You are on page 1of 13


Hydraulic press with remote operator station on left side of machine with a light curtain or twohand control used as the point-of-operation safeguard. A plain-door custom control box is on the right side of the press (not shown).

Straight-side hydraulic press with a hydraulic control that has control reliability and is safeguarded with either two-hand control or a light curtain.


Each hydraulic press must be looked at as an individual system. This system consists of, but is not limited to, the machine frame, all mechanical parts, hydraulic system, electrical or electronic systems, pneumatic systems, tooling or dies (present and future), tool or die setup, safeguarding, material handling, size or configuration of workpiece, maintenance requirements, and most importantly, production requirements. OSHA STANDARDS On hydraulic presses, the main safety requirements that must be complied with fall under OSHA 29 CFR 1910.212. This part of the standard requires pointof-operation safeguarding. Please see page 271 for the complete requirements in section 1910.212. If auxiliary equipment on the hydraulic power press has mechanical power-transmission apparatuses, then section 1910.219 (pages 272 through 275) must be complied with. For lockout/tagout, OSHA 29 CFR 1910.147 (pages 276 through 285) should be referenced. OSHAs Code of Federal Regulations can be purchased by contacting: U.S. Government Printing Office
P.O. Box 371954 Pittsburgh, PA 15250-7954 Phone: (212) 512-1800

Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 130 FAB

Fax 815-874-6144


ANSI STANDARDS There are several references available on hydraulic press safety; however, most industries use the ANSI (American National Standards Institute) B11.2 (1995) standard for the best safety practice. This standard can be purchased by contacting: ANSI
American National Standards Institute, Inc. 25 West 43rd Street, 4th Floor New York, NY 10036 Phone: (212) 642-4900 Fax: (212) 398-0023

The Association for Manufacturing Technology 7901 Westpark Drive McLean, VA 22102 Phone: (703) 893-2900 Fax (703) 893-1151

PSDI (PRESENCE-SENSING DEVICE INITIATION) ANSI B11.2 provides an excellent guideline for PSDI (presence-sensing device initiation). PSDI uses a light curtain to trip or start the press cycle rather than using the operators overt action on the hand or foot actuating means. The light curtain is also the point-of-operation safeguarding device. If the operator should put a hand or other body part in the plane of light during the hazardous portion of the stroke, a stop signal will be given. To equip a hydraulic power press with PSDI, see page 138 for the part numbering system. BASIC REQUIREMENTS When updating hydraulic presses to comply with the indicated safety standards, there are five basic requirements that must always be considered. They are: 1. Safeguarding (pp. 7-86) 2. Controls (pp. 90-102) 3. Disconnects (pp. 193-195) 4. Starters (pp. 193-195) 5. Covers (user to provide) This section of the catalog will provide information on safety requirements in these areas. SAFEGUARDING The following is a list of point-of-operation safeguarding choices for hydraulic presses: 1. Barrier guards (pp. 11-30) 2. Presence-sensing device (pp. 45-73) 3. Two-hand control device (p. 74) 4. Two-hand trip device (pp. 75-76) 5. Pullback device (p. 77) 6. Restraint device (pp. 78-79) 7. Movable barrier device (gate) (pp. 80-86) 8. Safe opening (p. 132) Guards* Mechanical guards can be used to enclose the point of operation. Presence-Sensing Devices* Of all the recognized point-of-operation safeguarding devices for hydraulic presses, the light curtain is the most versatile. Proper use of this device provides protection for all operators and passersby in production modes of operation. It also minimizes operator resistance to using safety devices. *Please refer to ANSI B11.2 for further details on the safety requirements that must be complied with when using any of the listed guards or devices.

15 Inverness Way East Englewood, CO 80112 Toll-Free: 1-800-624-3974

In ANSI B11.2, subclause 6.3 Control System, it states that All components and subsystems of the control system shall be designed to operate together to provide total system compliance with the requirements of this clause. Control components shall be selected, constructed and connected together in such a way as to withstand expected operational and environmental stresses. The control system shall meet the following design and construction requirements: 6.3.1 Press Pump Motors The control system shall not permit the initiation of slide(s) motion unless at least one pump motor is running. This requirement may not apply to die setting operationssee subclause 9.2.3 in ANSI B11.2. 6.3.2 Power Failure The control system shall be designed so that in the event of power failure, restoration of power will not result in any hazardous slide motion. 6.3.3 Control Reliability (See page 259) Control systems shall be designed and constructed so a single failure or fault within the system: 1. Does not prevent the normal stopping action from being applied to the press, when required; 2. Does not create unintended slide motion; 3. Does prevent initiation of a successive stroke until the failure is corrected. See Electrical Requirements in this section for other requirements found in ANSI B11.2. 6.6.5 Hydraulic Components and Circuits Hydraulic component circuits that control slide(s) motion shall comply with the above requirements of 6.3.3. Rockford Systems, Inc.

FAB 131


Two-Hand Control or Trip Devices* Two-hand trip or two-hand control, as a point-ofoperation safeguarding device for hydraulic presses, requires the actuation of the palm buttons along with other detailed requirements. They must also meet the safety distance as described on pages 74-76. Pullback Device* The pullback is a mechanical device operated from the linear motion of the slide or upper die. When adjusted properly, it pulls the operators hands back should they inadvertently be put into the point-of-operation hazard. The overhead-type design allows the operator freedom of movement for loading and unloading parts without interference. They must be properly worn, adjusted, and maintained at all times. Restraint Device* Similar to the overhead pullback, restraints are adjusted so that an operator cannot reach into the hazardous area at any time. If small parts are being fed into the die, a hand-feeding tool may be used. Restraint devices must be properly worn, adjusted, and maintained at all times. Movable Barrier Device* This is a barrier device (gate) that opens for feeding material and closes before the machine cycle is started. Safe Opening* The workpiece is used as part of the safeguarding. The workpiece must be in the proper position before the press is allowed to start its cycle. CONTROLS The controls described in this section include twohand control as a point-of-operation safeguarding device. The palm buttons must be depressed concurrently and maintained during the hazardous downstroke of the ram. Release of one or both palm buttons reverses or stops the action of the ram. The controls offered also include a light curtain interface. ELECTRICAL REQUIREMENTS The ANSI B11.2 standard requires a proper main power disconnect switch. A motor starter is also required that drops out when power is lost and will not restart automatically. All AC control circuits and solenoid valves must be powered by 120 V or less (obtained from the transformer), and the control system must be protected against false operation due to an accidental ground. COVERS Mechanical power-transmission apparatuses include components on a machine or auxiliary equipment including, shafts, splines, pulleys, sprockets, rolls, and couplings. These components can create hazards to personnel who work on or around the machines. They must be covered in accordance with OSHA 29 CFR 1910.219 and ANSI B15.1. All apparatuses that create a hazard up to 7' above the floor or platform must be guarded (covered). This is usually done by the user, either by modifying existing guards or by contacting a local sheet metal fabricator to make a new cover. CONDITION OF PRESS The equipment offered in this catalog can neither cure nor overcome a malfunctioning machine or prevent a hydraulic or mechanical failure of a component part thereof, nor prevent a repeat or unintended stroke (cycle) resulting from a hydraulic or mechanical malfunction, defect or failure of the machine itself. It is essential that the machine be thoroughly inspected and that all hydraulic, mechanical, electrical, and pneumatic components and systems, including all collateral equipment, be in first-class operating condition before any equipment is installed. A maintenance and inspection program must be established and implemented to keep machines in your plant in first-class condition. This program must include regular periodic inspections of each machine to ensure that, among other things, the hydraulic system, including valves, electrical systems, and mechanical components are operating and used properly. Any part of the machine that is worn, damaged, or not operating correctly must be immediately replaced or repaired before the machine is used. UPDATING HYDRAULIC PRESSES To update the electrical and hydraulic systems or to add point-of-operation safeguarding to a hydraulic press, the electrical and hydraulic schematic diagrams must be reviewed by Rockford Systems engineering department. Please provide these schematics to our sales personnel or factory-authorized representatives when they visit your plant to conduct a machine survey. If a control system is required for new hydraulic presses, please consult our sales or engineering personnel for assistance.

*Please refer to ANSI B11.2 for further details on the safety requirements that must be complied with when using any of the listed guards or devices. Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 132 FAB

Fax 815-874-6144


trol-reliable operation of the outputs in the event of a single control component failure in the control. The SSC-500 hydraulic press control has minimum requirements to properly interface to an existing press. These minimum requirements include a directional or one up and one down valve for the ram, a TOS (top-of-stroke) limit switch, and a BOS (bottom-of-stroke) limit or pressure switch. In most cases, if these already exist, they can be reused. Speed-change valves and limit switches can also be supported with the standard SSC-500 hydraulic control. If other valves exist (additional speed change valves, prefill, regeneration, level, bypass, etc.), please consult the factory for a quote on a custom-designed control. The standard control box (part No. HPC-000-FA) is a 24" x 24" x 8" NEMA 12 enclosure with the operator controls, ground indicator light, and keypad/display mounted in the door, as illustrated. If a starter or disconnect is required in the same enclosure as the standard SSC-500 control, see page 135. If a separate starter or disconnect, or combination starter disconnect is required, see pages 193-197.

Standard Control Box (HPC-000-FA Shown) SSC-500 STANDARD HYDRAULIC CONTROL BOX This SSC-500 solid-state control system is designed for use on hydraulic power presses. It is designed and built to comply with OSHA 29 CFR 1910.212 and ANSI B11.2 and B11.19. This control can update or replace existing relay-based or PLC control systems on hydraulic presses found in users plants or can be furnished for new or rebuilt hydraulic presses. This control includes control reliability, two-hand control, light curtain interface, and diagnostics (three user-programmable inputs). It also includes batch and stroke counters with presets, and a hard-wired emergency-stop master control relay. The SSC-500 is an economic, full-featured dualmicroprocessor-based control system. The system uses redundant inputs from devices such as palm buttons, foot switches, and light curtain(s). The system output to the solenoid valves is provided by one safety relay with force-guided contacts and two 115-VAC solid-state relays. These output relays are independently controlled and crosschecked by the microprocessors. This allows con-

Standard Control Box (Inside View)

Rockford Systems, Inc.

FAB 133


MODES OF OPERATION Off Two-hand inch Two-hand single stroke Foot single stroke Two-hand automatic (continuous) One-hand or trip (used in conjunction with a point-of-operation safeguard) PSDI (presence-sensing device initiation)* Automatic single stroke* *Additional components may be required to use these modes of operation. FEATURES Meets and exceeds OSHA 29 CFR 1910.212 and ANSI B11.2 and B11.19 Provides two-hand control safeguarding device NEMA 12 enclosure Redundant/cross-checking microprocessors Two monitored 115-V AC solid-state solenoid relays Up to three user-programmable sinking inputs (24 V DC) for diagnostic monitoring 1-line x 16-character LCD with 3-key keypad for operator interface Bottom dwell timer (0-60 seconds) Decompression timer (25-250 ms) Selector switch for ram return (pressure or distance) Light curtain interface with on/off selector switch Selector switch for high, high/low, and low speed (to support machines with a speedchange solenoid valve) The existing TOS (top-of-stroke) and BOS (bottom-of-stroke) limit switches can be reused 7-digit stroke and batch counters with presets Blocking valve monitoring PSDI (presence-sensing device initiation) singleand double-break modes of operation OPERATOR INTERFACE KEYPAD/DISPLAY The operator interface keypad/display is used to enter setup information, monitor machine operation, and display messages on a 1-line x 16-character LCD (liquid crystal display). As standard, this keypad is mounted on the control box door. For operator convenience, it can be installed in a remote operator station (see page 136). Programming is accessed by a keyed selector switch on the keypad.
Operator Interface Keypad/Display

PROGRAMMING The SSC-500 can be quickly and easily programmed. There are up to three 24-V DC currentsinking (NPN) programmable diagnostic inputs provided for the user. A fault message, input logic, and stop type can be assigned to each input from the following list. When a fault condition is detected, the machine will top stop or emergency stop, and the assigned message will be displayed. This feature helps when troubleshooting common fault conditions. Fault Message List:
Lube Fault High Lube Fault Low Lube Fault Low Lube Level Main Motor Overload Fault Lube Motor Overload Fault Auxiliary Motor Overload Fault Guard Open Fault Rear Guard Fault Left Guard Fault Right Guard Fault Feeder Fault Load Monitor Fault Safety Block Fault Stock Buckle End of Stock Die Protection Fault

To determine whether the SSC-500 hydraulic control can be used with the existing hydraulic system, please furnish both electrical and hydraulic schematics of the existing equipment to Rockford Systems engineering department for verification when requesting a quote or when ordering.

Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 134 FAB

Fax 815-874-6144


SSC-500 CUSTOM HYDRAULIC CONTROL BOX SSC-500 hydraulic custom control boxes are also available for hydraulic presses. These controls include the same features and modes of operation as the standard control box described on pages 133 and 134. These boxes are furnished with an IEC through-the-door main power fused disconnect switch and an IEC hydraulic pump magnetic motor starter (with push buttons). They are prewired and built into a NEMA 12 enclosure. Operator controls and the keypad/display are located on the front of the door, or a plain-door control or subpanel can be furnished. If a plain-door custom control or a subpanel custom control is ordered, a remote operator station or keypad/display kit is required. See ordering information on page 136. NEMA disconnect switches and motor starters, and brand-name components are also available. To ensure the starter(s) and disconnect are sized properly, please check horsepower for the main drive motor and slide adjust motor (if furnished) on the press, as well as full-load amps, and primary voltage to the press. After obtaining this information, please go to the chart on page 138 to determine the proper custom control box part number. Follow directions 1-8 to determine the correct part number. Example of part numbering system: The press requires a control with a PSD-400 light curtain interface and PSDI mode of operation, an IEC 60-A disconnect switch, an IEC 23-A nonreversing motor starter, and the keypad/display and all operators on the door of the enclosure, except for the motor controls which will be located remotely. The part number to order would be HPC-213-FA5.


Remote operator-style X, Y, and Z hydraulic control boxes include the same features and modes of operation as the standard SSC-500 control boxes. However, they do not have a control transformer. These control boxes are designed in a smaller enclosure so they can be conveniently located on the front of the machine near the operator. These controls are for applications where the machines existing magnetic motor starter, fused disconnect switch, and control transformer meet the safety requirements and can be reused. If the existing control transformer cannot be reused or a new one is required, please contact the factory. The keypad/display and all operator controls are located on the door (front) of the enclosure. CONTROL MODULE KIT Part No. HPC-000-KA A control module kit allows the end user to update the hydraulic control of a press with minimum equipment costs. The kit is supplied without the control enclosure, panel, control transformer, control fuse, terminal strips, wire duct, and wiring. A set of electrical prints is supplied to show typical wiring, and all mounting dimensions are provided in order for a qualified person to install the control module kit. The minimum area required on an existing control panel to install this kit is 14" H x 12" W x 5" D. This control module kit includes the control module, control relays, shock mounts, fasteners, suppressors, danger labels, and electrical prints. A keypad/display kit is required unless a remote operator station is used (see next page). If the automatic (continuous) mode of operation is used, a prior-action station, Part No. LLD-5000, is required. See page 140. SUBPANEL A subpanel control can also be furnished. It is the same as the standard control described on pages 133-134 without the enclosure. The minimum area required in an existing control enclosure is 2212" H x 1812" D x 8" W.

Rockford Systems, Inc.

FAB 135


KEYPAD/DISPLAY KIT Part No. LLD-5027 (for SSC-500 HPC Controls) Part No. LLD-5035 (for SSC-500 HPG Controls) The keypad/display kit can be used with any of the control boxes or the control module kit. This kit includes the keypad/display, an off/program/run selector switch, a light curtain off/on selector switch, a hand/foot selector switch, an inch/single/automatic selector switch, a high/low speed selector switch, a pressure/distance return selector switch, and 25' of cable. Additional push buttons, nameplates, and selector switches for the motor starter, PSDI, gate, etc., can be furnished depending on the features required. Please consult the factory.

REMOTE OPERATOR STATIONS For operator convenience, a remote operator station can be furnished for use with a plain-door standard control box, plain-door custom control box, module kit, or subpanel. The remote operator station contains the keypad/display, program selector switch, and other selector switches as required. Remote operator stations are available in a standard format or can be customized to meet any requirements. Select from the following remote operator stations.

Part No. LLD-5014 Remote Operator Station for Hydraulic Press

FEATURES Keypad/Display Off/Program/Run Selector Switch Inch/Single/Automatic Selector Switch Hand/Foot Selector Switch Light Curtain Off/On Selector Switch High/Low Speed Selector Switch Pressure/Distance Return Selector Switch PSDI (Presence-Sensing Device Initiation) Operators Main Motor Start and Stop Push Buttons Gate Off/On Selector Switch Prior-Action Button for Automatic Modes of Operation

5007 5008 5009 X X X X X X X X X X X X X X X X X X X X X X X

LLD-XXXX PART NO. 5010 5011 5012 5013 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

5014 X X X X X X X X X

5015 X X X X X X X

5016 X X X X X X X

5017 X X X X X X X

5018 X X X X X X X



The above remote operator stations are also available without the enclosure. Please consult the factory. Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 136 FAB

Fax 815-874-6144


PSDI (PRESENCE-SENSING DEVICE INITIATION) When PSDI is applied, a light curtain is used during production to initiate a machine cycle rather than with palm buttons or a foot switch. Use of PSDI may increase productivity and improve ergonomics. PSDI is most often applied to machines where an operator manually feeds and retrieves workpieces. A light curtain presence-sensing device is usually applied vertically between the operator and the pointof-operation hazard. With PSDI, the machine gets its signal to initiate a cycle when an object enters and leaves the light curtains plane of light (i.e., the hand and arm of an operator using a hand tool to feed a part). In most cases, not only is the light curtain an initiating means, it also serves as a safeguard during the hazardous portion of the cycle. During the nonhazardous portion of the cycle, the light curtain can be muted. Machines must have good stopping capability to apply PSDI. Light curtains must be installed at a safety distance so the operators hands cannot reach the hazardous area before the motion of the machine stops. To establish the safety distance, the stopping time during the hazardous portion of the cycle must be determined. Added factors such as reaction time and MOS (minimum object sensitivity) of the light curtain are part of the formula found in the ANSI standards. Also, if the machine has a stopping-performance monitor that allows overrun stopping time, this time must be added to the total stopping time in the formula. Once the total time is known, it is multiplied by 63 (63 inches per second being the hand speed constant) to determine the safety distance. The MOS must be taken into account when establishing the safety distance. The MOS of a light curtain is the smallest size of object that will always induce an output stop signal from the light curtain when inserted in the plane of light. For example, if a light curtain has a 1" MOS, any object that is an inch or larger will interrupt the light curtain and provide a stop signal when inserted into the plane of light. In this example, the additional distance (Dpf) that must be factored into the safety distance formula is 2.5" (see chart). When applying a light curtain to a machine for PSDI, the standards require the unit not to have more than 114" MOS. The equation from Annex D of ANSI B11.192003, Performance Criteria for Safeguarding, for establishing this safety distance is Ds = K (Ts + Tc + Tr + Tspm) + Dpf . Rockford Systems, Inc.
Where: Ds = safety distance K = maximum speed that an individual can approach the hazard (63 inches/second is commonly used) Ts = stop time of the machine measured at the final control element Tc = reaction time of the control system Tr = reaction time of the light curtain and its interface Tspm = additional time allowed for the stoppingperformance monitor to compensate for variations in normal stopping time Dpf = amount of penetration allowed by the light curtain into its sensing field before someone is detected The value of Dpf can be found using the previous chart and can then be used in the above equation. Single and Double Break The SSC-500 control offers single- and doublebreak tripping arrangements. Single break is used when the workpiece doesnt need to be manually retrieved. The operator can hand feed parts through the light curtain sensing field, and when the hand(s) is removed from the sensing field, the press will cycle. This interruption and withdrawal sequence is commonly referred to as a single break. The workpiece is usually blown, kicked, or dropped down from the point of operation. The double-break mode is used when a workpiece needs to be manually retrieved. The machine will cycle every other interruption of the light curtain sensing field. The operator can hand feed a part through the light curtain sensing field, and when the hand(s) is removed from the sensing field, the press will cycle. The operator can then obstruct the light curtain sensing field (preferably with a hand tool) to retrieve the workpiece without causing the press to cycle when the plane of light is cleared. Machines arranged with PSDI must have a control system, components, etc., that are control reliable. This means that the electrical, pneumatic, and hydraulic systems that are relied upon to stop the machine must provide a stop signal. The ANSI B11series standards are calling this performance of the safety related functions. Some other requirements of the standards include: the machine operator controls must be arranged for supervisory selection of the PSDI mode. the control must have a prior action before initiating a PSDI cycle. the control must have a timer to shut down the PSDI mode if the sequence of the workpiecefeeding operation doesnt take place within a preset time established by the user. The SSC-500 hydraulic control meets these and other requirements of the ANSI standards. For more information about PSDI, please contact the factory.

FAB 137


To determine the 8-digit configured part number for the hydraulic control required, follow directions 1-8 below and use the information in the PART NUMBERING SYSTEM CHART below. 1. The first 2 digits for all SSC-500 hydraulic controls are HP. 2. The 3rd digit determines the type of features the control offers. 3. The 4th digit determines the size of the disconnect switch, if provided, in the control enclosure. Zero (0) indicates no disconnect switch provided. 4. The 5th digit determines if a nonreversing motor starter is provided. Zeros (00) in both positions indicate no motor starter provided. 5. The 6th digit determines the size of nonreversing motor starter that is provided in the control enclosure. Zero (0) indicates no motor starter provided. 6. The 7th digit determines the location of the operator controls, or if it is a style X, Y, or Z control without the control transformer. 7. The 8th digit is for the type of light curtain interface provided. 8. The 9th digit (if required) will indicate the type of modifier provided: i.e., motor control operators remote.

3 4


HPC - 2 1 3 - F A 5

The sample shown, HPC-213-FA5, indicates that the custom control box with a PSD-400 light curtain interface and PSDI mode of operation will contain an IEC 60-A disconnect switch and an IEC 23-A nonreversing motor starter. The keypad/display and all operators will be on the door of the enclosure, except for the motor controls which will be located remote.


HP SSC-500 Hydraulic Control -2 5 8

Blank, No Modifier PSDI Operators Remote* Motor Operators Remote* PSDI and Motor Operators Remote*

C Control for Presses With PSDI G Control for Presses With Type B Gate InterfaceNo PSDI S Control for Press Brakes With PSDI


A Standard Rockford Systems Light CurtainPSD-400 B Data InstrumentsShadow I, II & IV C Sick OpticLUV D Data InstrumentsShadow V E ISB - 4 F Rockford SystemsPSD-900 G Rockford SystemsKYM-XXX7 & PSD-900 (DJI) H STI MiniSafe B Series J STI MiniSafe C Series K Banner MiniScreen L Frost Security Force M Rockford SystemsPSD-700/STI DuoSafe N Data InstrumentsShadow VI P Rockford SystemsKTR-2XX (DJI) R Banner Beam Array S Standard Rockford Systems Light CurtainPSD-300 T Link Black Max U ISB Merlin


0 1 2 3 4 5 No Disconnect Switch 30-A Disconnect 1- to 17-FLA Main Drive Motor 60-A Disconnect 18- to 34-FLA Main Drive Motor 100-A Disconnect 35- to 57-FLA Main Drive Motor 200-A Disconnect 58- to 114-FLA Main Drive Motor 400-A Disconnect115- to 228-FLA Main Drive Motor


0 No Starter 1 Nonreversing Starter


0 No Starter 1 2 3 4 5 6 7 8 9 A B C Motor Horsepower Chart 1-Phase 3-Phase IEC 115 V 230 V 208 V 230 V 460 V 1 12 A 3 1 1 16 A 2 2 3 3 7.5 23 A 1 3 5 5 10 30 A 2 7.5 7.5 15 37 A 5 10 20 43 A 3 10 25 60 A 7.5 15 15 30 72 A 5 10 20 20 40 85 A 15 25 50 110 A (B Series) 30 30 60 180 A (B Series) 50 60 125 250 A (B Series) 75 75 150 575 V 7.5 10 15 20 25 30 40 50 60 75 150 200


F Keypad/Display and All Operators on Door of Enclosure P Keypad/Display and All Operators Remote (Plain Door) S Subpanel OnlyWithout Enclosure, Keypad/Display, and Operators K Kit with Module and Control Relays OnlyWithout Enclosure, Subpanel, Transformer, Keypad/Display, and Operators X Same as F (above) Without Control Transformer Y Same as F (above) Without Control Transformer but With E-Stop, Return/Inch-up, and Prior Action on the Enclosure Z Same as F (above) Without Control Transformer but With E-Stop, Prior Action, and Two (2) Guarded Run/Inch Buttons on the Enclosure
*See pages 196-197 for remote stations.

Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 138 FAB

Fax 815-874-6144


LINEAR CAM AND LIMIT SWITCH ASSEMBLY Part No. CMT-048 The linear cam and limit switch assembly consists of two limit switches and two adjustable cams mounted on an extruded-aluminum bracket. This assembly can provide the linear timing of the top and bottom limits of the machine cycle on a hydraulic machine. HIGH/LOW LIMIT SWITCH ASSEMBLY Part No. CMT-049 An additional linear cam and limit switch assembly can be used for a high/low signal during the closing portion of the hydraulic stroke. This assembly consists of one limit switch and one adjustable cam mounted on an extruded-aluminum bracket.

PALM BUTTON ASSEMBLY Part No. CTL-525 Palm button assembly consists of two black run/ inch buttons (with ring guards), a red emergencystop button and a yellow return/inch-up button. Mounting boxes are furnished with each button. The electrical contact arrangement for all buttons is 1 NO and 1 NC.

Part No. CTL-525

FOOT SWITCH Part No. CTD-011 This foot switch is protected from unintentional operation. A heavy-duty die-cast cover protects the top and both sides, and the front is protected by a hinged flap. The flap must be lifted with the toe before the foot may enter the switch. The electrical contact arrangement is 1 NO and 1 NC. Foot Switch

Rockford Systems, Inc.

FAB 139


PRIOR-ACTION STATION Part No. LLD-5000 This prior-action station has a push button that must be depressed and released by the operator before depressing the actuating means in order to initiate the automatic mode of operation. This NEMA 12 enclosure size is 312" x 412" x 312". LLD-5000

PSDI REMOTE STATION Part No. LLD-5002 The optional PSDI (presence-sensing device initiation) remote station has a keyoperated selector switch for single or double break, a double-break armed indicator light, and a lighted prior-action push button. The prior-action light goes out when time expires. The PSDI prior-action station is housed in a 9" x 312" x 4" NEMA 12 enclosure. LLD-5002

SUPERVISORY CONTROL STATION Part No. LLD-5001 Part No. LLD-283 (required when a USC-000 is usedsee below) When two or more palm button or foot switch operating stations are required on one machine, one supervisory control station is required at each operator station. This remote control station consists of an off/on keyed selector switch and a station on indicator light. The on position allows the operator to use that station, and the off position deactivates only that station. The enclosure size is 514" x 3" x 314".

Supervisory Control Station

MULTIPLE-OPERATOR JUNCTION BOX Part No. USC-000 When multiple operator stations are required, this junction box is furnished separately for wiring up to four (4) operator stations. This junction box interfaces palm button assemblies/control bars and foot switches, and will not allow the press to run if palm buttons or a foot switch is actuated without its supervisory control station on. A lighted push button with nameplate indicates a fault condition of an operator station. The button is pushed to reset. The enclosure size is 16" x 14" x 6".

Multiple-Operator Junction Box

Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 140 FAB

Fax 815-874-6144


Company City Surveyed By State Date



Proposal Sequence Reference

INSTALLATION N Y If Y: Standard Stripdown Is special lift for large press required for installation? N Y When filling out this form, be sure the information is filled in for satisfying the basic areas of safety. Basic Areas1. Safeguarding 4. Starter 2. Control 5. Other Considerations 3. Disconnect For identification and reference, please fill in this area first. Machine No. Manufacturer Model No. Tonnage (always required) What is the maximum stroke of the ram? Type: Gap (OBS) Straight Side 4-Post H-Frame Is machine out of service? N Y 1. Safeguarding: Has Safeguard Provide Type, Series, or Size Pullback Restraint Barrier Guard When providing, please attach completed measurement data form. Sides and rear must be guarded. Type A or B Gate When providing, please attach completed measurement data form on guards for the sides of the point of operation. Two-Hand Control If press has two-hand control, are the palm buttons at the proper safety distance? N Y If we are to provide, what is proper safety distance?________" (See page 74 in FAB catalog for details.) Presence-Sensing Light Curtain If press has presence-sensing device, is it at the proper safety distance? N Y If we are to provide light curtain, what is the proper safety distance?________" Are Mounting Brackets required? N CTF (Customer to Y Furnish) If Y: EX-AL Swing-Away N Y If Y, please complete and attach SAB Measurement Form EX-AL Stationary N Y If Y, please complete and attach SLCMB Measurement Form Are Floor Stands required? N Y Are Mirrors required? N Y If Y: 1 2 If Yes, what size? ________" When providing any of the above safeguarding devices, the sides and rear of the point of operation must be safeguarded. If light curtain swing-away brackets are not furnished, are side & rear guards required? N CTF (Customer to Y Furnish) If Y, please complete and attach measurement form. Serial No.

2. Control (continued):
B. Information about press: 1. Hand Actuating N Y Stations: 1 2 3 4 (circle one) 2. Foot Actuating N Y Stations: 1 2 3 4 (circle one) 3. Modes: Inch Single Automatic Other_________ 4. Control Box Location: On Press N Y Remote N Y 5. Operator Controls: On Control Box N Y Remote N Y: (circle one): Box Bar Stand 6. If control reliability existence is questionable, please provide the following information: Solid-State Relay Logic If relay logic, control relays: Mfg._____________Part No.___________Qty.__________ 7. Are any components jumpered out? N Y 8. How does machine operate? a. Does the ram return when the actuating means (hand or foot) is released? N Y b. Does the ram stop at midstroke when the actuating means is released? N Y c. Does the ram automatically return when actuating means is held operated? N Y d. Does the ram change speed during stroke? N Y e. Does ram dwell at the bottom of stroke before returning? N Y C. Is Control Box to be furnished? N Y If Y: 1. Solid-State N Y Relay Logic N Y 2. Box: Standard N Y, Custom N Y, Remote Operator Style (X,Y,Z) N Y, Special N Y 3. Location of operators: (circle one) 1. Remote 2. Loose 3. Door 4. Console 5. Kit 4. Subpanel N Y (Min. space required is 2212" x 1812"x 8") Actual space available______"H x ______"W x _____"D 5. Module kit N Y (Min. space required is 14" x 12" x 5") Actual space available______"H x ______"W x _____"D 6. Modes required: Inch Single PSDI Automatic High/Low Dwell Other______________________ D. Cycle Timing Device? N Y Linear Cams & Limit Switches N Y Use Existing Other_______________________________ E. Actuating Means: How many operating stations: 1 2 3 4 1. Hand (Push Button) N Y Hand (other) N Y________ If Y: On Machine Control Bar Floor Stand 2. E-Stop Button N Y Return Button N Y 3. Foot Switch N Y Is Special Plug and Receptacle Required? N Y F. Blocking Monitored Dual Valve Required? N Y: If Y, contact OEM or a hydraulic fluid specialist G. What is Voltage of Existing Valves? 24 V DC 115 V 230 V 460 V What is Inlet flow? __________________________GPM What is Return flow? ________________________GPM NOTE: Please enclose photo and schematics of the hydraulic system. Enclosed Sending

2. Control:

A. Does control reliability need to be furnished for existing hydraulic control? N Y If Y, please send electrical and hydraulic schematic for engineering to review N/AHydraulic press is mechanically operated

1 of 2

Rockford Systems, Inc.

FAB 141


3. Disconnect: A. Present Location of Disconnect: 1. On Press or Off Press 2. With Hydraulic Control Separate From Hydraulic Control With Starter Only Not Furnished B. Is Electrical disconnect switch required? N Reuse Existing Customer to Furnish Y If Y, furnish HP, FLA, and voltage in Section 4D. C. How is disconnect to be furnished? Separate Box Combination W/Starter Box Custom Box 4. Starter: A. Present Location of Starter: 1. On Press or Off Press 2. With Hydraulic Control Separate From Hydraulic Control With Disconnect Only Not Furnished B. Is transformer for reducing voltage to starter required? N Y C. Is magnetic starter required for hydraulic pump motor? N Reuse Existing Customer to Furnish If N, existing starter must have 115-V coil and one normally open auxiliary contact. Y Estimate Actual D. If Y, provide: ______ Horsepower ______ ______ Full-Load Amps ______ ______ Voltage ______ E. How is starter to be furnished? Separate Box Combination W/Disconnect Box In Custom Box F. Is remote push-button station required? N Y 5. Other Considerations: A. Is safety block to be furnished? N Y If Y: What size is needed? ________" (Height) How many? _______ S M L (circle size required) Interlock N Y Holder N Y B. Does press have a lube system? N Y If Y, what kind of system? Manual or mechanical pump N Y Timer N Y Motorized N YProvide HP, FLA, and voltage if new starter is to be furnished HP ____________ FLA ____________ Voltage ____________ C. If questionable about any information furnished, please enclose photos of entire front, sides (left and right), and rear of press. Include close-up photos of the inside of the existing control box. Sending Enclosed For identification and reference, please fill in this area. Machine No. Model No. Manufacturer Serial No.

2 of 2

Rockford Systems, Inc.

Call Toll-Free 1-800-922-7533 142 FAB

Fax 815-874-6144