setting up and programming the SSC-1500 press control system on a part revolution press after installation. Refer to the LCD display on the control box or on the remote operator station.
  • Page 40 Wake Up Screen After completing the installation of the control box and control components, the SSC-1500 press control system must be initially programmed according to the flowchart in Figure 4.1 on page 39 to get the machine up and running. Before programming, the control must SSC-1500 first be powered up.
  • Page 41 Main Run Screen Overview sections of this manual have been read and understood. MAIN PROGRAM SCREENS The SSC-1500 press control has two main programming screens from which you can access all of the programmable features of the control. To program the control, select the ON position of the program OFF/ON selector switch.

  • Page 42: User Inputs

    USER INPUTS Figure 4.8 User Input Fault Messages The SSC-1500 press control has eight (8) programmable user inputs (6 static-type inputs and 2 static- or cyclic-type inputs) that can be CLUTCH/BRAKE AIR FLT programmed for equipment monitoring or other user-defined functions.
  • Page 43 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM USER INPUTS 1 - 6 (continued) Figure 4.10 Second User Inputs Screen Use ↓ and ↑ on the keypad to scroll through the user inputs. If you press ↓ when the arrow symbol (>) is next to INPUT #4, the second USER INPUTS SCREEN will be displayed.
  • Page 44 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control PROGRAMMABLE PARAMETERS FOR USER INPUTS 7 - 8 Figure 4.13 User Input Fault Messages 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 CLUTCH/BRAKE AIR FLT closed), and OFF (disabled).
  • Page 45 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM USER INPUTS 7 - 8 (continued) Figure 4.15 Second User Inputs Screen Use ↓ and ↑ on the keypad to scroll through the user inputs. If you press ↓ when the arrow symbol (>) is next to Input #4, the SECOND USER INPUTS SCREEN will be displayed.

  • Page 46: Brake Monitor

    BRAKE MONITOR The SSC-1500 press control has a time-based brake monitor with programmable warning and fault setpoints. The control also includes an STM (stop-time measurement) test. This test is used on the downstroke (usually at 90°) for establishing proper safety distance when applying two-hand control or a light curtain as the safeguarding device.
  • Page 47 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO RUN AN STM (STOP-TIME MEASUREMENT) TEST Figure 4.21 (continued) STM Test Screen Use ↓ and ↑ on the keypad to scroll up and down. Press ENTER when the arrow symbol (>) is next to STM Test. The STM Test Screen will be PROGRAMMING: displayed.
  • Page 48 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO CALCULATE THE BRAKE MONITOR WARNING AND FAULT SETPOINTS To determine the brake monitor warning and fault setpoints using the STM test feature, you need to determine the proper STM angle so the stop signal is given on the upstroke, and the angle stop point makes the press stop at TDC (top dead center).

  • Page 49: Counters

    COUNTERS The SSC-1500 press control has a batch counter that can be used for die maintenance, quality control checks, or part bin exchanges. This counter has a programmable preset that will signal the press to top stop when the preset is reached. The preset has a maximum of 9,999,999 strokes.

  • Page 50: System Setup

    SYSTEM SETUP The SSC-1500 press control has a system setup screen that is used to automatically zero the resolver, set the motion reference threshold, automatically set the sync switch position, restore the factory default settings, program the security code, and program the network settings.
  • Page 51 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO RUN THE REFERENCE CYCLE (continued) Figure 4.31 System Setup Screen After the correct security code has been entered, the SYSTEM SETUP SCREEN will be displayed. See Figure 4.31. >Reference Cycle Use ↓ and ↑ on the keypad to scroll up and down. Press ENTER when Restore Defaults the arrow symbol (>) is next to Reference Cycle.
  • Page 52 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM THE SECURITY CODE Figure 4.37 Security Code Screen Select the ON position of the program OFF/ON selector switch. One of the MAIN PROGRAM SCREENS will be displayed. ENTER SECURITY CODE On the MAIN PROGRAM SCREEN, use ↓...

  • Page 53: System Setup

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM THE NETWORK SETTINGS Figure 4.40 Security Code Screen Select the ON position of the program OFF/ON selector switch. One of the MAIN PROGRAM SCREENS will be displayed. ENTER SECURITY CODE On the MAIN PROGRAM SCREEN, use ↓...

  • Page 54: Angle Settings

    SSC-1500 Part Revolution Solid-State Control ANGLE SETTINGS The SSC-1500 press control has an angle settings screen that is used to program the single stroke top stop, continuous top stop, auto up (holding), and light curtain mute angles. SINGLE STROKE TOP-STOP ANGLE The single stroke top-stop angle is the angle at which the control gives the signal to stop the press at TDC (top dead center) while in the Single Stroke mode of operation.

  • Page 55: Angle Settings

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM THE ANGLE SETTINGS Figure 4.44 (continued) Angle Settings Screen After the correct security code has been entered, the ANGLE SETTINGS SCREEN will be displayed. See Figure 4.44. >Cont. T-Stop Angle SS T-Stop Angle Use ↓...

  • Page 56: Timed Settings

    SSC-1500 Part Revolution Solid-State Control TIMED SETTINGS The SSC-1500 press control has a timed settings screen that is used to program the anti-tie-down, timed inch, and signal time-out settings. ANTI-TIE-DOWN SETTING The anti-tie-down setting is the amount of time within which all actuating means (palm buttons or foot switch[es]) must be concurrently depressed.

  • Page 57: Timed Settings

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control Figure 4.47 HOW TO PROGRAM THE TIMED SETTINGS Timed Settings Screen (continued) After the correct security code has been entered, the TIMED SETTINGS > Anti-Tie-Down SCREEN will be displayed. See Figure 4.47. Timed Inch Use ↓...

  • Page 58: Optional Modes

    OPTIONAL MODES The SSC-1500 press control has two (2) optional modes screens that are used to turn on or off the following optional modes of operation: Continuous- On-Demand, Foot-Maintained Continuous, Two-Hand-Maintained Continuous, One-Hand or Foot Trip Single Stroke, and Automatic Single Stroke.
  • Page 59 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control OPTIONAL MODES (continued) ONE-HAND OR FOOT TRIP SINGLE STROKE To use One-Hand or Foot Trip Single Stroke, the mode selector switch must be set to SINGLE, and the actuating means selector switch must be set to FOOT.

  • Page 60: Optional Modes

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control Figure 4.50 HOW TO TURN ON OR OFF THE OPTIONAL MODES (continued) First Optional Modes Screen After the correct security code has been entered, the first OPTIONAL MODES SCREEN will be displayed. See Figure 4.50.

  • Page 61: Variable Speed Top-Stop Settings

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control VARIABLE SPEED TOP-STOP SETTINGS The variable speed top-stop settings screens are used to program the angles at which the control gives the signal to stop the press at TDC (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.

  • Page 62: Variable Speed Top-Stop Settings

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM THE VARIABLE SPEED TOP-STOP SETTINGS Figure 4.56 (continued) Third Variable Speed Top-Stop Settings Screen >>VAR TS #4 SPM VAR TS #5 ANGLE VAR TS #5 SPM VAR TS #6 ANGLE Figure 4.57...

  • Page 63: Pls Outputs

    SSC-1500 Part Revolution Solid-State Control PLS OUTPUTS The SSC-1500 press control provides two (2) PLS (programmable limit switch) output relays which are fused for 4 A @ 115 V. These user-programmable outputs can be used to sequence events during the press stroke.

  • Page 64: Auxiliary Output

    AUXILIARY OUTPUT The SSC-1500 press control provides one (1) auxiliary output relay that has two contacts which are fused for 4 A @ 115 V. When this auxiliary output is set to be on, it can be programmed to change state whenever any or all of the following stop conditions occur: the batch counter setting is reached, a fault condition occurs, the press stops, or the press emergency stops.
  • Page 65 SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control HOW TO PROGRAM THE AUXILIARY OUTPUT Figure 4.66 (continued) Second Programmable Parameters Screen >Aux Out Logic Use ↓ and ↑ on the keypad to scroll through the programmable parameters. If you press ↓ when the arrow symbol (>) is next to Aux Out E-Stop, the SECOND PROGRAMMABLE PARAMETERS SCREEN will be displayed.

  • Page 66: Quick Reference Table-Factory Settings And Valid Ranges

    SECTION 4—PROGRAMMING SSC-1500 Part Revolution Solid-State Control QUICK REFERENCE TABLE - FACTORY SETTINGS AND VALID RANGES Table 4.1 Program Setting Valid Entry Range Factory Default Setting Logic: Off, N.O. (Normally Open), Logic: or N.C. (Normally Closed) User Inputs 1 - 6...

  • Page 67: Section 5-Fatal Fault Messages And General Fault Messages

    TDC and note the reference time reported. Possible circuit failure; consult factory. The control detected motion prior to starting a press cycle. Check for correct wiring to the resolver connection on the SSC-1500 control module. Verify the chain is on the MOTION, NO RUN sprocket for the resolver and is tight.
  • Page 68 The light curtain cycle check wired to the MTS input on the light curtain(s) failed LC CYCLE FLT to cycle on the upstroke. Check the LED for the K4 relay on the SSC-1500 control module, and fuses F5 and F6 for the LC cycle output contacts.
  • Page 69 SECTION 5—FAULT MESSAGES AND GENERAL MESSAGES SSC-1500 Part Revolution Solid-State Control General Fault Messages Most general fault messages can be cleared by touching ENTER on the keypad. MESSAGE DESCRIPTION/SOLUTION The stopping time has exceeded the programmed limit for the brake warning setting.

  • Page 70: Section 6-Operating Considerations

    SECTION 6—OPERATING CONSIDERATIONS SSC-1500 Part Revolution Solid-State Control SSC-1500 Operation Checklist 1. Is all wiring to the machine, the solid-state control module (black box), and keypad/display correct when verified with the drawings sent with the solid-state control? ..................................Y or N 2.

  • Page 71: Section 6—Operating Considerations

    SECTION 6—OPERATING CONSIDERATIONS SSC-1500 Part Revolution Solid-State Control TROUBLESHOOTING OUTLINE Use the control drawing schematics in conjunction with the following troubleshooting outline: NO VOLTAGE—POSSIBLE CAUSES: 1. Check the line voltage on the transformer primary with a volt meter. 2. Check for correct transformer primary connections (wiring) and the secondary for 120 V AC using a volt meter.

  • Page 72: Section 7-Maintenance And Inspection

    SECTION 7—MAINTENANCE AND INSPECTION SSC-1500 Part Revolution Solid-State Control A part revolution clutch mechanical power press consists of engaging parts, springs, electrical components, air components and other mechanical equipment. Because of this inherent design, machine parts will ultimately wear, get out of adjustment or break which could cause a malfunction and/ or mechanical failure.

  • Page 73: Section 7—Maintenance And Inspection

    SECTION 7—MAINTENANCE AND INSPECTION SSC-1500 Part Revolution Solid-State Control Air System 1. Be sure to turn the air pressure off, bleed air from the system or component, and lockout before maintaining any air equipment. 2. Inspection of the entire air system is dependent on the frequency of machine operation and the cleanliness of the plant air lines. Both free moisture and solids should be removed automatically by the air filter.

  • Page 74: Section 8-Replacement Procedures

    SECTION 8—REPLACEMENT PROCEDURES SSC-1500 Part Revolution Solid-State Control Replacing the Core Module All power to the machine must be off before replacing the control module or any other parts. Photo 8.2 Photo 8.1 1. Locate the control module inside the control box.
  • Page 75 1. Remove the control module from the control box (steps 1 - 3 on page 74). 2. Remove the top cover plate from the SSC-1500 control module by removing the four small screws. 3. Locate fuses F1 - F6. Grasp the faulty fuse and pull straight up.

  • Page 76: Section 8—Replacement Procedures

    1. Remove the control module from the control box (steps 1 - 5 on page 74). 2. Remove the top cover plate from the SSC-1500 control module by removing the four screws. 3. Locate the battery on the control module. See Photo 8.12. Carefully lift the battery clip up and remove the battery.

  • Page 77: Section 9-Methods Of Safeguarding

    SECTION 9—METHODS OF SAFEGUARDING SSC-1500 Part Revolution Solid-State Control OSHA 1910.217 (c) under General Requirements states: It shall be the responsibility of the employer to provide and insure the usage of “point-of-operation guards” or properly applied and adjusted point-of-operation devices on every operation performed on a mechanical power press.

  • Page 78: Section 9—Methods Of Safeguarding

    ANSI B11.1 standard entitled “Mechanical Power Presses—Safety Requirements for the Construction, Care and Use.” Also see the enclosed Rockford Systems’ booklet entitled “Mechanical Power Press Safety” (MPPS). When using any of the devices described for point-of-operation safeguarding, the sides and rear of the hazardous point-of-operation area must be safeguarded to protect the operator and other employees in the machine area (OSHA 29 CFR 1910.212).

  • Page 79: Section 10-Return Materials Authorization Request Form

    To return material for any reason contact the sales department in our organization at 1-800-922-7533 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, IL 61109-2695.

  • Page 80: Section 11-Order Form For Signs And Literature

    City State Phone Name Purchase Order No. Date Part No. Description Quantity Required KSL-253 Installation Manual—SSC-1500 Control KSC-000 Precaution Pamphlet (English) KSC-000S 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”...

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