Rockford Systems SSC-1000 User manual

INSTALLATION MANUAL FOR
SSC-1000 CONTROL SYSTEMS ON
PART REVOLUTION CLUTCH MACHINES
IMPORTANT: PLEASE REVIEW THIS ENTIRE PUBLICATION
BEFORE INSTALLING, OPERATING OR MAINTAINING THE
SOLID-STATE CLUTCH/BRAKE CONTROL SYSTEM.
SSC-1000
Control Box
Opti-Cam and DC
Tachometer Generator
Chain and sprock-
et cover removed
for photo.
Dual Solenoid Air
Valve
Operator Interface
Keypad/Display
5795 Logistics Parkway • Rockford, Illinois 61109 • Toll Free 1-800-922-7533 (USA only) • Phone [phone]
Fax [phone] • Web Site: www.rockfordsystems.com • E-Mail: [email protected]
Manual No. KSL-212

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TABLE OF CONTENTS
SSC-1000 Part Revolution Solid-State Control
Section 1—IN GENERAL ...................................................3 - 10
Section 2—INtroduction ................................................11 - 15
Section 3—INSTALLATION OF SSC-1000 CONTROL SYSTEM
Components.................................................................16 - 33
Literature Folder...................................................................16
Control Box.................................................................. 16 - 19
Dual Solenoid Air Valve and Muffler Assembly .......................20
Filter-Regulator-Gauge and Lubricator (FRL) Assembly ...........20
Air Pressure Switch..............................................................21
Check Valves for Counterbalance System ..............................21
Opti-CAM™ Assembly ................................................. 21 - 23
Sprocket Set .......................................................................23
Chain...................................................................................23
Palm Button Assembly.................................................. 24 - 27
Foot Switch (Optional)...........................................................27
Supervisory Control Station...................................................28
Lockout Air Valve ......................................................... 29 - 30
Main Power Disconnect Switch .............................................30
Motor Starter .......................................................................31
Custom or Special Control Box..............................................31
Flywheel and Gear Covers ....................................................31
Collateral Equipment ............................................................31
Point-of-Operation Safeguards..............................................31
Other Installation Considerations ..................................31 - 33
Section 4—PROGRAMMING ...........................................34 - 49
Setup of Control System ........................................................34
Initial Setup Procedure .........................................................34
Programming Overview..........................................................35
Brake Monitor ms.................................................................36
Clear Stroke.........................................................................37
Clear Batch..........................................................................37
Batch Preset ........................................................................38
Timed-Inch ms.....................................................................38
Anti-tie-down ms .................................................................39
PLS Output ..........................................................................39
PLS Delay ms ......................................................................40
PLS On Time ms..................................................................40
PLS Counter ........................................................................41
User Inputs .................................................................. 41 - 42
Stop-Time Measurement Test ms .........................................43
Reference Cycle...................................................................44
Automatic Single Mode.........................................................45
Automatic Single Timer sec ..................................................45
Inch/Top-Stop Mode............................................................45A
SPM Display Calibration %...................................................45A
Default Settings...................................................................45B
Variable Continuous Top-Stop....................................... 46 - 47
Optional Modes of Operation .........................................48 - 49
Section 5—OPERATING CONSIDERATIONS.................... 50 - 51
Section 6—FAULT MESSAGES .......................................52 - 54
Section 7—MAINTENANCE & INSPECTION .................... 55 - 56
Section 8—METHODS OF SAFEGUARDING ...................57 - 58
RETURN MATERIALS REQUEST FORM ....................................59
ORDER FORM ..........................................................................60
FIGURES
Figure 2.1 Block Diagram .........................................................14
Figure 3.1 Opti-CAM™ & Tachometer Generator.......................22
Figure 3.2 Cam and Switch Settings..........................................22
Figure 3.3 Palm Button Assembly Installation.............................24
Figure 3.4 Illustration of Electrical System..................................28
Figure 3.5 Illustration of Lockout Installation ..............................29
Figure 4.1 Initial Setup Procedure Flowchart ..............................34
Figure 4.2 Initial Information on Display .....................................34
Figure 4.3 Main Program Menu Flowchart .................................35
Figure 4.4 Brake Monitor Flowchart...........................................36
Figure 4.5 Clear Stroke Flowchart .............................................37
Figure 4.6 Clear Batch Flowchart ..............................................37
Figure 4.7 Batch Preset Flowchart.............................................38
Figure 4.8 Timed Inch Flowchart ...............................................38
Figure 4.9 Anti-tie-down Flowchart............................................39
Figure 4.10 PLS Output Timing Chart ........................................39
Figure 4.11 PLS Delay Flowchart...............................................40
Figure 4.12 PLS On Time Flowchart ..........................................40
Figure 4.13 PLS Counter Flowchart ...........................................41
Figure 4.14 User Input Fault Messages Chart.............................41
Figure 4.15 Input # 1 - 4 Flowchart ..........................................42
Figure 4.16 STM Test Flowchart................................................43
Figure 4.17 Reference Cycle Flowchart......................................44
Figure 4.18 ASingle Mode Flowchart .........................................45
Figure 4.19 ASingle Tmr Flowchart............................................45
Figure 4.19A Inch/Top-Stop Mode Flowchart ............................45A
Figure 4.19B SPM Display Calibration Flowchart.......................45A
Figure 4.19C Default Settings Flowchart...................................45B
Figure 4.20 Top-Stop Chart ......................................................46
Figure 4.21 Var SPM Low Lim Flowchart ...................................47
Figure 4.22 Var SPM High Lim Flowchart...................................47
Figure 4.23 Var SPM Flowchart.................................................47
Figure 4.24 Optional Modes Setup Flowchart.............................48
TABLES
Table 3.1 OSHA Safety Distance Chart.......................................25
Table 3.2 Lockout Air Valve Part No. Chart.................................30
Table 4.1 Quick Reference Table...............................................49
Table 6.1 Fatal Fault Messages ........................................ 52 - 53
Table 6.2 General Fault Messages ............................................54
© 2017 Rockford Systems, LLC All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A.

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
Efficient and safe machine operation depends on the development, implementation and enforcement of a safety program. This program
requires, among other things, the proper selection of point-of-operation guards and safety devices for each particular job or operation and a
thorough safety training program for all machine personnel. This program should include instruction on the proper operation of the machine,
instruction on the point-of-operation guards and safety devices on the machine, and a regularly scheduled inspection and maintenance program.
Rules and procedures covering each aspect of your safety program should be developed and published both in an operator’s safety manual, as
well as in prominent places throughout the plant and on each machine. Some rules or instructions which must be conveyed to your personnel
and incorporated into your program include:
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.
WHEN YOU SEE THIS SYMBOL , BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY, AND
CAREFULLY READ THE MESSAGE THAT FOLLOWS.
A company’s safety program must involve everyone in the company, from top management to operators, since only as a group can any
operational problems be identified and resolved. It is everyone’s responsibility to implement and communicate the information and material
contained in catalogs and instruction manuals to all persons involved in machine operation. If a language barrier or insufficient education would
prevent a person from reading and understanding various literature available, it should be translated, read or interpreted to the person, with
assurance that it is understood.
Never place your hands or any part of your body in this machine.
Never operate this machine without proper eye, face and body protection.
Never operate this machine unless you are fully trained and instructed and unless you have read the instruction manual.
Never operate this machine if it is not working properly – stop operating and advise your supervisor immediately.
Never use a foot switch to operate this machine unless a point-of-operation guard or device is provided and
properly maintained.
Never operate this machine unless two-hand trip, two-hand control or presence sensing device is installed at the
proper safety distance. Consult your supervisor should you have any questions regarding the proper safety distance.
Never tamper with, rewire or bypass any control or component on this machine.
DANGER
“ ”
“ ”
Safety Precautions
DANGER
DANGER
FOR MAINTENANCE AND INSPECTION ALWAYS REFER TO THE OEM’s (ORIGINAL EQUIPMENT
MANUFACTURER’S) MAINTENANCE MANUAL OR OWNER’S MANUAL. If you do not have an owner’s
manual, please contact the original equipment manufacturer.

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
OSHA’ s A ct and Federal R egulations
Since the enclosed equipment can never overcome a mechanical
deficiency, defect or malfunction in the machine itself, OSHA
(Occupational Safety and Health Administration) has established
certain safety regulations that the employers (users) must comply with
so that the machines used in their plants, factories or facilities are
thoroughly inspected and are in first-class operating condition before
any of the enclosed equipment is installed.
1. An Act – Public Law 91 - 596, 91st Congress, S. 2193,
December 29, 1970
Duties:
Sec. 5. (a) Each employer —
(1) shall furnish to each of his employees employment and a
place of employment which are free from recognized hazards
that are causing or are likely to cause death or serious physical
harm to his employees;
(2) shall comply with occupational safety and health standards
promulgated under this Act.
(b) Each employee shall comply with occupational safety and
health standards and all rules, regulations, and orders issued
pursuant to this Act which are applicable to his own actions and
conduct.
2. OSHA’s Code of Federal Regulations, Subpart O, that an
employer (user) must comply with include:
Section 1910.211 Definitions
Section 1910.212 (a) General Requirements for all Machines
Section 1910.217 Mechanical Power Presses
Section 1910.219 (b)(1) Mechanical Power-Transmission
Apparatus (Flywheel and Gear Covers)
3. OSHA’s 29 Code of Federal Regulations, Subpart J 1910.147
The Control of Hazardous Energy (Lockout / Tagout)
4. OSHA’s Publications
a. “General Industry Safety and Health Regulations Part 1910,”
Code of Federal Regulations, Subpart O
b. “Concepts and Techniques of Machine Safeguarding,” OSHA
3067, Revised 1992
These publications can be acquired by contacting:
US Department of Labor
Occupational Safety and Health Administration
Washington, DC 20210
ANSI Safety Standards for Machines
The most complete safety standards for machine tools are published
in the ANSI (American National Standards Institute) B11 series. The
following is a list of each ANSI B11 Standard available at the printing
of this publication.
B11.1 Mechanical Power Presses
B11.2 Hydraulic Presses
B11.3 Power Press Brakes
B11.4 Shears
B11.5 Ironworkers
B11.6 Lathes
B11.7 Cold Headers and Cold Formers
B11.8 Drilling, Milling and Boring
B11.9 Grinding Machines
B11.10 Sawing Machines
B11.11 Gear Cutting Machines
B11.12 Roll Forming and Roll Bending
B11.13 Automatic Screw/Bar and Chucking
B11.14 Coil Slitting Machines
B11.15 Pipe, Tube and Shape Bending
B11.16 Metal Powder Compacting Presses
B11.17 Horizontal Hydraulic Extrusion Presses
B11.18 Coil Processing Systems
B11.19 Performance Criteria for the Design, Construction,
Care and Operation of Safeguards as Referenced in the
Other B11 Machine Tool Safety Standards
B11.20 Safety Requirements for Manufacturing Systems/Cells
B11.21 Lasers
B11.22 CNC Turning Machines
B11.23 Machining Centers
B11/TR1 Ergonomic Considerations for the Design, Installation and
Use of Machine Tools
B11/TR2 Mist Control
B11/TR3 Hazard ID and Control
B11/TR4 Control Reliability
These standards can be purchased by contacting:
American National Standards Institute, Inc.
11 West 42nd Street
New York, New York 10036
[phone]
OR
AMT - The Association of Manufacturing Technology
7901 Westpark Drive
McLean, Virginia 22102-4269
[phone]

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
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 This warranty will not apply to any product which will have been subject to misuse, negligence,
accident, restriction and use not in accordance with Rockford Systems, LLC’s instructions or which will have been altered or repaired by persons
other than the authorized agent or employees of Rockford Systems, LLC Rockford Systems, LLC’s warranties as to any component part is expressly
limited to that of the manufacturer of the component part.
Warranty, Disclaimer and Limitation of Liability
National Safety Council Safety Manuals and Data
Sheets
Other good references for safety on machine tools are the National
Safety Council’s Safety Manuals and Data Sheets. These manuals and
data sheets are written by various committees including the Power
Press, Forging and Fabricating Executive Committee. The following
publications are available for all types of machines:
MANUALS
Power Press Safety Manual - 4th Edition
Safeguarding Concept Illustrations - 6th Edition
Forging Safety Manual
DATA SHEETS
Bench and Pedestal Grinding Wheel Operations
12304-0705
Boring Mills, Horizontal Metal 12304-0269
Boring Mills, Vertical 12304-0347
Coated Abrasives 12304-0452
Cold Shearing Billets and Bars in the Forging Industry
12304-0739
Degreasing (Liquid), Small Metal Parts 12304-0537
Dies, Setup and Removal of Forging Hammer
12304-0716
Drill Presses, Metalworking 12304-0335
Drills, Portable Reamer 12304-0497
Drop Hammers, Steam 12304-0720
Electrical Controls for Mechanical Power Presses
12304-0624
Forging Hammer Dies, Setup and Removal of
12304-0716
Forging Presses, Mechanical 12304-0728
Gear-Hobbing Machines 12304-0362
Handling Materials in the Forging Industry 12304-0551
Kick (Foot) Presses 12304-0363
Lathes, Engine 12304-0264
Milling Machines, Metalworking 12304-0364
Planers, Metal 12304-0383
Power Press (Mechanical) Point-of-Operation
Safeguarding, Concepts of 12304-0710
Power Press Point-of-Operation
Safeguarding: Two-Hand Control and
Two-Hand Tripping Devices 12304-0714
Power Press Point-of-Operation Safeguarding: Type A and B Movable
Barrier Devices 12304-0712
Power Press Point-of-Operation Safeguarding:
Point-of-Operation Guards 12304-0715
Power Press Point-of-Operation Safeguarding:
Presence Sensing Devices 12304-0711
Power Press Point-of-Operation Safeguarding:
Pullbacks and Restraint Devices 12304-0713
Power Presses (Mechanical), Inspection and
Maintenance of 12304-0603
Power Presses (Mechanical), Removing Pieceparts
from Dies in 12304-0534
Power Press, Setting Up and Removing Dies
12304-0211
Press Brakes 12304-0419
Robots 12304-0717
Saws, Metal (Cold Working) 12304-0584
Shapers, Metal 12304-0216
Shears, Alligator 12304-0213
Shears, Squaring, Metal 12304-0328
Upsetters, 12304-0721
These manuals and data sheets can be purchased by contacting:
National Safety Council
1121 Spring Lake Drive
Itasca, IL 60143-3201
1-800-621-7615 ext. 2199
For additional safety information and assistance in devising, imple-
menting or revising your safety program, please contact the machine
manufacturer, your state and local safety councils, insurance carriers,
national trade associations and your state’s occupational safety and
health administration.
DISCLAIMER
The foregoing Warranty is made in lieu of all other warranties, expressed or
implied, and of all other liabilities and obligations on the part of Rockford
Systems, LLC, including any liability for negligence, strict liability, or
otherwise, and any implied warranty of merchantability or fitness for a
particular purpose is expressly disclaimed.
LIMITATION OF LIABILITY
Under no circumstances, including any claim of negligence, strict liability, or otherwise,
shall Rockford Systems, LLC be liable for any incidental or consequential damages, or
any loss or damage resulting from a defect in the product of Rockford Systems, LLC

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
Front
Back
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. This
precaution pamphlet is to be given to
all operators, including setup people,
maintenance personnel and supervisors.
This pamphlet should also be attached to
the machine, readily accessible and visible
to the operator. (A hole in the corner of
this precaution pamphlet is provided for
attaching purposes.) Additional copies of
this precaution are available. Please call,
write, fax, or use the order form found on a
later page in this manual.
When a language barrier or insufficient
education prevents a person from reading or
understanding the contents of this operator
safety precaution pamphlet, you should
either translate this information or have it
read or interpreted to the person. Make sure
that the person understands the information.
To order this pamphlet in Spanish, use Part
No. KSC-000S; in French, use Part No. KSC-
000F.
This precaution pamphlet must be reviewed
daily.
Operator Safety Precaution Pamphlet – attachment for anyone operating this machine
Do Not Operate This Machine
Until You Read and Understand the
Following Safety Precautions.
Never operate this machine until you understand that this
machine is dangerous and if you place your hands, or any
part of your body in this machine it could result in the loss of
fingers, limbs or even death.
Never operate this machine without the use of a guard or
safety device that will always protect you from bodily injury.
Never use a foot switch to operate this machine unless
a point-of-operation guard or device is provided and
properly maintained.
Never “ride” the foot pedal or foot switch. Never rest your
foot on top of the foot pedal or inside the foot switch. Always
remove your foot completely from the foot pedal or foot
switch after each cycle and any time you are not intending
to trip the machine.
Always use hand tools for feeding or retrieving material
from the point of operation or any other hazardous part of the
machine. Never reach through or into die area for any reason.
Never operate this machine unless you feel you have been
fully trained and have received and understand all operating
instructions. Make sure you know how the machine works
and how it is controlled.
Never operate this machine until you test the machine with its
guard or safety device before you start or restart production.
Do not begin operating the machine unless you are sure the
safeguarding is adjusted properly and working correctly. If you
are not sure call your supervisor.
Never operate this machine if it is not working properly or if
you notice any unusual noise or change in the performance
of the machine. Stop operating the machine immediately and
advise your supervisor.
Never operate this machine with pullbacks unless they are
adjusted properly for you. Have your supervisor show you
manually that when the ram descends the pullbacks will
pull your fingers clear of any pinch points. Always wear your
wristlets properly and securely.
Never operate this machine with pullbacks without reading
and understanding the instructions. Instructions must be kept
with the pullback device at all times and made available to
you. Obtain, read and follow these instructions.
Never operate this machine unless two-hand trip, two-hand
control or presence sensing device are installed correctly and
at the proper safety distance. Consult your supervisor should
you have any questions regarding the proper safety distance.
Never tamper with, rewire or bypass any control, component
or safeguard on this machine.
Always wear safety glasses, ear protection and any other
personal protection equipment needed when operating this
machine.
Be sure all persons are clear of the machine before it is
cycled, especially when multiple operators are present. Do
not operate machine unless you and every operator and/or
helper are protected from injury by a guard or safety device.
Always stay alert (don’t daydream) and never operate this
machine while under the influence of alcohol or any other drug
including prescription medications.
Maintenance and Die Set-Up Personnel: Never work on
this machine unless power is off, flywheel is at rest, safety
blocks are used between dies, ram and bolster plate and
all energy (electrical, air, hydraulic, etc.) are in a zero state.
1
2
3
4
5
6
7
8
10
11
16
15
14
13
12
9
NOTICE TO EMPLOYER: A copy of this “Operator Safety Precautions” must be given to all operators (including die set-
up people, maintenance personnel and supervisors) of this machine. A copy should also be hung on the machine
readily accessible and visible to the operator. Additional copies of this precaution are available upon request.
Just call or write.
IMPORTANT: Where a language barrier or insufficient schooling would prevent a person from reading and understand-
ing the contents of this Operator Safety Precaution, you should either translate this information or have it read or
interpreted to the person, with assurance that it is understood.
THIS PRECAUTION MUST BE REVIEWED DAILY.

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
Danger Sign(s) to be Mounted on Machine
Never operate this machine unless the danger sign(s) is in place.
If any danger sign becomes destroyed or unreadable, the sign must be replaced immediately. Contact factory for replacement danger sign(s).
“M echanical P ower P ress S afety ” B ooklet
A copy of Booklet No. MPPS (“Mechanical Power Press Safety”) is enclosed. This booklet is copied verbatim from the CFR (Code of Federal
Regulations) and contains all relevant sections of the OSHA Regulations concerning power presses with which an employer (user) must comply.
The enclosed equipment must be installed, used and maintained to meet these regulations. Specifically, any time a foot switch is used, a suitable
point-of-operation safeguard or device must be used to prevent bodily injury. In addition, every press must be provided with a point-
of-operation safeguard! Please review this booklet before installing the enclosed equipment. If you are unfamiliar with these detailed safety
regulations, which include regulations on safeguarding the point of operation properly, you may want to attend our regularly scheduled machine
safeguarding seminars. To obtain detailed information about these training seminars, please call, fax or write. Our address, telephone and fax
numbers are on the front cover of this manual.
Part No. KSC-054 Danger Sign - Standard
Part No. KSC-054S - Spanish
Part No. KSC-054F - French
Reverse Side
Part No. KSC-055 Danger Sign
(Foot) - Standard
Part No. KSC-055S - Spanish
Part No. KSC-055F - French
See page 6 for
details on this
pamphlet.
Front Side
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. ALWAYS
mount this sign with bolts or rivets when installing the enclosed equipment. If a foot switch is ordered, a 5” x 6” poly-
ethylene danger sign, Part No. KSC-055 is provided. This sign must also be mounted according to the above instructions.
Front Side

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution 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. 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

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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
Toll Free: 1-800-922-7533 (USA only)
Phone: [phone]
Fax: [phone]
Web Site: www.rockfordsystems.com
E-Mail: [email protected]
Photo 1.2
SSC-1000 Control Box

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SECTION 1—IN GENERAL
SSC-1000 Part Revolution Solid-State Control
Front View Left Side View
Lifting
Lug
Crown
Lubricator
Upright
or Column
Air Pressure Switch
for Counterbalance
Air Pressure Switch
for Clutch/Brake
Dual
Solenoid
Valve
Air
Releasing
Brake
Main Drive
Belts
Sheave
Main Gear
Flywheel
Air
Friction
Clutch
Cover
Resolver/Cam
Limit Switch
Assembly
Knockout
Bracket
Knockout
Rod
Top-
Stop
Button
Run
Buttons
Gib
Slide
(Ram)
Slide
Adjusting
Mechanism
Connection
(Pitman)
Crankshaft
Tie Rod
Tie-Rod
Nut
Knockout
Bar
Clutch/Brake
Control Panel
with Starter and
Disconnect Switch
Air Counterbalance Cylinders
Filter-Regulator-Gauge &
Lubricator Assembly for
Clutch/Brake Operator’s
Station
Bed
Filter-Regulator-Gauge
for Die
Cushion
Emergency-Stop
Button
Bolster
Rear Guard
Side Guard
Air
Surge
Tank
Part Revolution Straight-Side Press
Press Components Identification
Part Revolution OBI Press
PART REVOLUTION OBI PRESS
Front View Left Side View
Motor
Motor
Starter
Dual
Solenoid
Valve
Disconnect
Switch
Clutch/Brake Control
Panel
Inclining
Mechanism
Frame
(Body)
Leg
Air Pressure
Switch for
Counterbalance
Knockout
Bar
Slide
(Ram)
Operator’s
Station
Knockout
Bracket
Resolver/Cam
Limit Switch
Assembly Belts
Sheave
Lifting Bolt
Flywheel
Air Friction
Clutch
Cover
Slide
Adjusting
Screw
Run
Buttons
Gib
Bolster
Bed
Leg Tie
Rod
Foot
Switch
Emergency-
Stop
Button
Crankshaft
Connection
(Pitman)
Lubricator
Top-
Stop
Button
Die
Clamp
Leg
Bolts
Knockout
Rod
Air
Releasing
Brake
Air
Counterbalance
Filter-Regulator-
Gauge &
Lubricator for Clutch/
Brake
Air Pressure
Switch for
Clutch/Brake
Side Guard
Rear Guard
Lubricator

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(Continued on next page.)
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” Booklet, and our latest catalog
2. Control box - standard (custom or special includes motor controls and/or disconnect switch) with danger and warning signs
3. Dual solenoid air valve assembly including exhaust muffler
4. Filter-regulator-gauge and lubricator assembly including connector and mounting bracket
5. Air pressure switch (two required if machine has air counterbalance)
6. Check valve for counterbalance system (if required)
7. Opti-CAM™ with DC tachometer generator, spring base, and 25’ cable
8. Sprocket set to drive Opti-CAMTM (if required)
9. Chain (10 feet with master link) (if required)
10. Palm button assembly (Includes two black palm buttons, two palm button guards, one red emergency-stop button, and mounting boxes. When
the “continuous” mode of operation is included, one yellow top-stop button with mounting box is furnished.) If multiple operator stations are
on a machine, more than one assembly is furnished.
11. Foot switch (optional) - If multiple operator stations are on a machine, more than one foot switch is furnished.
12. Supervisory control station (Required when multiple operator stations are used on the machine; one sta-tion is required for each operator.)
13. Other required components and safeguarding that may be necessary for machine (See packing list for details.)
Individual packages may vary in contents. However, a packing list is always enclosed showing exactly what material was shipped on this order.
Please check the components actually received against this packing list immediately. In most cases, this control package system includes two-hand
control which can be used as a point-of-operation safeguarding device provided the palm buttons are mounted correctly and at the proper safety
distance (see formulas on pages 25 and 26 of this manual). If the optional foot switch is provided, a safeguard must always be used. Examples
of safeguards include barrier guards, presence sensing devices, pullbacks, restraints, gates, or two-hand control. The hands or any other part of
the body of an operator, maintenance person, setup person, etc., must never be put into the point-of-operation hazard for any reason, at any time.
These controls can neither cure nor overcome a malfunctioning machine. They cannot compensate for or prevent a
mechanical defect or failure of a machine part. These controls cannot prevent a repeat or unintended stroke (cycle)
resulting from a mechanical malfunction, defect or failure of the machine itself.
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. Refer to the front cover, other line drawings and photos, then make a rough sketch of your installation to plan the location of the enclosed
equipment on the machine.
3. This may be an opportunity to strip down the entire machine by removing all components, piping, wire, etc. Clean, paint and check the
entire mechanical condition of the machine, including the clutch and brake, for proper adjustment and required replacement parts before
proceeding with the installation of the furnished equipment.

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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. Special attention must be given to the machine
clutch and brake. The clutch and brake must be maintained in an operating condition which is within the specifications set by the machine
manufacturer. If you have any doubts or questions concerning the condition of the machine, contact the machine manufacturer for assistance.
Repair or replace all parts not operating properly before proceeding.
Inspection and maintenance programs must be established and implemented to keep machines in first-class condition.
Programs must include thorough inspections of each machine on a weekly basis and records kept of these inspections.
Any part of the machine that is worn, damaged or is not operating properly must be replaced immediately or repaired
before the machine is used.
5. Verify that the machine is in first-class condition and operating properly; shut off all power to the machine. Padlock the disconnecting means
in the “off” position and do not actuate the machine again until the installation of all package components has been completed. Lockout/tagout
energy isolation procedures must always be practiced and enforced.
6. If the machine has a mechanical-friction clutch (usually found on older presses and press brakes), an air cylinder is required to engage and
disengage the clutch. Install the air cylinder in the most logical place to actuate the clutch. Please see the enclosed Installation Manual No.
KSL-096 if an air cylinder was ordered. Note: On machines equipped with air-operated friction clutches, an air cylinder is not required.
Safeguard Interlocks and Other Types Of Interlocks
SAFEGUARD INTERLOCKS
The machine will not operate or must not be operated until you either: (1) Electrically interlock or (2) Mechanically guard the machine’s point of
operation with a safeguarding system or device.
When an electrically interlocked method of safeguarding the point of operation is chosen, connect the interlock to the safeguard interlock terminal
86 (marked with “ ★”) in the control box, as shown on the control wiring schematic.
Point-of-operation electrically interlocked safeguards, when opened, prevent or stop normal machine operation during operator cycling modes.
Examples of these types of interlocks are barrier guard interlocks and gate device interlocks.
When a mechanical guard or device (nonelectrically interlocked) is chosen, the safeguard interlock terminal (marked with “ ★”) is not used. In
order for the machine to operate with the use of a mechanical guard or device, the safeguard interlock terminal 86 (“ ★”) must be connected to
(COM). Please see the wiring schematic.
The mechanical guard or device must be properly installed, used and maintained and must always prevent all personnel
from bodily injury.
If the mechanical guard or device is not used, is removed, or is defeated, an electrically interlocked method of safeguarding
must be used and connected to the safeguard interlock terminal 86 (marked with “ ★”).
Never operate this machine without point-of-operation safeguarding.
Note: Additional equipment that can help safeguard machines includes indexing tables, electrically controlled sliding bolsters, and automatic
feeding systems. These systems usually require additional control logic circuitry. Please contact the factory for a quotation itemizing the
interface equipment necessary for these types of systems as well as others (see page 28). Please send complete schematics, including the
hydraulic and pneumatic systems, of the particular system to be interfaced.

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SECTION 2—INTRODUCTION
SSC-1000 Part Revolution Solid-State Control
Safeguard Interlocks and Other Types Of Interlocks (continued)
OTHER ELECTRICAL INTERLOCKS
There are basically two types of electrical interlocks as applied to machine control circuitry:
• Interlocks for the purpose of personnel protection, as explained on page 12.
• Interlocks intended for the purpose of protecting the machine and its control components.
There are other locations for interlocks that, when opened, prevent all machine functions. Examples of these types of interlocks are safety block
electrical cut-off systems, lubricating systems, die protection equipment, and tonnage monitoring systems.
Be sure to connect the various electrical interlocks to the proper terminals, in the control box, according to the machine wiring schematics. If your
schematics do not include these electrical interlocks, please send this information to the factory and they can be added to your drawings. There is
an additional charge for this service.
General Features of the SSC-1000 Control
• Redundant/cross-checking microprocessors from different manufacturers
• Redundant microprocessor logic power supplies
• Two (2) captive-contact solenoid relays
• 1 x 16-character LCD display/membrane keypad operator interface
• Time-based brake monitor
• Stop-time measurement (STM) test
• Regular, adjustable timed inch, and inch/top-stop
• Automatic continuous top stop
• Four (4) user programmable diagnostic inputs
• Seven-digit stroke counter and batch counter with preset
• Interface provided for light curtain(s)
• One (1) PLS output (N.O.) - time/counter based
• LCD display choices while in run mode: Mode-SPM, Stop Time, Stroke Counter, or Batch Counter
• Fused outputs (F1, F2, F3, and F4)
• Standard modes of operation:
Two-hand inch (regular, adjustable, and inch/top-stop)
Two-hand single stroke
Foot-single stroke
Continuous
Automatic single stroke
• Optional modes of operation
Foot maintained continuous
Continuous-on-demand
One-hand trip (use with light curtain only)
Two-hand maintained continuous

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SECTION 2—INTRODUCTION
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.
1 X 16 CHAR. LCD DISPLAY
L1 (120VAC)
N
GND
FOOT - NO
FOOT - NC
L. RUN/INCH - NC
R. RUN/INCH - NC
L/R RUN/INCH - NO
SS CAM - #1
SS CAM - #2
AUX-1 IN
HAND
INCH
SINGLE
SEQ. STOP
FOOT
LC OFF/ON
LC - NO
LC - NC
MAIN MTR FWD
SAFEGUARD INT
USER IN#1
USER IN#2
RS-422
SSC-1000
CONTROL MODULE

K2
SOL
#2
K1
SOL
#1
DUAL SOL
DUAL SOL
OPTI-CAM
TACH UNIT
TACH -
TACH +
SHIELD
SEQ CAM
+8VDC
+8GND
SSC-1000
DISPLAY / OPERATOR I/F
MODULE
REMOTE
150' MAX.
CPU
#2
RUN
CPU
#1
RUN
+5V
#1
+5V
#2
+24V
K3
LC
CYC
LC CYCLE
LC CYCLE
K4
AUX
OUT
AUX OUT
AUX OUT
OFF PROG RUN
ENTER
24COM
USER IN#3
USER IN#4
AUX - 3 IN
AUX - 2 IN
P1
P2

P3


MCR-NO
P5
24COM
P4
+24VDC
Figure 2.1
Block Diagram

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SECTION 2—INTRODUCTION
SSC-1000 Part Revolution Solid-State Control
SSC-1000 Control Box
The SSC-1000 Press Control is a full-featured, dual-microprocessor based press control for part revolution mechanical power presses. This control
system is designed to comply with current ANSI Standards B11.1, B11.3, B11.19, and OSHA Regulations 1910.217. It is a replacement for
existing relay-based control systems, found in user’s plants or can be furnished for new or rebuilt presses.
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. The master-control relay is used to provide a hard-wired emergency-stop function.
When this control box is to be wired to an existing main motor starter, the starter must have a 120 volt 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, LLC for a replacement magnetic
starter.
The system uses redundant inputs from devices such as palm buttons, foot switches, and light curtain(s). The system output to the solenoid valve(s)
is provided by two safety relays, with force-guided contacts, which are socketed to the printed circuit board. These output relays are independently
controlled and cross-checked by the microprocessors. This allows control-reliable operation of the outputs in the event of a single control component
failure. Each microprocessor also has its own logic power supply. This decreases the possibility of simultaneous control failure because of a fault
within the power supply system. All inputs and outputs are optically isolated for electrical noise immunity. Timing and motion detection of the
crankshaft is provided by the Opti-CAM™ unit. The operator provides setup information through the use of the keypad/display and messages are
shown on the 16-character LCD display.
Overview of Sequence of Operation - Single Stroke
The redundant inputs are used by both processors to control the operation of the press. When the actuating means is depressed, and primary
safeguard interlock conditions are met, the processors turn on their appropriate relays (K1 and K2). The dual solenoid valve is energized sending
air to the clutch and brake. The crankshaft is engaged to the flywheel drive and the brake is released allowing the ram to move. Within the motion
reference time window, the microprocessors must see a voltage signal from the DC tachometer in the Opti-CAM unit that represents motion or
a motion fault is generated. If the actuating means is released prior to the holding angle, the press slide movement will stop. The stroke can be
finished by depressing the actuating means again.
Once the cycle is started, the Opti-CAM provides inputs for holding and top-stop angles. When the holding/t-stop cams change state, the actuating
means can be released at this point and the stroke will continue until the holding/ t-stop cams change state again. The processors turn off their
appropriate relays (K1 and K2). The dual solenoid valve is deenergized, exhausting air from the clutch and brake. The crankshaft is disengaged from
the flywheel drive and the brake is applied stopping the ram.
The control starts a timer when the relays are deenergized. This timer stops when the motion from the tachometer in the Opti-CAM has stopped. This
stop-time value is then compared against the brake stop-time set point. If the stop time exceeds this setting, a BRAKE FAULT message is displayed.
The reason for the increased stop time should be investigated and corrected before operating the press again. (See page 36 for programming the
brake monitor.)

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SECTION 3—INSTALLATION OF COMPONENTS
SSC-1000 Part Revolution Solid-State Control
Installation of Control Package Components
LITERATURE FOLDER
Included with every shipment is a literature folder. This includes installation manuals, “Operator Safety Precaution” Pamphlet (Part No. KSC-000),
danger sign(s) (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.
Danger Sign (Standard) - Part No. KSC-054
As illustrated on page 7, a 5” x 6” polyethylene danger sign is supplied. It is imperative that this sign be firmly
attached to the machine in a location readily visible to all personnel. Suggested mounting instructions are shown on
the reverse side of this sign.
This sign must be the first thing mounted to prevent any possibility that it might be overlooked. If this sign becomes
destroyed or unreadable, it must be replaced immediately. Contact factory for replacement and do not operate the
machine until the danger sign is in place.
Foot Switch Danger Sign - Part No. KSC-055
If a foot switch is ordered, a 5” x 6” polyethylene danger sign is furnished. This sign must be firmly attached to the
machine in a location readily visible to all personnel.
CONTROL BOX WITH SSC-1000 CONTROL MODULE ASSEMBLY
The clutch/brake 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; however, if it is a custom control box with a starter and disconnect, the control box enclosure will be
larger. The keypad/display, ground indicator light and off/program/run selector can also be furnished in a remote station. This option provides easier
accessibility to the operator. Clutch/brake and motor controls can also be furnished in a floor standing control console.
Sign No. KSC-054
Sign No. KSC-055
Photo 3.1
Standard Control Box with Keypad/Display
Photo 3.2
Inside View of Standard Control Box
Control Transformer
Master Control Relay
SSC-1000 Control
Module Assembly
Logic Power Supply
Transformers
Terminal Strip
Keypad/Display

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SECTION 3—INSTALLATION OF COMPONENTS
Output Red LEDs
Input Red LEDs
Power Supply
Transformers
Top Cover
Power/Status
Green LEDs
Photo 3.3
Top View of Control Module with Cover
Control Module Assembly
The solid-state control module assembly below, Part No. FTL-024, measures 7”W x 8”H x 4”D. It 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. To remove the module from the shock/vibration mounts, turn power off to the control.
Remove all terminal strips from the left and right sides of the printed circuit board, (P1, P2, P3, P4, and P5). Loosen the four Allen-head bolts and
lift up on the module. Pull the unit straight out.
There are red and green LEDs that allow for visual indication of control operation and the status of inputs and outputs. All LED names are indicated
on the cover of the module next to each LED. See photo below. The five green power/status LEDs provide indication of proper operation and logic
power to both CPUs (Central Processing Units).
Relays
Opti-CAM LEDs

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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.
The dual CPU circuit board is then exposed as shown in the photo below.
The only user serviceable parts on the “dual CPU” board are the EPROM, the relays, and the fuses. Fuse F1 is the circuit protection for the CPU
board. Fuse F2 is the circuit protection for the PLS output. Fuse F3 is circuit protection for the light curtain cycle relays. Fuse F4 is circuit protection
of the K1 and K2 relays. If any changes to the circuit boards are required, instructions will be sent with the new parts. See page 56 for instructions
on replacing the EPROM.
Photo 3.4
Top View of Control Module without Cover
CPU #1
Solenoid and PLS Relay
Valve Outputs P4
24VDC Control Inputs P2
Battery Backed NVRAM
Relays
Main Eprom
Display P5
CPU #2
Opti-CAM P3
Power P1
Fuse F1
Power Supply
Transformers

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SECTION 3—INSTALLATION OF COMPONENTS
SSC-1000 Part Revolution Solid-State Control
The keypad/display can be furnished in a remote enclosure up to a
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.
If the keypad/display is supplied in a remote enclosure, please refer to
the section on wiring (page 32) and the electrical schematic prints that
came with the control box on the proper wiring connection.
Mounting the Control Box
Solidly mount the control box in an accessible location, either on or
near the machine to be controlled. A convenient location will keep
conduit runs to a minimum length.
Note: On inclinable (O.B.I.) presses, caution must be used to ensure
that the control box location does not interfere with the ability to
incline the press to its maximum position. On inclined presses,
the length and flexibility of each individual conduit run must be
carefully planned.
Although operation of this control will not be adversely affected by
normal machine operation, excessive shock or vibration may require
shock mounting in specific applications.
The key must be removed from the off/program/run
selector switch after the control is programmed and
before the machine is released to production. All keys
must be supervisory controlled at all times.
Photo 3.6
Back Side of
Keypad/Display
Photo 3.5
Operator Interface Keypad/Display
Off/Run/Program
Selector Switch
Keypad/Display CPU
Connector P5
Contrast
Adjustment R2
The keypad/display assembly (shown above) is used to enter setup infor-
mation and to monitor machine operation.

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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. An accumulator (air surge tank) is recommended. The tank should
be installed in the incoming air line directly ahead of the valve to assure sufficient air volume to the
clutch and brake.
The exhaust air muffler must be kept clean at all times. Never operate the machine unless
the muffler is clean. The muffler must be removed and cleaned on a regular basis. If the
machine has a split clutch and brake, two valves may be required. Both valves must be
dual monitored valves with an electrical output signal.
FILTER-REGULATOR-GAUGE AND LUBRICATOR ASSEMBLY (FRL) (If furnished, see enclosed Installation Manual No. KSL-208. Reference
pages 29 and 30 for installation instructions on the lockout air valve.)
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 to the proper amount to engage the
clutch and release the brake. The lubricator keeps the solenoid air valve, the clutch/
brake, or the air cylinder (if required), properly lubricated.
The filter-regulator unit with one threaded pipe plug, lubricator, gauge, mounting
bracket, and a connector or nipple are shipped together.
Unpack the filter-regulator unit and install the connector between the filter/regulator
lubricator (see arrow for air flow direction). Tighten this assembly and position the two
units with both bowls in alignment. Be sure to check air flow direction and the location
of the dual valve to avoid excessive piping.
Choose an appropriate location on the machine for mounting this assembly. If possible,
it should be accessible from floor level.
Install the pressure gauge in the threaded port opposite the mounting surface and plug
the unused port. Attach the mounting bracket to the machine and then mount the FRL
Assembly using the lock nut supplied.
The length of the air line run to the surge tank is not critical; however, the port and pipe
sizes should be maintained.
Fill the lubricator with a good quality lubricant (see OEM’s specifications) to the level
indicated by the maximum fill line on the transparent reservoir. Do not overfill. When the
machine is cycled, the lubricator drip rate may be adjusted according to the Instruction
Manual. Please check the machine owner’s manual for proper specifications for oil, if
required. Some clutch and brake assemblies do not require lubrication.
The air filter must be kept clean at all times. Never operate the machine unless the air filter is clean.
The lubricator must not be filled while under pressure.
Photo 3.7
Muffler
Lubricator
Photo 3.9
Part No. RCL-046 - 1”
Photo 3.8
Part No. RCL-045 - 3/4”