This document is an installation and operation manual for the Rockford Systems SSC-1000 Control Module, designed for use with part revolution clutch presses. The SSC-1000 is a full-featured, dual-microprocessor based press control system that enhances safety and operational efficiency for mechanical power presses.
Function Description:
The SSC-1000 Control Module serves as the central control unit for part revolution clutch presses, managing critical functions such as press operation, safety interlocks, and programming. It integrates with various components of the press, including the clutch/brake, motor starter, dual solenoid air valve, and an Opti-CAM™ with DC tachometer generator. The system is designed to provide precise control over press cycles, ensuring compliance with safety standards like OSHA 1910.217 and ANSI B11.1.
The control module facilitates several modes of operation, including single stroke, automatic single stroke, and continuous operation, all with integrated safety features. It monitors the press's motion, ensuring that all components are synchronized and operating within safe parameters. The system uses redundant inputs from devices such as palm buttons, foot switches, and light curtains to initiate press cycles, and it provides outputs to control the clutch/brake and other press components.
A key feature is the Operator Interface Keypad/Display, which allows operators to program and monitor various press parameters. This includes setting brake monitor fault set points, clear stroke, clear batch, batch preset, timed-inch operations, anti-tie-down times, PLS (Programmable Limit Switch) delays, PLS ON time, PLS counter, user inputs, STM test timer, automatic single-stroke mode, inch/top-stop mode, SPM display calibration, and default settings. The display provides real-time feedback on press status, fault messages, and programmed values.
The system also incorporates a Supervisory Control Station which is a remote control station that provides "on" and "off" selector switch functions, a key-locked "off/on" selector switch, and a "run" push button. This allows for flexible control configurations depending on the application and safety requirements.
Important Technical Specifications:
The SSC-1000 Control Module is housed in a 20" W x 16" H x 8" D NEMA 12 enclosure, designed for industrial environments. It operates on a 120 VAC coil and includes a master control relay. The system is equipped with dual microprocessors for enhanced reliability and safety.
Key components and their specifications include:
- Opti-CAM™ with DC Tachometer Generator: Provides precise motion sensing and control. It is a compact unit housed in a 6" x 6" x 6" hinge cover enclosure, with a 3/4" double-ended shaft. It can be mounted in an existing press shaft or coupled directly. It features two redundant adjustable photo-electric "cams" for continuous top-stop angle and single stroke permissive, and two additional adjustable photo-electric "cams" for "walking single stroke" and "top stop" angle.
- Dual Solenoid Air Valve and Muffler Assembly: Available in pipe sizes 3/4" and 1". The muffler is designed to reduce noise and must be kept clean to ensure proper airflow. The valve requires 30 to 40 PSI for proper operation.
- Filter-Regulator-Gauge and Lubricator (FRL) Assembly: Available in pipe sizes 1/2", 3/4", and 1". These components ensure clean, regulated, and lubricated air supply to the pneumatic components of the press.
- Air Pressure Switch: Required if the machine has an air counterbalance.
- Sprocket Set: Available with various numbers of teeth (usually 48) to adjust the length of the chain for the Opti-CAM™ assembly.
- Palm Button Assembly: Includes two black palm buttons, two yellow top-stop buttons, and one red emergency-stop button.
- Foot Switch: Individual multiple operator stations are available.
- Supervisory Control Station: Remote control station with "on" and "off" selector switches, a key-locked "off/on" selector switch, and a "run" push button.
- Light Curtains: Used as point-of-operation safeguarding devices.
- Input/Output: Four (4) user programmable diagnostic inputs and seven-digit stroke counter and batch counter with preset. One (1) PLS output (N.O.) - time/counter based. LCD display choices include Mode-SPM, Stop Time, Stroke Counter, or Batch Counter. Fused outputs (F1, F2, F3, and F4).
The system supports various timing parameters, including:
- Brake Monitor Fault Set Point: 0-999 ms.
- Timed-Inch: 0-9999 ms.
- Anti-Tie-Down Time: 100-7000 ms.
- PLS Delay: 0-9999 ms.
- STM Test Timer: 0-9999 ms.
- Automatic Single-Stroke Mode: 005-120 sec.
- Variable Speed Continuous Top Stop: 0-500 spm / 0-999 ms.
Usage Features:
- User-Friendly Interface: The keypad/display allows for intuitive programming and monitoring of press operations.
- Multiple Operating Modes: Supports single stroke, automatic single stroke, and continuous operation, providing flexibility for various production needs.
- Enhanced Safety: Integrates multiple safety interlocks, including light curtains, palm buttons, and foot switches, to ensure operator protection and compliance with safety regulations.
- Diagnostic Capabilities: The system provides fault messages and diagnostic information on the display, aiding in troubleshooting and minimizing downtime.
- Programmable Limit Switches (PLS): Allows for precise control of auxiliary functions based on press position, enhancing automation and efficiency.
- Opti-CAM™ Integration: Provides advanced motion control and monitoring, crucial for high-precision applications.
- Adjustable Parameters: Most operational parameters are adjustable via the keypad, allowing customization for specific press requirements and materials.
- Language Support: The manual emphasizes the availability of the Operator Safety Precaution pamphlet in English, Spanish, and French, indicating a commitment to clear communication for a diverse user base.
Maintenance Features:
- Modular Design: Components like the control module, keypad/display, and Opti-CAM™ are designed for relatively easy installation and replacement, simplifying maintenance.
- Clear Wiring Diagrams: The manual includes detailed electrical schematics and wiring diagrams to assist with installation, troubleshooting, and repair.
- Preventive Maintenance Guidelines: Instructions for cleaning air filters and mufflers are provided, highlighting the importance of maintaining pneumatic components for optimal performance and longevity.
- Fault Message System: The system's ability to display specific fault messages (e.g., NV-RAM fault, K1 ON FLT, MOTION LATE FLT) helps technicians quickly identify and address issues.
- EPROM Replacement: Instructions are provided for replacing the "U4" EPROM on the main control board, a common maintenance task for updating or repairing the system's firmware.
- Documentation: The manual emphasizes the importance of consulting additional literature, such as the "Operator Safety Precaution" pamphlet and "Mechanical Power Press Safety" booklet, for comprehensive safety and maintenance information.
- Return Materials Authorization (RMA) Request Form: A dedicated form is included for requesting authorization to return materials for repair, restocking, or warranty replacement, streamlining the service process.
- Order Form for Signs and Literature: Allows users to order replacement safety signs and additional documentation, ensuring that all necessary safety warnings and operational information are available.
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