Rockford Fosgate DETECT-A-FINGER RKC-502 Installation Manual

Drop probe device for resistance-type spot welders

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INSTALLATION MANUAL FOR

DETECT-A-FINGER

FOR RESISTANCE-TYPE SPOT WELDERS

Danger Sign

Control Box

IMPORTANT: PLEASE REVIEW THIS ENTIRE

PUBLICATION BEFORE INSTALLING,

OPERATING OR MAINTAINING THIS DEVICE.

5795 Logistics Parkway • Rockford Systems, LLC, Illinois 61109-2695 • Toll-Free 1-800-922-7533 • Phone 815-874-7891

Fax 815-874-6144 • Web Site www.rockfordsystems.com • E-Mail sales@rockfordsystems.com

DROP PROBE DEVICE

Instruction Manual No. KSL-022

Sensing Probe

Assembly

Sensing Probe

Table of Contents

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Summary of Contents for Rockford Fosgate DETECT-A-FINGER RKC-502

Page 1 INSTALLATION MANUAL FOR DETECT-A-FINGER DROP PROBE DEVICE ® FOR RESISTANCE-TYPE SPOT WELDERS Danger Sign Sensing Probe Assembly Sensing Probe Control Box IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION BEFORE INSTALLING, OPERATING OR MAINTAINING THIS DEVICE. 5795 Logistics Parkway • Rockford Systems, LLC, Illinois 61109-2695 • Toll-Free 1-800-922-7533 • Phone 815-874-7891 Fax 815-874-6144 •...
Page 2: Table Of Contents
SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® SECTION 3 - OPERATING PROCEDURES & SECTION 1 - IN GENERAL ..........2 - 8 TROUBLESHOOTING ............17-18 SECTION 2 - INSTALLATION OF COMPONENTS ..9 - 16 SECTION 4 - REPLACEMENT PARTS ....... 19 Control Box ................
Page 3: Section 1-In General
SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® Safety References ANSI SAFETY STANDARDS FOR MACHINES The most complete safety standards for machine tools OSH ACT AND FEDERAL REGULATIONS are published in the ANSI (American National Standards Since the enclosed equipment can never overcome Institute) B11 series.
Page 4 SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® NATIONAL SAFETY COUNCIL SAFETY MANUALS OTHER SAFETY SOURCES (continued) Other good references for safety on machine tools are Robotic Industries Association (RIA) the National Safety Council’s Safety Manuals. These 900 Victors Way, Suite 140 manuals are written by various committees including P.O.
Page 5 SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® Operator Safety Precautions Sign Accompanying this equipment is an ⁄ ” x 11” operator safety precautions sign, Part No. KSC-000, for anyone operating the machine where this equipment will be installed. These precautions are to be given to all operators, including setup people, maintenance...
Page 6 SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® Danger Sign(s) to be Mounted on Machine Accompanying this equipment is a 5” x 6” polyethylene danger sign, Part No. KSC-055. This sign MUST BE PERMANENTLY MOUNTED IN A PROMINENT LOCATION on the machine where this equipment is installed.
Page 7 SECTION 1—IN GENERAL Detect-A-Finger Drop Probe Device-Welder ® General Overview The purpose of the Detect-A-Finger® Drop Probe Device is to effectively reduce accidents on applications where the operator’s fingers may enter the point of operation. The components of this system are a sensing probe shaped to fit over or around the workpiece, a drop-probe assembly, and a control box.
Page 8: Section 2-Installation Of Components
SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Preliminary Steps Before Installation Before proceeding with the installation of the enclosed equipment, you should undertake the following preliminary steps. 1. Read and make sure you understand this entire installation manual. 2.
Page 9: Control Box
SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Control Box The RKC-500 series Detect-A-Finger® system control box is housed in a NEMA enclosure (approximately 6 ⁄ ” wide by 9 ⁄ ” high by 4 ⁄ ” deep) and consists of a through-the-door fuse holder, relay, terminal strips, transformer, and PC board assembly.
Page 10 SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Sensing Probe Assembly The drop rod is allowed to drop by gravity when the rotary solenoid is energized. The action arm return spring returns this assembly when the power is removed. The DC voltage for the rotary solenoid is obtained from a full-wave bridge rectifier.
Page 11: Sensing Probe
SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Sensing Probe Two 18-inch pieces of ⁄ (.156) inch diameter aluminum rods are furnished with each Detect-A-Finger®. Other materials or custom made configurations may also be used. The only restriction is the total weight of the probe assembly (including the clamp).
Page 12: Other Components That May Be Required
SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Other Components That May Be Required Main Power Disconnect Switch A main power disconnect switch may have been supplied in the package shipment. This switch is designed to disconnect the primary voltage to the machine and lock it out. Refer to the enclosed wiring schematics for proper wiring of this switch.
Page 13 SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Other Components That May Be Required For Mechanically Operated Welders Most welders are controlled electrically, pneumatically or mechanically; if not, other components may be required. Review this section for typical applications of the Detect-A-Finger®. Accessory equipment and components, such as solenoid air valves or air cylinders are available from Rockford Systems for your convenience.
Page 14 SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Other Components That May Be Required For Mechanically Operated Welders (continued) Solenoid AiR Valve Assembly (If furnished—See enclosed manual KSL-151) The solenoid air valve is a three-way, normally closed, quick exhaust type. This assembly consists of the electric air solenoid valve, steel mounting bracket, and flexible hose.
Page 15 SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Other Components That May Be Required For Mechanically Operated Welders (continued) Filter-regulator-lubricator (frl) assembly (If furnished—See enclosed manual KSL-208) The filter cleans air that goes to the solenoid air valve (and air cylinder, if furnished). The regulator and gauge are used to adjust air pressure.
Page 16 SECTION 2—INSTALLATION OF COMPONENTS Detect-A-Finger Drop Probe Device-Welder ® Other Installation Consideration PIPING 1. An air lockout valve must be installed in the air line usually just before the filter-regulator-lubricator assembly to meet OSHA 29 CFR 1910.147 Lockout/tagout requirements. However, a separate lockout valve could be furnished for each air system on the machine such as counterbalance, clutch/brake, air cylinder, and blow-off.
Page 17: Section 3-Operating Procedures & Troubleshooting
SECTION 3—OPERATING PROCEDURES & TROUBLESHOOTING Detect-A-Finger Drop Probe Device-Welder ® Operating Procedure 1. Apply power. If the power does not come on, check that the main disconnect switch is on, fuse is connected, and check for proper wiring. 2. Measure the incoming voltage at terminals 1 and 2. It should be 115 V AC ± 15%. Shut off power for the next step. 3.
Page 18 SECTION 3—OPERATING PROCEDURES & TROUBLESHOOTING Detect-A-Finger Drop Probe Device-Welder ® Troubleshooting Resistant Measurement Troubleshooting RESISTANCE TERMINAL OHMS From ∞ (-DC) ∞ (+DC) ∞ ∞ Power off with components not connected. Bridge Rectifier, Terminal Identification Readings may vary slightly from meter to meter. However, the trend established between infinity (∞...
Page 19: Section 4 - Replacement Parts
SECTION 4—REPLACEMENT PARTS Detect-A-Finger Drop Probe Device-Welder ® Replacement Parts REPLACEMENT PARTS FOR CONTROL BOX RKC-501 Part No. Description RFT-017 Relay RSC-327 Transformer RTY-003 Fuse 1 Amp FTL-020 PC Board REPLACEMENT PARTS FOR SENSING PROBE ASSEMBLY RKC-502 Part No. Description CMF-108 Rotary Solenoid FKC-101...
Page 20 SECTION 5—ORDER FORM FOR SIGNS & LITERATURE—RMA FORM Detect-A-Finger Drop Probe Device-Welder ® ORDER FORM FOR SIGNS AND LITERATURE 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.) Company Address...

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Detect-a-finger rkc-500 series