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Rockford Systems SSC-1000 Installation Manual

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INSTALLATION MANUAL FOR
SSC-1000 CONTROL SYSTEMS ON
PART REVOLUTION CLUTCH MACHINES
Opti-Cam and DC
Tachometer Generator
Operator Interface
Keypad/Display
SSC-1000
Control Box
IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION
BEFORE INSTALLING, OPERATING OR MAINTAINING THE
SOLID-STATE CLUTCH/BRAKE 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: customerservice@rockfordsystems.com
Chain and sprock-
et cover removed
for photo.
Manual No. KSL-212
Dual Solenoid Air
Valve

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Do you have a question about the SSC-1000 and is the answer not in the manual?

Questions and answers

Chad Hartman
April 14, 2025

NVRAM FLT stays up and won’t let me get into interface to change anything .tryed tips in manual but doesn’t go away

User image 67fd1d1c76e55
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1 comments:
Mr. Anderson
April 14, 2025

To resolve the NVRAM FLT issue on the Rockford Systems SSC-1000:

1. The nonvolatile (NV) RAM memory may be faulty and cannot be reset to factory default.
2. The battery socket or RAM chip may be inoperative and may need repair or reprogramming.
3. If the issue persists, consult the factory for assistance.

Access to the interface may not be possible until the NVRAM issue is fixed.

This answer is automatically generated

0

Related Manuals for Rockford Systems SSC-1000

Summary of Contents for Rockford Systems SSC-1000

  • Page 1 INSTALLATION MANUAL FOR SSC-1000 CONTROL SYSTEMS ON PART REVOLUTION CLUTCH MACHINES Opti-Cam and DC Dual Solenoid Air Tachometer Generator Valve Chain and sprock- et cover removed for photo. Operator Interface Keypad/Display SSC-1000 Control Box IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION BEFORE INSTALLING, OPERATING OR MAINTAINING THE SOLID-STATE CLUTCH/BRAKE CONTROL SYSTEM.

  • Page 2: Table Of Contents

    Section 7—MAINTENANCE & INSPECTION ....55 - 56 (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-1000 Part Revolution Solid-State Control Safety Precautions “ ” DANGER Danger is used to indicate the presence of a hazard which WILL cause SEVERE 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-1000 Part Revolution Solid-State Control OSHA’s Act and Federal Regulations ANSI Safety Standards for Machines Since the enclosed equipment can never overcome a mechanical The most complete safety standards for machine tools are published deficiency, defect or malfunction in the machine itself, OSHA in the ANSI (American National Standards Institute) B11 series.
  • Page 5 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...
  • Page 6 SECTION 1—IN GENERAL SSC-1000 Part Revolution Solid-State Control Operator Safety Precaution Pamphlet – attachment for anyone operating this machine 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-1000 Part Revolution 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 If any of these labels become destroyed or unreadable, labels MUST be replaced. Contact factory immedi- ately for replacement labels and do not operate machine until danger and warning labels are all in place. KSS - 027 Photo 1.1 Inside View of SSC-1000 Control Box (Continued on next page.) Rockford Systems, LLC Call: 1-800-922-7533...

  • Page 9: Rockford Systems, Llc

    SECTION 1—IN GENERAL SSC-1000 Part Revolution Solid-State Control FOR REPLACEMENT SIGNS CALL, E-MAIL, OR FAX FACTORY OR USE ORDER FORM ON BACK COVER. Rockford Systems, LLC 5795 Logistics Parkway Rockford, Illinois 61109 Photo 1.2 Toll Free: 1-800-922-7533 (USA only) SSC-1000 Control Box...
  • Page 10 SECTION 1—IN GENERAL SSC-1000 Part Revolution Solid-State Control Press Components Identification Part Revolution OBI Press PART REVOLUTION OBI PRESS Resolver/Cam Motor Limit Switch Counterbalance Motor Assembly Belts Starter Dual Sheave Solenoid Releasing Valve Lifting Bolt Brake Crankshaft Disconnect Flywheel Switch...

  • Page 11: Section 2-Introduction

    SECTION 2—INTRODUCTION SSC-1000 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 16) containing installation manuals, “Operator Safety Precaution” Pamphlet, danger sign(s), electrical control schematics, “Mechanical Power Press Safety”...
  • Page 12 SECTION 2—INTRODUCTION SSC-1000 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 that 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 13 There is an additional charge for this service. General Features of the SSC-1000 Control • Redundant/cross-checking microprocessors from different manufacturers •...

  • Page 14: Figure 2.1 Block Diagram

    SSC-1000 Part Revolution Solid-State Control Theory of Operation The SSC-1000 press control consists of three major components: the control module, the keypad display module, and the Opti-CAM™ assembly, which provides all press timing and motion detection. See the block diagram in Figure 2.1 below.
  • Page 15 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-1000 control module assembly. As standard, this is furnished in a 20”W x 16”H x 8”D NEMA 12 enclosure.

  • Page 16: Components

    (below), electrical schematics, and a booklet entitled “Mechanical Power Press Safety” (MPPS). These publications must be available and fully understood by all appropriate personnel, before any retrofit installation begins. Please notify Rockford Systems, LLC immediately if there are any questions about the components received.
  • Page 17 CPUs (Central Processing Units). Photo 3.3 Top View of Control Module with Cover Relays Output Red LEDs Power Supply Transformers Top Cover Power/Status Opti-CAM LEDs Input Red LEDs Green LEDs (Continued on next page.) Rockford Systems, LLC Call: 1-800-922-7533 (USA)
  • Page 18 SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control Control Module Assembly (continued) If necessary, the cover of the module can be taken off by removing the eight screws on the corners and pulling the top straight off over the relays.
  • Page 19 The keypad/display can be furnished in a remote enclosure up to a Operator Interface Keypad/Display maximum of 150’ from the SSC-1000 control module. Display modes during the machine run cycle are MODE - SPM, STOP TIME, STROKE COUNTER, or BATCH COUNTER. All programming is accessed by a key selector switch on the keypad/display unit.

  • Page 20: Dual Solenoid Air Valve And Muffler Assembly

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control DUAL SOLENOID AIR VALVE AND MUFFLER (If furnished, see enclosed Installation Manual No. 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.

  • Page 21: Air Pressure Switch

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control PART NO. CTD-062 - AIR PRESSURE SWITCH (If furnished, see enclosed Installation Manual No. KSL-165) The clutch/brake or cylinder air supply must be monitored by an air pressure switch on all part revolution power presses.

  • Page 22: Figure 3.1 Opti-Cam™ & Tachometer Generator

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control OPTI-CAM™ AND DC TACHOMETER GENERATOR (continued) Figure 3.1 Top View of Opti-CAM with DC Tachometer Generator Opti-CAM and DC Tachometer Generator Setup (Cover Open) Locate and mount the Opti-CAM unit and spring base (if used) to the press.

  • Page 23: Sprocket Set

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control OPTI-CAM™ AND DC TACHOMETER GENERATOR (continued) When installing a chain and sprocket, or coupling to the 3/4” shaft, start with the machine at TDC (Top Dead Center) and the keyway pointing up.

  • Page 24: P Alm Button Assembly

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control 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 single stroke, and continuous 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 top-stop button).

  • Page 25: Table 3.1 Osha Safety Distance Chart

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control PALM BUTTON ASSEMBLY (continued) OSHA 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...
  • Page 26 To obtain the stopping time at 90° position of crankshaft rotation, either a built-in system (provided with the control system) or portable stop-time measurement unit can be used. (For a portable unit, please contact Rockford Systems, LLC) WHEN USING PACKAGES THAT INCLUDE “TWO-HAND CONTINUOUS,” FOOT SWITCH SINGLE STROKE, OR “AUTOMATIC SINGLE STROKE”...

  • Page 27: Foot Switch (Optional)

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control PALM BUTTON ASSEMBLY (continued) Red Emergency-Stop Palm 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 includes a double hub mounting box.

  • Page 28: Supervisory Control Station

    Hour Meter Robot Die Protection Material Feeding Equipment Programmable Limit Switch Lubrication System The electrical or electronic schematics are required if Rockford Systems is to interface this equipment to the control. (Continued on next page.) Rockford Systems, LLC Call: 1-800-922-7533...

  • Page 29: Lockout Air Valve

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control Other Required Components (Not supplied as part of standard package unless specifically ordered) LOCKOUT AIR VALVE The OSHA Regulation, under Subpart J, Section 1910.147, requires that all employers develop a complete hazardous energy control program. This regulation covers the servicing and maintenance of machines and equipment where the unexpected energization or start-up of the machines or equipment, or release of stored energy could cause injury to employees.

  • Page 30: Main Power Disconnect Switch

    If this is not possible, or an electrical disconnect switch is not provided, then you must obtain and install a proper disconnect switch. (For proper disconnect switch, please contact Rockford Systems, LLC) (Continued on next page.)

  • Page 31: Motor Starter

    SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control Motor Starter A reversing or nonreversing motor starter may have been supplied with this control package. The main purpose of this starter is to drop out the main drive motor and the hard-wired emergency-stop relay when a power failure occurs. Please refer to the enclosed wiring schematics for proper wiring of this starter.
  • Page 32 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-1000 control module terminal strip P3, and blue terminals as shown in the schematic prints that were sent with the control box. Please contact Rockford Systems, LLC if a longer cable is required.
  • Page 33 SECTION 3—INSTALLATION OF COMPONENTS SSC-1000 Part Revolution Solid-State Control WIRING ( ontinued) Air Pressure Switches Run 1/2” nominal conduit from pressure switch(es) to the control box. Pull two red and two blue wires through conduit. Number per diagram and connect to terminals at both ends. These pressure switches always use the normally open contact which is held closed by normal air pressure.

  • Page 34: 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 and programming the SSC-1000 press control system on a part revolu- components, the SSC-1000 press control system must be initially tion press after installation.

  • Page 35: Programming Overview

    SSC-1000 Part Revolution Solid-State Control Programming Overview Figure 4.3 Main Program Menu Flowchart The following sections outline the programming of the SSC-1000 press control system on a part revolution press after installation of all components has been completed. PROG MAIN PROGRAM MENU All programming is done by selecting PROG (Program) on the key selector switch as shown in Figure 4.3.

  • Page 36: Brake Monitor Ms

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control BRAKE MONITOR ms Figure 4.4 Select the PROG position on the Program/Run selector switch. BRAKE MONITOR Programming Flowchart Press the buttons on the keypad to scroll through the BRAKE MONITOR ms program options. Press ENTER when the LCD displays BRAKE MONITOR ms.

  • Page 37: Clear Stroke

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control CLEAR STROKE Figure 4.5 CLEAR STROKE Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the CLEAR STROKE program options. Press ENTER when the LCD displays CLEAR STROKE.

  • Page 38: Batch Preset

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control Figure 4.7 BATCH PRESET BATCH PRESET Programming Flowchart Select the PROG position on the Program/Run selector switch. BATCH PRESET Press the buttons on the keypad to scroll through the program options. Press ENTER when the LCD displays BATCH PRESET.

  • Page 39: Anti-Tie-Down Ms

    ROGRAMMABLE IMIT WITCH Setting Type: Time - ms (milliseconds) The SSC-1000 has one (1) normally open PLS relay output. This relay Range: 100 - 7000 ms contact is rated for 10A at 120VAC. Two programmable timers and Factory Setting: 250 ms one programmable counter are used to control the PLS output.

  • Page 40: Pls Delay Ms

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control PLS (P ) OUTPUT (continued) Figure 4.11 ROGRAMMABLE IMIT WITCH PLS DELAY Programming Flowchart PLS DELAY ms (Programmable Timer 1) Select the PROG position on the Program/Run selector switch. PLS DELAY ms Press the buttons on the keypad to scroll through the program options.

  • Page 41: Pls Counter

    Range: 0000 - 9999 Factory Setting: 0000 The SSC-1000 has four (4) programmable user inputs. These inputs are 24VDC sinking (NPN) type. There are three (3) parameters that can Figure 4.14 User Input Fault Messages Chart be programmed for each input.

  • Page 42: Figure 4.15 Input # 1 - 4 Flowchart

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control Figure 4.15 USER INPUTS (continued) 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 43: Stop-Time Measurement Test Ms

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control STM TEST [Make sure the press is at TDC (Top Figure 4.16 Dead Center) before proceeding with the STM STM TEST Programming Flowchart TEST!] STM TEST Select the PROG position on the Program/Run selector switch.

  • Page 44: Reference Cycle

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control REFERENCE CYCLE [Make sure the press is at Figure 4.17 TDC (Top Dead Center) before proceeding with the REFERENCE CYCLE Programming Flowchart Reference Cycle!] REFERENCE CYCLE Select the PROG position on the Program/Run selector switch.

  • Page 45: Automatic Single Mode

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control ASINGLE MODE (A Figure 4.18 UTOMATIC INGLE TROKE ASINGLE MODE Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the ASINGLE MODE program options.
  • Page 46 SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control INCH/TSTOP MODE (I Figure 4.19A INCH/TSTOP MODE Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the INCH/TSTOP MODE program options. Press ENTER when the LCD displays INCH/TSTOP MODE.
  • Page 47 SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control DEFAULT SETTINGS Figure 4.19C DEFAULT SETTINGS Programming Flowchart Select the PROG position on the Program/Run selector switch. Press the buttons on the keypad to scroll through the program DEFAULT SETTINGS options. Press ENTER when the LCD displays DEFAULT SETTINGS.

  • Page 48: Figure 4.20 Top-Stop Chart

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control VARIABLE SPEED CONTINUOUS TOP STOP The variable speed continuous top-stop (CTS) table is used by the control to stop the press at approximately TDC automatically when the top-stop palm button is activated with the press operating at various speeds in the continuous mode of operation. This is accomplished by programming a timer value, to be added to the CTS ON point for each of the 4 SPM steps, within the SPM range the press operates in.

  • Page 49: Figure 4.21 Var Spm Low Lim Flowchart

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control VAR SPM LOW LIM Figure 4.21 - VAR SPM LOW LIM Flowchart Select the PROG position on the Program/Run selector switch. Press VAR SPM LOW LIM buttons on the keypad to scroll through the program options.

  • Page 50: Figure 4.24 Optional Modes Setup Flowchart

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control Figure 4.24 - OPTIONAL MODES SETUP Flowchart OPTIONAL MODES SETUP There are four optional operating modes that can be configured using the options menu. To access the options menu, refer to the following PROG programming descriptions and flowchart.

  • Page 51: Inch/Top-Stop Mode

    SECTION 4—PROGRAMMING SSC-1000 Part Revolution Solid-State Control Optional Modes: OPTIONS EDIT Turn the main power disconnect off. Turn the PROG/RUN key selector FOOT M/CONT OFF (ON) switch on the keypad/display to OFF. Hold the ENTER button on the CONT/DEMAND OFF (ON) keypad and turn the main power disconnect ON.

  • Page 52: Section 5-Operating Considerations

    SECTION 5—OPERATING CONSIDERATIONS SSC-1000 Part Revolution Solid-State Control SSC-1000 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 53 SECTION 5—OPERATING CONSIDERATIONS SSC-1000 Part Revolution Solid-State Control Electrical Troubleshooting All troubleshooting, as well as installation, must be performed by qualified and properly trained personnel. Also, when a defective component is found, do not operate the machine until that component has been replaced with an exact replacement part.

  • Page 54: Section 6-Fault Messages

    REFERENCE CYCLE procedure described on page 44. MOTION DROP FLT Check for correct wiring to the Opti-CAM and terminals on the SSC-1000 control module. Verify that the chain The control detected a loss of motion during a or coupling for the Opti-CAM is connected and tight.
  • Page 55 SECTION 6—FAULT MESSAGES SSC-1000 Part Revolution Solid-State Control FATAL FAULT MESSAGES FOR SSC-1000 Table 6.1 (continued) Message Cause Action To Take KEYPAD FLT Check for correct wiring to the keypad and KEYPAD failure. terminals. RUN/INCH PB FLT Check for correct wiring to the palm buttons and RUN/INCH palm button failure.
  • Page 56 SECTION 6—FAULT MESSAGES SSC-1000 Part Revolution Solid-State Control GENERAL FAULT MESSAGES FOR SSC-1000 GENERAL FAULT MESSAGES can be cleared by touching ENTER on the KEYPAD/DISPLAY. Table 6.2 Message Cause/Solution The initiating means is in the foot mode. This selection must be in the hand mode to allow the HAND MODE ONLY requested mode of operation.

  • Page 57: Section 7-Maintenance & Inspection

    SECTION 7—MAINTENANCE AND INSPECTION SSC-1000 Part Revolution Solid-State Control A part revolution mechanical power press consists of engaging parts, springs, 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 58 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-1000 Control Module (See Photo 3.4 on page 18). When they are removed, pull the cover straight off over the relays and transformers.

  • Page 59: Return Materials Request Form

    SECTION 8—METHODS OF SAFEGUARDING PRESSES SSC-1000 Part Revolution 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 60: Order Form

    Power Presses, ANSI’s B11.1 booklet entitled “Safety Requirements for the Construction, Care and Use of Mechanical Power Presses.” Also see the enclosed Rockford Systems’ booklet entitled “Mechanical Power Press Safety” (MPPS). When using the devices described, for point-of-operation protection, sides and rear of hazardous area must be guarded to protect the operator and other employees in the machine area (OSHA Section 1910.212).
  • Page 61 RETURN MATERIALS AUTHORIZATION REQUEST FORM SSC-1000 Part Revolution 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 materi- als 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 62 City State Phone Name Purchase Order No. Date Part No. Description Quantity Required KSL-212 Installation Manual SSC-1000 for Part Revolution Presses KSC-000 Precaution Pamphlet (English) KSC-000S Precaution Pamphlet (Spanish) KSC-000F Precaution Pamphlet (French) KST-134 Danger Label 4-3/8” x 8” KST-135 Danger Label 5”...

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