Rockford Fosgate SSC-500 Installation Manual
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Rockford Fosgate SSC-500 Installation Manual

Rockford Fosgate SSC-500 Installation Manual

Control systems on hydraulic presses
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INSTALLATION MANUAL FOR
SSC-500 CONTROL SYSTEMS
ON HYDRAULIC PRESSES
Operator Interface
Keypad/Display
Program/Run
Selector Switch
Remote Operator
Station (Optional)
IMPORTANT:
PUBLICATION BEFORE INSTALLING, OPERATING OR
MAINTAINING THE SOLID-STATE HYDRAULIC PRESS
ELECTRICAL CONTROL SYSTEM.
5795 Logistics Parkway • Rockford, Illinois 61109 • Toll Free 1-800-922-7533 (USA only) • Phone (815) 874-7891
Fax (815) 874-6144 • Web Site: www.rockfordsystems.com • E-Mail: sales@rockfordsystems.com
PLEASE REVIEW THIS ENTIRE
Manual No. KSL-249
SSC-500 Control Box
(Not Shown)

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Summary of Contents for Rockford Fosgate SSC-500

  • Page 1 INSTALLATION MANUAL FOR SSC-500 CONTROL SYSTEMS ON HYDRAULIC PRESSES Operator Interface Keypad/Display SSC-500 Control Box (Not Shown) Program/Run Selector Switch Remote Operator Station (Optional) IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION BEFORE INSTALLING, OPERATING OR MAINTAINING THE SOLID-STATE HYDRAULIC PRESS ELECTRICAL CONTROL SYSTEM.

  • Page 2: Table Of Contents

    SECTION 1—IN GENERAL ..........3 - 9 SE CTION 10—LAYOUT SKETCH ..........42 SE CTION 2—INTRODUCTION .........10 - 14 SE CTION 11—RETURN AUTHORIZATION FORM ......43 SE CTION 3—INSTALLATION OF SSC-500 CONTROL SYSTEM SE CTION 12—ORDER FORM ............44 COMPONENTS ............14 - 24 FIGURES, PHOTOS, AND TABLES Literature Packetr ............14 - 15...

  • Page 3: Section 1-In General

    SECTION 1 — IN GENERAL SSC-500 Hydraulic Press 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-500 Hydraulic Press 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 SSC-500 Hydraulic Press Solid-State Control NATIONAL SAFETY COUNCIL SAFETY MANUALS AND DATA Power Press Point-of-Operation Safeguarding: Presence Sensing Devices 12304-0711 SHEETS Power Press Point-of-Operation Safeguarding: Other good references for safety on machine tools are the National Pullbacks and Restraint Devices 12304-0713 Safety Council’s Safety Manuals and Data Sheets.
  • Page 6 SECTION 1 — IN GENERAL SSC-500 Hydraulic Press Solid-State Control Operator Safety Precaution Pamphlet - (Attachment for machine operators) Part No. KSC-000 Accompanying this equipment is an 8-1/2” x 11” operator safety precaution pamphlet, Part No. KSC-000, for anyone operating the machine where this equipment will be installed.
  • Page 7 SECTION 1 — IN GENERAL SSC-500 Hydraulic Press Solid-State Control Danger Sign(s) to be Mounted on Machine Accompanying this equipment is a 5” x 6” polyethylene danger sign, Part No. KSC-054. This sign MUST BE PERMANENTLY MOUNTED IN A PROMINENT LOCATION on the machine where this equipment is installed. This sign must be in a LOCATION THAT IS EASILY VISIBLE to the operator, setup person, or other personnel who work on or around this machine.
  • Page 8 SECTION 1 — IN GENERAL SSC-500 Hydraulic Press Solid-State Control Danger and Warning Labels Provided on Control Box The illustrated danger and warning labels are affixed to all control boxes provided. All personnel operating or working around the machine, where this control box is installed, must be required to read, understand and adhere to all dangers and warnings.
  • Page 9 SECTION 1 — IN GENERAL SSC-500 Hydraulic Press Solid-State Control FOR REPLACEMENT SIGNS CALL, FAX, E-MAIL, OR FACTORY OR USE ORDER FORM ON A LATER PAGE OF THIS MANUAL. Rockford Systems, LLC 5795 Logistics Parkway Rockford, Illinois 61109 Toll Free: 1-800-922-7533 (USA only) Photo 1.2...

  • Page 10: Se Ction 2-Introduction

    SECTION 2 — INTRODUCTION SSC-500 Hydraulic Press Solid-State Control General Description of Components in the System A complete control package for hydraulic machines includes the following: 1. Literature folder (see page 14) containing installation manuals, “Operator Safety Precaution” Pamphlet, danger sign(s), electrical control schematics, and our latest catalog 2.
  • Page 11 There is an additional charge for this service. Features of the SSC-500 Control - Hydraulic Press • Redundant/cross-checking microprocessors •...
  • Page 12 The basic control consists of a multi-tap voltage control transformer, color-coded terminal strips, ground indicator light, selector switches, keypad/ display, a master control relay, and the SSC-500 control module assembly. As standard, this is furnished in a NEMA 12 enclosure. The master-con- trol relay is used to provide a hard-wired emergency-stop function.
  • Page 13 SECTION 2 —INTRODUCTION SSC-500 Hydraulic Press Solid-State Control Overview of Sequence of Operation (continued) AUTOMATIC To initiate this mode of operation, set the Control Selector to “Automatic” and set the Actuating Means Selector to the “Hand” position. In this mode of operation, press the “Automatic Prior-Action”...
  • Page 14 SECTION 2 — INTRODUCTION SSC-500 Hydraulic Press Solid-State Control USER INPUTS Up to four programmable user inputs are available to monitor and diagnose common problems with auxiliary equipment on the machine. See the USER INPUT programming section on pages 31 - 32 for the user input choices. Refer to the wiring schematics for information on wiring the inputs to the proper terminals.

  • Page 15: Components

    Sign No. KSC-055 CONTROL BOX WITH SSC-500 CONTROL MODULE ASSEMBLY The control box furnished for your machine may vary with the equipment furnished. The standard control box is furnished with the keypad/display on the front of the enclosure;...
  • Page 16 SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control Control Module Assembly The solid-state control module assembly (Photo 3.3) is mounted to the panel with four shock/vibration 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 removing the Allen-head mounting bolts, if replacement is required.
  • Page 17 The keypad/display can be furnished in a remote enclosure up to a maximum of 150’ from the SSC-500 control module. Display mode choices during the machine run cycle are MODE-STATUS, STROKE COUNTER, or BATCH COUNTER. All programming is accessed by a keyed selector switch on the keypad/display unit.
  • Page 18 SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control Photo 3.6 Back Side of Keypad/Display Contrast Adjustment R2 Keypad/Display CPU Off/Run/Program Selector Switch Connector P5 PART NO. CTL-525 - PALM BUTTON ASSEMBLY (If furnished, see Installation Manual No. KSL-071 or KSL-073) When the standard modes of operation of off, inch, single stroke, automatic, and auto single are furnished, the palm button assembly will consist of four buttons (two run/inch buttons with ring guards, one red emergency-stop button, and one yellow return/inch-up button).

  • Page 19: P Alm Button Assembly

    SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control PALM BUTTON ASSEMBLY (continued) The two “run” palm buttons, on hydraulic machines, can be used to initiate a machine cycle and as a method of safeguarding the point of operation.
  • Page 20 SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control Yellow Return/Inch-Up Button The yellow return/inch-up button is used to stop the machine when it is in the “automatic” mode of operation. When the operator depresses the button, almost anywhere in the stroke of the machine, it will return the ram to the up position.

  • Page 21: Motor Starter

    SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control PART NO. LLD-701 - SUPERVISORY CONTROL STATION (Required for multiple operator stations) When multiple operator stations are required, this supervisory control station is furnished separately for each oper- ator station. Please refer to the electrical control schematics furnished with your order for proper wiring of each station.
  • Page 22 SECTION 3 — INSTALLATION OF COMPONENTS SSC-500 Hydraulic Press Solid-State Control Other Required Components (continued) PRESENCE SENSING DEVICE According to ANSI B11.2 - 1995, the total stopping time of the press (for presence sensing devices) should include the total response time of the presence sensing device, as stated by the manufacturer, the response time of the interface, the response time of the control system and the time it takes the press to cease slide motion.

  • Page 23: Other Installation Considerations

    25’ of cable is supplied as standard and can be cut to length if required. Do not splice or interrupt signals. The cable should be wired directly into the SSC-500 control module terminal strip P5, as shown in the schematic prints that were sent with the control box.

  • Page 24: Section 4-Programming

    The flowchart in Figure 4.1 outlines the order and method of setting up After completing the installation of the control box and control com- and programming the SSC-500 control system on a hydraulic press ponents, the SSC-500 control system must be initially programmed in after installation.
  • Page 25 SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control Standard Programming Overview Figure 4.3 Main Program Menu Flowchart The following sections outline the standard programming of the SSC- 500 control system on hydraulic machines after installation of all components has been completed.

  • Page 26: Clear Stroke

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control QUICK REFERENCE TABLE - FACTORY SETTINGS AND VALID RANGES Table 4.1 Program Setting Valid Entry Range Factory Preset Setting Clear Stroke Clear/Abort Clear batch Clear/Abort Batch Preset 0000000 - 9999999 0000000...

  • Page 27: Clear Batch

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control Figure 4.5 CLEAR BATCH CLEAR BATCH Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the pro- CLEAR BATCH gram options. Press ENTER when the LCD displays CLEAR BATCH.

  • Page 28: Bottom Dwell

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control Figure 4.7 BOTTOM DWELL ms BOTTOM DWELL Programming Flowchart Select the PROG position on the Program/Run selector switch. BOTTOM DWELL ms Press the buttons on the keypad to scroll through the program options.

  • Page 29: Anti-Tiedown Ms

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control ANTI-TIEDOWN ms Figure 4.9 ANTI-TIEDOWN Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the program ANTI-TIEDOWN ms options. Press ENTER when the LCD displays ANTI-TIEDOWN ms.

  • Page 30: Psdi Timer

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control Optional Programming Overview Figure 4.11 (requires options module) PSDI TIMER Programming Flowchart PSDI TIMER sec PSDI TMR sec Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the program options.

  • Page 31: User Inputs

    MAIN MENU USER INPUTS Time - seconds Setting Type: The SSC-500 has four (4) programmable user inputs.* These inputs Range: 005 - 120 sec are 24VDC sinking (NPN) type. There are three (3) parameters that can 005 sec Factory Setting: be programmed for each input.

  • Page 32: Input #1

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control USER INPUTS (continued) Figure 4.15 INPUT #1, 2, 3, 4 Programming Flowchart* INPUT #1 (2, 3, 4) INPUT #X Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the program options.

  • Page 33: Options Edit

    SECTION 4 — PROGRAMMING SSC-500 Hydraulic Press Solid-State Control OPTIONS EDIT Figure 4.16 OPTIONS EDIT Flowchart The optional modes that can be configured using the options menu are—TOS LS LOGIC (N.O./N.C.), BOS LS LOGIC (N.O./N.C.), FOOT TRIP (OFF/ON), SC SOL ON (SLOW/FAST), SC LS (N.O./N.C.), HI ON BOS (OFF/ON), AND VALVE LS (N.O./N.C.).

  • Page 34: Section 5-Psdi

    SECTION 5 — PSDI SSC-500 Hydraulic Press Solid-State Control Sequence of Operation SINGLE BREAK When the slide is at the TOS limit switch and waiting for the prior action, the display reads PSDI 1 — STOP. To arm the PSDI mode, press the prior action push button.

  • Page 35: Section 6-Operating Considerations

    SECTION 6 — OPERATING CONSIDERATIONS SSC-500 Hydraulic Press Solid-State Control SSC-500 Operation Checklist 1. Is all wiring to the machine, the solid-state control module, and keypad/display correct when verified with the drawings sent with the solid-state control? ................................Y or N 2.

  • Page 36: Section 7-Fault Messages

    SECTION 7 — FAULT MESSAGES SSC-500 Hydraulic Press Solid-State Control FATAL FAULT MESSAGES FOR SSC-500 FATAL fault messages can NOT be cleared. An E-STOP is required for the press brake to recover. The problem should be fixed and then power restored to the machine.
  • Page 37 SECTION 7 — FAULT MESSAGES SSC-500 Hydraulic Press Solid-State Control FATAL FAULT MESSAGES FOR SSC-500 Table 7.1 (continued) MESSAGE CAUSE ACTION TO TAKE KEYPAD FLT KEYPAD failure. Check for correct wiring to the keypad and terminals. RUN/INCH PB FLT RUN/INCH palm button failure.

  • Page 38: Section 8-Maintenance & Inspection

    SECTION 8 — MAINTENANCE AND INSPECTION SSC-500 Hydraulic Press Solid-State Control This control system can never cure nor overcome a misadjusted, worn, broken or malfunctioning part or mechanical failure. Inspect all parts for adjustment, excessive wear, looseness or breakage. Do not operate this machine until all parts are adjusted, repaired or replaced.
  • Page 39 1. Shut off power to the main motor. Turn the main disconnect switch to the OFF position and lock it out. Open the door of the control enclosure. Remove the eight screws on the cover of the SSC-500 Control Module (See Photo 3.3 on page 16). When they are removed, pull the cover straight off over the relays and transformers.

  • Page 40: Section 9-Methods Of Safeguarding

    SECTION 9 — METHODS OF SAFEGUARDING MACHINES SSC-500 Hydraulic Press Solid-State Control OSHA 1910.217 Section (c) under General Requirements states: (i) 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 41 SECTION 9 — METHODS OF SAFEGUARDING MACHINES SSC-500 Hydraulic Press Solid-State Control Type “A” or “B” Gate on Power Presses Restraint (Holdout) on Power Presses OSHA 1910.217 Section (c)(3)(vi) OSHA 1910.217 Section (c)(3)(ii)(c) Restraint or Holdout Gate or Movable Barrier Device (Ref.

  • Page 42: Se Ction 10-Layout Sketch

    SECTION 10 — LAYOUT SKETCH SSC-500 Hydraulic Press Solid-State Control (Continued on next page.) Rockford Systems, LLC Call: 1-800-922-7533...
  • Page 43 SECTION 11 — RETURN MATERIALS AUTHORIZATION FORM SSC-500 Hydraulic Press Solid-State Control To return material for any reason contact the sales department in our organization at 1-800-922-7533 for an R.M.A. Number. All returned materials shipments must be prepaid. Complete this form and send with material to 5795 Logistics Parkway, Rockford, IL 61109. Make sure the R.M.A.

  • Page 44: Se Ction 12-Order Form

    SECTION 12 — ORDER FORM SSC-500 Hydraulic Press Solid-State Control This instruction manual references signs and literature available for your machines. This order form is for your convenience to order additional signs and/or literature as needed. (This order form is part of your installation manual so please make a copy of it when ordering.)

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