Rockford Systems Turnkey Safeguarding Solutions Catalog (all in one)
Comprehensive 370-page catalog that combines all of our catalogs into one handy resource, specifically our Rockford Systems Introductory Brochure, our Safety Shields Catalog for Cutting and Turning Machines, our Machine Safeguarding Devices for Industrial Machinery, our EX-AL™ Barrier and Perimeter Guarding Systems, our Hand-Feeding Tools for Presses and Press Brakes, our Control Systems for Presses and Press Brakes, our Die Safety Blocks for Presses and Press Brakes, our Machine Safeguarding Seminars Brochure, and our Quick Reference Sheets Brochure.
Comprehensive 370-page catalog that combines all of our catalogs into one handy resource, specifically our Rockford Systems Introductory Brochure, our Safety Shields Catalog for Cutting and Turning Machines, our Machine Safeguarding Devices for Industrial Machinery, our EX-AL™ Barrier and Perimeter Guarding Systems, our Hand-Feeding Tools for Presses and Press Brakes, our Control Systems for Presses and Press Brakes, our Die Safety Blocks for Presses and Press Brakes, our Machine Safeguarding Seminars Brochure, and our Quick Reference Sheets Brochure.
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<strong>Turnkey</strong> Mach<strong>in</strong>e<br />
<strong>Safeguard<strong>in</strong>g</strong> <strong>Solutions</strong><br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong><br />
www.rockfordsystems.com
deliver<strong>in</strong>g trusted<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g solutions<br />
for organizations work<strong>in</strong>g with<br />
<strong>in</strong>dustrial mach<strong>in</strong>ery<br />
“<br />
Mach<strong>in</strong>e Guard<strong>in</strong>g has<br />
been on OSHA’s Top 10<br />
Most Cited Violations<br />
report for the last 15<br />
plus years*<br />
“<br />
WHY SAFEGUARD?<br />
Accord<strong>in</strong>g to Occupational Safety and Health<br />
Adm<strong>in</strong>istration (OSHA) statistics, nearly 18,000<br />
workers <strong>in</strong> metal fabricat<strong>in</strong>g plants suffer non-fatal<br />
<strong>in</strong>juries annu<strong>all</strong>y <strong>in</strong> the United States. Even with strict<br />
mach<strong>in</strong>e and operator safety regulations <strong>in</strong> place,<br />
unguarded hazardous mach<strong>in</strong>ery rema<strong>in</strong>s a major<br />
source of fatalities, amputations and other traumatic<br />
<strong>in</strong>juries <strong>in</strong> manufactur<strong>in</strong>g plants. A recent survey<br />
showed an alarm<strong>in</strong>g 50 percent or more of metal<br />
fabricat<strong>in</strong>g mach<strong>in</strong>ery <strong>in</strong> the United States are not<br />
<strong>in</strong> compliance with the critical safety requirements<br />
for guard<strong>in</strong>g outl<strong>in</strong>ed by OSHA and the American<br />
National Standards Institute (ANSI).<br />
S<strong>in</strong>ce 1971, the Fortune 500 and many of North<br />
America’s largest manufacturers have depended<br />
upon <strong>Rockford</strong> <strong>Systems</strong> for customized mach<strong>in</strong>e<br />
safeguard<strong>in</strong>g solutions to br<strong>in</strong>g their operations <strong>in</strong>to<br />
compliance with today’s OSHA regulations, ANSI, RIA<br />
and NFPA standards to ensure they are prepared for<br />
tomorrow’s safety ch<strong>all</strong>enges.<br />
“<br />
50 percent or more<br />
of metal fabricat<strong>in</strong>g<br />
mach<strong>in</strong>ery <strong>in</strong> the<br />
United States are not<br />
<strong>in</strong> compliance with<br />
the critical safety<br />
requirements for<br />
guard<strong>in</strong>g outl<strong>in</strong>ed by<br />
OSHA and ANSI<br />
“<br />
2 | ROCKFORD SYSTEMS TURNKEY SOLUTIONS
“<br />
88% of the total<br />
number of OSHA<br />
Mach<strong>in</strong>e Guard<strong>in</strong>g<br />
violations were<br />
classified as “Serious,”<br />
mean<strong>in</strong>g “<strong>one</strong> <strong>in</strong> which<br />
there is a substantial<br />
probability that death<br />
or serious physical<br />
harm could result, and<br />
the employer knew or<br />
should have known of<br />
the hazard.”*<br />
“<br />
OUR MISSION<br />
Our aim is to enhance the long-term health and<br />
quality of life of workers <strong>in</strong> high-risk occupations,<br />
while improv<strong>in</strong>g the bottom l<strong>in</strong>e of the organizations<br />
we serve by <strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk,<br />
lower<strong>in</strong>g costs, and improv<strong>in</strong>g productivity.<br />
ROCKFORD SYSTEMS CAN HELP<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at mach<strong>in</strong>e<br />
guard<strong>in</strong>g because it has been our sole focus for over<br />
45 years. We stand committed to the prevention of<br />
<strong>in</strong>juries and fatalities. We are here to help <strong>in</strong>surance<br />
agencies, academic <strong>in</strong>stitutions, and bus<strong>in</strong>esses,<br />
large and sm<strong>all</strong>, address mach<strong>in</strong>e safety ch<strong>all</strong>enges<br />
and to remove the burden of manag<strong>in</strong>g the grow<strong>in</strong>g<br />
legal complexity of OSHA and ANSI requirements<br />
from simple turnkey solutions, to more complex<br />
customized solutions.<br />
“<br />
“<br />
Nearly 18,000 workers<br />
<strong>in</strong> metal fabricat<strong>in</strong>g<br />
plants suffer non-fatal<br />
<strong>in</strong>juries annu<strong>all</strong>y <strong>in</strong> the<br />
United States al<strong>one</strong>*<br />
*OSHA’s Top Ten Most Cited Violations Report 2017<br />
ROCKFORD SYSTEMS TURNKEY SOLUTIONS | 3
PROTECTING WORKERS.<br />
INCREASING PRODUCTIVITY.<br />
ENHANCING PROFITABILITY.<br />
MACHINE<br />
SAFETY<br />
SOLUTIONS<br />
Tra<strong>in</strong><strong>in</strong>g and Education<br />
Mach<strong>in</strong>e Risk Assessment<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment<br />
Customized, Eng<strong>in</strong>eered<br />
Integration <strong>Solutions</strong><br />
Recommended For<br />
Recommended For<br />
Recommended For<br />
Recommended For<br />
Personnel <strong>in</strong> EH&S, Production/<br />
Operations/ Ma<strong>in</strong>tenance, and<br />
Risk Management roles that need<br />
safeguard<strong>in</strong>g tra<strong>in</strong><strong>in</strong>g<br />
Description<br />
Sem<strong>in</strong>ars and web<strong>in</strong>ars that teach<br />
people how to safeguard <strong>in</strong>dustrial<br />
mach<strong>in</strong>ery to be <strong>in</strong> compliance<br />
with OSHA regulations, and ANSI/<br />
RIA/NFPA standards<br />
Output / Result<br />
<strong>Safeguard<strong>in</strong>g</strong> Sem<strong>in</strong>ar Certificate<br />
Organizations with new and/<br />
or relocated metal work<strong>in</strong>g<br />
mach<strong>in</strong>es or automation cells<br />
that need hazard identification<br />
and risk scor<strong>in</strong>g<br />
Description<br />
Identifies the task and<br />
associated hazards on mach<strong>in</strong>ery<br />
Scores the risk level us<strong>in</strong>g the<br />
ANSI B11.0-2015 safety<br />
standard methods<br />
Output / Result<br />
Hazard Analysis Report<br />
Organizations with new, old,<br />
refurbished and/or relocated<br />
metal work<strong>in</strong>g mach<strong>in</strong>es, robots<br />
or automation cells that need<br />
safeguard<strong>in</strong>g solutions and<br />
associated costs<br />
Description<br />
Identifies the task and<br />
associated hazards on mach<strong>in</strong>ery<br />
Recommends safeguard<strong>in</strong>g<br />
solutions us<strong>in</strong>g the current OSHA<br />
regulations, and ANSI/RIA/NFPA<br />
standards (or Corporate Standards<br />
where applicable)<br />
Output / Result<br />
Included with<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment<br />
Description<br />
Delivers customized<br />
eng<strong>in</strong>eered and<br />
automated safety device<br />
<strong>in</strong>terfaces or specialized<br />
controls for mach<strong>in</strong>es<br />
or robots<br />
Output / Result<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment & Proposal<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment & Proposal<br />
4 | ROCKFORD SYSTEMS TURNKEY SOLUTIONS
THAT’S WHAT MAKES ROCKFORD<br />
SYSTEMS THE SAFE CHOICE FOR<br />
INDUSTRIAL MACHINE SAFEGUARDING<br />
Over 10,000<br />
<strong>Safeguard<strong>in</strong>g</strong> Products<br />
Recommended For<br />
Expert Inst<strong>all</strong>ation Services<br />
Recommended For<br />
Technical Support and<br />
In-Field Support<br />
Recommended For<br />
Ongo<strong>in</strong>g Compliance Validation<br />
Recommended For<br />
Included with Mach<strong>in</strong>e<br />
<strong>Safeguard<strong>in</strong>g</strong> Assessment<br />
Description<br />
Ensures that <strong>in</strong>dustrial mach<strong>in</strong>es<br />
and automation cells are fully<br />
safeguarded to OSHA regulations,<br />
and ANSI/RIA/NFPA standards<br />
Includes shields, guards, presence<br />
sens<strong>in</strong>g devices, controls,<br />
disconnects, starters, covers<br />
and more for <strong>all</strong> metal work<strong>in</strong>g<br />
mach<strong>in</strong>es<br />
Output / Result<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment & Proposal<br />
Included with Mach<strong>in</strong>e<br />
<strong>Safeguard<strong>in</strong>g</strong> Assessment<br />
Description<br />
OSHA tra<strong>in</strong>ed <strong>in</strong>st<strong>all</strong>ers safely<br />
<strong>in</strong>tegrate safeguard<strong>in</strong>g products<br />
<strong>in</strong>to sophisticated mach<strong>in</strong>e controls<br />
and tra<strong>in</strong> operators on proper use<br />
Output / Result<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong><br />
Assessment & Proposal<br />
Included with <strong>all</strong> purchases<br />
and <strong>in</strong>st<strong>all</strong>ations<br />
Description<br />
Every purchase is backed<br />
up with a professional,<br />
highly-tra<strong>in</strong>ed team of<br />
Technical Support Advisers<br />
In-Field Service Technicians<br />
are available for more complex<br />
troubleshoot<strong>in</strong>g and repairs<br />
Output / Result<br />
Post purchase support via ph<strong>one</strong>,<br />
fax, onl<strong>in</strong>e or onsite<br />
Organizations who have<br />
completed a guard<strong>in</strong>g<br />
<strong>in</strong>st<strong>all</strong>ation that seek ongo<strong>in</strong>g<br />
compliance validation<br />
Description<br />
Ensures that safeguard<strong>in</strong>g<br />
products are <strong>in</strong>place, work<strong>in</strong>g<br />
at optimal performance, and<br />
operators are us<strong>in</strong>g safeguard<strong>in</strong>g<br />
solutions as designed and tra<strong>in</strong>ed<br />
Output / Result<br />
Included with <strong>all</strong> Mach<strong>in</strong>e<br />
<strong>Safeguard<strong>in</strong>g</strong> Assessment<br />
ROCKFORD SYSTEMS TURNKEY SOLUTIONS | 5
Safety Shields<br />
For Cutt<strong>in</strong>g and Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
www.rockfordsystems.com
Safety Shields is a comprehensive catalog that<br />
features a complete l<strong>in</strong>e of equipment to protect<br />
operators of cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es.<br />
The polycarbonate and steel shields found <strong>in</strong><br />
this catalog can be applied to drill presses,<br />
lathes, mill<strong>in</strong>g mach<strong>in</strong>es, bench gr<strong>in</strong>ders, band<br />
saws, and disc and belt sanders.<br />
The catalog also offers emergency-stop<br />
devices, disconnect switches, magnetic motor<br />
starters, lockouts, and danger signs.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong>
TABLE OF CONTENTS<br />
INTRODUCTION..................................................................... 3-7<br />
SAFEGUARDING.................................................................. 8-58<br />
ELECTRICALLY INTERLOCKED HEAVY-DUTY SHIELDS......... 8-21<br />
Electric<strong>all</strong>y Interlocked Drill Press Shields....................... 8-11<br />
Electric<strong>all</strong>y Interlocked Lathe Chuck Shields.................. 12-14<br />
Electric<strong>all</strong>y Interlocked Crosslide/Carriage<br />
Travel Lathe Shields..........................................................15<br />
Electric<strong>all</strong>y Interlocked Mill<strong>in</strong>g Mach<strong>in</strong>e Shields............. 16-18<br />
Electric<strong>all</strong>y Interlocked Gr<strong>in</strong>der & Tool Gr<strong>in</strong>der Shields.........19<br />
Electric<strong>all</strong>y Interlocked Surface Gr<strong>in</strong>der Shields...................20<br />
Electric<strong>all</strong>y Interlocked Slott<strong>in</strong>g & Broach<strong>in</strong>g<br />
Type Mach<strong>in</strong>e Shields....................................................21<br />
SAFETY ON DRILL PRESSES.......................................... 22-25<br />
Safety Chip Shields...........................................................24<br />
Heavy-Duty Alum<strong>in</strong>um Drill Press Shields...........................25<br />
Spr<strong>in</strong>g-Loaded/Self-Eject<strong>in</strong>g Chuck Keys<br />
for Drill Presses.................................................................25<br />
SAFETY ON LATHES...................................................... 26-35<br />
Slid<strong>in</strong>g Lathe Shields.........................................................28<br />
Crosslide-Travel Lathe Shields...........................................29<br />
Sm<strong>all</strong> Steel Lathe Chuck Shields........................................30<br />
Large Steel Lathe Chuck Shields........................................31<br />
Transparent Lathe Chuck Shields.......................................32<br />
Lathe Mount<strong>in</strong>g Brackets...................................................33<br />
Lathe Chuck Wrenches................................................ 34-35<br />
SAFETY ON MILLING MACHINES................................... 36-42<br />
Chip Shields for Bridgeport Mills.................................. 38-39<br />
Bridgeport Vertical Mill Controls.........................................39<br />
Slide and Sw<strong>in</strong>g-Aside Shields..................................... 40-41<br />
Rear Shield Assemblies.....................................................41<br />
Mill<strong>in</strong>g Mach<strong>in</strong>e Belt Covers...............................................42<br />
Electrical Interlock Assembly..............................................42<br />
SAFETY ON BENCH GRINDERS...................................... 43-46<br />
Double-Wheel Gr<strong>in</strong>der Shields............................................44<br />
S<strong>in</strong>gle-Wheel Gr<strong>in</strong>der Shields.............................................44<br />
Standard-Mount Gr<strong>in</strong>der Shields........................................45<br />
Heavy-Duty S<strong>in</strong>gle Buffer Shield.........................................45<br />
Bench Gr<strong>in</strong>der Safety Gauge..............................................46<br />
SAFETY ON BAND SAWS.....................................................47<br />
SAFETY ON DISC AND BELT SANDERS................................48<br />
ALL-PURPOSE SHIELDS................................................ 49-59<br />
Adjustable Slide Shields.....................................................49<br />
Rigid-Arm Magnetic-Base Shields......................................50<br />
Universal B<strong>all</strong> & Socket Shields.................................... 52-53<br />
Flexible Spr<strong>in</strong>g-Steel Arm Shields................................. 54-57<br />
On/Off Magnetic-Base Shields...........................................58<br />
Free-Stand<strong>in</strong>g Shield Assembly..........................................59<br />
DISCONNECT SWITCHES, MOTOR STARTERS, AND<br />
ACCESSORIES............................................................... 60-66<br />
Lockouts .........................................................................60<br />
Tagouts .........................................................................60<br />
Lockout Valves..................................................................61<br />
S<strong>in</strong>gle-Phase Disconnect/Starter........................................61<br />
Sens<strong>in</strong>g Saf-Start ® Packages.............................................62<br />
Enclosed Transformers......................................................63<br />
IEC Fused Disconnect Switches, Magnetic<br />
Motor Starters, and Comb<strong>in</strong>ations..................................63<br />
Disconnect and Starter Part Number<strong>in</strong>g System Chart.........64<br />
Remote Operator Station Part Number<strong>in</strong>g System Chart......65<br />
Remote Operator Stations..................................................66<br />
DANGER SIGNS AND LABELS............................................ 67-68<br />
SURVEY FOR CUTTING AND TURNING MACHINES............. 69-70<br />
OSHA STANDARDS..................................................................71<br />
MACHINE SAFEGUARDING SEMINARS.............................. 72-73<br />
INDEX................................................................................ 74-75<br />
The applications described <strong>in</strong> this catalog are for <strong>in</strong>structional and <strong>in</strong>formational purposes only; the photos <strong>in</strong> this catalog are for illustrative purposes<br />
only. They may not represent actual usage. This catalog has been carefully checked for accuracy and is thought to be fully consistent with the<br />
products described here<strong>in</strong>. However, <strong>Rockford</strong> <strong>Systems</strong>, LLC does not assume liability for the contents of this publication or for the use of any<br />
products described here<strong>in</strong>. <strong>Rockford</strong> <strong>Systems</strong>, LLC reserves the right to make changes to the products and documentation without further notice.<br />
This document conta<strong>in</strong>s proprietary <strong>in</strong>formation protected by copyright. No part of this catalog may be reproduced, transmitted, stored <strong>in</strong> a retrieval<br />
system, or translated <strong>in</strong>to any language, <strong>in</strong> any form or by any means without prior written permission from <strong>Rockford</strong> <strong>Systems</strong>, LLC, 5795 Logistics<br />
Parkway, <strong>Rockford</strong>, Ill<strong>in</strong>ois 61109. <strong>Rockford</strong> <strong>Systems</strong> reserves the right to make changes or revisions to the material conta<strong>in</strong>ed <strong>in</strong> this catalog and<br />
cannot be held liable for <strong>in</strong>cidental or consequential damages result<strong>in</strong>g from the furnish<strong>in</strong>g, performance or use of this material.<br />
Copyright © 2019 by <strong>Rockford</strong> <strong>Systems</strong>, LLC. All rights reserved. Not to be reproduced <strong>in</strong> whole or <strong>in</strong> part without written permission. Litho <strong>in</strong> U.S.A.<br />
2 | SAFETY SHIELDS
INTRODUCTION<br />
There are basic requirements for safeguard<strong>in</strong>g cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es. These basic safety requirements <strong>in</strong>clude safeguard<strong>in</strong>g, controls,<br />
disconnects, starters, covers, and other considerations. We have expla<strong>in</strong>ed the basic safety requirements below and have arranged this catalog so<br />
you can make your safeguard<strong>in</strong>g choices quickly and easily.<br />
1. SAFEGUARDING: When safeguard<strong>in</strong>g the po<strong>in</strong>t of operation on a cutt<strong>in</strong>g or turn<strong>in</strong>g mach<strong>in</strong>e, shields (barriers) can be <strong>in</strong>st<strong>all</strong>ed between the hazard<br />
and the operator. These shields can deflect chips, sparks, and coolant that are generated at the po<strong>in</strong>t of operation.<br />
2. CONTROLS: Most cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es are directly driven by a motor. When the motor is turned on, the tool or workpiece rotates caus<strong>in</strong>g<br />
a po<strong>in</strong>t-of-operation hazard. When the motor is turned off, the tool or workpiece coasts to a stop and the hazard is elim<strong>in</strong>ated. The basic requirement,<br />
for controls, is that <strong>all</strong> cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es must have an emergency-stop device located with<strong>in</strong> reach of the operator. Some of the motor<br />
stop/start operator stations offered <strong>in</strong> this catalog are equipped with an emergency-stop push button to meet this requirement. These emergencystop<br />
buttons can also be supplied separately.<br />
3. DISCONNECTS: All cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es must have a disconnect<strong>in</strong>g means to shut off <strong>all</strong> pneumatic, electrical, and hydraulic power<br />
sources com<strong>in</strong>g to the mach<strong>in</strong>e. It must be capable of be<strong>in</strong>g locked only <strong>in</strong> the off position to comply with OSHA 1910.306 (j) (4), applicable ANSI<br />
standards, and OSHA 29 CFR 1910.147 (lockout/tagout).<br />
4. STARTERS: All cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es must have a starter that will automatic<strong>all</strong>y drop out when the control voltage is lost to the mach<strong>in</strong>e.<br />
To restart the mach<strong>in</strong>e when power is restored, some<strong>one</strong> must start the motor with some type of overt action, for example, press<strong>in</strong>g the start push<br />
button. This prevents the mach<strong>in</strong>e from automatic<strong>all</strong>y restart<strong>in</strong>g when the voltage is restored.<br />
5. COVERS: All cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es must have the mechanical power-transmission apparatuses covered (guarded) if below a 7' level from<br />
the floor or work<strong>in</strong>g platform. This <strong>in</strong>cludes motor shafts, belts, pulleys, cha<strong>in</strong>s, sprockets, gears, etc. This catalog offers a pulley and belt cover<br />
for Bridgeport mills as shown on page 42. If special covers are required, visit www.rockfordsystems.com for our Mechanical Motions Cover (CVR)<br />
catalog, or contact the OEM or a local fabricator to satisfy this requirement.<br />
6. OTHER CONSIDERATIONS: Other auxiliary safeguard<strong>in</strong>g equipment may be required to make cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es as safe as possible.<br />
This equipment <strong>in</strong>cludes safety switches which can be used to <strong>in</strong>terlock the shield or guard to the mach<strong>in</strong>e’s starter. Electronic motor brakes are<br />
available for mach<strong>in</strong>es that have a long coastdown time. These brakes are used to decrease the long coast<strong>in</strong>g time after the motor is turned off.<br />
This <strong>in</strong>creases productivity because the operator does not have to wait for the mach<strong>in</strong>e comp<strong>one</strong>nts to coast to a stop. Signs are used to warn of<br />
the hazards on a mach<strong>in</strong>e.<br />
SAFETY SHIELDS | 3
INTRODUCTION (CONTINUED)<br />
When safeguard<strong>in</strong>g cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es, the general<br />
requirements that apply to these types of mach<strong>in</strong>es are <strong>in</strong> OSHA<br />
(Occupational Safety and Health Adm<strong>in</strong>istration) Title 29 of the Code of<br />
Federal Regulations. The follow<strong>in</strong>g is a list:<br />
1. An Act–Public Law 91-596, 91st Congress, S. 2193,<br />
December 29, 1970, Duties, Section 5(a)(1)(2)(b)<br />
2. OSHA 29 CFR sections that an employer (user) must comply<br />
with <strong>in</strong>clude:<br />
1910.211 Def<strong>in</strong>itions<br />
1910.212 General requirements for <strong>all</strong> mach<strong>in</strong>es<br />
1910.213 Woodwork<strong>in</strong>g mach<strong>in</strong>ery requirements<br />
1910.215 Abrasive wheel mach<strong>in</strong>ery<br />
1910.219 Mechanical power-transmission apparatus<br />
3. OSHA 29 CFR 1910.147 The control of hazardous energy<br />
(lockout/tagout).<br />
4. OSHA 29 CFR 1910.301-1910.399 Electrical<br />
These publications can be acquired by contact<strong>in</strong>g:<br />
U.S. Government Pr<strong>in</strong>t<strong>in</strong>g Office<br />
P.O. Box 371954<br />
Pittsburgh, PA 15250-7954<br />
(202) 512-1800 • http://bookstore.gpo.gov<br />
The basic OSHA standard, 29 CFR 1910.212, states that any mach<strong>in</strong>e<br />
that creates a hazard must be safeguarded to protect the operator and<br />
other employees. OSHA can also cite violations us<strong>in</strong>g other standards<br />
such as the ANSI (American National Standards Institute) B11 series.<br />
The follow<strong>in</strong>g is a list of applicable and related ANSI standards available<br />
at the pr<strong>in</strong>t<strong>in</strong>g of this publication.<br />
ANSI Publications<br />
B11–2008 General Safety Requirements<br />
Common to ANSI B11 Mach<strong>in</strong>es<br />
B11.1 Mechanical Power Presses<br />
B11.2 Hydraulic Power Presses<br />
B11.3 Power Press Brakes<br />
B11.4 Shears<br />
B11.5 Iron Workers<br />
B11.6* Lathes<br />
B11.7 Cold Headers and Cold Formers<br />
B11.8* Drill<strong>in</strong>g, Mill<strong>in</strong>g, and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.9* Gr<strong>in</strong>d<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.10* Metal Saw<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.11* Gear and Spl<strong>in</strong>e Cutt<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.12 Roll Form<strong>in</strong>g and Roll Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.13 Automatic Screw/Bar and Chuck<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.14 Withdrawn (now see ANSI B11.18)<br />
B11.15 Pipe, Tube, and Shape Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.16 Metal Powder Compact<strong>in</strong>g Presses<br />
B11.17 Horizontal Hydraulic Extrusion Presses<br />
B11.18 Coil Process<strong>in</strong>g <strong>Systems</strong><br />
B11.19* Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong><br />
B11.20 Integrated Manufactur<strong>in</strong>g <strong>Systems</strong><br />
B11.21 Mach<strong>in</strong>e Tools Us<strong>in</strong>g Lasers for<br />
Process<strong>in</strong>g Materials<br />
B11.22* Turn<strong>in</strong>g Centers and CNC Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.23* Mach<strong>in</strong><strong>in</strong>g Centers and CNC Mill<strong>in</strong>g, Drill<strong>in</strong>g,<br />
and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.24 Transfer Mach<strong>in</strong>es<br />
B11.TR1 Ergonomic Guidel<strong>in</strong>es<br />
B11.TR2 Mist Control Considerations<br />
B11.TR3* Risk Assessment and Risk Reduction<br />
B11.TR4 Selection of Programmable Electronic <strong>Systems</strong><br />
(PES/PLC) for Mach<strong>in</strong>e Tools<br />
B11.TR5 Sound Level Measurement Guidel<strong>in</strong>es<br />
B11.TR7 Design For Safety and Lean Manufactur<strong>in</strong>g<br />
R15.06 Robotic <strong>Safeguard<strong>in</strong>g</strong><br />
B15.1 Mechanical Power Transmission Apparatus<br />
B56.5 Guide Industrial Vehicles and Automated Function<br />
of Manned Industrial Vehicles<br />
B65.1 Pr<strong>in</strong>t<strong>in</strong>g Press <strong>Systems</strong><br />
B65.2 B<strong>in</strong>d<strong>in</strong>g and F<strong>in</strong>ish<strong>in</strong>g <strong>Systems</strong><br />
B65.5 Stand-Al<strong>one</strong> Platen Presses<br />
B151.1 Horizontal (Plastic) Injection Mold<strong>in</strong>g Mach<strong>in</strong>es<br />
B152.1 Hydraulic Die Cast<strong>in</strong>g Presses<br />
B155.1 Packag<strong>in</strong>g and Packag<strong>in</strong>g-Related Convert<strong>in</strong>g<br />
Mach<strong>in</strong>ery<br />
01.1* Woodwork<strong>in</strong>g Mach<strong>in</strong>ery<br />
*ANSI Standards for Cutt<strong>in</strong>g and Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
These standards can be purchased by contact<strong>in</strong>g:<br />
ANSI (American National Standards Institute, Inc.)<br />
25 West 43rd Street, 4th Floor<br />
New York, New York 10036<br />
(212) 642-4900 • www.ansi.org<br />
Another good reference for safety on mach<strong>in</strong>e tools is the follow<strong>in</strong>g<br />
publication from the National Safety Council:<br />
<strong>Safeguard<strong>in</strong>g</strong> Concepts Illustrated—7th Edition<br />
This publication can be purchased by contact<strong>in</strong>g:<br />
National Safety Council<br />
1121 Spr<strong>in</strong>g Lake Drive<br />
Itasca, IL 60143-3201<br />
1-800-621-7619, ext. 2199 • www.nsc.org<br />
Other sources that can be used for reference <strong>in</strong>clude:<br />
1. NFPA 79, Electrical Standard for Industrial Mach<strong>in</strong>ery<br />
2. NEC (National Electrical Code) Handbook<br />
3. NEMA (National Electrical Manufacturers Association)<br />
For additional safety <strong>in</strong>formation and assistance <strong>in</strong> devis<strong>in</strong>g,<br />
implement<strong>in</strong>g or revis<strong>in</strong>g your safety program, please contact the<br />
mach<strong>in</strong>e manufacturer, your state and local safety councils, <strong>in</strong>surance<br />
carriers, national trade associations, and your state’s occupational safety<br />
and health adm<strong>in</strong>istration.<br />
4 | SAFETY SHIELDS
INTRODUCTION (CONTINUED)<br />
This catalog offers a variety of equipment <strong>in</strong>clud<strong>in</strong>g a l<strong>in</strong>e of shields<br />
(barriers), cord and plug lockouts, fused disconnect switches, magnetic<br />
motor starters, self-latch<strong>in</strong>g emergency stops, and accessories which<br />
are available to meet the electrical energy source portion of these<br />
standards. If a shield is not represented with<strong>in</strong> this catalog, please<br />
contact us for an alternative solution.<br />
The shields (barriers) offered <strong>in</strong> this catalog are usu<strong>all</strong>y <strong>in</strong>st<strong>all</strong>ed on<br />
drill<strong>in</strong>g mach<strong>in</strong>es, lathes, mill<strong>in</strong>g mach<strong>in</strong>es, gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>es, band<br />
saws, belt sanders, and disc sanders. Many of the shields can be used<br />
on other types of equipment <strong>in</strong>clud<strong>in</strong>g woodwork<strong>in</strong>g mach<strong>in</strong>es. Most of<br />
these shields are <strong>in</strong>tended to deflect chips (swarf), sparks, splash<strong>in</strong>g<br />
coolant, or lubricant away from the operator and other employees <strong>in</strong><br />
the mach<strong>in</strong>e area. Shields will provide visibility to the po<strong>in</strong>t of operation.<br />
Although these shields provide some degree of guard<strong>in</strong>g for the operator,<br />
they cannot be considered guards. When us<strong>in</strong>g these shields, and<br />
before any of the shields illustrated <strong>in</strong> this catalog are moved from their<br />
norm<strong>all</strong>y applied position, power must always be turned off.<br />
In some cases, more than <strong>one</strong> type of shield per mach<strong>in</strong>e may be<br />
necessary to provide protection. For example, on lathes, a chuck shield<br />
may be required along with a magnetic-base shield where the tool<br />
comes <strong>in</strong>to contact with the workpiece.<br />
This catalog offers several different types of shields. When consider<strong>in</strong>g<br />
shield<strong>in</strong>g for your mach<strong>in</strong>es, be sure to choose the shield that fits your<br />
mach<strong>in</strong><strong>in</strong>g applications and still ma<strong>in</strong>ta<strong>in</strong>s current levels of productivity.<br />
DRILLING MACHINES<br />
As with other cutt<strong>in</strong>g mach<strong>in</strong>es, the operator must be shielded from the<br />
rotat<strong>in</strong>g chuck and swarf that is produced by the drill bit. A wide variety<br />
of shields can be attached to the mach<strong>in</strong>e and used to protect this area.<br />
The ANSI standard for drill<strong>in</strong>g mach<strong>in</strong>es is ANSI B11.8.<br />
LATHES<br />
There are three ma<strong>in</strong> safety considerations for lathes (eng<strong>in</strong>e, turret,<br />
etc.). One is the rotat<strong>in</strong>g chuck that could catch the operator’s cloth<strong>in</strong>g,<br />
jewelry, hair, or hand and pull it <strong>in</strong>to the mach<strong>in</strong>e. The second is the<br />
hazardous fly<strong>in</strong>g chips and splash<strong>in</strong>g coolant that are generated at<br />
the po<strong>in</strong>t of operation (where the tool contacts the workpiece be<strong>in</strong>g<br />
mach<strong>in</strong>ed). To protect these areas, two shields can be applied—<strong>one</strong><br />
around a portion of the chuck and the other at the po<strong>in</strong>t of operation.<br />
See the photo on page 28. Larger slid<strong>in</strong>g shields can protect both<br />
areas, provid<strong>in</strong>g the workpiece is not too long. The third is the rotat<strong>in</strong>g<br />
transmission comp<strong>one</strong>nts that must be covered to prevent entanglement.<br />
On VTLs (vertical turret lathes), the safety concern is the rotat<strong>in</strong>g table<br />
and the po<strong>in</strong>t-of-operation swarf. Special barriers may have to be<br />
fabricated around the tables of these mach<strong>in</strong>es; shields can be provided<br />
at the po<strong>in</strong>t of operation.<br />
If rail<strong>in</strong>gs are used to keep operators away from hazard areas, these<br />
rail<strong>in</strong>gs must be 42" above the floor or platform.<br />
The ANSI standard for lathes is ANSI B11.6.<br />
MILLING MACHINES<br />
The ma<strong>in</strong> safety consideration for mill<strong>in</strong>g mach<strong>in</strong>es is the swarf that<br />
is generated at the po<strong>in</strong>t of operation. Another safety concern is the<br />
tool cutter, which could catch operator’s cloth<strong>in</strong>g, jewelry, hair, or any<br />
other part of the body. Usu<strong>all</strong>y on sm<strong>all</strong>er mills, the operator and other<br />
employees <strong>in</strong> the mach<strong>in</strong>e area are protected by shields. These shields<br />
can be applied around the perimeter of the table or bed area or close to<br />
the cutter, depend<strong>in</strong>g on the size of the workpiece and the application.<br />
On larger mill<strong>in</strong>g mach<strong>in</strong>es, operators are sometimes protected by<br />
location; however, when work<strong>in</strong>g close to a cutt<strong>in</strong>g tool, operators must<br />
be protected from swarf.<br />
The ANSI standard for mill<strong>in</strong>g mach<strong>in</strong>es is ANSI B11.8.<br />
GRINDING MACHINES<br />
Shields are usu<strong>all</strong>y applied to gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>es to protect the operator<br />
from chips (swarf), sparks, splash<strong>in</strong>g coolant, or lubricant.<br />
Other safety concerns for gr<strong>in</strong>ders are the adjustment of the work rests<br />
and the adjustable tongues or ends of the peripheral members at the<br />
top of each wheel. Work rests sh<strong>all</strong> be kept adjusted closely to the wheel<br />
with a maximum open<strong>in</strong>g of 1/8". The distance between the wheel<br />
periphery and the adjustable tongue or the end of the peripheral member<br />
at the top sh<strong>all</strong> never exceed ¼".<br />
Gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>es are covered by OSHA <strong>in</strong> 29 CFR 1910.215. The ANSI<br />
standards for gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>es are B11.9 and B7.1.<br />
BAND AND TABLE SAWS<br />
Shields are applied to band saws and table saws to protect the operator<br />
from fly<strong>in</strong>g chips, spl<strong>in</strong>ters, and dust. As with other cutt<strong>in</strong>g mach<strong>in</strong>es,<br />
care must be taken around the mov<strong>in</strong>g blade of the mach<strong>in</strong>e. Avoid<br />
wear<strong>in</strong>g loose cloth<strong>in</strong>g and jewelry; properly restra<strong>in</strong> long hair.<br />
Band saws and table saws for woodwork<strong>in</strong>g are covered by OSHA <strong>in</strong><br />
29 CFR 1910.212 and 1910.213. The ANSI standard for metal saw<strong>in</strong>g<br />
mach<strong>in</strong>es is ANSI B11.10.<br />
DISC/BELT SANDERS/GRINDERS<br />
Shields can be applied to disc/belt sanders/gr<strong>in</strong>ders to protect the<br />
operator from fly<strong>in</strong>g chips, spl<strong>in</strong>ters, and dust. As with other mach<strong>in</strong>es<br />
with rotat<strong>in</strong>g parts, care must be taken around the po<strong>in</strong>t of operation.<br />
Avoid wear<strong>in</strong>g loose cloth<strong>in</strong>g and jewelry; properly restra<strong>in</strong> long hair.<br />
Disc and belt sanders for woodwork<strong>in</strong>g are covered by OSHA <strong>in</strong> 29 CFR<br />
1910.212 and 1910.213. The ANSI standards for gr<strong>in</strong>d<strong>in</strong>g mach<strong>in</strong>es<br />
are B11.9 and B7.1.<br />
LOCKOUT/TAGOUT<br />
As stated <strong>in</strong> OSHA 29 CFR 1910.147 The control of hazardous energy<br />
(lockout/tagout): “(a)(1)(i) This standard covers the servic<strong>in</strong>g and<br />
ma<strong>in</strong>tenance of mach<strong>in</strong>es and equipment <strong>in</strong> which the unexpected<br />
SAFETY SHIELDS | 5
INTRODUCTION (CONTINUED)<br />
energiz<strong>in</strong>g or start-up of the mach<strong>in</strong>es or equipment, or release of stored<br />
energy could cause <strong>in</strong>jury to employees. This standard establishes<br />
m<strong>in</strong>imum performance requirements for the control of such hazardous<br />
energy.”<br />
One source of energy to be locked out is the electrical energy sources:<br />
1. Unplug the mach<strong>in</strong>e and use an electrical plug lockout or use a<br />
disconnect switch with padlocks, lockouts, and tags.<br />
2. Disconnect and ensure that <strong>all</strong> power sources are locked and tagged out.<br />
3. Stored electrical energy must be bled to obta<strong>in</strong> zero energy state.<br />
4. Use a volt meter to make sure <strong>all</strong> circuits are dead.<br />
ELECTRICAL REQUIREMENTS<br />
NFPA 79, ELECTRICAL STANDARD FOR<br />
INDUSTRIAL MACHINERY<br />
INCOMING SUPPLY CIRCUIT CONDUCTOR TERMINATIONS<br />
Under 5.1.1, it states that “where practicable, the electrical equipment of<br />
a mach<strong>in</strong>e sh<strong>all</strong> be connected to a s<strong>in</strong>gle power supply circuit.”<br />
SUPPLY CIRCUIT DISCONNECTING (ISOLATING) MEANS<br />
In 5.3.1.1, it states that a supply circuit disconnect<strong>in</strong>g means sh<strong>all</strong> be<br />
provided for each <strong>in</strong>com<strong>in</strong>g supply circuit to a mach<strong>in</strong>e. Accord<strong>in</strong>g to<br />
5.3.1.1.1, each disconnect<strong>in</strong>g means sh<strong>all</strong> be legibly marked to <strong>in</strong>dicate<br />
its purpose. Under 5.3.1.3, “The supply circuit disconnect<strong>in</strong>g means<br />
other than attachment plugs and receptacles sh<strong>all</strong> be mounted with<strong>in</strong> the<br />
control enclosure or immediately adjacent thereto. Exception: Extern<strong>all</strong>y<br />
mounted supply circuit disconnect<strong>in</strong>g means, whether <strong>in</strong>terlocked or not<br />
<strong>in</strong>terlocked with the control enclosure, supply<strong>in</strong>g mach<strong>in</strong>es total<strong>in</strong>g 2 hp<br />
or less sh<strong>all</strong> be permitted to be mounted up to 6 m (20 ft) away from the<br />
enclosure provid<strong>in</strong>g that the disconnect<strong>in</strong>g means is <strong>in</strong> sight from and<br />
readily accessible to the operator.” Under 5.3.3, the disconnect<strong>in</strong>g means<br />
sh<strong>all</strong> be provided with permanent means for lock<strong>in</strong>g <strong>in</strong> the off position<br />
only (for other than attachment plugs). In accordance with 5.3.4.1, “The<br />
center of the grip of the operat<strong>in</strong>g handle of the disconnect<strong>in</strong>g means,<br />
when <strong>in</strong> its highest position, sh<strong>all</strong> not be more than 2.0 m (6 ft 7 <strong>in</strong>)<br />
above the floor. A permanent operat<strong>in</strong>g platform, readily accessible by<br />
means of a permanent stair or ladder, sh<strong>all</strong> be considered as the floor<br />
for the purpose of this requirement.” Accord<strong>in</strong>g to 5.3.2 (6), the supply<br />
circuit disconnect<strong>in</strong>g means can be an attachment plug and receptacle<br />
(plug/socket comb<strong>in</strong>ation) for cord connection to motor loads total<strong>in</strong>g 2<br />
hp or less.<br />
CONTROL CIRCUIT SUPPLY, VOLTAGE, AND PROTECTION<br />
In 9.1.1.1, it states that “Control transformers sh<strong>all</strong> be used for<br />
supply<strong>in</strong>g the control circuits.” Accord<strong>in</strong>g to 9.1.1.3, “Transformers sh<strong>all</strong><br />
not be required if the supply voltage does not exceed 120 volts ac.”<br />
In accordance with 9.1.2.1, “The ac voltage for control circuits sh<strong>all</strong> not<br />
exceed 120 volts, ac s<strong>in</strong>gle phase.”<br />
Accord<strong>in</strong>g to 9.1.3, control circuits sh<strong>all</strong> be provided with overcurrent<br />
protection.<br />
OVERLOAD PROTECTION OF MOTORS<br />
Accord<strong>in</strong>g to 7.3.1, “Overload devices sh<strong>all</strong> be provided to protect each<br />
motor, motor controller, and branch-circuit conductor aga<strong>in</strong>st excessive<br />
heat<strong>in</strong>g due to motor overloads or failure to start.”<br />
STOP FUNCTIONS<br />
Accord<strong>in</strong>g to 9.2.2, “The three categories of stop functions sh<strong>all</strong> be as<br />
follows:<br />
(1) Category 0 is an uncontrolled stop by immediately remov<strong>in</strong>g power<br />
to the mach<strong>in</strong>e actuators.<br />
(2) Category 1 is a controlled stop with power to the mach<strong>in</strong>e actuators<br />
available to achieve the stop then remove power when the stop is<br />
achieved.<br />
(3) Category 2 is a controlled stop with power left available to the<br />
mach<strong>in</strong>e actuators.”<br />
In 9.2.5.3.1, it states that “Each mach<strong>in</strong>e sh<strong>all</strong> be equipped with a<br />
Category 0 stop.” Accord<strong>in</strong>g to 9.2.5.3.2, “Category 0, Category 1, and/<br />
or Category 2 stops sh<strong>all</strong> be provided where <strong>in</strong>dicated by an analysis of<br />
the risk assessment and the functional requirements of the mach<strong>in</strong>e.<br />
Category 0 and Category 1 stops sh<strong>all</strong> be operational regardless of<br />
operat<strong>in</strong>g modes, and Category 0 sh<strong>all</strong> take priority. Stop function sh<strong>all</strong><br />
operate by de-energiz<strong>in</strong>g that relevant circuit and sh<strong>all</strong> override related<br />
start functions.”<br />
EMERGENCY STOP FUNCTIONS<br />
In accordance with 9.2.5.4.1, emergency stop functions sh<strong>all</strong> be<br />
designed to be <strong>in</strong>itiated by a s<strong>in</strong>gle human action. In addition to the<br />
requirements for stop, 9.2.5.4.1.1 states that “the emergency stop sh<strong>all</strong><br />
have the follow<strong>in</strong>g requirements:<br />
(1) It sh<strong>all</strong> override <strong>all</strong> other functions and operations <strong>in</strong> <strong>all</strong> modes.<br />
(2) Power to the mach<strong>in</strong>e actuators, which causes a hazardous<br />
condition(s), sh<strong>all</strong> be removed as quickly as possible without creat<strong>in</strong>g<br />
other hazards (e.g., by the provision of mechanical means of stopp<strong>in</strong>g<br />
requir<strong>in</strong>g no external power, by reverse current brak<strong>in</strong>g for a Category<br />
1 stop).<br />
(3) The reset of the command sh<strong>all</strong> not restart the mach<strong>in</strong>ery but only<br />
permit restart<strong>in</strong>g.”<br />
In 9.2.5.4.1.2, it states that “Where required, provisions to connect<br />
additional emergency stop devices sh<strong>all</strong> be provided.” Accord<strong>in</strong>g to<br />
9.2.5.4.1.3, “The emergency stop sh<strong>all</strong> function as either a Category<br />
0 or a Category 1 stop. The choice of the category of the emergency<br />
stop sh<strong>all</strong> be determ<strong>in</strong>ed by the risk assessment of the mach<strong>in</strong>e.” In<br />
accordance with 9.2.5.4.1.4, “Where a Category 0 or Category 1 stop<br />
is used for the emergency stop function, it sh<strong>all</strong> have a circuitry design<br />
(<strong>in</strong>clud<strong>in</strong>g sensors, logic, and actuators) accord<strong>in</strong>g to the relevant<br />
risk as required by Section 4.1 and 9.4.1. F<strong>in</strong>al removal of power to<br />
the mach<strong>in</strong>e actuators sh<strong>all</strong> be ensured and sh<strong>all</strong> be by means of<br />
electromechanical comp<strong>one</strong>nts. Where relays are used to accomplish a<br />
Category 0 emergency stop function, they sh<strong>all</strong> be nonretentive relays.<br />
Exception: Drivers, or solid state output devices, designed for safetyrelated<br />
functions sh<strong>all</strong> be <strong>all</strong>owed to be the f<strong>in</strong>al switch<strong>in</strong>g element,<br />
when designed accord<strong>in</strong>g to relevant safety standards.”<br />
6 | SAFETY SHIELDS
INTRODUCTION (CONTINUED)<br />
DEVICES FOR STOP AND EMERGENCY STOP<br />
In accordance with 10.7.1.1, “Stop and emergency stop pushbuttons<br />
sh<strong>all</strong> be cont<strong>in</strong>uously operable and readily accessible.” Accord<strong>in</strong>g to<br />
10.7.1.2, “Stop or emergency stop pushbuttons sh<strong>all</strong> be located at each<br />
operator control station and at other locations where emergency stop is<br />
required.”<br />
In 10.7.2.1, it states that “The types of devices for emergency stop sh<strong>all</strong><br />
<strong>in</strong>clude, but are not limited to, the follow<strong>in</strong>g:<br />
(1) Pushbutton-operated switches<br />
(2) Pull-cord-operated switches<br />
(3) Foot-operated switches without a mechanical guard<br />
(4) Push-bar-operated switches<br />
(5) Rod-operated switches”<br />
Accord<strong>in</strong>g to 10.7.2.2, “Pushbutton-type devices for emergency stop<br />
sh<strong>all</strong> be of the self-latch<strong>in</strong>g type and sh<strong>all</strong> have direct open<strong>in</strong>g<br />
operation.” In accordance with 10.7.2.3, “Emergency stop switches<br />
sh<strong>all</strong> not be flat switches or graphic representations based on software<br />
applications.” For restoration of normal function after emergency<br />
switch<strong>in</strong>g off, 10.8.3 says that “It sh<strong>all</strong> not be possible to restore an<br />
emergency switch<strong>in</strong>g off circuit until the emergency switch<strong>in</strong>g off circuit<br />
has been manu<strong>all</strong>y reset.” Accord<strong>in</strong>g to 10.7.3, “Actuators of emergency<br />
stop devices sh<strong>all</strong> be colored RED. The background immediately around<br />
pushbuttons and disconnect switch actuators used as emergency stop<br />
devices sh<strong>all</strong> be colored YELLOW. The actuator of a pushbutton-operated<br />
device sh<strong>all</strong> be of the palm or mushroom-head type and sh<strong>all</strong> effect an<br />
emergency stop when depressed. The RED/YELLOW color comb<strong>in</strong>ation<br />
sh<strong>all</strong> be reserved exclusively for emergency stop applications. Exception:<br />
The RED/YELLOW color comb<strong>in</strong>ation sh<strong>all</strong> be permitted for emergency<br />
stop actuators <strong>in</strong> accordance with 10.8.4.”<br />
Under 10.8.5, “Where the supply disconnect<strong>in</strong>g means is to be loc<strong>all</strong>y<br />
operated for emergency switch<strong>in</strong>g off, it sh<strong>all</strong> be readily accessible and<br />
sh<strong>all</strong> meet the color requirements of 10.8.4.1.” Accord<strong>in</strong>g to 10.8.4.1,<br />
“Actuators of emergency switch<strong>in</strong>g off devices sh<strong>all</strong> be colored RED. The<br />
background immediately around the device actuator sh<strong>all</strong> be permitted<br />
to be colored YELLOW.”<br />
PUSHBUTTON ACTUATORS<br />
Accord<strong>in</strong>g to 10.2.1, “Pushbutton actuators used to <strong>in</strong>itiate a stop<br />
function sh<strong>all</strong> be of the extended operator or mushroom-head type.” As<br />
stated <strong>in</strong> 10.2.2.1, “The preferred color of start or on sh<strong>all</strong> be GREEN,<br />
except that BLACK, WHITE, or GRAY sh<strong>all</strong> be permitted. RED sh<strong>all</strong> not<br />
be used for start or on.” In 10.2.2.2, it states that “the preferred color<br />
for stop or off sh<strong>all</strong> be RED, except that BLACK, WHITE, or GRAY sh<strong>all</strong><br />
be permitted. GREEN sh<strong>all</strong> not be used for stop or off.” Accord<strong>in</strong>g<br />
to 10.2.2.6, “Pushbuttons that cause movement when pressed and<br />
stop movement when they are released (e.g., jogg<strong>in</strong>g) sh<strong>all</strong> be BLACK,<br />
WHITE, GRAY, or BLUE, with a preference for BLACK.” In accordance with<br />
10.2.3.1, “A legend sh<strong>all</strong> be provided for each operator <strong>in</strong>terface device<br />
to identify its function and sh<strong>all</strong> be located so that it can be easily read<br />
by the mach<strong>in</strong>e operator from the normal operator position. The legends<br />
sh<strong>all</strong> be durable and suitable for the operat<strong>in</strong>g environment.”<br />
START DEVICES<br />
Accord<strong>in</strong>g to 10.6, “Actuators used to <strong>in</strong>itiate a start function or the<br />
movement of mach<strong>in</strong>e elements (e.g., slides, sp<strong>in</strong>dles, carriers) sh<strong>all</strong> be<br />
constructed and mounted to m<strong>in</strong>imize <strong>in</strong>advertent operation.”<br />
Protection Aga<strong>in</strong>st Supply Interruption or Voltage Reduction and<br />
Subsequent Restoration<br />
Under 7.5.1, “Where a supply <strong>in</strong>terruption or a voltage reduction can<br />
cause a hazardous condition or damage to the mach<strong>in</strong>e or to the work<br />
<strong>in</strong> progress, undervoltage protection sh<strong>all</strong> be provided (e.g., to switch<br />
off the mach<strong>in</strong>e) at a predeterm<strong>in</strong>ed voltage level.” For restart<strong>in</strong>g, 7.5.3<br />
states that “Upon restoration of the voltage or upon switch<strong>in</strong>g on the<br />
<strong>in</strong>com<strong>in</strong>g supply, automatic or un<strong>in</strong>tentional restart<strong>in</strong>g of the mach<strong>in</strong>e<br />
sh<strong>all</strong> be prevented when such a restart causes a hazardous condition.”<br />
PROTECTIVE INTERLOCKS<br />
In 9.3.6, it states that “Where doors or guards have <strong>in</strong>terlocked switches<br />
used <strong>in</strong> circuits with safety related functions, the <strong>in</strong>terlock<strong>in</strong>g devices<br />
sh<strong>all</strong> be listed, have either positive (direct) open<strong>in</strong>g operation, or provide<br />
similar reliability and prevent the operation of the equipment when the<br />
doors or guards are open (difficult to defeat or bypass).” Under 9.3.1,<br />
“The reclos<strong>in</strong>g or resett<strong>in</strong>g of an <strong>in</strong>terlock<strong>in</strong>g safeguard sh<strong>all</strong> not <strong>in</strong>itiate<br />
mach<strong>in</strong>e motion or operation that results <strong>in</strong> a hazardous condition.”<br />
OTHER SAFETY CONSIDERATIONS<br />
Each mach<strong>in</strong>e should be surveyed as an <strong>in</strong>dividual system. This <strong>in</strong>cludes,<br />
but is not limited to, the proper shield(s), controls, drives, tool<strong>in</strong>g,<br />
feed<strong>in</strong>g methods, material handl<strong>in</strong>g methods, configuration and weight<br />
of workpiece, rotat<strong>in</strong>g and reciprocat<strong>in</strong>g parts, mach<strong>in</strong>e production<br />
requirements, and future mach<strong>in</strong>e needs. The proper disconnect switch,<br />
motor starter, lockout equipment and covers for mach<strong>in</strong>e rotat<strong>in</strong>g<br />
comp<strong>one</strong>nts must also be considered. See pages 69 and 70 for a survey<br />
report.<br />
When operat<strong>in</strong>g the various mach<strong>in</strong>es to which shields can be applied,<br />
the operator must wear proper personal protective safety equipment and<br />
be properly tra<strong>in</strong>ed. The operator must not wear loose cloth<strong>in</strong>g, have<br />
unrestra<strong>in</strong>ed long hair, and must not wear jewelry.<br />
When operat<strong>in</strong>g any cutt<strong>in</strong>g or turn<strong>in</strong>g mach<strong>in</strong>e, the<br />
hands or any part of a person’s body must never be put<br />
<strong>in</strong>to the po<strong>in</strong>t of operation or any other hazard area of<br />
the mach<strong>in</strong>e. Hand tools, fixtures, and other methods<br />
must be used so that operators are not exposed to hazards. If<br />
the hands or any part of a person’s body is put <strong>in</strong>to the hazard,<br />
it could cause serious physical <strong>in</strong>jury or death.<br />
SAFETY SHIELDS | 7
ELECTRICALLY INTERLOCKED DRILL PRESS SHIELDS<br />
DRILL PRESS SHIELDS<br />
(PAGES 9–11)<br />
LATHE CHUCK SHIELDS<br />
(PAGES 12–14)<br />
CROSSLIDE/CARRIAGE<br />
TRAVEL LATHE SHIELDS<br />
(PAGE 15)<br />
MILLING MACHINE SHIELDS<br />
(PAGES 16-18)<br />
GRINDER & TOOL GRINDER SHIELDS<br />
(PAGE 19)<br />
SURFACE GRINDER SHIELDS<br />
(PAGES 20)<br />
SLOTTING & BROACHING TYPE<br />
MACHINE SHIELDS<br />
(PAGE 21)<br />
8 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED DRILL PRESS SHIELDS (CONTINUED)<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
PTR 04/140<br />
This electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shield is ideal for sm<strong>all</strong> to<br />
medium size drill presses and similar mach<strong>in</strong>es. When the shield is<br />
swung out of position, the positive contacts on the microswitch open,<br />
send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e control. The shield is furnished with<br />
an IP 67 rated safety microswitch.<br />
The shield consists of a high impact-resistant, transparent polycarbonate<br />
semi-octagonal front shield that provides operator protection from fly<strong>in</strong>g<br />
chips and coolant. The adjustable shield clamps to a steel support rod<br />
that rotates 180° and operates the shield safety microswitch. The shield<br />
mounts to the left side of the mach<strong>in</strong>e us<strong>in</strong>g a steel mount<strong>in</strong>g bracket.<br />
PTR 02/130, PTR 02/180, PTR 20/300, PTR 20/350<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are ideal for larger<br />
drill presses and radial drill presses. When the shields are swung out of<br />
position, the positive contacts on the microswitch open, send<strong>in</strong>g a stop<br />
signal to the mach<strong>in</strong>e control. The safety microswitch electrical wires are<br />
furnished with a protective cover and connect to the safety circuit of the<br />
mach<strong>in</strong>e that switches off the control to the movement of the sp<strong>in</strong>dle. The<br />
shields are furnished with an IP 67 rated safety microswitch.<br />
The shields consist of a high impact-resistant, transparent polycarbonate<br />
semi-octagonal front shield that provides operator protection from fly<strong>in</strong>g<br />
chips and coolant. The adjustable shields clamp to a steel support<br />
rod that rotates 180° and operates the shield safety microswitch. The<br />
shields mount to the left side of the mach<strong>in</strong>e us<strong>in</strong>g a steel mount<strong>in</strong>g<br />
bracket.<br />
These shields are available <strong>in</strong> different sizes and provide double vertical<br />
adjustment. The PTR 20-series shields have a tubular steel telescopic<br />
shield support rod.<br />
Electric<strong>all</strong>y <strong>in</strong>terlocked shield for sm<strong>all</strong> to<br />
medium size drill presses.<br />
MADE FROM DURABLE PRESSED STEEL<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NC<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC, .<br />
3 A @ 250 V DC<br />
Mechanical Life .................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
Electric<strong>all</strong>y <strong>in</strong>terlocked shield for larger drill presses<br />
and radial drill presses.<br />
SAFETY SHIELDS | 9
ELECTRICALLY INTERLOCKED DRILL PRESS SHIELDS (CONTINUED)<br />
PTR 04/140 PTR 02/130 & PTR 02/180<br />
PTR 20/300 & PTR 20/350<br />
Order<strong>in</strong>g Information<br />
PART NO. ARM LENGTH A B C<br />
REPLACEMENT<br />
SHIELD<br />
PTR 04/140 13.77" (350 mm) 7.87" (200 mm) 5.51" (140 mm) 3.93" (100 mm) PTR 04/140SS<br />
PTR 02/130 17.71" (450 mm) 9.05" (230 mm) 5.11" (130 mm) 4.52" (115 mm) PTR 02/130SS<br />
PTR 02/180 17.71" (450 mm) 9.05" (230 mm) 7.08" (180 mm) 4.52" (115 mm) PTR 02/180SS<br />
PTR 20/300 17.32"-27.55" (440-700 mm) 11.81" (300 mm) 7.87" (200 mm) 5.90" (150 mm) PTR 20/300SS<br />
PTR 20/350 17.32"-27.55" (440-700 mm) 13.77" (350 mm) 9.44" (240 mm) 6.88" (175 mm) PTR 20/350SS<br />
10 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED DRILL PRESS SHIELDS (CONTINUED)<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are ideal for larger<br />
drill presses and radial drill presses. When the shields are swung out of<br />
position, the positive contacts on the microswitch open, send<strong>in</strong>g a stop<br />
signal to the mach<strong>in</strong>e control. The safety microswitch electrical wires are<br />
furnished with a protective cover and connect to the safety circuit of the<br />
mach<strong>in</strong>e that switches off the control to the movement of the sp<strong>in</strong>dle.<br />
The shields are furnished with an IP 67 rated safety microswitch.<br />
The shields consist of a high impact-resistant, transparent polycarbonate<br />
semi-octagonal front shield that provides operator protection from fly<strong>in</strong>g<br />
chips and coolant. The adjustable shields clamp to a steel support<br />
rod that rotates 180° and operates the shield safety microswitch. The<br />
shields mount to the left side of the mach<strong>in</strong>e us<strong>in</strong>g a steel mount<strong>in</strong>g<br />
bracket.<br />
These shields are available <strong>in</strong> different sizes and provide double vertical<br />
adjustment. The PTR 20-series shields have a tubular steel telescopic<br />
shield support rod.<br />
4.53"-8.46"<br />
(115–215 mm)<br />
9.05"<br />
(230 mm)<br />
0.98"-3.54"<br />
25 mm-90 mm<br />
1.38"<br />
(35 mm)<br />
60°<br />
120°<br />
180°<br />
A<br />
B<br />
C<br />
PTR 10/140 & PTR 10/180<br />
PTR 11/140 & PTR 11/180<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C<br />
PTR 10/140 - PTR 11/140 7.87" (200 mm) 5.51" (140 mm) 4.33" (110 mm)<br />
PTR 10/180 - PTR 11/180 7.87" (200 mm) 7.08" (180 mm) 4.33" (110 mm)<br />
SAFETY SHIELDS | 11
ELECTRICALLY INTERLOCKED LATHE CHUCK SHIELDS<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are for lathe chucks.<br />
When the lathe chuck shield is lifted up, the positive contacts on the<br />
microswitch open, send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e control. The<br />
safety mircroswitch electrical wires are furnished with a protective<br />
sheath and connect to the safety circuit of the mach<strong>in</strong>e that switches off<br />
the control to the movement of the chuck. The shield is furnished with<br />
an IP 67 rated safety microswitch.<br />
They have a thermo-formed shield made from high impact-resistant,<br />
transparent polycarbonate that protects operators from direct contact<br />
with the upper portion of the rotat<strong>in</strong>g chuck. The shields, <strong>in</strong> tubular-steel<br />
frames, are attached with a steel clamp to a support arm that rotates<br />
90° and operates the safety microswitch.<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked lathe chuck shields are available <strong>in</strong> several<br />
sizes. A handle is furnished for lift<strong>in</strong>g the shield up and out of the way for<br />
easy access to the workpiece and for chang<strong>in</strong>g chucks.<br />
Note: May be purchased without safety microswitch<br />
MADE FROM DURABLE PRESSED STEEL<br />
Electric<strong>all</strong>y <strong>in</strong>terlocked chuck shield on lathe.<br />
DIMENSIONS<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NC<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC, .<br />
3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C<br />
REPLACEMENT<br />
SHIELD ONLY<br />
REPLACEMENT SHIELD<br />
(WITH FRAME)<br />
PTO 01/300 11.81" (300 mm) 7.87" (200 mm) 7.08" (180 mm) PTO 01/300SS PTO 01/300SC<br />
PTO 0¼00 15.74" (400 mm) 9.25" (235 mm) 9.05" (230 mm) PTO 0¼00SS PTO 01/40SC<br />
PTO 01/500 19.68" (500 mm) 9.25" (235 mm) 11.02" (280 mm) PTO 01/500SS PTO 01/500SC<br />
PTO 01/600 23.62" (600 mm) 9.25" (235 mm) 12.99" (330 mm) PTO 01/600SS PTO 01/600SC<br />
12 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED LATHE CHUCK SHIELDS (CONTINUED)<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are for lathe chucks.<br />
When the lathe chuck shield is lifted up, the positive contacts on the<br />
microswitch open, send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e control. The<br />
safety mircroswitch electrical wires are furnished with a protective<br />
sheath and connect to the safety circuit of the mach<strong>in</strong>e that switches off<br />
the control to the movement of the chuck. The shield is furnished with<br />
an IP 67 rated safety microswitch.<br />
They have a thermo-formed shield made from high impact-resistant,<br />
transparent polycarbonate that protects operators from direct contact<br />
with the upper portion of the rotat<strong>in</strong>g chuck. The shields, <strong>in</strong> tubular-steel<br />
frames, are attached with a steel clamp to a support arm that rotates<br />
90° and operates the safety microswitch.<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked lathe chuck shields are available <strong>in</strong> several<br />
sizes. A handle is furnished for lift<strong>in</strong>g the shield up and out of the way for<br />
easy access to the workpiece and for chang<strong>in</strong>g chucks.<br />
Note: May be purchased without safety microswitch<br />
Max. Dimensions<br />
H= A + 15.74" (400 mm)<br />
C<br />
D<br />
5.90"-23.62"<br />
(150-600 mm)<br />
5.90"-11.81"<br />
(150-300 mm)<br />
E<br />
B<br />
Ø<br />
G<br />
F<br />
Range<br />
A + 6.69"<br />
(170 mm)<br />
A<br />
PTO 20/400, PTO 20/600, & PTO 20/800<br />
Order<strong>in</strong>g Information<br />
PART NO. Ø A B C D E F G<br />
PTO 20/400<br />
PTO 20/600<br />
PTO 20/800<br />
15.74"-19.68"<br />
(400-500 mm)<br />
23.62"-27.55"<br />
(600-700 mm)<br />
31.49"-35.43"<br />
(800-900 mm)<br />
17.71"<br />
(450 mm)<br />
17.71"<br />
(450 mm)<br />
17.71"<br />
(450 mm)<br />
16.92"<br />
(430 mm)<br />
20.47"<br />
(520 mm)<br />
25.19"<br />
(640 mm)<br />
25.78"<br />
(655 mm)<br />
33.66"<br />
(855 mm)<br />
41.93"<br />
(1,065 mm)<br />
18.89"<br />
(480 mm)<br />
25.19"<br />
(640 mm)<br />
31.49"<br />
(800 mm)<br />
13.77"<br />
(350 mm)<br />
16.92"<br />
(430 mm)<br />
20.86"<br />
(530 mm)<br />
4.92"<br />
(125 mm)<br />
5.90"<br />
(150 mm)<br />
7.08"<br />
(180 mm)<br />
11.02"-21.26"<br />
(280-540 mm)<br />
12.59"-29.13"<br />
(320-740 mm)<br />
14.56"-37.40"<br />
(370-950 mm)<br />
SAFETY SHIELDS | 13
ELECTRICALLY INTERLOCKED LATHE CHUCK SHIELDS (CONTINUED)<br />
I<br />
C<br />
G<br />
H<br />
E<br />
B<br />
D<br />
F<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C D E F G H I<br />
PTO 21/080<br />
PTO 21/120<br />
21.65"<br />
(550 mm)<br />
21.65"<br />
(550 mm)<br />
39.37"<br />
(1,000 mm)<br />
59.05"<br />
(1,500 mm)<br />
A<br />
39.37"<br />
(1,000 mm)<br />
55.11"<br />
(1,400 mm)<br />
20.39"<br />
(518 mm)<br />
36.14"<br />
(918 mm)<br />
11.10"<br />
(282 mm)<br />
11.10"<br />
(282 mm)<br />
31.49"<br />
(800 mm)<br />
47.24"<br />
(1,200 mm)<br />
11.81"<br />
(300 mm)<br />
11.81"<br />
(300 mm)<br />
15.35"-23.22"<br />
(390-590 mm)<br />
15.35"-23.22"<br />
(390-590 mm)<br />
36.61"-58.66"<br />
(930-1,490 mm)<br />
36.61"-58.66"<br />
(930-1,490 mm)<br />
I<br />
C<br />
G<br />
H<br />
E<br />
B<br />
D<br />
F<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C D E F G H I<br />
PTO 22/080<br />
PTO 22/120<br />
21.65"<br />
(550 mm)<br />
21.65"<br />
(550 mm)<br />
39.37"<br />
(1,000 mm)<br />
59.05"<br />
(1,500 mm)<br />
A<br />
39.37"<br />
(1,000 mm)<br />
55.11"<br />
(1,400 mm)<br />
20.39"<br />
(518 mm)<br />
36.14"<br />
(918 mm)<br />
11.10"<br />
(282 mm)<br />
11.10"<br />
(282 mm)<br />
31.49"<br />
(800 mm)<br />
47.24"<br />
(1,200 mm)<br />
11.81"<br />
(300 mm)<br />
11.81"<br />
(300 mm)<br />
15.35"-23.22"<br />
(390-590 mm)<br />
15.35"-23.22"<br />
(390-590 mm)<br />
36.61"-58.66"<br />
(930-1,490 mm)<br />
36.61"-58.66"<br />
(930-1,490 mm)<br />
14 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED CROSSLIDE/CARRIAGE TRAVEL LATHE SHIELDS<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
These are electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty crosslide/carriage travel<br />
shields. When the shield is swung out of position, the positive contacts<br />
on the microswitch open, send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e control.<br />
The safety mircroswitch electrical wires are furnished with a protective<br />
sheath and connect to the safety circuit of the mach<strong>in</strong>e that switches off<br />
the control to the movement of the chuck. The shield is furnished with<br />
an IP 67 rated safety microswitch.<br />
The shields consist of a high impact-resistant, transparent polycarbonate<br />
front panel with an alum<strong>in</strong>um top plate that provides operator protection<br />
from fly<strong>in</strong>g chips and coolant. The adjustable shield attaches to tubularsteel<br />
arms that provide additional adjustability at the jo<strong>in</strong>t and steel<br />
base. The steel base which houses the safety microswitch mounts to the<br />
backside of the horizontal carriage of the mach<strong>in</strong>e.<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked crosslide/carriage travel lathe shields are<br />
available <strong>in</strong> different sizes. Because the shield, arms, and base are<br />
adjustable, the shield can be positi<strong>one</strong>d for maximum protection dur<strong>in</strong>g<br />
operation and can be swung out of the way for easy access to the<br />
workpiece and tool<strong>in</strong>g.<br />
Note: May be purchased without safety microswitch<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NC<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC,<br />
.3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
DIMENSIONS<br />
MADE FROM DURABLE PRESSED STEEL<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C<br />
REPLACEMENT<br />
SHIELD<br />
PTO 10/350 13.77" (350 mm) 11.81" (300 mm) 11.02" (280 mm) PTO 10/350SC<br />
PTO 10/435 15.74" (400 mm) 13.77" (350 mm) 12.20" (310 mm) PTO 10/435SC<br />
SAFETY SHIELDS | 15
ELECTRICALLY INTERLOCKED MILLING MACHINE SHIELDS<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
SEMICIRCULAR SHIELD<br />
These are electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields for vertical mill<strong>in</strong>g<br />
mach<strong>in</strong>es with two (2) safety microswitch locations. When the shield is<br />
swung out of position at either safety microswitch location, the positive<br />
contacts on the microswitch open, send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e<br />
control. The safety microswitch electrical wires are furnished with a<br />
protective sheath and connect to the safety circuit of the mach<strong>in</strong>e that<br />
switches off the control to the movement of the sp<strong>in</strong>dle. Shields are<br />
furnished with IP 67 rated safety microswitches.<br />
These have a thermo-formed shield made from high impact-resistant,<br />
transparent polycarbonate that provides operator protection from fly<strong>in</strong>g<br />
chips and coolant. The shields, <strong>in</strong> tubular-steel frames, clamp to a<br />
support rod that rotates 180° and operates the shield safety microswitch.<br />
Tubular-steel arms provide additional adjustability at the jo<strong>in</strong>t and steel<br />
base. The steel base, which houses a second safety microswitch, can be<br />
later<strong>all</strong>y adjusted from .59" to 7.87" (15 to 200 mm).<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked mill<strong>in</strong>g mach<strong>in</strong>e shields are available <strong>in</strong><br />
different sizes and are available as left-mount or right-mount models.<br />
Because the shield, arms, and base are adjustable, the shield can be<br />
positi<strong>one</strong>d for maximum protection dur<strong>in</strong>g operation and can be swung<br />
out of the way for easy access to the workpiece and tool<strong>in</strong>g.<br />
Note: May be purchased without safety microswitch<br />
DIMENSIONS<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........Two safety switches—2 NC contacts<br />
per switch<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC,<br />
.3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
Order<strong>in</strong>g Information<br />
LEFT MOUNT<br />
PART NO.<br />
RIGHT MOUNT<br />
PART NO.<br />
A<br />
B<br />
REPLACEMENT<br />
SHIELD ONLY<br />
REPLACEMENT<br />
SHIELD W/ FRAME<br />
PFR 01/300/SX PFR 01/300/DX 11.81" (300 mm) 7.87" (200 mm) PFR 01/300SS PFR 01/300SC<br />
PFR 0¼00/SX PFR 01/400/DX 15.74" (400 mm) 9.25" (235 mm) PFR 01/400SS PFR 01/400SC<br />
PFR 01/500/SX PFR 01/500/DX 19.68" (500 mm) 9.25" (235 mm) PFR 01/500SS PFR 01/500SC<br />
PFR 01/600/SX PFR 01/600/DX 23.62" (600 mm) 9.25" (235 mm) PFR 01/600SS PFR 01/600SC<br />
MADE FROM DURABLE PRESSED STEEL<br />
16 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED MILLING MACHINE SHIELDS (CONTINUED)<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........Two safety switches—2 NC contacts<br />
per switch<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC, .<br />
3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
ANGLED SHIELD<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are for vertical mill<strong>in</strong>g<br />
mach<strong>in</strong>es. They have two (2) safety microswitch locations. When the<br />
shield is swung out of position at either safety microswitch location, the<br />
positive contacts on the microswitch open, send<strong>in</strong>g a stop signal to the<br />
mach<strong>in</strong>e control. The safety microswitch electrical wires are furnished<br />
with a protective sheath and connect to the safety circuit of the mach<strong>in</strong>e<br />
that switches off the control to the movement of the sp<strong>in</strong>dle. Shields are<br />
furnished with IP 67 rated safety microswitches.<br />
These have a thermo-formed shield made from high impact-resistant,<br />
transparent polycarbonate that provides operator protection from fly<strong>in</strong>g<br />
chips and coolant. The shield has an alum<strong>in</strong>um upper frame and clamps<br />
to a support rod that rotates 180° and operates the shield safety<br />
microswitch. Tubular-steel arms provide additional adjustability at the<br />
jo<strong>in</strong>t and steel base. The steel base, which houses a second safety<br />
microswitch, can be later<strong>all</strong>y adjusted from .59" to 7.87" (15 to 200<br />
mm).<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked mill<strong>in</strong>g mach<strong>in</strong>e shields are available <strong>in</strong><br />
different sizes and are available as left-mount or right-mount models.<br />
Because the shield, arms, and base are adjustable, the shield can be<br />
positi<strong>one</strong>d for maximum protection dur<strong>in</strong>g operation and can be swung<br />
out of the way for easy access to the workpiece and tool<strong>in</strong>g.<br />
Note: May be purchased without safety microswitch<br />
DIMENSIONS<br />
Flat Shield Made From Durable Pressed Steel<br />
Angled Shield Made From Durable Pressed Steel<br />
Order<strong>in</strong>g Information<br />
Shield<br />
Type<br />
Left Mount<br />
Part No.<br />
Right Mount<br />
Part No.<br />
A B C D<br />
Replacement<br />
Shield Only<br />
Replacement<br />
Shield W/ Frame<br />
Angled PFR 02/625/SX PFR 02/625/DX 24.41" (620 mm) 7.87" (200 mm) 6.69" (170 mm) 15.94" (405 mm) PFR 02/625SS PFR 02/625SC<br />
Angled PFR 02/725/SX PFR 02/725/DX 28.54" (725 mm) 11.81" (300 mm) 7.87" (200 mm) 16.92" (430 mm) PFR 02/725SS PFR 02/725SC<br />
Flat PFR 02/625/SPL001 PFR 02/625/SPL001 13.78” (350 mm) 11.81” (300 mm) NA NA NA PBF 10/435SC<br />
Flat PFR 02/625/SPL002 PFR 02/625/SPL002 15.75” (400 mm) 13.78” (350 mm) NA NA NA PBF 10/435SC<br />
SAFETY SHIELDS | 17
ELECTRICALLY INTERLOCKED MILLING MACHINE SHIELDS (CONTINUED)<br />
3.15"-16.14"<br />
(80-410 mm)<br />
B<br />
C<br />
180º<br />
A<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C<br />
PFR 10/420 15.74" (400 mm) 7.87" (200 mm) 32.67" (830 mm) ??<br />
PFR 10/430 15.74" (400 mm) 11.81" (300 mm) 32.67" (830 mm) ??<br />
PFR 10/530 19.68" (500 mm) 11.81" (300 mm) 36.61" (930 mm) ??<br />
REPLACEMENT SHIELD<br />
ONLY (EACH)<br />
14.17"<br />
(360 mm)<br />
‡<br />
3.93"-8.85"<br />
(100-225 mm)<br />
*<br />
* **<br />
0"-9.05"<br />
(0-230 mm)<br />
B §<br />
2.16"<br />
(55 mm)<br />
C<br />
A<br />
Reversible safety guard<br />
0"-9.05" (0-230 mm)<br />
*<br />
§ 1.18"-8.85" (30-225 mm)<br />
** * 4.33"-12.79" (110-325 mm)<br />
‡ 3.93"-8.66" (100-220 mm)<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C<br />
PFR 20/218 9.84" (250 mm) 7.08" (180 mm) 4.33" (110 mm)<br />
PFR 20/320 11.81" (300 mm) 7.87" (200 mm) 4.92" (125 mm)<br />
18 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED GRINDER AND TOOL GRINDER SHIELDS<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields for gr<strong>in</strong>der and tool gr<strong>in</strong>ders are ideal for s<strong>in</strong>gle- and double-wheel gr<strong>in</strong>ders. When the shield is<br />
swung out of position, the positive contacts on the microswitch open, send<strong>in</strong>g a stop signal to the mach<strong>in</strong>e control. The safety microswitch electrical<br />
wires are furnished with a protective sheath and connect to the safety circuit of the mach<strong>in</strong>e that switches off the control to the movement of the<br />
gr<strong>in</strong>d<strong>in</strong>g wheel. The shield is furnished with an IP 67 rated safety microswitch.<br />
The multi-adjustable, hexagonal steel arm structure <strong>all</strong>ows easy mount<strong>in</strong>g on the most diverse gr<strong>in</strong>ders. A versatile clamp <strong>all</strong>ows horizontal and<br />
vertical adjustment of the shield.<br />
Each shield consists of a high impact-resistant, transparent polycarbonate shield with an alum<strong>in</strong>um profile support and provides operator protection<br />
from fly<strong>in</strong>g chips and coolant.<br />
SINGLE SHIELD<br />
DOUBLE SHIELD<br />
MADE FROM DURABLE PRESSED STEEL<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NC<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC, .<br />
3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
S<strong>in</strong>gle (Right/Left Reversible) Shield<br />
PART NO. A B<br />
REPLACEMENT<br />
SHIELD ONLY (EACH)<br />
PMA 10/112 6.29" (160 mm) 5.70" (145 mm) PMA 02/112SC<br />
PMA 10/216 7.87" (200 mm) 7.28" (185 mm) PMA 02/216SC<br />
Double Shield<br />
PART NO. A B<br />
REPLACEMENT<br />
SHIELD ONLY (EACH)<br />
PMA 11/112 6.29" (160 mm) 5.70" (145 mm) PMA 02/112SC<br />
PMA 1½16 7.87" (200 mm) 7.28" (185 mm) PMA 02/216SC<br />
SAFETY SHIELDS | 19
ELECTRICALLY INTERLOCKED SURFACE GRINDER SHIELDS<br />
D= A / 2<br />
Useful Open<strong>in</strong>g<br />
A / 2 + 1.96" (50 mm)<br />
C =<br />
B + 3.34"<br />
(85 mm)<br />
B<br />
Order<strong>in</strong>g Information<br />
PRE 01/650 47.24" (1,200 mm) 19.68" (500 mm)<br />
PRE 01/860 62.99" (1,600 mm) 23.62" (600 mm)<br />
100°<br />
A<br />
Note: May be purchased without<br />
safety microswitch<br />
²<br />
¹<br />
¹ 7.08" (180 mm)<br />
² 7.87" (200 mm)<br />
PRE 01/650 AND PRE 01/860<br />
Useful Open<strong>in</strong>g<br />
A - 5.11" (130 mm)<br />
B<br />
Inner <strong>in</strong>cl<strong>in</strong>ed<br />
structure for lubricant<br />
liquid collection<br />
Order<strong>in</strong>g Information<br />
PRE 10/550 39.37" (1,000 mm) 20.07" (510 mm)<br />
3.54"<br />
(90 mm)<br />
1.96"<br />
(50 mm)<br />
9.84" (250 mm)<br />
A<br />
5.90" (150 mm)<br />
PRE 10/655 47.24" (1,200 mm) 22.04" (560 mm)<br />
PRE 10/860 62.99" (1,600 mm) 25.98" (660 mm)<br />
Note: May be purchased without<br />
safety microswitch<br />
20 | SAFETY SHIELDS
ELECTRICALLY INTERLOCKED SLOTTING AND BROACHING TYPE MACHINE SHIELDS<br />
GOES BEYOND OSHA AND ANSI SAFETY REQUIREMENTS<br />
These electric<strong>all</strong>y <strong>in</strong>terlocked heavy-duty shields are designed for<br />
slott<strong>in</strong>g and broach<strong>in</strong>g type mach<strong>in</strong>es. When the shield is swung out of<br />
position, the positive contacts on the microswitch open, send<strong>in</strong>g a stop<br />
signal to the mach<strong>in</strong>e control. The safety microswitch electrical wires are<br />
furnished with a protective sheath and connect to the safety circuit of<br />
the mach<strong>in</strong>e that switches off the control to the movement of the slide<br />
or broach. The shield is furnished with an IP 67 rated safety microswitch.<br />
The vertical shield support arm made of tubular sta<strong>in</strong>less steel is<br />
attached to a depth-adjustable mount<strong>in</strong>g bracket which provides easy<br />
mount<strong>in</strong>g on the most diverse mach<strong>in</strong>es. The adjustable shield-arm<br />
fix<strong>in</strong>g clamps made of pressed steel <strong>all</strong>ow horizontal and vertical<br />
adjustment of the shield.<br />
Each shield consists of a high impact-resistant, oil-resistant, transparent<br />
polycarbonate shield that protects operators from fly<strong>in</strong>g chips and<br />
coolant, and h<strong>in</strong>ders access to the alternate mov<strong>in</strong>g parts of the vertical<br />
slide or broach. The shield can be mounted on the left or right side of<br />
the mach<strong>in</strong>e base.<br />
Note: May be purchased without safety microswitch<br />
MADE FROM DURABLE PRESSED STEEL<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NC<br />
Operat<strong>in</strong>g Temperature........23º to 113º F (-5º to 45º C)<br />
Switch<strong>in</strong>g Ability..................4 A @ 24 V AC, 4 A @ 120/250 V AC<br />
2 A @ 24 V DC, .4 A @ 120 V DC,<br />
.3 A @ 250 V DC<br />
Mechanical Life..................1 Million Switch<strong>in</strong>g Cycles<br />
Enclosure Rat<strong>in</strong>g.................IP 67<br />
Order<strong>in</strong>g Information<br />
LEFT MOUNT<br />
PART NO.<br />
RIGHT MOUNT<br />
PART NO.<br />
A B C D E<br />
REPLACEMENT<br />
SHIELD ONLY<br />
PST 0½40/SX PST 0½40/DX 15.74" (400 mm) 15.74" (400 mm) 7.87" (200 mm) 9.84" (250 mm) 23.62" (600 mm) PST 0½40SS<br />
PST 0½60/SX PST 0½60/DX 15.74" (400 mm) 15.74" (400 mm) 7.87" (200 mm) 9.84" (250 mm) 31.49" (800 mm) PST 0½60SS<br />
SAFETY SHIELDS | 21
ROTATING MEMBERS AND TOOLS<br />
You are exposed to mov<strong>in</strong>g mach<strong>in</strong>e parts<br />
that can crush, dismember and cause death.<br />
DO NOT operate this mach<strong>in</strong>e without shield(s) <strong>in</strong><br />
place.<br />
NEVER place your f<strong>in</strong>gers, hands or any part of<br />
your body on or near the rotat<strong>in</strong>g parts<br />
of this mach<strong>in</strong>e.<br />
NEVER operate this mach<strong>in</strong>e with loose cloth<strong>in</strong>g,<br />
jewelry, or unrestra<strong>in</strong>ed long hair.<br />
FAILURE to obey will result <strong>in</strong> loss of f<strong>in</strong>gers or<br />
limbs, or could cause death.<br />
Part No. KSC-046<br />
FLYING PARTS<br />
You are exposed to mov<strong>in</strong>g mach<strong>in</strong>e parts<br />
that can cause eye or bodily <strong>in</strong>jury due<br />
to hazardous fly<strong>in</strong>g chips, sparks, and<br />
coolant splash.<br />
NEVER operate this mach<strong>in</strong>ery without proper<br />
eye and body protection.<br />
FAILURE<br />
to obey will result <strong>in</strong> eye <strong>in</strong>jury or<br />
severe personal <strong>in</strong>jury.<br />
ALWAYS wear proper personal protective equipment when operat<strong>in</strong>g this mach<strong>in</strong>e.<br />
This sign does not cover <strong>all</strong> dangers that could happen while operat<strong>in</strong>g this mach<strong>in</strong>e.<br />
Do Not Remove or Cover This Sign – See Back For Mount<strong>in</strong>g Instructions<br />
UNGUARDED DRILL PRESS<br />
SAFEGUARDED DRILL PRESS<br />
Danger Sign<br />
Comb<strong>in</strong>ation Disconnect Switch,<br />
Motor Starter and Emergency Stop<br />
Precautions Sign<br />
Drill Shield<br />
22 | SAFETY SHIELDS
SAFETY ON DRILL PRESSES<br />
ELECTRICALLY<br />
INTERLOCKED HEAVY-<br />
DUTY DRILL<br />
PRESS SHIELDS<br />
(PAGES 9-11)<br />
SAFETY CHIP SHIELDS<br />
(PAGE 24)<br />
HEAVY-DUTY<br />
ALUMINUM DRILL<br />
PRESS SHIELDS<br />
(PAGE 25)<br />
DRILL PRESS CHUCK KEYS<br />
(PAGE 25)<br />
(www.rockfordsystems.com/onl<strong>in</strong>e/<br />
safeguard<strong>in</strong>g/drill-press-chuck-keys.cfm)<br />
RIGID-ARM MAGNETIC-BASE<br />
SHIELDS<br />
(PAGE 50)<br />
FLEXIBLE SPRING-STEEL<br />
ARM SHIELDS<br />
(PAGES 54-57)<br />
UNIVERSAL BALL &<br />
SOCKET SHIELDS<br />
(PAGES 51-53)<br />
ON/OFF MAGNETIC-BASE<br />
SHIELDS<br />
(PAGE 58)<br />
ADJUSTABLE SLIDE SHIELDS<br />
(PAGE 49)<br />
SENSING SAF-START ®<br />
(PAGE 62)<br />
DISCONNECT SWITCHES,<br />
MOTOR STARTERS &<br />
ACCESSORIES<br />
(PAGES 63)<br />
SAFETY SHIELDS | 23
SAFETY CHIP SHIELDS<br />
These sturdy safety chip shields provide protection from fly<strong>in</strong>g chips,<br />
coolant, and rotat<strong>in</strong>g parts. They are usu<strong>all</strong>y applied to sm<strong>all</strong> drill presses,<br />
mill<strong>in</strong>g mach<strong>in</strong>es, etc., and can be magnetic<strong>all</strong>y or permanently mounted.<br />
The shield can be attached to any smooth ferrous surface on the<br />
mach<strong>in</strong>e by an 80-lb pull, 3¼" diameter magnetic base. If a smooth,<br />
ferrous surface is not available, a 3¼" x 5¼" mount<strong>in</strong>g plate is also<br />
furnished with each shield.<br />
The impact-resistant, 3/16"-thick clear polycarbonate shield provides<br />
visibility to the po<strong>in</strong>t of operation. It adjusts and locks <strong>in</strong> any vertical position.<br />
14½"<br />
5"<br />
9"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
KYL-001 5" x 9" Shield With ½" Diameter Black PVC Arm 14½" High<br />
KYM-001 5" x 9" Replacement Shield Only<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
KYL-055 5" x 11" Shield With 1" Square Extruded Alum<strong>in</strong>um Arm 18" High<br />
KYL-044 5" x 11" Replacement Shield Only<br />
18"<br />
5"<br />
3 ¼” x 5 ¼” Mount<strong>in</strong>g Plate Furnished<br />
With Each Type of Shield For Mount<strong>in</strong>g<br />
to a Rough, Nonferrous Surface<br />
11"<br />
24 | SAFETY SHIELDS
HEAVY-DUTY ALUMINUM DRILL PRESS SHIELDS<br />
These cast-alum<strong>in</strong>um drill press shields are furnished with a standard<br />
1¾" bore. The user can bore this shield to a size up to 3½" for<br />
attach<strong>in</strong>g to the quill of a mach<strong>in</strong>e.<br />
This shield is available <strong>in</strong> 2-tier or 3-tier models which provides 3" to 6"<br />
travel of the drill press.<br />
The top of the holder attaches to the quill of the drill press. The shields<br />
are open <strong>in</strong> the back. The bottom section has a clear panel for visibility.<br />
For chang<strong>in</strong>g chucks or drill bits, the 2- or 3-tier section can be swung<br />
forward and upward out of the way. Also available are shields with a side<br />
h<strong>in</strong>ge that sw<strong>in</strong>g to the left side.<br />
3-tier shield shown <strong>in</strong> mach<strong>in</strong><strong>in</strong>g position.<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
DZS-001 3-Tier Front H<strong>in</strong>ge 4½" M<strong>in</strong>; 10½" Max; 6" Stroke; Max Chuck Diameter 2½"<br />
DZS-003 2-Tier Front H<strong>in</strong>ge 4 5 ⁄16" M<strong>in</strong>; 7" Max; 2 11 ⁄16" Stroke; Max Chuck Diameter 2¾"<br />
DZS-004 2-Tier Front H<strong>in</strong>ge 6" M<strong>in</strong>; 10½" Max; 4½" Stroke; Max Chuck Diameter 2¾"<br />
DZS-005 2-Tier Side H<strong>in</strong>ge 6" M<strong>in</strong>; 10½" Max; 4½" Stroke; Max Chuck Diameter 2¾"<br />
DZS-006 3-Tier Side H<strong>in</strong>ge 4½" M<strong>in</strong>; 10½" Max; 6" Stroke; Max Chuck Diameter 2½"<br />
DZS-002 Replacement Polycarbonate W<strong>in</strong>dow<br />
M<strong>in</strong>.<br />
Max.<br />
M<strong>in</strong>. Max.<br />
1¾" diameter;<br />
User to Bore to Size up to 3½"<br />
4½"<br />
7¼"<br />
6"<br />
10½"<br />
10½"<br />
Front h<strong>in</strong>ge shield shown<br />
open for tool change.<br />
Dimensions of Part<br />
No. DZS-001<br />
Dimensions of Part<br />
No. DZS-005<br />
SPRING-LOADED/SELF-EJECTING DRILL PRESS CHUCK KEYS<br />
Spr<strong>in</strong>g-loaded/self-eject<strong>in</strong>g drill press chuck<br />
keys are available to fit a wide variety of chucks.<br />
Visit www.rockfordsystems.com/keys<br />
SAFETY SHIELDS | 25
WARNING<br />
Can cause serious <strong>in</strong>jury<br />
or death if hand or any part<br />
of body is placed <strong>in</strong> this<br />
electrical enclosure.<br />
Turn off ma<strong>in</strong> power and<br />
lock out the disconnect<br />
switch before open<strong>in</strong>g this<br />
electrical enclosure.<br />
DO NOT REMOVE OR COVER THIS SIGN<br />
KST-152<br />
ROTATING MEMBERS AND TOOLS<br />
You are exposed to mov<strong>in</strong>g mach<strong>in</strong>e parts<br />
that can crush, dismember and cause death.<br />
DO NOT operate this mach<strong>in</strong>e without shield(s) <strong>in</strong><br />
place.<br />
NEVER place your f<strong>in</strong>gers, hands or any part of<br />
your body on or near the rotat<strong>in</strong>g parts<br />
of this mach<strong>in</strong>e.<br />
NEVER operate this mach<strong>in</strong>e with loose cloth<strong>in</strong>g,<br />
jewelry, or unrestra<strong>in</strong>ed long hair.<br />
FAILURE to obey will result <strong>in</strong> loss of f<strong>in</strong>gers or<br />
limbs, or could cause death.<br />
Part No. KSC-046<br />
FLYING PARTS<br />
You are exposed to mov<strong>in</strong>g mach<strong>in</strong>e parts<br />
that can cause eye or bodily <strong>in</strong>jury due<br />
to hazardous fly<strong>in</strong>g chips, sparks, and<br />
coolant splash.<br />
NEVER operate this mach<strong>in</strong>ery without proper<br />
FAILURE<br />
eye and body protection.<br />
to obey will result <strong>in</strong> eye <strong>in</strong>jury or<br />
severe personal <strong>in</strong>jury.<br />
ALWAYS wear proper personal protective equipment when operat<strong>in</strong>g this mach<strong>in</strong>e.<br />
This sign does not cover <strong>all</strong> dangers that could happen while operat<strong>in</strong>g this mach<strong>in</strong>e.<br />
Do Not Remove or Cover This Sign – See Back For Mount<strong>in</strong>g Instructions<br />
UNGUARDED LATHE<br />
SAFEGUARDED LATHE<br />
Danger and<br />
Precautions Sign<br />
Emergency-Stop<br />
Button<br />
Chuck Shield<br />
Crosslide-Travel<br />
Shield<br />
Magnetic-Base Shield<br />
Disconnect Switch and<br />
Motor Starter<br />
Electronic Motor<br />
Brake<br />
26 | SAFETY SHIELDS
SAFETY ON LATHES<br />
ELECTRICALLY INTERLOCKED<br />
HEAVY-DUTY LATHE SHIELDS<br />
(PAGES 12-14)<br />
ELECTRICALLY<br />
INTERLOCKED HEAVY-DUTY<br />
CROSSLIDE/CARRIAGE<br />
TRAVEL LATHE SHIELDS<br />
(PAGE 15)<br />
SLIDING LATHE SHIELDS<br />
(PAGE 28)<br />
CROSSLIDE-TRAVEL<br />
LATHE SHIELDS<br />
(PAGE 29)<br />
SMALL STEEL LATHE<br />
CHUCK SHIELDS<br />
(PAGE 30)<br />
LARGE STEEL LATHE<br />
CHUCK SHIELDS<br />
(PAGE 31)<br />
TRANSPARENT LATHE<br />
CHUCK SHIELDS<br />
(PAGE 32)<br />
RIGID-ARM<br />
MAGNETIC-BASE<br />
SHIELDS<br />
(PAGE 50)<br />
FLEXIBLE SPRING-<br />
STEEL ARM SHIELDS<br />
(PAGES 54-57)<br />
UNIVERSAL BALL &<br />
SOCKET SHIELDS<br />
(PAGES 51-53)<br />
ON/OFF MAGNETIC-BASE<br />
SHIELDS<br />
(PAGE 58)<br />
LATHE MOUNTING<br />
BRACKETS<br />
(PAGE 33)<br />
LATHE CHUCK WRENCHES<br />
(PAGES 34-35)<br />
SENSING SAF-START ®<br />
(PAGE 62)<br />
DISCONNECT SWITCHES, MOTOR<br />
STARTERS & ACCESSORIES<br />
(PAGES 63)<br />
SAFETY SHIELDS | 27
SLIDING LATHE SHIELDS<br />
Shield slid <strong>in</strong>to position. Mach<strong>in</strong>e is ready for mach<strong>in</strong><strong>in</strong>g workpiece.<br />
These heavy-duty slid<strong>in</strong>g lathe shields are furnished <strong>in</strong> four different<br />
sizes. They are constructed of high quality, 12-gauge re<strong>in</strong>forced steel<br />
with a polycarbonate w<strong>in</strong>dow. These shields are available for operator<br />
protection on large standard lathes, CNC mach<strong>in</strong>es, and OD gr<strong>in</strong>ders.<br />
The shields are designed to fit lathes with chucks up to 48" <strong>in</strong> diameter.<br />
Four adjustable flanged mount<strong>in</strong>g posts are provided for easy mount<strong>in</strong>g.<br />
These posts are used to securely mount the shield’s b<strong>all</strong>-bear<strong>in</strong>g<br />
carriage to the top of the headstock, as illustrated (mount<strong>in</strong>g hardware<br />
not <strong>in</strong>cluded). This means the posts can be attached without <strong>in</strong>terfer<strong>in</strong>g<br />
with any part of the equipment housed with<strong>in</strong> the headstock.<br />
These slid<strong>in</strong>g shields slide out-of-the-way over the headstock, <strong>all</strong>ow<strong>in</strong>g<br />
the operator access to the po<strong>in</strong>t of operation for load<strong>in</strong>g and unload<strong>in</strong>g<br />
workpieces, chang<strong>in</strong>g tool<strong>in</strong>g, chang<strong>in</strong>g chucks, remov<strong>in</strong>g swarf, etc.<br />
Each shield has approximately 22" of travel.<br />
When order<strong>in</strong>g these slid<strong>in</strong>g shields, check lathe dimensions and<br />
reference draw<strong>in</strong>gs. Special sizes are available on request.<br />
DIMENSIONS<br />
W<strong>in</strong>dow<br />
12" Max. Can Be<br />
Cut to Length as<br />
Required<br />
Adjustable From<br />
2"–12"<br />
15¾" Ctrs.<br />
B<br />
A<br />
20"<br />
Order<strong>in</strong>g Information<br />
PART NO. A B CHUCK DIAMETER REPLACEMENT POLYCARBONATE WINDOW<br />
MAJ-700 26" 21" 28" MAW-001<br />
MAJ-800 27¼" 23" 32" MAW-002<br />
MAJ-100 29½" 27" 40" MAW-003<br />
MAJ-120 33¼" 30 ¾ " 48" MAW-004<br />
28 | SAFETY SHIELDS
CROSSLIDE-TRAVEL LATHE SHIELDS<br />
These lathe shields mount on and travel with the crosslide for protection<br />
when mach<strong>in</strong><strong>in</strong>g long workpieces. The 18-gauge re<strong>in</strong>forced steel<br />
structure provides protection from fly<strong>in</strong>g chips and coolant. The highimpact-resistant<br />
polycarbonate w<strong>in</strong>dow permits visibility <strong>in</strong>to the po<strong>in</strong>t<br />
of operation. The front portion of the shield h<strong>in</strong>ges up for access. These<br />
shields are ideal for lathes with long beds. Special sizes are available<br />
on request.<br />
Mount<strong>in</strong>g Rod<br />
H<strong>in</strong>ges up for<br />
access.<br />
Support Rod<br />
LXS-650<br />
Mount<strong>in</strong>g<br />
Bracket<br />
Shield travels with the crosslide for operator protection.<br />
MOUNTING BRACKETS ARE SOLD<br />
SEPARATELY—SEE PAGE 33<br />
DIMENSIONS<br />
A<br />
B<br />
C<br />
D<br />
HINGE<br />
W<strong>in</strong>dow<br />
4"<br />
E<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C D E<br />
TXS-100 17" 8" 10" 12" 12"<br />
TXS-200 23" 11" 12" 14 ½ " 13 ¾ "<br />
TXW-000 Replacement Polycarbonate W<strong>in</strong>dow<br />
SAFETY SHIELDS | 29
SMALL STEEL LATHE CHUCK SHIELDS<br />
These sturdily constructed steel chuck shields are fabricated of<br />
18-gauge steel with re<strong>in</strong>forced sides and can be used on sm<strong>all</strong>er lathes<br />
that have up to 18½" diameter chucks.<br />
Each shield is furnished with a 1" x 13" mount<strong>in</strong>g rod which can be cut<br />
to length if required. This mount<strong>in</strong>g rod is fastened to the headstock<br />
of the lathe. The mount<strong>in</strong>g rod is also used to h<strong>in</strong>ge the entire shield.<br />
The shield can be lifted and swung up for quick and easy access to the<br />
chuck and the part be<strong>in</strong>g mach<strong>in</strong>ed. This shield <strong>in</strong>cludes a high-impactresistant<br />
polycarbonate w<strong>in</strong>dow which permits visibility <strong>in</strong>to the po<strong>in</strong>t of<br />
operation. Various types of mount<strong>in</strong>g brackets are available and are sold<br />
separately—see page 33.<br />
If shields for larger lathes are required, please see the next page.<br />
Shield <strong>in</strong> position. Mach<strong>in</strong>e is ready for mach<strong>in</strong><strong>in</strong>g workpiece.<br />
MOUNTING BRACKETS ARE SOLD<br />
SEPARATELY—SEE PAGE 33<br />
DIMENSIONS<br />
Mount<strong>in</strong>g<br />
Bracket<br />
1-3/8" Bore<br />
W<strong>in</strong>dow<br />
Four ¼-20<br />
Setscrews<br />
1"<br />
13" Rod<br />
8"<br />
7"<br />
D<br />
Order<strong>in</strong>g Information<br />
PART NO. A B C D REPLACEMENT POLYCARBONATE WINDOW<br />
TPS-300 12" 7½" 11" 4¾" TPW-003<br />
TPS-400 15½" 9¼" 14½" 6¼" TPW-004<br />
TPS-500 19¼" 11½" 18¼" 8" TPW-005<br />
30 | SAFETY SHIELDS
LARGE STEEL LATHE CHUCK SHIELDS<br />
These fabricated 18-gauge steel chuck shields with re<strong>in</strong>forced sides can<br />
be used on large lathes that have chucks up to 47" <strong>in</strong> diameter. They are<br />
double h<strong>in</strong>ged for access to the chuck, workpiece, and tool. The front<br />
h<strong>in</strong>ged portion can be swung up for workpiece changes, and the entire<br />
shield can be h<strong>in</strong>ged back for chang<strong>in</strong>g chucks.<br />
Each shield is furnished with a mount<strong>in</strong>g rod, plate and support bar for<br />
mount<strong>in</strong>g the shield to the face of the headstock. The rear mount<strong>in</strong>g<br />
bracket h<strong>in</strong>ges the entire shield, and the side mount<strong>in</strong>g bracket supports<br />
the shield <strong>in</strong> its normal operat<strong>in</strong>g position.<br />
The h<strong>in</strong>ged portion can sw<strong>in</strong>g up for workpiece changes.<br />
H<strong>in</strong>ge<br />
Support Bar<br />
A<br />
13-3/4"<br />
Mount<strong>in</strong>g Rod and<br />
Plate<br />
Order<strong>in</strong>g Information<br />
PART NO. DIMENSION A<br />
TPS-600 24"<br />
TPS-800 32"<br />
TPS-100 40"<br />
TPS-120 47½"<br />
SAFETY SHIELDS | 31
TRANSPARENT LATHE CHUCK SHIELDS<br />
These quality-constructed lathe chuck shields have a semicircular shape<br />
made from high-impact-resistant transparent polycarbonate. The shields<br />
themselves are attached to a 1" z<strong>in</strong>c-plated extension tube. This tube is<br />
<strong>in</strong>serted <strong>in</strong>to <strong>one</strong> of the mount<strong>in</strong>g brackets described on the next page.<br />
The shield assembly does not <strong>in</strong>clude the mount<strong>in</strong>g bracket.<br />
The semicircular shield covers half the circumference of the lathe chuck<br />
because it is mounted an equal distance from the chuck center.<br />
Access to the chuck and workpiece is quick and easy. The shield is lifted<br />
up and out of the way for the operator.<br />
The shield size depends on the center height of the lathe and the<br />
diameter of the chuck. On lathes with a center height up to 7", there is a<br />
sm<strong>all</strong> variation <strong>in</strong> diameter between the 3- and 4-jaw chucks; therefore,<br />
<strong>one</strong> size shield will do the job.<br />
On lathes with a center height <strong>in</strong> excess of 7", there is a greater variation<br />
<strong>in</strong> diameter between the chucks; therefore, it is advisable to use two<br />
different size shields to provide adequate protection.<br />
3-jaw chuck lathe with shield held <strong>in</strong> position by bracket Type B.<br />
DIMENSIONS<br />
Type B Bracket<br />
A Max. Dia.<br />
High-Impact-Resistant<br />
Clear Polycarbonate<br />
Sw<strong>in</strong>gs up for<br />
Access<br />
B<br />
C<br />
Type B2 Bracket<br />
D<br />
1"<br />
Rod<br />
E<br />
Optional Mount<strong>in</strong>g Bracket With<br />
Electrical Safety Interlock<br />
Order<strong>in</strong>g Information<br />
Support Assembly<br />
PART NO. A B C D E REPLACEMENT SHIELD<br />
LXS-300 10" 12" 7" 6 ½ " 10" LXS-301<br />
LXS-400 14" 15 ½ " 8 ½ " 7¾" 13" LXS-401<br />
LXS-500 18" 19 ½ " 10 ½ " 7¾" 13" LXS-501<br />
LXS-600 23 ½ " 24¼" 12¾" 7¾" 13" LXS-601<br />
LXS-700 26" 28" 14¾" 7¾" 13" LXS-701<br />
MOUNTING BRACKETS ARE SOLD<br />
SEPARATELY—SEE FOLLOWING PAGE.<br />
32 | SAFETY SHIELDS
LATHE MOUNTING BRACKETS<br />
The z<strong>in</strong>c-plated extension tube, to which the polycarbonate and steel<br />
shields are fastened, is mounted to the headstock of the lathe by a<br />
mount<strong>in</strong>g bracket.<br />
There are two pr<strong>in</strong>cipal types of mount<strong>in</strong>g brackets available. Type A is<br />
used for mount<strong>in</strong>g to the top or the side of the headstock. Type B is used<br />
for mount<strong>in</strong>g to the <strong>in</strong>side face of the headstock.<br />
For difficult mount<strong>in</strong>g conditions, bracket Type A1 may be used. This<br />
bracket <strong>in</strong>corporates a telescopic height adjustment (up to 2") and can<br />
be swiveled up to an angle of 90° as required.<br />
BRACKET TYPE A<br />
PART NO. LXS-650<br />
For mount<strong>in</strong>g to the top or side of the<br />
headstock.<br />
Bracket Type B2 is a two-socket mount<strong>in</strong>g. It can be fastened to the face<br />
of the headstock where shields with different diameters may be used. It<br />
accommodates 3-jaw and 4-jaw chucks. The <strong>in</strong>ner socket is used for the<br />
3-jaw chuck shield. When chang<strong>in</strong>g over to a 4-jaw chuck, the shield is<br />
removed from the <strong>in</strong>ner socket and replaced by a larger diameter shield<br />
<strong>in</strong>serted <strong>in</strong>to the outer socket. This accommodates the 4-jaw chuck.<br />
Full dimensions, show<strong>in</strong>g the transparent shield <strong>in</strong> relation to the chuck,<br />
are illustrated on page 32.<br />
The sm<strong>all</strong> steel (page 30) and transparent (page 32) lathe chuck shields<br />
can be <strong>in</strong>terlocked to the motor starter. When the chuck shield is lifted<br />
up, the contact on the switch is opened. This causes the mach<strong>in</strong>e to<br />
stop. The switch is attached to a heavy-duty mount<strong>in</strong>g bracket.<br />
Part number FKT-781 <strong>in</strong>terlock<strong>in</strong>g bracket assembly shown below<br />
<strong>in</strong>cludes mount<strong>in</strong>g bracket LXS-652.<br />
PART NO. FKT-781 INTERLOCKING BRACKET<br />
Assembly shown with rod of shield.<br />
BRACKET TYPE A1<br />
PART NO. LXS-651<br />
For extended mount<strong>in</strong>g to the top or<br />
side of the headstock.<br />
BRACKET TYPE B2<br />
PART NO. LXS-653<br />
For mount<strong>in</strong>g to the face of the<br />
headstock when two different sized<br />
shields are used.<br />
BRACKET TYPE B<br />
PART NO. LXS-652<br />
For mount<strong>in</strong>g to the face of the headstock.<br />
Rod of Shield<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contact Arrangement..........2 NO and 2 NC<br />
Operat<strong>in</strong>g Temperature........-13º to 176º F (-25º to 80º C)<br />
Switch<strong>in</strong>g Ability..................3 A @ 230 V AC,<br />
0.27 A @ 230 V DC<br />
Actuat<strong>in</strong>g Directions............4<br />
Conduit Adapter M20 to ½"<br />
SAFETY SHIELDS | 33
STANDARD SIZE LATHE CHUCK WRENCHES<br />
One of the most common accidents on lathes or other mach<strong>in</strong>es <strong>in</strong>volves<br />
a chuck wrench or key which is thrown from the chuck. This happens<br />
when some<strong>one</strong> forgets to remove the wrench from the chuck before the<br />
mach<strong>in</strong>e is turned on.<br />
The spr<strong>in</strong>g-loaded or self-eject<strong>in</strong>g chuck wrenches can be used on<br />
lathes or other mach<strong>in</strong>es equipped with manu<strong>all</strong>y adjusted chucks. The<br />
spr<strong>in</strong>g-loaded sleeve ejects the wrench from the chuck after each use.<br />
These wrenches are eng<strong>in</strong>eered and designed to provide proper loads<br />
for self-removal of the wrench weight.<br />
Bar<br />
Diameter<br />
Adjust<strong>in</strong>g the chuck us<strong>in</strong>g a spr<strong>in</strong>g-loaded chuck wrench.<br />
ALL PARTS BLACK OXIDE COATED<br />
5/8" Engagement Length<br />
Over<strong>all</strong><br />
Diameter<br />
Handle Length<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
NOMINAL<br />
SIZE<br />
ACTUAL<br />
SIZE<br />
BAR<br />
DIAMETER<br />
OVERALL<br />
DIAMETER<br />
HANDLE<br />
LENGTH<br />
CW-SM0281-S 9<br />
⁄32" SQ .271" ¾" 1.050" 5½"<br />
CW-SM0312-S 5<br />
⁄16" SQ .303" ¾" 1.050" 5½"<br />
CW-SM0375-S 3<br />
⁄8" SQ .365" ¾" 1.050" 5½"<br />
CW-SM0438-S 7<br />
⁄16" SQ .427" ¾" 1.050" 5½"<br />
CW-SM0500-S ½" SQ .490" ¾" 1.050" 5½"<br />
CW-SM0563-S 9<br />
⁄16" SQ .552"<br />
15<br />
⁄16" 1.315" 9½"<br />
CW-SM0625-S 5<br />
⁄8" SQ .615"<br />
15<br />
⁄16" 1.315" 9½"<br />
CW-SM0688-S<br />
11<br />
⁄16" SQ .678"<br />
15<br />
⁄16" 1.315" 9½"<br />
CW-SM0750-S ¾" SQ .740"<br />
15<br />
⁄16" 1.315" 9½"<br />
CW-HM0500-S ½" HEX .490" ¾" 1.050" 5½"<br />
CW-HM0625-S 5<br />
⁄8" HEX .615" ¾" 1.050" 9½"<br />
CW-HM0750-S ¾" HEX .740"<br />
15<br />
⁄16" 1.315" 9½"<br />
Safety Yellow V<strong>in</strong>yl-<br />
Coated Handle<br />
Spr<strong>in</strong>g-Loaded Sleeve Fully<br />
Encloses Spr<strong>in</strong>g (Sleeve<br />
Pushed Up for Photo)<br />
8" Body<br />
34 | SAFETY SHIELDS
LONGER LATHE CHUCK WRENCHES<br />
Thumb Screw<br />
18" Slid<strong>in</strong>g Handle<br />
Spr<strong>in</strong>g-Loaded Sleeve Fully<br />
Encloses Spr<strong>in</strong>g<br />
18" Slid<strong>in</strong>g Handle<br />
Adjust<strong>in</strong>g the chuck us<strong>in</strong>g a long-handled spr<strong>in</strong>g-loaded chuck wrench.<br />
ALL PARTS BLACK OXIDE COATED<br />
10" Body<br />
The 18" handle can be slid <strong>in</strong>to position and locked <strong>in</strong> place with the thumb screw.<br />
Bar<br />
Diameter<br />
5/8" Engagement Length<br />
Over<strong>all</strong><br />
Diameter<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
NOMINAL<br />
SIZE<br />
ACTUAL<br />
SIZE<br />
BAR<br />
DIAMETER<br />
OVERALL<br />
DIAMETER<br />
CW-SM0281-L 9<br />
⁄32" SQ .271" ¾" 1.050"<br />
CW-SM0312-L 5<br />
⁄16" SQ .303" ¾" 1.050"<br />
CW-SM0375-L 3<br />
⁄8" SQ .365" ¾" 1.050"<br />
CW-SM0438-L 7<br />
⁄16" SQ .427" ¾" 1.050"<br />
CW-SM0500-L ½" SQ .490" ¾" 1.050"<br />
CW-SM0563-L 9<br />
⁄16" SQ .552"<br />
15<br />
⁄16" 1.315"<br />
CW-SM0625-L 5<br />
⁄8" SQ .615"<br />
15<br />
⁄16" 1.315"<br />
CW-SM0688-L<br />
11<br />
⁄16" SQ .678"<br />
15<br />
⁄16" 1.315"<br />
CW-SM0750-L ¾" SQ .740"<br />
15<br />
⁄16" 1.315"<br />
CW-HM0500-L ½" HEX .490" ¾" 1.050"<br />
CW-HM0625-L 5<br />
⁄8" HEX .615" ¾" 1.050"<br />
CW-HM0750-L ¾" HEX .740"<br />
15<br />
⁄16" 1.315"<br />
SAFETY SHIELDS | 35
WARNING<br />
KST-152<br />
DO NOT REMOVE OR COVER THI SIGN<br />
UNGUARDED MILLING MACHINE<br />
SAFEGUARDED MILLING MACHINE<br />
Belt Cover<br />
Remote Station With<br />
Emergency Stop<br />
Danger Sign<br />
Shield<br />
Disconnect Switch<br />
Motor Starter<br />
Disconnect Switch and<br />
Motor Starter<br />
Can cause serious <strong>in</strong>jury<br />
or death if hand or any part<br />
of body is placed <strong>in</strong> this<br />
electrical enclosure.<br />
Turn o f ma<strong>in</strong> power and<br />
lock ou the disco nect<br />
switch before open<strong>in</strong>g this<br />
electrical enclosure.<br />
Precautions Sign<br />
36 | SAFETY SHIELDS
SAFETY ON MILLING MACHINES<br />
ELECTRICALLY INTERLOCKED HEAVY-DUTY<br />
MILLING MACHINE SHIELDS (PAGES 16-18)<br />
BRIDGEPORT MILLING<br />
MACHINE SHIELDS—FRONT<br />
(PAGE 38)<br />
BRIDGEPORT MILLING MACHINE<br />
SHIELDS—REAR (PAGE 39)<br />
SLIDE AND SWING-ASIDE SHIELDS<br />
(PAGES 40-41)<br />
RIGID-ARM MAGNETIC-<br />
BASE SHIELDS<br />
(PAGE 50)<br />
FLEXIBLE SPRING-<br />
STEEL ARM SHIELDS<br />
(PAGES 54-57)<br />
UNIVERSAL BALL &<br />
SOCKET SHIELDS<br />
(PAGES 51-53)<br />
ON/OFF MAGNETIC-<br />
BASE SHIELDS<br />
(PAGE 58)<br />
ADJUSTABLE SLIDE SHIELDS<br />
(PAGE 49)<br />
MILLING MACHINE<br />
BELT COVERS<br />
(PAGE 42)<br />
DRAW BAR COVER<br />
(SEE ROCKFORDSYSTEMS.COM)<br />
ELECTRICAL<br />
INTERLOCK<br />
ASSEMBLY<br />
(PAGE 42)<br />
BRIDGEPORT MILLING<br />
MACHINE CONTROLS<br />
(PAGE 39)<br />
SENSING<br />
SAF-START ®<br />
(PAGE 62)<br />
DISCONNECT SWITCHES,<br />
MOTOR STARTERS &<br />
ACCESSORIES<br />
(PAGES 63)<br />
SAFETY SHIELDS | 37
CHIP SHIELDS FOR BRIDGEPORT MILLING MACHINES<br />
These speci<strong>all</strong>y designed, quality-constructed shields are ideal for<br />
Bridgeport mill<strong>in</strong>g mach<strong>in</strong>es. They place a barrier between fly<strong>in</strong>g chips<br />
(swarf), sparks, coolant from the mach<strong>in</strong>e, and the operators or other<br />
employees <strong>in</strong> the area. They can be easily moved <strong>in</strong> or out of position to<br />
provide quick tool and part changes.<br />
These shields are quick and easy to <strong>in</strong>st<strong>all</strong>. They attach directly to exist<strong>in</strong>g<br />
head mach<strong>in</strong>e bolts so no additional drill<strong>in</strong>g or tapp<strong>in</strong>g is required.<br />
These shields are constructed of high-impact-resistant polycarbonate<br />
material. Attached at the bottom of each section of the shield is durable,<br />
flexible neoprene material to keep fly<strong>in</strong>g chips and swarf conta<strong>in</strong>ed as<br />
the bed moves up and down.<br />
FRONT SHIELDS<br />
The front shield is mounted on a heavy-duty universal steel arm which<br />
is used to sw<strong>in</strong>g it back <strong>in</strong>to the exact position it was before tool or<br />
workpiece changes. The arm is 29" long and has an adjust<strong>in</strong>g knob<br />
for rais<strong>in</strong>g and lower<strong>in</strong>g the shield. The shield itself can also be used to<br />
hold a pr<strong>in</strong>t.<br />
9" 9¼"<br />
9"<br />
KYL-019 front chip shield.<br />
5¼"<br />
4"<br />
19"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
KYL-019 9¼" H x 19" W Front Shield With Two 45° Bends<br />
KYL-065 9¼" x 19" Front Replacement Shield Only<br />
9"<br />
9¼"<br />
6"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
5¼"<br />
KYL-059<br />
9¼" H x 15" W Front Shield With One 45° Bend and One 90º Bend<br />
4"<br />
15"<br />
38 | SAFETY SHIELDS
CHIP SHIELDS FOR BRIDGEPORT MILLING MACHINES (CONTINUED)<br />
REAR SHIELD<br />
A rear shield is also available to protect the back area of the mill<strong>in</strong>g<br />
mach<strong>in</strong>e. This shield is easy to <strong>in</strong>st<strong>all</strong> and mounts directly onto the<br />
mach<strong>in</strong>e frame with a setscrew to hold it <strong>in</strong> place.<br />
6"<br />
9"<br />
6"<br />
3¼"<br />
4"<br />
18" Rear shield only (front shield not shown).<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
KYL-020 7¼" H x 18" W Rear Shield With Two 45° Bends<br />
KYL-065 7¼" x 18" Rear Replacement Shield Only<br />
BRIDGEPORT VERTICAL MILLING MACHINE CONTROLS<br />
This control is designed for Bridgeport vertical mill<strong>in</strong>g mach<strong>in</strong>es that have a table motor. Each mill<strong>in</strong>g mach<strong>in</strong>e control is housed <strong>in</strong> a NEMA 12<br />
enclosure that <strong>in</strong>cludes a disconnect switch, revers<strong>in</strong>g magnetic ma<strong>in</strong> drive motor starter, a control relay for the table motor, and a 100 VA transformer<br />
that is generic<strong>all</strong>y numbered and wired to term<strong>in</strong>als. A remote station provides the operator controls consist<strong>in</strong>g of a self-latch<strong>in</strong>g red emergency-stop<br />
palm button, an illum<strong>in</strong>ated green table motor reset push button, and a ma<strong>in</strong> motor reverse/off/forward selector switch. These Bridgeport vertical<br />
mill<strong>in</strong>g mach<strong>in</strong>e controls are available for mach<strong>in</strong>es with 230 or 460 V AC and 1 to 3 HP.<br />
17"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
BVM-230-1 For 1 HP, 230-V AC Mach<strong>in</strong>es<br />
BVM-230-15 For 1.5 HP, 230-V AC Mach<strong>in</strong>es<br />
BVM-230-2 For 2 HP, 230-V AC Mach<strong>in</strong>es<br />
BVM-230-3 For 3 HP, 230-V AC Mach<strong>in</strong>es<br />
BVM-460-1 For 1 HP, 460-V AC Mach<strong>in</strong>es<br />
BVM-460-15 For 1.5 HP, 460-V AC Mach<strong>in</strong>es<br />
BVM-460-2 For 2 HP, 460-V AC Mach<strong>in</strong>es<br />
BVM-460-3 For 3 HP, 460-V AC Mach<strong>in</strong>es<br />
3½"<br />
10"<br />
8¼"<br />
SAFETY SHIELDS | 39
SLIDE AND SWING-ASIDE SHIELDS<br />
Part No. SSA-000 with door closed.<br />
INTRODUCTION<br />
These shields protect operators when mach<strong>in</strong><strong>in</strong>g either sm<strong>all</strong> workpieces<br />
or large cast<strong>in</strong>gs that sometimes overhang the mill<strong>in</strong>g mach<strong>in</strong>e table. At<br />
the same time, they can provide immediate and complete access to the<br />
workpiece or cast<strong>in</strong>g be<strong>in</strong>g mach<strong>in</strong>ed by slid<strong>in</strong>g or sw<strong>in</strong>g<strong>in</strong>g aside the<br />
door(s), as illustrated.<br />
THE SHIELD<br />
The transparent portion of the shield is constructed of impact-resistant<br />
polycarbonate. The frame of the shield is made of 1" x 2" extruded<br />
alum<strong>in</strong>um. The shield has front slid<strong>in</strong>g panel(s) and two side fixed<br />
panels. The side panels are attached at both ends of the table.<br />
These assemblies can be mounted or removed <strong>in</strong> a matter of m<strong>in</strong>utes by<br />
us<strong>in</strong>g two lock<strong>in</strong>g T-bolts with nuts.<br />
Each of the front panels can slide to the right or left and sw<strong>in</strong>g aside on<br />
their own axis out of the way (see draw<strong>in</strong>gs).<br />
The advantage of the slide and sw<strong>in</strong>g-aside movement is that you can<br />
obta<strong>in</strong> immediate access to the whole length of the table for load<strong>in</strong>g and<br />
unload<strong>in</strong>g large workpieces. Although the panels slide aside, they will not<br />
take up any more room than the actual length of the table itself, because<br />
the slid<strong>in</strong>g and sw<strong>in</strong>g-aside action takes place <strong>in</strong> <strong>one</strong> movement by<br />
simply lift<strong>in</strong>g a latch.<br />
Part No. SSA-000 with door open.<br />
THE SHIELD CONSTRUCTION<br />
The par<strong>all</strong>el slid<strong>in</strong>g bars enable the shield to be adjusted to the distance<br />
required from the front of the table to the shield. The adjustment on<br />
these bars caters to cast<strong>in</strong>gs or large comp<strong>one</strong>nts which overhang<br />
the table. This adjustment is achieved by loosen<strong>in</strong>g the two socket<br />
cap screws at either end of the table. This permits the complete shield<br />
assembly to be moved backwards or forwards to the position required.<br />
A safety latch is provided where the two front panels or the front and side<br />
panels come together which holds the panels <strong>in</strong> place. The latch has to<br />
be released manu<strong>all</strong>y prior to open<strong>in</strong>g the panels.<br />
The unique construction <strong>all</strong>ows the front panels to<br />
slide and sw<strong>in</strong>g aside expos<strong>in</strong>g the entire table.<br />
40 | SAFETY SHIELDS
SLIDE AND SWING-ASIDE SHIELDS (CONTINUED)<br />
There are three sizes of shields available which cover table sizes up to a<br />
maximum length of 76". On bed-type mill<strong>in</strong>g mach<strong>in</strong>es, where the table<br />
length is well <strong>in</strong> excess of 76", it is still possible to use the SSA-300<br />
shield. In many <strong>in</strong>stances, only part of the maximum length of the table<br />
is used. If this is the case, the SSA-300 shield would be suitable as long<br />
as the longitud<strong>in</strong>al traverse used does not exceed the maximum length<br />
of the shield. For a table length of less than 36", the SSA-000 shield<br />
may be used.<br />
D<br />
These shields have been generously designed to give protection to the<br />
operator; this will be noted <strong>in</strong> dimension H, which gives the height of the<br />
shields. Special height panels are available upon request.<br />
The standard shield does not provide protection on the back of the table.<br />
The rear shields (below) are used to m<strong>in</strong>imize coolant splash and fly<strong>in</strong>g<br />
chips that may fly out of the back of the mach<strong>in</strong>e.<br />
L<br />
H<br />
End elevation show<strong>in</strong>g<br />
shield <strong>in</strong> maximum<br />
forward position.<br />
Table<br />
A<br />
Par<strong>all</strong>el<br />
Slid<strong>in</strong>g Bar<br />
Table<br />
Front view with slid<strong>in</strong>g shields closed<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
L–LENGTH OF<br />
TABLE WORK SURFACE<br />
H<br />
HEIGHT<br />
*Has <strong>one</strong> slid<strong>in</strong>g and sw<strong>in</strong>g front door<br />
**Has two slid<strong>in</strong>g and sw<strong>in</strong>g front panels.<br />
D<br />
DEPTH<br />
A<br />
MAXIMUM ADJUSTMENT<br />
SSA-000* 24"-36" 20" 20" 13"<br />
SSA-200** 36"-56" 20" 20" 13"<br />
SSA-300** 56"-76" 20" 20" 13"<br />
REAR SHIELD ASSEMBLIES<br />
These shield assemblies can be used to protect personnel from swarf<br />
and chips at the rear of the table on both sides of the mach<strong>in</strong>e column.<br />
They can be used on mill<strong>in</strong>g mach<strong>in</strong>es or other equipment that require<br />
these types of shields. The two ¼"-thick polycarbonate panels are<br />
mounted to the frame of the mach<strong>in</strong>e with mounts (see photo). Each<br />
panel has extruded alum<strong>in</strong>um fram<strong>in</strong>g to hold the polycarbonate <strong>in</strong><br />
place. The mounts are also attached to this frame. The assembly is<br />
available <strong>in</strong> two sizes and <strong>in</strong>cludes two shields, <strong>one</strong> set of mounts, and<br />
connectors. Special sizes are available upon request.<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
SSA-420 24" x 24" Rear Shields With Mounts (Set)<br />
SSA-430 24" x 36" Rear Shields With Mounts (Set)<br />
Rear shield assembly on left side<br />
of mach<strong>in</strong>e column.<br />
SAFETY SHIELDS | 41
MILLING MACHINE BELT COVER<br />
OSHA requires under 29 CFR 1910.219 that <strong>all</strong> mechanical powertransmission<br />
apparatuses on mach<strong>in</strong>ery that create a hazard be covered<br />
if below a 7-foot level from the floor or work<strong>in</strong>g platform. The sheaves<br />
and belts on mill<strong>in</strong>g mach<strong>in</strong>es must be covered to meet this requirement.<br />
These unique patented belt covers are made of durable cast alum<strong>in</strong>um.<br />
The h<strong>in</strong>ged covers are sold <strong>in</strong> pairs for the right and left sides and are<br />
permanently attached to the mach<strong>in</strong>e. Sp<strong>in</strong>dle speed changes are d<strong>one</strong><br />
quickly and efficiently by simply pull<strong>in</strong>g down the belt cover.<br />
This belt cover is made for Bridgeport model J.<br />
Order<strong>in</strong>g Information<br />
Part No. Description<br />
KYL-021J Model J Belt Cover With H<strong>in</strong>ges—11" W x 2 ¾ " H x 3 ⁄8" Thick<br />
Cover closed.<br />
Cover open on model J Bridgeport mill<strong>in</strong>g mach<strong>in</strong>e.<br />
ELECTRICAL INTERLOCK ASSEMBLY<br />
MAGNETIC SAFETY SWITCH AND BRACKET ASSEMBLY<br />
PART NO. FKT-876<br />
Additional operator safety can be provided by the <strong>in</strong>st<strong>all</strong>ation<br />
of this magnetic safety switch and bracket assembly.<br />
INTERLOCK SWITCH SPECIFICATIONS<br />
Contacts.............................1 NO<br />
Operat<strong>in</strong>g Temperature........14º to 149º F (-10º to 65º C)<br />
Rated Current.....................2 A, fuse extern<strong>all</strong>y 1.6 A quick act<strong>in</strong>g<br />
Rated Voltage.....................250 V AC<br />
Cable.................................13 ft of prewired 2-conductor flexible cable<br />
(Mounted on <strong>in</strong>side of<br />
front panels.)<br />
42 | SAFETY SHIELDS
UNGUARDED GRINDER<br />
SAFEGUARDED GRINDER<br />
Shields<br />
Gr<strong>in</strong>der Gauge—Used To<br />
Measure Tongue and Work<br />
Rest Open<strong>in</strong>gs<br />
Danger Sign<br />
Disconnect, Motor Starter, and<br />
Emergency Stop<br />
SAFETY ON BENCH GRINDERS<br />
RIGID-ARM MAGNETIC-<br />
BASE SHIELDS<br />
(PAGE 50)<br />
ELECTRICALLY INTERLOCKED<br />
HEAVY-DUTY BENCH<br />
BUFFER SHIELDS<br />
(PAGE 19)<br />
DOUBLE-WHEEL<br />
FLEXIBLE-ARM SHIELDS<br />
(PAGE 44)<br />
SINGLE-WHEEL<br />
FLEXIBLE-ARM SHIELDS<br />
(PAGE 44)<br />
STANDARD-MOUNT<br />
GRINDER SHIELDS<br />
(PAGE 45)<br />
UNIVERSAL BALL &<br />
SOCKET SHIELDS<br />
(PAGES 51-53)<br />
HEAVY-DUTY SINGLE<br />
BUFFER SHIELDS<br />
(PAGE 45)<br />
BENCH GRINDER<br />
SAFETY GAUGE<br />
(PAGE 46)<br />
SENSING<br />
SAF-START ®<br />
(PAGE 62)<br />
DISCONNECT SWITCHES,<br />
MOTOR STARTERS,<br />
AND ACCESSORIES<br />
(PAGES 63)<br />
SAFETY SHIELDS | 43
DOUBLE- AND SINGLE-WHEEL FLEXIBLE-ARM GRINDER SHIELDS<br />
Double-Wheel Gr<strong>in</strong>der Shield<br />
Bench gr<strong>in</strong>der shields are designed to m<strong>in</strong>imize the debris and hazards<br />
associated with bench gr<strong>in</strong>ders and buffers. Both double- and s<strong>in</strong>glewheel<br />
gr<strong>in</strong>der shields are available.<br />
The double-wheel gr<strong>in</strong>der shield provides protection for both wheels of<br />
the gr<strong>in</strong>der with <strong>one</strong> cont<strong>in</strong>uous shield. The durable shield is made of<br />
clear, 3/16"-thick polycarbonate and measures 18" x 6". A special shield<br />
bracket adds stability to the top of the shield.<br />
The s<strong>in</strong>gle-wheel gr<strong>in</strong>der shield is made of clear, 3/16"-thick<br />
polycarbonate and measures 6" x 6". This sturdy, impact-resistant shield<br />
is designed for use when a s<strong>in</strong>gle wheel needs safeguard<strong>in</strong>g.<br />
The flexible spr<strong>in</strong>g-steel arms come <strong>in</strong> three lengths: 12", 18" and 24".<br />
MOUNTING OPTIONS<br />
There are two mount<strong>in</strong>g options for the double- and s<strong>in</strong>gle-wheel gr<strong>in</strong>der<br />
shields.<br />
• Direct-mount base—attaches directly to the gr<strong>in</strong>der table or<br />
pedestal<br />
• Magnetic base—3" diameter magnet<br />
If an adequate flat, smooth, ferrous mount<strong>in</strong>g surface is not available,<br />
an optional steel mount<strong>in</strong>g plate is available that can be permanently<br />
attached to the mach<strong>in</strong>e to hold the magnetic base.<br />
DOUBLE-WHEEL GRINDER SHIELDS—<br />
18" X 6" FLAT SHIELD<br />
PART NO.<br />
KYL-183<br />
KYL-184<br />
KYL-185<br />
KYL-186<br />
KYL-187<br />
KYL-188<br />
KYL-177<br />
FKT-1072<br />
FKT-1106<br />
DESCRIPTION<br />
12" Direct-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
18" Direct-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
24" Direct-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
12" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
18" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
24" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
18" x 6" Flat Replacement Shield Only<br />
Flat Mount<strong>in</strong>g Bracket for 18" x 6" Shield<br />
3½" x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate for Magnetic Base<br />
SINGLE-WHEEL GRINDER SHIELDS—<br />
6" X 6" FLAT SHIELD<br />
PART NO.<br />
KYL-178<br />
KYL-179<br />
KYL-180<br />
KYL-181<br />
KYL-182<br />
KYL-176<br />
FKT-1106<br />
DESCRIPTION<br />
18" Direct-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
24" Direct-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
12" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
18" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
24" Magnetic-Mount Flexible Spr<strong>in</strong>g-Steel Arm<br />
6" x 6" Flat Replacement Shield Only<br />
3½" x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate for Magnetic Base<br />
S<strong>in</strong>gle-Wheel Gr<strong>in</strong>der Shield<br />
Part No. FKT-1106<br />
Steel Mount<strong>in</strong>g Plate<br />
44 | SAFETY SHIELDS
STANDARD-MOUNT GRINDER SHIELDS<br />
These gr<strong>in</strong>der shields are available <strong>in</strong> various sizes for protection from<br />
the swarf of bench or pedestal gr<strong>in</strong>ders. The frames are constructed of<br />
re<strong>in</strong>forced fiber nylon or heavy cast alum<strong>in</strong>um. Each shield is furnished<br />
with a threaded support rod. The transparent shield is high-impactresistant<br />
polycarbonate to m<strong>in</strong>imize scratch<strong>in</strong>g and provide durability.<br />
Order<strong>in</strong>g Information<br />
PART NO. DESCRIPTION (EACH SOLD SEPARATELY) REPLACEMENT POLYCARBONATE WINDOW<br />
GWG-201 6 ¼ " H x 5 ¼ " W Shield—Nylon Frame GWW-001<br />
GWG-202 8 ½ " H x 6" W Shield—Nylon Frame GWW-002<br />
GWG-203 12 ¾ " H x 12" W Shield—Alum<strong>in</strong>um Frame GWW-003<br />
HEAVY-DUTY SINGLE BUFFER SHIELDS<br />
These buffer shields are available <strong>in</strong> various sizes for protection from<br />
the swarf of bench or pedestal gr<strong>in</strong>ders. The frames are constructed of<br />
re<strong>in</strong>forced fiber nylon or heavy cast alum<strong>in</strong>um. Each shield is furnished<br />
with a threaded support rod. The transparent shield is high-impactresistant<br />
polycarbonate to m<strong>in</strong>imize scratch<strong>in</strong>g and provide durability.<br />
5.19"<br />
(130 mm)<br />
¹<br />
²<br />
B<br />
A<br />
¹ 1.18" (30 mm) ² 0.98" (25 mm)<br />
Order<strong>in</strong>g Information<br />
PART NO. A B<br />
PMA 02/112 6.3" (160 mm) 5.71" (145 mm)<br />
PMA 02/216 7.87" (200 mm) 7.28" (185 mm)<br />
SAFETY SHIELDS | 45
BENCH GRINDER SAFETY GAUGE—PART NO. KSC-096<br />
Front<br />
Back<br />
The bench gr<strong>in</strong>der safety gauge is laser-cut, Grade 5052 alum<strong>in</strong>um with H32 hardness. The safety yellow, durable powder-coated gauge has silkscreened<br />
text and graphics. It measures 2¾" wide by 2¼" high by .1000” thick and has a ¼" hole for attachment to the bench gr<strong>in</strong>der.<br />
OSHA 29 CFR 1910.215 specifies that work rests must be kept adjusted closely to the wheel with a maximum open<strong>in</strong>g of 1/8" to prevent the<br />
workpiece from be<strong>in</strong>g jammed between the wheel and the rest. OSHA also states that the distance between the gr<strong>in</strong>d<strong>in</strong>g wheel and the adjustable<br />
tongue must never exceed ¼".<br />
Check<strong>in</strong>g tongue open<strong>in</strong>g.<br />
Check<strong>in</strong>g work rest open<strong>in</strong>g.<br />
46 | SAFETY SHIELDS
BAND SAW SHIELD ASSEMBLIES<br />
These high-quality band saw shields place a barrier between an operator and fly<strong>in</strong>g debris generated at the po<strong>in</strong>t of operation. The transparent,<br />
L-shaped portion of the band saw shield is constructed of high-impact-resistant, 3/16"- thick clear polycarbonate.<br />
Flexible spr<strong>in</strong>g-steel arms come <strong>in</strong> standard lengths of 12", 18", and 24" for attach<strong>in</strong>g the shield.<br />
The band saw shield assemblies are offered with a direct-mount base that is attached directly to the band saw. Mount<strong>in</strong>g hardware is <strong>in</strong>cluded.<br />
DIMENSIONS<br />
6"<br />
6"<br />
4"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
KYL-189 12" Direct-Mount Arm With 6" H x 6" W L-Shaped Shield (4" D)<br />
KYL-190 18" Direct-Mount Arm With 6" H x 6" W L-Shaped Shield (4" D)<br />
KYL-191 24" Direct-Mount Arm With 6" H x 6" W L-Shaped Shield (4" D)<br />
KYL-175 6" x 6" L-Shaped Replacement Shield Only<br />
SAFETY SHIELDS | 47
DISC AND BELT SANDER SHIELD ASSEMBLIES<br />
These high-quality, adjustable disc and belt sander shields place a<br />
barrier between an operator and fly<strong>in</strong>g debris generated at the po<strong>in</strong>t of<br />
operation. They fasten directly to the mach<strong>in</strong>e us<strong>in</strong>g 1" x 2" extruded<br />
alum<strong>in</strong>um with mount<strong>in</strong>g hardware <strong>in</strong>cluded. The transparent portion<br />
of the shield is constructed of high-impact-resistant, 3/16"-thick clear<br />
polycarbonate. Easy vertical adjustment of the shields is achieved simply<br />
by loosen<strong>in</strong>g and tighten<strong>in</strong>g the black knobs.<br />
These shields can also be used on a comb<strong>in</strong>ation belt sander & disc sander.<br />
14"<br />
Upper Shield<br />
Disc Sander Shield<br />
PART NO.<br />
Disc sander shield assembly.<br />
DESCRIPTION<br />
REPLACEMENT<br />
SHIELD<br />
KYL-228 9" Disc Sander Shield Assembly (6" x 13" Shield) KYL-229<br />
KYL-230 12" Disc Sander Shield Assembly (7" x 16" Shield) KYL-231<br />
KYL-232 16" Disc Sander Shield Assembly (9" x 20" Shield) KYL-233<br />
KYL-234 20" Disc Sander Shield Assembly (11" x 24" Shield) KYL-235<br />
KYL-236 24" Disc Sander Shield Assembly (13" x 28" Shield) KYL-237<br />
BELT SANDER SHIELD ASSEMBLIES<br />
Upper<br />
Shield<br />
Lower Belt Shield<br />
PART NO.<br />
DESCRIPTION<br />
KYL-224 Lower Belt Shield Assembly (6" x 8" Shield)<br />
KYL-225 Lower Belt Shield Only (6" x 8")<br />
14"<br />
3½"<br />
8"<br />
Upper Belt Shield<br />
PART NO.<br />
DESCRIPTION<br />
KYL-226 Upper Belt Shield Assembly (L-Shaped Shield)<br />
KYL-227 Upper Belt Shield Only (L-Shaped)<br />
Lower<br />
Shield<br />
3½"<br />
6"<br />
Belt sander shield assembly.<br />
48 | SAFETY SHIELDS
ADJUSTABLE SLIDE SHIELDS<br />
These high-quality adjustable slide shields can be used on drills, mills,<br />
saws, or special mach<strong>in</strong>e applications. The transparent portion of these<br />
shields is constructed of durable, clear 3/16"-thick polycarbonate. The<br />
shield places a barrier between an operator and the fly<strong>in</strong>g chips (swarf),<br />
sparks, and coolant generated at the po<strong>in</strong>t of operation.<br />
These shields can be mounted vertic<strong>all</strong>y or horizont<strong>all</strong>y on the<br />
flat surface of any mach<strong>in</strong>e. The transparent portion of the shield<br />
attaches to the mount<strong>in</strong>g brackets and offers a slide adjustment of<br />
3½". Two standard size shields with 30° sides are available: 7¾" x<br />
11" and 9½" x 19". Contact <strong>Rockford</strong> <strong>Systems</strong> for other shield sizes<br />
or longer adjustments.<br />
Adjustable slide shield on front column of mach<strong>in</strong>e.<br />
5 1 ⁄8"<br />
5"<br />
7 ¾ "<br />
Adjustable Slide Shield—7" Front<br />
PART NO.<br />
DESCRIPTION<br />
KYL-192 Adjustable Slide Shield With 30° Angle and 7" Front<br />
KYL-012 Replacement Shield—7" Front<br />
7" Front<br />
8 3 ⁄8"<br />
5"<br />
9 ½ "<br />
Adjustable Slide Shield—10 3 ⁄8" Front<br />
PART NO.<br />
DESCRIPTION<br />
KYL-193 Adjustable Slide Shield With 30° Angle and 10 3 ⁄8" Front<br />
KYL-017 Replacement Shield—10 3 ⁄8" Front<br />
10 3 ⁄8" Front<br />
SAFETY SHIELDS | 49
RIGID-ARM MAGNETIC-BASE SHIELDS<br />
Magnetic-base flat shield shown on a lathe<br />
Magnetic-base concave shield shown on a lathe<br />
These rugged magnetic-base shields can be used on lathes, sm<strong>all</strong> mill<strong>in</strong>g mach<strong>in</strong>es, drills, gr<strong>in</strong>ders, band saws, etc. These shields can be attached<br />
to any ferrous surface on the mach<strong>in</strong>e by an 80-lb pull magnetic base. If a flat, smooth, ferrous surface is not available, a mount<strong>in</strong>g plate (3½" x<br />
4-5/8") is also furnished. Large polypropylene plastic handles are used for easy position<strong>in</strong>g and lock<strong>in</strong>g.<br />
The transparent portion of the chip shield is constructed of high-impact-resistant, 3/16"-thick clear polycarbonate material. It is furnished with a<br />
circular base which measures 3¼" <strong>in</strong> diameter. An 8" alum<strong>in</strong>um base extrusion is provided and attaches to the magnetic base. Also available is a<br />
12" extruded-alum<strong>in</strong>um arm extension. This arm can be cut to a shorter length if required for your application.<br />
8" Arm<br />
PART NO. DESCRIPTION REPLACEMENT SHIELD ONLY<br />
CBS-1C1 Base With 6" x 8" Flat Shield CSAA-3<br />
CBS-2C1 Base With 10" x 12" Flat Shield CSAA-5<br />
CBS-3C1 Base With 14" x 16" Flat Shield CSAA-7<br />
12" Arm<br />
Extension<br />
PART NO. DESCRIPTION REPLACEMENT SHIELD ONLY<br />
CBS-1C1B 6" x 8" Flat Shield With 12" Arm Extension CSAA-3<br />
CBS-2C1B 10" x 12" Flat Shield With 12" Arm Extension CSAA-5<br />
CBS-3C1B 14" x 16" Flat Shield With 12" Arm Extension CSAA-7<br />
PART NO. DESCRIPTION REPLACEMENT SHIELD ONLY<br />
CBS-6C1 Base With 8" x 10" Concave Shield CSAD-2<br />
CBS-7C1 Base With 10" x 12" Concave Shield CSAD-3<br />
PART NO. DESCRIPTION REPLACEMENT SHIELD ONLY<br />
CBS-6C1B 8" x 10" Concave Shield With 12" Arm Extension CSAD-2<br />
CBS-7C1B 10" x 12" Concave Shield With 12" Arm Extension CSAD-3<br />
Mount<strong>in</strong>g<br />
Plate<br />
50 | SAFETY SHIELDS
UNIVERSAL BALL & SOCKET SHIELDS<br />
A variety of these quality-constructed, very versatile shields are<br />
available. They are ideal for mills, drills, lathes, gr<strong>in</strong>ders, band saws, or<br />
similar equipment <strong>in</strong>clud<strong>in</strong>g woodwork<strong>in</strong>g mach<strong>in</strong>es. The shield places a<br />
barrier between operators or other employees <strong>in</strong> the area and the fly<strong>in</strong>g<br />
chips (swarf), sparks, and coolant generated from the tool. These shields<br />
are furnished with heavy universal steel b<strong>all</strong>-and-socket arms to provide<br />
simple movement and adjustment. Large polypropylene plastic handles<br />
are used for position<strong>in</strong>g and lock<strong>in</strong>g. Arms mount easily to the frame or<br />
column of the mach<strong>in</strong>e and <strong>in</strong>clude standard mount<strong>in</strong>g hardware.<br />
The shields offered are made of high-impact-resistant 3/16"-thick clear<br />
polycarbonate, selected for its toughness under impact to protect the<br />
operator. Each shield, except for the flat shield, has a hole <strong>in</strong> the left and<br />
right corners so the arm can be conveniently mounted on either side of<br />
the mach<strong>in</strong>e. Special size shields are available upon request.<br />
Universal b<strong>all</strong> & socket shield on a mill<strong>in</strong>g mach<strong>in</strong>e.<br />
Universal b<strong>all</strong> & socket shield shown on a drill press.<br />
Universal b<strong>all</strong> & socket shield shown on a band saw.<br />
SAFETY SHIELDS | 51
UNIVERSAL BALL & SOCKET SHIELDS (CONTINUED)<br />
All Steel Pivot B<strong>all</strong>s Are Hardened For Longevity<br />
PART NO.<br />
KYL-104<br />
KYL-105<br />
KYL-106<br />
CSAA-3<br />
CYF-016<br />
DESCRIPTION<br />
6" x 8" Flat Shield With 21" Universal Arm<br />
6" x 8" Flat Shield With 31" Universal Arm<br />
6" x 8" Flat Shield With 44" Universal Arm<br />
6" x 8" Flat Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-107<br />
KYL-108<br />
KYL-109<br />
CSAA-5<br />
CYF-016<br />
DESCRIPTION<br />
10" x 12" Flat Shield With 21" Universal Arm<br />
10" x 12" Flat Shield With 31" Universal Arm<br />
10" x 12" Flat Shield With 44" Universal Arm<br />
10" x 12" Flat Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-110<br />
KYL-111<br />
KYL-112<br />
KYL-012<br />
CYF-016<br />
DESCRIPTION<br />
30° Angle Shield 8" H (7" Front) With 21" Universal Arm<br />
30° Angle Shield 8" H (7" Front) With 31" Universal Arm<br />
30° Angle Shield 8" H (7" Front) With 44" Universal Arm<br />
30° Angle 8" H (7" Front) Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-113<br />
KYL-114<br />
KYL-115<br />
KYL-017<br />
CYF-016<br />
DESCRIPTION<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) With 21" Universal Arm<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) With 31" Universal Arm<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) With 44" Universal Arm<br />
30° Angle 9 ½ " H (10 3 ⁄8" Front) Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
52 | SAFETY SHIELDS
UNIVERSAL BALL & SOCKET SHIELDS (CONTINUED)<br />
THE 90º SIDE PREVENTS INTERFERENCE WITH A DRILL PRESS HANDLE<br />
PART NO.<br />
KYL-127<br />
KYL-128<br />
KYL-129<br />
KYL-126<br />
CYF-016<br />
DESCRIPTION<br />
30° & 90° Angle Shield 9½" H (10 3 ⁄8" Front) With 21" Universal Arm<br />
30° & 90° Angle Shield 9½" H (103⁄8" Front) With 31" Universal Arm<br />
30° & 90° Angle Shield 9½" H (103⁄8" Front) With 44" Universal Arm<br />
30° & 90° Angle 9½" H (103⁄8" Front) Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-116<br />
KYL-117<br />
KYL-118<br />
KYL-018<br />
CYF-016<br />
DESCRIPTION<br />
90° Angle Shield 9½" H (11" Front) With 21" Universal Arm<br />
90° Angle Shield 9½" H (11" Front) With 31" Universal Arm<br />
90° Angle Shield 9½" H (11" Front) With 44" Universal Arm<br />
90° Angle 9½" H (11" Front) Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-119<br />
KYL-120<br />
KYL-121<br />
CSAD-2<br />
CYF-016<br />
DESCRIPTION<br />
8" x 10" Concave Shield With 21" Universal Arm<br />
8" x 10" Concave Shield With 31" Universal Arm<br />
8" x 10" Concave Shield With 44" Universal Arm<br />
8" x 10" Concave Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
PART NO.<br />
KYL-122<br />
KYL-123<br />
KYL-124<br />
CSAD-3<br />
CYF-016<br />
DESCRIPTION<br />
10" x 12" Concave Shield With 21" Universal Arm<br />
10" x 12" Concave Shield With 31" Universal Arm<br />
10" x 12" Concave Shield With 44" Universal Arm<br />
10" x 12" Concave Replacement Shield Only<br />
Clamp Kit for Attach<strong>in</strong>g to Table or Ledge<br />
CYF-016—Clamp kit attaches<br />
to table or ledge.<br />
SAFETY SHIELDS | 53
FLEXIBLE SPRING-STEEL ARM SHIELDS<br />
These flexible arms are made of high-quality, heavy-duty ¾"-diameter<br />
spr<strong>in</strong>g steel covered with v<strong>in</strong>yl to protect from grease, oil, and<br />
contam<strong>in</strong>ants that could weaken their hold<strong>in</strong>g power. They offer virtu<strong>all</strong>y<br />
unlimited adjustment possibilities and long-term hold<strong>in</strong>g power.<br />
The shield can be used on lathes, drill presses, mill<strong>in</strong>g mach<strong>in</strong>es,<br />
gr<strong>in</strong>ders, band saws, woodwork<strong>in</strong>g mach<strong>in</strong>es, and similar equipment.<br />
It places a barrier between an operator and fly<strong>in</strong>g chips (swarf),<br />
sparks, and splash<strong>in</strong>g coolant generated at the po<strong>in</strong>t of operation. The<br />
transparent portion of these flexible-arm shields is constructed of highimpact-resistant,<br />
3/16"-thick polycarbonate. Special shield sizes are<br />
available up to 12" x 12"; please c<strong>all</strong> our sales department at 1-800-<br />
922-7533 for more <strong>in</strong>formation.<br />
The flexible-arm shields have two mount<strong>in</strong>g options: direct or magnetic.<br />
The direct-mount base can be fastened directly to a mach<strong>in</strong>e with two<br />
¼" fasteners (<strong>in</strong>cluded). The magnetic base consists of a 3"-diameter<br />
magnet with 100-lb hold<strong>in</strong>g force. If an adequate flat, smooth, ferrous<br />
mount<strong>in</strong>g surface is not available, an optional steel mount<strong>in</strong>g plate can<br />
be permanently attached to the mach<strong>in</strong>e to hold the magnetic base.<br />
Flexible spr<strong>in</strong>g-steel arm shield on mill<strong>in</strong>g mach<strong>in</strong>e.<br />
Flexible spr<strong>in</strong>g-steel arm shield on mill<strong>in</strong>g mach<strong>in</strong>e.<br />
Flexible spr<strong>in</strong>g-steel arm shield on lathe.<br />
54 | SAFETY SHIELDS
FLEXIBLE SPRING-STEEL ARM SHIELDS (CONTINUED)<br />
MADE OF ¾ "-DIAMETER VINYL-COVERED SPRING STEEL<br />
PART NO.<br />
KYL-096<br />
KYL-097<br />
KYL-132<br />
CSAA-3<br />
DESCRIPTION<br />
6" x 8" Flat Shield and 12" Arm With Direct-Mount Base<br />
6" x 8" Flat Shield and 18" Arm With Direct-Mount Base<br />
6" x 8" Flat Shield and 24" Arm With Direct-Mount Base<br />
6" x 8" Flat Replacement Shield Only<br />
PART NO.<br />
KYL-100<br />
KYL-101<br />
KYL-133<br />
CSAA-3<br />
FKT-1106<br />
DESCRIPTION<br />
6" x 8" Flat Shield and 12" Arm With Magnetic Base<br />
6" x 8" Flat Shield and 18" Arm With Magnetic Base<br />
6" x 8" Flat Shield and 24" Arm With Magnetic Base<br />
6" x 8" Flat Replacement Shield Only<br />
Optional 3½" x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
PART NO.<br />
KYL-098<br />
KYL-099<br />
KYL-134<br />
CSAA-5<br />
DESCRIPTION<br />
10" x 12" Flat Shield and 12" Arm With Direct-Mount Base<br />
10" x 12" Flat Shield and 18" Arm With Direct-Mount Base<br />
10" x 12" Flat Shield and 24" Arm With Direct-Mount Base<br />
10" x 12" Flat Replacement Shield Only<br />
PART NO.<br />
KYL-102<br />
KYL-103<br />
KYL-135<br />
CSAA-5<br />
FKT-1106<br />
DESCRIPTION<br />
10" x 12" Flat Shield and 12" Arm With Magnetic Base<br />
10" x 12" Flat Shield and 18" Arm With Magnetic Base<br />
10" x 12" Flat Shield and 24" Arm With Magnetic Base<br />
10" x 12" Flat Replacement Shield Only<br />
Optional 3½" x 4 5 ⁄z" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
Optional Mount<strong>in</strong>g Plate<br />
SAFETY SHIELDS | 55
FLEXIBLE SPRING-STEEL ARM SHIELDS (CONTINUED)<br />
PART NO.<br />
KYL-136<br />
KYL-137<br />
KYL-138<br />
KYL-012<br />
DESCRIPTION<br />
30° Angle Shield 8" H (7" Front) and 12" Arm With Direct-Mount Base<br />
30° Angle Shield 8" H (7" Front) and 18" Arm With Direct-Mount Base<br />
30° Angle Shield 8" H (7" Front) and 24" Arm With Direct-Mount Base<br />
30° Angle 8" H (7" Front) Replacement Shield Only<br />
PART NO.<br />
KYL-139<br />
KYL-140<br />
KYL-141<br />
KYL-012<br />
FKT-1106<br />
DESCRIPTION<br />
30° Angle Shield 8" H (7" Front) and 12" Arm With Magnetic Base<br />
30° Angle Shield 8" H (7" Front) and 18" Arm With Magnetic Base<br />
30° Angle Shield 8" H (7" Front) and 24" Arm With Magnetic Base<br />
30° Angle 8" H (7" Front) Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
PART NO.<br />
KYL-142<br />
KYL-143<br />
KYL-144<br />
KYL-017<br />
DESCRIPTION<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 12" Arm With Direct-Mount Base<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 18" Arm With Direct-Mount Base<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 24" Arm With Direct-Mount Base<br />
30° Angle 9 ½ " H (10 3 ⁄8" Front) Replacement Shield Only<br />
PART NO.<br />
KYL-145<br />
KYL-146<br />
KYL-147<br />
KYL-017<br />
FKT-1106<br />
DESCRIPTION<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 12" Arm With Magnetic Base<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 18" Arm With Magnetic Base<br />
30° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 24" Arm With Magnetic Base<br />
30° Angle 9 ½ " H (10 3 ⁄8" Front) Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
PART NO.<br />
KYL-148<br />
KYL-149<br />
KYL-150<br />
KYL-126<br />
DESCRIPTION<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 12" Arm With Direct-Mount Base<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 18" Arm With Direct-Mount Base<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 24" Arm With Direct-Mount Base<br />
30° & 90° Angle 9 ½ " H (10 3 ⁄8" Front) Replacement Shield Only<br />
PART NO.<br />
KYL-151<br />
KYL-152<br />
KYL-153<br />
KYL-126<br />
FKT-1106<br />
DESCRIPTION<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 12" Arm With Magnetic Base<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 18" Arm With Magnetic Base<br />
30° & 90° Angle Shield 9 ½ " H (10 3 ⁄8" Front) and 24" Arm With Magnetic Base<br />
30° & 90° Angle 9 ½ " H (10 3 ⁄8" Front) Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
56 | SAFETY SHIELDS
FLEXIBLE SPRING-STEEL ARM SHIELDS (CONTINUED)<br />
PART NO.<br />
KYL-154<br />
KYL-155<br />
KYL-156<br />
KYL-018<br />
DESCRIPTION<br />
90° Angle Shield 9 ½ " H (11" Front) and 12" Arm With Direct-Mount Base<br />
90° Angle Shield 9 ½ " H (11" Front) and 18" Arm With Direct-Mount Base<br />
90° Angle Shield 9 ½ " H (11" Front) and 24" Arm With Direct-Mount Base<br />
90° Angle 9 ½ " H (11" Front) Replacement Shield Only<br />
PART NO.<br />
KYL-157<br />
KYL-158<br />
KYL-159<br />
KYL-018<br />
KYL-1106<br />
DESCRIPTION<br />
90° Angle Shield 9 ½ " H (11" Front) and 12" Arm With Magnetic Base<br />
90° Angle Shield 9 ½ " H (11" Front) and 18" Arm With Magnetic Base<br />
90° Angle Shield 9 ½ " H (11" Front) and 24" Arm With Magnetic Base<br />
90° Angle 9 ½ " H (11" Front) Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
PART NO.<br />
KYL-160<br />
KYL-161<br />
KYL-162<br />
CSAD-2<br />
DESCRIPTION<br />
8" x 10" Concave Shield and 12" Arm With Direct-Mount Base<br />
8" x 10" Concave Shield and 18" Arm With Direct-Mount Base<br />
8" x 10" Concave Shield and 24" Arm With Direct-Mount Base<br />
8" x 10" Concave Replacement Shield Only<br />
PART NO.<br />
KYL-163<br />
KYL-164<br />
KYL-165<br />
CSAD-2<br />
FKT-1106<br />
DESCRIPTION<br />
8" x 10" Concave Shield and 12" Arm With Magnetic Base<br />
8" x 10" Concave Shield and 18" Arm With Magnetic Base<br />
8" x 10" Concave Shield and 24" Arm With Magnetic Base<br />
8" x 10" Concave Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
PART NO.<br />
KYL-166<br />
KYL-167<br />
KYL-168<br />
CSAD-3<br />
DESCRIPTION<br />
10" x 12" Concave Shield and 12" Arm With Direct-Mount Base<br />
10" x 12" Concave Shield and 18" Arm With Direct-Mount Base<br />
10" x 12" Concave Shield and 24" Arm With Direct-Mount Base<br />
10" x 12" Concave Replacement Shield Only<br />
PART NO.<br />
KYL-169<br />
KYL-170<br />
KYL-171<br />
CSAD-3<br />
FKT-1106<br />
DESCRIPTION<br />
10" x 12" Concave Shield and 12" Arm With Magnetic Base<br />
10" x 12" Concave Shield and 18" Arm With Magnetic Base<br />
10" x 12" Concave Shield and 24" Arm With Magnetic Base<br />
10" x 12" Concave Replacement Shield Only<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
SAFETY SHIELDS | 57
ON/OFF MAGNETIC-BASE SHIELDS<br />
These versatile on/off magnetic-base shields can be used on lathes,<br />
drills, mills, gr<strong>in</strong>ders, or any equipment that has a flat, ferrous mount<strong>in</strong>g<br />
surface. The heavy-duty magnetic base is 2¾" square with a V-groove<br />
and measures 3" high. The 200-lb hold<strong>in</strong>g force keeps the shield<br />
<strong>in</strong> place when the magnet is on. If an adequate flat, smooth, ferrous<br />
mount<strong>in</strong>g surface is not available, an optional steel mount<strong>in</strong>g plate (Part<br />
No. FKT-1106) can be used.<br />
The 12", 18", and 24" flexible spr<strong>in</strong>g-steel arms are covered with v<strong>in</strong>yl<br />
to protect them from grease, oil, and contam<strong>in</strong>ants that would weaken<br />
their hold<strong>in</strong>g power. They offer virtu<strong>all</strong>y unlimited adjustment possibilities<br />
and have long-term hold<strong>in</strong>g power.<br />
The transparent portion of these shields is constructed of high-impactresistant,<br />
3/16"-thick clear polycarbonate. The shield places a barrier<br />
between an operator and the fly<strong>in</strong>g chips (swarf), sparks, and coolant<br />
generated at the po<strong>in</strong>t of operation. A variety of flat, angled, and concave<br />
shields are available.<br />
On/Off magnetic-base shield on a lathe.<br />
2 ¾ "<br />
2 ¾ "<br />
Optional Mount<strong>in</strong>g Plate<br />
3 1 ⁄8"<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
REPLACEMENT<br />
SHIELD<br />
KYL-197 6" x 8" Flat Shield With 12" Arm CSAA-3<br />
KYL-198 6" x 8" Flat Shield With 18" Arm CSAA-3<br />
KYL-199 6" x 8" Flat Shield With 24" Arm CSAA-3<br />
KYL-200 30° Angle Shield 7" Front With 12" Arm KYL-012<br />
KYL-201 30° Angle Shield 7" Front With 18" Arm KYL-012<br />
KYL-202 30° Angle Shield 7" Front With 24" Arm KYL-012<br />
KYL-203 10" x 12" Flat Shield With 12" Arm CSAA-5<br />
KYL-204 10" x 12" Flat Shield With 18" Arm CSAA-5<br />
KYL-205 10" x 12" Flat Shield With 24" Arm CSAA-5<br />
KYL-206 30° Angle Shield 10 3 ⁄8" Front With 12" Arm KYL-017<br />
KYL-207 30° Angle Shield 10 3 ⁄8" Front With 18" Arm KYL-017<br />
KYL-208 30° Angle Shield 10 3 ⁄8" Front With 24" Arm KYL-017<br />
KYL-209 30° & 90° Angle Shield 10 3 ⁄8" Front With 12" Arm KYL-126<br />
KYL-210 30° & 90° Angle Shield 10 3 ⁄8" Front With 18" Arm KYL-126<br />
KYL-211 30° & 90° Angle Shield 10 3 ⁄8" Front With 24" Arm KYL-126<br />
KYL-212 90° Angle Shield 11" Front With 12" Arm KYL-018<br />
KYL-213 90° Angle Shield 11" Front With 18" Arm KYL-018<br />
KYL-214 90° Angle Shield 11" Front With 24" Arm KYL-018<br />
KYL-215 8" x 10" Concave Shield With 12" Arm CSAD-2<br />
KYL-216 8" x 10" Concave Shield With 18" Arm CSAD-2<br />
KYL-217 8" x 10" Concave Shield With 24" Arm CSAD-2<br />
KYL-218 10" x 12" Concave Shield With 12" Arm CSAD-3<br />
KYL-219 10" x 12" Concave Shield With 18" Arm CSAD-3<br />
KYL-220 10" x 12" Concave Shield With 24" Arm CSAD-3<br />
FKT-1106<br />
Optional 3 ½ " x 4 5 ⁄8" Steel Mount<strong>in</strong>g Plate (Fasteners Not Included)<br />
58 | SAFETY SHIELDS
FREE-STANDING SHIELD ASSEMBLY<br />
These shields can be used to protect the area between mach<strong>in</strong>es, the<br />
backside of mach<strong>in</strong>es, along aisles, etc.<br />
These free-stand<strong>in</strong>g adjustable shield assemblies are available <strong>in</strong> a<br />
wide range of sizes. They are constructed of 3/16"-thick polycarbonate<br />
material surrounded by alum<strong>in</strong>um fram<strong>in</strong>g. The shield can easily be<br />
adjusted up or down on the stands. The stands are constructed of<br />
2"-square extruded alum<strong>in</strong>um. Each base <strong>in</strong>cludes four holes for<br />
permanent mount<strong>in</strong>g to the floor. Four standard sizes are available.<br />
Special size shield assemblies are available upon request.<br />
Clear<br />
Polycarbonate<br />
Free-stand<strong>in</strong>g shield used to protect the area<br />
around a mill<strong>in</strong>g mach<strong>in</strong>e from fly<strong>in</strong>g chips.<br />
Order<strong>in</strong>g Information<br />
PART NO. DESCRIPTION<br />
KYL-026 48" H x 48" L Shield Size<br />
KYL-027 48" H x 60" L Shield Size<br />
KYL-028 48" H x 72" L Shield Size<br />
KYL-029 48" H x 96" L Shield Size<br />
Stands<br />
SAFETY SHIELDS | 59
LOCKOUTS<br />
ELECTRICAL PLUG LOCKOUT<br />
PART NO. KYM-088<br />
This lockout conta<strong>in</strong>er can lockout<br />
plugs up to 3" wide and 5½" long with<br />
a maximum cord diameter of 1¼".<br />
The lockout consists of a round<br />
conta<strong>in</strong>er and two cover plates made of<br />
a durable and chemic<strong>all</strong>y resistant thermoplastic. The cover plates, when<br />
used s<strong>in</strong>gularly or comb<strong>in</strong>ed, are locked to produce a univers<strong>all</strong>y fitt<strong>in</strong>g<br />
electrical plug lockout device.<br />
This lockout is bright yellow so it can also serve as a visual warn<strong>in</strong>g to<br />
other plant personnel.<br />
LOCK-A-PLUGS<br />
PLUG HUGGER—PART NO. KYM-199<br />
This device is ideal for frequently locked-out<br />
cords. It slides over the plug’s blades and<br />
locks with a key. It can only be used on<br />
standard 125-V, 15-A plugs (polarized or<br />
nonpolarized) with a hole on both blades.<br />
LOCKOUT HASPS<br />
These lockout hasps are made from 12-gauge<br />
steel that is epoxy-coated for superior rust<br />
resistance and added dielectric strength. The<br />
yellow plastic coat<strong>in</strong>g on the lock area is for<br />
visibility. These devices accept up to six padlocks<br />
with 9/32" maximum shackle diameter.<br />
PART NO. KYM-988 1" Diameter Lockout Hasp<br />
PART NO. KYM-989 1½" Diameter Lockout Hasp<br />
KYM-989<br />
KYM-988<br />
KYM-984<br />
KYM-987<br />
These lockout devices accommodate a large variety of electrical plugs.<br />
The large device (KYM-987) also locks out necked-down pneumatic<br />
male fitt<strong>in</strong>gs commonly attached to compressed air hoses. These<br />
devices accommodate up to four padlocks with 9/32" maximum<br />
shackle diameter.<br />
PART NO. KYM-984<br />
For plugs up to 1½" wide, 1½" high, and 3" long with a maximum<br />
cord diameter of ½"<br />
PART NO. KYM-987<br />
For plugs up to 3½" wide, 3½" high, and 6" long with a maximum<br />
cord diameter of ¾"<br />
PLUGOUT<br />
PART NO. KYM-983<br />
This lockout conta<strong>in</strong>er accepts lockout plugs<br />
up to 2¾" wide and 4¾" long with a maximum<br />
cord diameter of 2¾". It is constructed of<br />
high-impact, yellow UV-stabilized polymer.<br />
I t<br />
has an easy to use two-step close and slide assembly. It <strong>all</strong>ows the use<br />
of four <strong>in</strong>dividual padlocks (up to 3/8" shackle diameter). A lockout hasp<br />
can be used if more locks are required. An advantage to this plug lockout<br />
is that it can be stored on the cord when not <strong>in</strong> use. This device is 4¼"<br />
wide and 7¼" long.<br />
ELECTRICAL POWER CUTOFF SYSTEM<br />
(INTERLOCK)<br />
This <strong>in</strong>terlock assembly can be <strong>in</strong>terfaced <strong>in</strong>to<br />
the control system so when the plug is pulled,<br />
the mach<strong>in</strong>e or equipment becomes <strong>in</strong>operable.<br />
It <strong>in</strong>cludes a two-prong plug, a 24" cha<strong>in</strong>, a<br />
receptacle, and an electrical mount<strong>in</strong>g box.<br />
PART NO. KTS-518<br />
One-Contact Interlock System With 24" Cha<strong>in</strong><br />
PART NO. KTS-533<br />
Two-Contact Interlock System With 24" Cha<strong>in</strong><br />
TAGOUTS<br />
These tagouts are 2-7/8" x 5½" x .055" thick, and made of a<br />
polyethylene material. They meet the requirements of OSHA 29 CFR<br />
1910.147 for lockout/tagout. The reverse side of each tagout is the<br />
same.<br />
PART NO.<br />
KYM-192<br />
PART NO.<br />
KYM-193<br />
PART NO.<br />
KYM-194<br />
PART NO.<br />
KYM-195<br />
PART NO.<br />
KYM-196<br />
REVERSE<br />
SIDE<br />
60 | SAFETY SHIELDS
LOCKOUT VALVES<br />
SLIDE-OPERATED VALVE<br />
This three-way valve is operated with the manual movement of a<br />
slide that opens and closes the valve. This valve shuts off air at the<br />
mach<strong>in</strong>e and then bleeds off downstream air. It can be locked only<br />
<strong>in</strong> the off position.<br />
EEZ-ON VALVE<br />
This valve shuts off air supply to the mach<strong>in</strong>e and bleeds downstream<br />
air when the valve is closed. When the valve is open, it gradu<strong>all</strong>y <strong>all</strong>ows<br />
air <strong>in</strong>to the air system to prevent damage to air comp<strong>one</strong>nts. It can be<br />
locked only <strong>in</strong> the off position. This valve is furnished with a muffler.<br />
PART NO.<br />
RCD-113 ½"<br />
RCD-114 ¾"<br />
PART NO.<br />
PORT SIZE<br />
IN-OUT<br />
IN-OUT<br />
PORT SIZE<br />
RCD-121 ½" ¾"<br />
RCD-122 ¾" ¾"<br />
EXHAUST<br />
SINGLE-PHASE DISCONNECT SWITCH WITH MAGNETIC MOTOR<br />
STARTER AND SELF-LATCHING EMERGENCY-STOP BUTTON<br />
This s<strong>in</strong>gle-phase unit is designed for motors that have built-<strong>in</strong> overloads. Typical applications for<br />
these comb<strong>in</strong>ations <strong>in</strong>clude sm<strong>all</strong>er crimp<strong>in</strong>g mach<strong>in</strong>es, gr<strong>in</strong>ders, drill presses, and <strong>all</strong> types of saws.<br />
PART NO. CSS-055 (115 V, ½ HP MAX.)<br />
The 115-V, 15-A disconnect switch and nonrevers<strong>in</strong>g magnetic motor starter are housed <strong>in</strong> a NEMA<br />
12 enclosure. Enclosure size is 8" x 6" x 3½". It <strong>in</strong>cludes a self-latch<strong>in</strong>g red emergency-stop palm<br />
button and a green motor control on push button. It can be used on mach<strong>in</strong>es with 115-V power and<br />
is rated up to ½ HP maximum.<br />
The disconnect switch has a rotary operat<strong>in</strong>g handle which is lockable <strong>in</strong> the off position only. This<br />
meets OSHA regulations and ANSI standards.<br />
For mach<strong>in</strong>es with 230-V AC s<strong>in</strong>gle-phase motors, a transformer is required to reduce the control<br />
circuit voltage to 115-V AC <strong>in</strong> order to comply with NFPA 79. See the RSD series disconnect<br />
switches, motor starters, and comb<strong>in</strong>ations on pages 64-65.<br />
SINGLE-PHASE STARTER WITH SELF-LATCHING EMERGENCY-<br />
STOP BUTTON<br />
PART NO. CSF-082 (115 V, ½ HP MAX.)<br />
The 115-V, 15-A nonrevers<strong>in</strong>g magnetic motor starter, self-latch<strong>in</strong>g red emergency-stop palm<br />
button, and green motor control on push button are housed <strong>in</strong> a NEMA 4 polycarbonate enclosure.<br />
Enclosure size is 5" x 5" x 4". It can be used for mach<strong>in</strong>es with 115-V power and is rated up to ½<br />
HP maximum.<br />
For mach<strong>in</strong>es with 230-V AC s<strong>in</strong>gle-phase motors, a transformer is required to reduce the control<br />
circuit voltage to 115-V AC <strong>in</strong> order to comply with NFPA 79. See the RSD series disconnect<br />
switches, motor starters, and comb<strong>in</strong>ations on pages 63-64.<br />
PART NO. CSF-301 (115 V, 2 HP MAX.)<br />
The 115-V, 30-A nonrevers<strong>in</strong>g magnetic motor starter, self-latch<strong>in</strong>g red emergency-stop palm<br />
button, and green motor control on push button are housed <strong>in</strong> a NEMA 12 enclosure. Enclosure size<br />
is 8" x 6" x 6". It can be used for mach<strong>in</strong>es with 115-V power and is rated up to 2 HP maximum.<br />
For mach<strong>in</strong>es with 230-V AC s<strong>in</strong>gle-phase motors, a transformer is required to reduce the control<br />
circuit voltage to 115-V AC <strong>in</strong> order to comply with NFPA 79. See the RSD series disconnect<br />
switches, motor starters, and comb<strong>in</strong>ations on pages 63-64.<br />
SAFETY SHIELDS | 61
SENSING-SAF-START ® PACKAGES<br />
This Sens<strong>in</strong>g-Saf-Start ® package is designed for <strong>in</strong>st<strong>all</strong>ation on 120-V<br />
(15-A maximum) mach<strong>in</strong>es. When <strong>in</strong>st<strong>all</strong>ed correctly, the Saf-Start ®<br />
package will prevent the mach<strong>in</strong>e from automatic<strong>all</strong>y or un<strong>in</strong>tention<strong>all</strong>y<br />
restart<strong>in</strong>g when a power <strong>in</strong>terruption occurs. The mach<strong>in</strong>e cannot restart<br />
until power has been restored, the mach<strong>in</strong>e has been turned off, and the<br />
reset button pushed.<br />
FOR USE ON 120-V MACHINES<br />
• Drill Presses<br />
• Scroll Saws<br />
• Tool Gr<strong>in</strong>ders<br />
• Table Saws<br />
• Mill<strong>in</strong>g Mach<strong>in</strong>es • Cut-Off Mach<strong>in</strong>es<br />
• Lathes<br />
• Belt Sanders<br />
• Band Saws<br />
• Disc Sanders<br />
• Radial Arm Saws • Polish<strong>in</strong>g Mach<strong>in</strong>es<br />
SAFS-300 Sens<strong>in</strong>g-Saf-Start ® package on a table saw.<br />
SAFS-300 PACKAGE<br />
This <strong>one</strong>-box SAFS-300 package is housed <strong>in</strong> a NEMA 4 polycarbonate<br />
enclosure (5" x 5" x 4") that <strong>in</strong>cludes a reset button and E-stop.<br />
The Saf-Start ® complies with OSHA requirements and the NFPA 79<br />
electrical standard.<br />
SAFS-200 PACKAGE<br />
The SAFS-200 package <strong>in</strong>cludes a 120-V AC Sens<strong>in</strong>g-Saf-Start ® with a<br />
20" cord for the mach<strong>in</strong>e end and an 8' cord with molded plug on the<br />
power end, plus an E-stop <strong>in</strong> a NEMA 4 polycarbonate enclosure (5" x<br />
5" x 4"). The Saf-Start ® complies with OSHA requirements and the NFPA<br />
79 electrical standard.<br />
SAFS-300 Package<br />
SAFS-200<br />
Package<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
DESCRIPTION<br />
SAFS-200 Comb<strong>in</strong>ation Sens<strong>in</strong>g-Saf-Start ® and E-Stop Package<br />
SAFS-300 One-Box Sens<strong>in</strong>g-Saf-Start ® With Reset Button and E-Stop Package<br />
62 | SAFETY SHIELDS
ENCLOSED TRANSFORMERS<br />
These transformers comply with OSHA regulations and ANSI standards<br />
and are available for use when the motor start/stop station is remotely<br />
located from the starter enclosure, and voltage to these buttons must<br />
be 115 V or less. These transformers mount directly to the frame of the<br />
mach<strong>in</strong>e. If the exist<strong>in</strong>g motor starter operat<strong>in</strong>g coils are a higher voltage<br />
(208, 230, 460, 575 V), they must be replaced with a 115-V coil when<br />
furnish<strong>in</strong>g these transformers. A replaceable fuse is accessible from the<br />
outside of the transformer hous<strong>in</strong>g.<br />
4 ½ "<br />
3 ½ "<br />
5 ½ "<br />
Order<strong>in</strong>g Information<br />
PART NO.<br />
RSF-021<br />
RSF-030<br />
DESCRIPTION<br />
100-VA, 230/460-V Primary and 115-V Fused Secondary With a 1 A, 230-V Fuse<br />
150-VA, 230/460-V Primary and 115-V Fused Secondary With a 1.5 A, 230-V Fuse<br />
IEC FUSED DISCONNECT SWITCHES, MAGNETIC MOTOR STARTERS, AND COMBINATIONS<br />
These three-phase disconnect/starters are housed <strong>in</strong> a NEMA 12 metal enclosure. The enclosure size will vary depend<strong>in</strong>g on the motor starter<br />
required. These units can be used on mach<strong>in</strong>es with 208, 230, 460, or 575 V. They are furnished with an overload relay and have operat<strong>in</strong>g coils of<br />
115 V, 60 Hz. The disconnect operat<strong>in</strong>g handle is lockable <strong>in</strong> the off position only. These comb<strong>in</strong>ation units meet OSHA regulations, ANSI standards,<br />
and NFPA 79.<br />
To obta<strong>in</strong> the part number of the motor starter required, please refer to the part number<strong>in</strong>g chart on the next page.<br />
A remote station is required when us<strong>in</strong>g any pla<strong>in</strong>-door starter. To obta<strong>in</strong> the part number of the remote operator station required, please refer to<br />
the part number<strong>in</strong>g chart on the page 65.<br />
PART NO.<br />
VOS-2100<br />
PART NO. RSD-2210-P-1<br />
PART NO. RSD-1230-F<br />
Note: Please furnish the exact motor horsepower, voltage, and full-load amps when order<strong>in</strong>g any of the disconnects or starters on page 64. This<br />
<strong>in</strong>formation is usu<strong>all</strong>y on the motor nameplate. Voltage can be 208, 230, 460, or 575 V. If other sizes are required, please consult <strong>Rockford</strong> <strong>Systems</strong>.<br />
SAFETY SHIELDS | 63
SELECTING A DISCONNECT, STARTER, OR COMBINATION DISCONNECT/STARTER(S)<br />
To determ<strong>in</strong>e the 9-digit configured part number for a disconnect, starter, or comb<strong>in</strong>ation disconnect/starter(s) required, follow directions 1-7 below<br />
and use the <strong>in</strong>formation <strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
The first 3 digits for <strong>all</strong> disconnects, starters, or comb<strong>in</strong>ation disconnect/starter(s) are RSD.<br />
The 4th digit determ<strong>in</strong>es the size of the disconnect switch, if required. Zero (0) <strong>in</strong>dicates no disconnect switch provided.<br />
The 5th digit determ<strong>in</strong>es the type of the ma<strong>in</strong> motor starter and/or 2nd motor starter. Zero (0) <strong>in</strong>dicates no starters.<br />
The 6th digit determ<strong>in</strong>es the size of the ma<strong>in</strong> motor starter. Zero (0) <strong>in</strong>dicates no ma<strong>in</strong> motor starter.<br />
The 7th digit determ<strong>in</strong>es the size of the 2nd motor starter. Zero (0) <strong>in</strong>dicates no 2nd motor starter.<br />
The 8th digit (if required) determ<strong>in</strong>es the configuration and location of the operator controls.<br />
The 9th digit determ<strong>in</strong>es if a transformer and/or wir<strong>in</strong>g is required.<br />
DISCONNECT AND STARTER(S) PART NUMBERING SYSTEM CHART<br />
R S D - X X X X - X - X<br />
RSD<br />
DISCONNECT AND STARTER(S)<br />
—Separate or Comb<strong>in</strong>ation<br />
DISCONNECT SWITCH SIZE (IEC)<br />
(PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 —30-A CC Disconnect—1- to 17-FLA Total Motor Current<br />
2 —30-A J Disconnect—1- to 20-FLA Total Motor Current<br />
3 —60-A J Disconnect—21- to 40-FLA Total Motor Current<br />
4 —100-A J Disconnect—41- to 66-FLA Total Motor Current<br />
5 —200-A J Disconnect—67- to 133-FLA Total Motor Current<br />
6 —400-A J Disconnect—134- to 266-FLA Total Motor Current<br />
REVERSING/NONREVERSING MOTOR STARTER<br />
0 —No Starters<br />
1 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter<br />
2 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter<br />
3 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter & Nonrevers<strong>in</strong>g 2nd Motor<br />
4 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter & Revers<strong>in</strong>g 2nd Motor<br />
5 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter & Nonrevers<strong>in</strong>g 2nd Motor<br />
6 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter & Revers<strong>in</strong>g 2nd Motor<br />
7 —Nonrevers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starter<br />
8 —Revers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starter<br />
9 —Nonrevers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starer & Nonrev. 2nd Motor<br />
A —Nonrevers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starter & Revers<strong>in</strong>g 2nd Motor<br />
B —Revers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starter & Nonrevers<strong>in</strong>g 2nd Motor<br />
C —Revers<strong>in</strong>g 2-Speed Ma<strong>in</strong> Motor Starter & Revers<strong>in</strong>g 2nd Motor<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Ma<strong>in</strong> Motor Starter<br />
Motor Horsepower Chart<br />
1-Phase 3-Phase<br />
IEC 115 V 230 V 208 V 230 V 460 V 575 V<br />
1 —12 A 1/2 1 2 3 7.5 7.5<br />
2 —18 A 3/4 2 5 5 10 10<br />
3 —25 A 2 3 5 7.5 15 15<br />
4 —32 A 2 5 7.5 10 20 20<br />
5 —40 A 3 7.5 10 10 30 30<br />
6 —50 A 3 10 15 15 30 40<br />
7 —65 A 5 10 20 20 50 50<br />
8 —80 A 7.5 15 25 30 60 75<br />
9 —95 A 7.5 20 30 30 60 75<br />
A —115 A 10 25 30 40 75 100<br />
B —185 A 15 30 50 60 125 150<br />
C —265 A – – 75 100 200 200<br />
MODIFIER<br />
- —Blank—No Specific Configuration, Term<strong>in</strong>als, Transformer,<br />
or Wir<strong>in</strong>g<br />
1 —Generic<strong>all</strong>y Numbered and Wired to Term<strong>in</strong>als<br />
—Includes Transformer<br />
2 —Generic<strong>all</strong>y Numbered and Wired to Term<strong>in</strong>als<br />
—Without Transformer<br />
CONFIGURATION & OPERATOR LOCATION<br />
- —Blank—No Specific Configuration<br />
P —All Operators Remote (Pla<strong>in</strong> Door)<br />
F —All Motor Operators on Door of Enclosure<br />
X —F Configuration With E-Stop <strong>in</strong> Place of S<strong>in</strong>gle-Motor Stop<br />
Y —F Configuration With Addition of E-Stop<br />
2nd MOTOR STARTER SIZE<br />
0 —No Ma<strong>in</strong> Motor Starter<br />
Motor Horsepower Chart<br />
1-Phase<br />
3-Phase<br />
IEC 115 V 230 V 208 V 230 V 460 V 575 V<br />
1 —12 A 1/2 1 2 3 7.5 7.5<br />
2 —18 A 3/4 2 3 5 10 10<br />
3 —25 A 2 3 5 7.5 15 15<br />
4 —32 A 2 5 7.5 10 20 20<br />
5 —40 A 3 7.5 10 10 30 30<br />
6 —50 A 3 10 15 15 30 40<br />
7 —65 A 5 10 20 20 50 50<br />
8 —80 A 7.5 15 25 30 60 75<br />
9 —95 A 7.5 20 30 30 60 75<br />
A —115 A 10 25 30 40 75 100<br />
B —185 A 15 30 50 60 125 150<br />
C —265 A – – 75 100 200 200<br />
Please see page 65 for an example of a<br />
disconnect and starter(s) part number.<br />
64 | SAFETY SHIELDS
SELECTING A REMOTE OPERATOR STATION<br />
To determ<strong>in</strong>e the 8-digit configured part number for a remote operator station required, follow directions 1-3 below and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
The first 3 digits determ<strong>in</strong>e the orientation of the remote operator station.<br />
Digits 4 through 7 determ<strong>in</strong>e motor operators. Zero (0) <strong>in</strong>dicates no operator(s).<br />
The 8th digit (if required) determ<strong>in</strong>es the 2nd motor operators.<br />
REMOTE OPERATOR STATION PART NUMBERING SYSTEM CHART<br />
X X X - X X X X - X<br />
HOS<br />
VOS<br />
REMOTE OPERATOR STATION ORIENTATION<br />
—Horizontal Operator Station<br />
—Vertical Operator Station<br />
MAIN MOTOR START/STOP/E-STOP OPERATORS<br />
1 —Start/Stop Push Buttons<br />
2 —Start/E-Stop Push Buttons<br />
3 —Start/Stop/E-Stop Buttons<br />
4 —E-Stop Button Only<br />
MAIN MOTOR FORWARD/REVERSE OPERATORS<br />
0 —No Forward/Reverse Operators<br />
1 —Forward/Reverse Selector Switch*<br />
2 —Forward/Reverse Push Buttons<br />
* Must be configured with a start push button<br />
DISCONNECT AND STARTERS PART NUMBER EXAMPLE<br />
1 2 3 4 5 6 7<br />
R S D - 3 5 2 1 - P - 1<br />
The example shown above, RSD-3521-P-1, <strong>in</strong>dicates that the<br />
enclosure conta<strong>in</strong><strong>in</strong>g the comb<strong>in</strong>ation disconnect/starter(s) has a 60-A<br />
disconnect switch, a 17-A revers<strong>in</strong>g ma<strong>in</strong> motor starter, and a 12-A<br />
nonrevers<strong>in</strong>g 2nd motor starter. All motor controls will be <strong>in</strong> a remote<br />
station. This disconnect/starter(s) will be generic<strong>all</strong>y numbered and<br />
wired to term<strong>in</strong>als and will <strong>in</strong>clude a transformer.<br />
2nd MOTOR OPERATORS<br />
- —Blank—No 2nd Motor<br />
1 —Start/Stop Push Buttons<br />
2 —Start/Stop Push Buttons &<br />
Forward/Reverse Selector Switch<br />
MAIN MOTOR JOG<br />
0 —No Jog<br />
1 —Jog/Run Selector Switch<br />
MAIN MOTOR SPEED CHANGE<br />
0 —No Speed Change<br />
1 —Fast/Slow Selector Switch<br />
2 —Fast/Slow Push Buttons<br />
REMOTE OPERATOR PART NUMBER EXAMPLE<br />
1 2 3<br />
V O S - 3 1 0 0 - 1<br />
The example shown above, VOS-3100-1, <strong>in</strong>dicates that it is a verticaloriented<br />
remote operator station which <strong>in</strong>cludes ma<strong>in</strong> motor start/stop/Estop<br />
buttons, ma<strong>in</strong> motor forward/reverse selector switch, and start/stop<br />
push buttons for the 2nd motor starter.<br />
SAFETY SHIELDS | 65
REMOTE OPERATOR STATIONS<br />
PART NO. HOS-4200<br />
PART NO. HOS-4000<br />
This 4½" x 3½" x 3" station has a selflatch<strong>in</strong>g<br />
red emergency-stop palm button<br />
<strong>in</strong> a NEMA 12 metal enclosure. To reset<br />
this button, turn it to the right.<br />
PART NO. HOS-4000<br />
(FOR USE WITH REVERSING<br />
MOTOR STARTERS)<br />
This 3½" x 8¾" x 3" station has motor<br />
forward and reverse push buttons<br />
and a self-latch<strong>in</strong>g emergency-stop<br />
palm button <strong>in</strong> a NEMA 12 metal<br />
enclosure.<br />
PART NO. HOS-4200<br />
PART NO. VOS-2000<br />
(FOR USE WITH NONREVERSING<br />
MOTOR STARTERS)<br />
This 6¾" x 3½" x 3" station has a motor<br />
on push button and a self-latch<strong>in</strong>g red<br />
emergency-stop palm button <strong>in</strong> a NEMA<br />
12 metal enclosure.<br />
PART NO. VOS-2000<br />
PART NO. VOS-1100<br />
(FOR USE WITH REVERSING MOTOR<br />
STARTERS)<br />
This 8¾" x 3½" x 3" station has motor on and<br />
stop push buttons and a motor forward/reverse<br />
selector switch <strong>in</strong> a NEMA 12 metal enclosure.<br />
PART NO. VOS-1100<br />
PART NO. VOS-2100<br />
PART NO. HOS-4201<br />
(FOR USE WITH REVERSING<br />
MOTOR STARTERS)<br />
This 3½" x 10½" x 3" station has<br />
a motor jog/run selector switch,<br />
forward and reverse push buttons,<br />
and a self-latch<strong>in</strong>g emergencystop<br />
palm button <strong>in</strong> a NEMA 12<br />
metal enclosure.<br />
PART NO. HOS-4201<br />
(FOR USE WITH REVERSING MOTOR<br />
STARTERS)<br />
This 8¾" x 3½" x 3" station has a motor<br />
forward/reverse selector switch, a motor<br />
on push button, and a self-latch<strong>in</strong>g red<br />
emergency-stop palm button <strong>in</strong> a NEMA 12<br />
metal enclosure.<br />
PART NO. PB5R00-01—<br />
Self-Latch<strong>in</strong>g Emergency-Stop Mushroom-<br />
Head Push Button<br />
PART NO. VOS-2100<br />
PART NO. VOS-1000<br />
(FOR USE WITH NONREVERSING<br />
MOTOR STARTERS)<br />
This 6¾" x 3½" x 3" station has motor<br />
on and stop push buttons <strong>in</strong> a NEMA 12<br />
metal enclosure.<br />
PART NO. VOS-1000<br />
PART NO. CTM-506—<br />
Yellow Emergency-Stop<br />
Nameplate (22.5 mm hole)<br />
PART NO. CTC-550—<br />
Push/Pull to Release<br />
Emergency-Stop Push Button<br />
PART NO. CTM-548—<br />
Yellow Emergency-Stop<br />
Nameplate (30 mm hole)<br />
66 | SAFETY SHIELDS
DANGER SIGNS AND LABELS<br />
The signs offered <strong>in</strong> this catalog are .055" thick l<strong>in</strong>ear polyethylene. They are semi-rigid plastic and are capable of withstand<strong>in</strong>g a temperature range<br />
of -60° to 130° F. They are resistant to tears and may be mounted with nails, rivets, screws, bolts, nylon lock-straps, double-face adhesive tape, etc.<br />
Each sign is protected from fad<strong>in</strong>g, chipp<strong>in</strong>g, scratch<strong>in</strong>g, weather extremes, physical abuse, grease, oil, moisture, chemicals and acids. These signs<br />
do not rust, dent, or corrode. They do not curl up or rip and are lightweight and easy to handle.<br />
OPERATOR SAFETY PRECAUTIONS FOR METAL-CUTTING MACHINERY—8½" X 11" X .055" THICK<br />
PART NO. KSC-048—ENGLISH<br />
PART NO. KSC-048S—SPANISH<br />
PART NO. KSC-048F—FRENCH<br />
KSC-048 FRONT (ENGLISH)<br />
KSC-048 BACK (ENGLISH)<br />
No Opere Esta Máqu<strong>in</strong>a<br />
Hasta Haber Leído y Comprendido las<br />
Siguientes Medidas de Precaución y Seguridad.<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
Nunca opere esta máqu<strong>in</strong>a hasta haber<br />
comprendido que es peligrosa. Nunca ponga las<br />
manos ni n<strong>in</strong>guna parte del cuerpo en esta<br />
máqu<strong>in</strong>a, pues podría perder dedos, miembros o<br />
hasta morir.<br />
Nunca opere esta máqu<strong>in</strong>a s<strong>in</strong> usar la defensa,<br />
protección o dispositivo de seguridad correspondiente<br />
a ese “lugar de operación”* el cual le<br />
protegerá en todo momento evitando que sufra<br />
lesi<strong>one</strong>s.<br />
Siempre use lentes de seguridad, protección para<br />
la cara, o ambos, así como cualquier otro equipo<br />
de protección y seguridad personal, cuando opere<br />
esta máqu<strong>in</strong>a.<br />
Nunca use ropa suelta, joyas, ni el cabello suelto,<br />
pues p<strong>one</strong>n en peligro su seguridad personal.<br />
Cuando hay piezas en movimiento, tales como<br />
cortadoras, sujetadores y mesas, preste especial<br />
atención a la ropa y cabellos sueltos, corbatas,<br />
anillos, collares, pulseras de reloj, etc.<br />
Siempre use herramientas de mano para colocar<br />
o retirar material del lugar de trabajo, o cualquier<br />
otra parte peligrosa de la máqu<strong>in</strong>a. Si necesita<br />
alcanzar algo no lo haga sobre ni a través de la<br />
máqu<strong>in</strong>a.<br />
Nunca opere esta máqu<strong>in</strong>a a menos que haya<br />
sido debidamente entrenado y haya recibido y<br />
entienda todas las <strong>in</strong>strucci<strong>one</strong>s de operación.<br />
Asegúrese de saber cómo funciona la máqu<strong>in</strong>a y<br />
cómo es controlada.<br />
Nunca opere esta máqu<strong>in</strong>a a menos que esté<br />
seguro que la protección está colocada<br />
correctamente y en perfecto funcionamiento. Si<br />
tiene dudas, llame a su supervisor.<br />
Nunca opere esta máqu<strong>in</strong>a si no está funcionando<br />
correctamente, o si usted nota cualquier ruido<br />
<strong>in</strong>usual o cambio en el funcionamiento de la<br />
misma. Suspenda la operación <strong>in</strong>mediatamente y<br />
avise a su supervisor.<br />
Siempre notifique <strong>in</strong>mediatamente a su supervisor<br />
si observa una acción o condición peligrosa.<br />
Siempre mantenga ordenada la zona de trabajo.<br />
Especialmente, guarde las herramientas o piezas<br />
que pudieren soltarse y provocar una situación de<br />
peligro.<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
Nunca ponga la máqu<strong>in</strong>a en funcionamiento con<br />
la llave para tuercas en el mandril. Se debe<br />
retirar del mandril la llave para mandril<br />
<strong>in</strong>mediatamente después de usarla, o de lo<br />
contrario, usar una llave para mandril con resorte.<br />
Nunca usar n<strong>in</strong>gún comp<strong>one</strong>nte de esta máqu<strong>in</strong>a<br />
ni dispositivo de seguridad para apisonar, ni<br />
tampoco alterarlos, retirarlos o romperlos.<br />
Todos los Empleados encargados de ajustar,<br />
p<strong>one</strong>r en posición o <strong>in</strong>stalar el equipo,<br />
dispositivos, defensas o protectores de seguridad<br />
deben seguir las <strong>in</strong>strucci<strong>one</strong>s del empleador.<br />
Siempre verificar la <strong>in</strong>stalación durante cada<br />
turno y entre un trabajo y otro, para asegurarse de<br />
que todos los dispositivos de seguridad estén en<br />
funcionamiento y que la operación se realizará de<br />
una manera segura. Cuando las condici<strong>one</strong>s de<br />
operación son extremadamente peligrosas, puede<br />
ser necesario verificar con más frecuencia.<br />
Asegúrese de que todas las personas estén<br />
lejos de la máqu<strong>in</strong>a antes de comenzar el ciclo,<br />
especialmente cuando hay varios operadores<br />
presentes. No operar la máqu<strong>in</strong>a a menos que<br />
usted y todos los operadores y/o ayudantes estén<br />
protegidos contra lesi<strong>one</strong>s por una defensa o<br />
dispositivo de seguridad.<br />
Siempre esté alerta (no se distraiga) y nunca<br />
opere esta máqu<strong>in</strong>a bajo la <strong>in</strong>fluencia del alcohol<br />
o cualquier droga, <strong>in</strong>cluyendo medicamentos<br />
recetados por el médico.<br />
Personal encargado del mantenimiento e<br />
<strong>in</strong>stalación: Nunca trabajar en esta máqu<strong>in</strong>a a<br />
menos que esté apagada y atrancada, que los<br />
comp<strong>one</strong>ntes giratorios estén detenidos y que<br />
toda la energía (eléctrica, eólica, hidráulica, etc.)<br />
esté en cero.<br />
Siempre esté preparado para una situación de<br />
emergencia. Usted debe saber cómo detener y<br />
apagar la máqu<strong>in</strong>a si es necesario.<br />
Nunca opere esta máqu<strong>in</strong>a a menos que todos<br />
los aparatos mecánicos de transmisión de energía<br />
(ejes, engranajes, etc.) y equipo auxiliar, estén<br />
libres de riesgos.<br />
* Lugar de Operación-“El lugar de la máqu<strong>in</strong>a-herramienta donde se coloca el material y se realiza el proceso.” (ANSI B11.19)<br />
NOTIFICATION AL EMPLEADOR: Se debe dar estas “Precauci<strong>one</strong>s Para la Seguridad del Operador” a todos<br />
los operadores (<strong>in</strong>cluyendo al personal que realiza la <strong>in</strong>stalación, el mantenimiento y los supervisores)<br />
de esta máqu<strong>in</strong>a. Además, se debe colgar esta cartilla sobre la máqu<strong>in</strong>a, en lugar accesible y visible al<br />
operador. Si lo solicita, puede obtener cartillas adicionales.<br />
IMPORTANTE: Cuando por desconocimiento del idioma o <strong>in</strong>strucción <strong>in</strong>suficiente una persona esté impedida<br />
de leer y comprender el contenido de estas Precauci<strong>one</strong>s Para la Seguridad del Operador, usted debe<br />
traducir esta <strong>in</strong>formación, o hacerla leer o <strong>in</strong>terpretar para esa persona. Asegúrese de que la haya<br />
comprendido. Si se requiere cartillas en <strong>in</strong>gles o en francés, sírvase consultar a la fábrica.<br />
SE DEBE REVISAR ESTAS PRECAUCIONES DIARAMENTE<br />
KSC-048S FRONT (SPANISH)<br />
OSPPS/XXXX/299<br />
KSC-048S BACK (SPANISH)<br />
SAFETY SHIELDS | 67
SHIELD SIGN—5" X 6" X .055" THICK<br />
GENERAL MACHINE SIGN—10" X 12" X .055" THICK<br />
PART NO. KSC-046—ENGLISH<br />
PART NO. KSC-046S—SPANISH<br />
PART NO. KSC-046F—FRENCH<br />
PART NO. KSC-056—ENGLISH<br />
PART NO. KSC-056S—SPANISH<br />
PART NO. KSC-056F—FRENCH<br />
SAW BLADE SIGN—5" X 6" X .055" THICK<br />
REVERSE SIDE OF SIGNS<br />
PART NO. KSC-058—ENGLISH<br />
PART NO. KSC-058S—SPANISH<br />
PART NO. KSC-058F—FRENCH<br />
ELECTRICAL LABEL: WARNING—HAZARDOUS VOLTAGE<br />
ELECTRICAL LABEL: DANGER—HIGH VOLTAGE<br />
PART NO. KST-152—2½" X 1½" X .002" THICK<br />
PART NO. KST-153—3" X 5" X .002" THICK<br />
PART NO. KST-194—2-7⁄8" X 5-7⁄8" X .003" THICK<br />
68 | SAFETY SHIELDS
SFM-2010-FULL-new_SFM <strong>Catalog</strong> - 2010 11/10/10 2:31 PM Page 72<br />
Survey for Cutt<strong>in</strong>g and Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
5795 Logistics Parkway 4620 Hydraulic • <strong>Rockford</strong>, RoadIL 61109<br />
<strong>Rockford</strong>, IL 61109-2695<br />
Toll-Free: 1-800-922-7533 Toll-Free 1-800-922-7533<br />
• Ph<strong>one</strong>: 815-874-7891 • Fax: 815-874-6144<br />
Web site: www.rockfordsystems.com Ph<strong>one</strong> 815-874-7891• E-mail: sales@rockfordsystems.com<br />
Fax 815-874-6144<br />
Company<br />
Address<br />
City, State, Zip<br />
Attention<br />
Teleph<strong>one</strong> No. Date Representative<br />
Fax No.<br />
Surveyed By<br />
No.<br />
(Proposal Sequence Reference)<br />
When fill<strong>in</strong>g out this form, be sure the <strong>in</strong>formation is filled <strong>in</strong> for satisfy<strong>in</strong>g the basic areas of safety.<br />
Basic Areas—1. <strong>Safeguard<strong>in</strong>g</strong> 2. Control 3. Disconnect 4. Starter 5. Cover 6. Other Considerations<br />
For identification and reference, please fill <strong>in</strong> this area first. Mach<strong>in</strong>e No.__________________ Dept._____________________<br />
Manufacturer________________________________ Model No.______________________ Serial No.___________________<br />
INSTALLATION ■ N ■ Y Is mach<strong>in</strong>e presently out of service? ■ N ■ Y<br />
1<br />
1. <strong>Safeguard<strong>in</strong>g</strong>: ■ Has ■ Provide ■ Contact Manufacturer<br />
■ Drill: ■ Press ■ Gang: No. of Heads:_________ ■ Radial ■ Other____________<br />
Is a drill shield required? ■ N ■ Y<br />
If Y, what style? (circle <strong>one</strong>) Alum<strong>in</strong>um–Telescop<strong>in</strong>g–Chip: Sm. or Lg.–Universal–Flexible<br />
If alum<strong>in</strong>um: Is front h<strong>in</strong>ge required? ■ N ■ Y If Y, ■ 2-Tier: Sm or Lg ■ 3-Tier<br />
Is side h<strong>in</strong>ge required? ■ N ■ Y If Y, ■ 2-Tier ■ 3-Tier<br />
If telescop<strong>in</strong>g: (check <strong>one</strong>) ■ 2-Tier ■ 3-Tier ■ Quill Dia._____" ■ Lug Type<br />
If universal:<br />
What is the arm length? (circle <strong>one</strong>) 21" 31" 44"<br />
What style is required? (circle <strong>one</strong>)<br />
Sm. 30° Lg. 30° 90° 30°/90° Sm. Flat Lg. Flat Sm. Concave Lg. Concave<br />
If flexible: What is the arm length? (circle <strong>one</strong>) 12" 18" 24" What style? DM MB<br />
What size shield?(circle <strong>one</strong>) 6" x 8" 10" x 12" (circle <strong>one</strong>)<br />
■ Lathe: ■ Eng<strong>in</strong>e ■ Turret ■ VTL ■ Other _________________________<br />
Is a lathe chuck shield required? ■ N ■ Y<br />
If Y, what is the chuck diameter when jaws are extended? ______________________"<br />
Style: (circle <strong>one</strong>) Transparent Steel: Sm or Lg. Slid<strong>in</strong>g<br />
Is a mount<strong>in</strong>g bracket required? (required with transparent and sm<strong>all</strong> steel) ■ N ■ Y<br />
If Y, what type? (circle <strong>one</strong>) A A1 B B2<br />
Is an electrical <strong>in</strong>terlock<strong>in</strong>g bracket assembly required? ■ N ■ Y<br />
Is a spr<strong>in</strong>g-loaded chuck wrench required? ■ N ■ Y<br />
If Y, what size________"? What style? Standard Longer What shape? Square Hex<br />
Is a crosslide-travel shield required? ■ N ■ Y (circle style and shape)<br />
If Y, what model? (circle <strong>one</strong>) Sm<strong>all</strong> Large<br />
Are supplemental shields required? ■ N ■ Y<br />
If Y, what style(s)?______________________________________________________<br />
■ Mill: ■ Vertical ■ Horizontal ■ Jig ■ Bridge Size: ■ Sm<strong>all</strong> ■ Med. ■ Large<br />
Is a mill<strong>in</strong>g mach<strong>in</strong>e shield required? ■ N ■ Y<br />
If Y, what style? (circle <strong>one</strong>) Slide/Sw<strong>in</strong>g Aside–Bridgeport–Chip: Sm. or Lg.–Universal–Flexible<br />
If slide and sw<strong>in</strong>g aside:<br />
What is the length of the bed?______" Are rear shields required? ■ N ■ Y<br />
Is an electrical <strong>in</strong>terlock<strong>in</strong>g bracket assembly required? ■ N ■ Y<br />
If Bridgeport: (circle <strong>one</strong>) Front Shield Rear Shield<br />
If universal or flexible: See drill section above.<br />
If chip: See drill section above.<br />
Are supplemental shields required? ■ N ■ Y<br />
If Y, what style(s)?______________________________________________________<br />
Are Bridgeport belt covers required? ■ N ■ Y (Model J)<br />
■ Gr<strong>in</strong>der: ■ Bench/Pedestal ■ Surface ■ OD ■ ID ■ Other________________<br />
Is a gr<strong>in</strong>der shield required? ■ N ■ Y<br />
If Y, what style?<br />
■ Double-Wheel Shield (6" x 18") ■ S<strong>in</strong>gle-Wheel Shield (6" x 6")<br />
■ Pivot Mount (6" x 6 3 ⁄8") ■ Standard Mount: 6 1 ⁄4" x 5 1 ⁄4" 8 1 ⁄2" x 6" 12 3 ⁄4" x 12"<br />
Quantity_________________<br />
(circle size)<br />
■ Saw: ■ Table ■ Cutoff ■ Radial Arm ■ Band ■ Other____________<br />
Is a shield for a saw required? ■ N ■ Y If Y, use other mach<strong>in</strong>e specs for furnish<strong>in</strong>g shield.<br />
72 C<strong>all</strong> Toll-Free 1-800-922-7533<br />
SAFETY SHIELDS | 69
SFM-2010-FULL-new_SFM <strong>Catalog</strong> - 2010 11/10/10 2:31 PM Page 73<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
■ Other: ■ Borer ■ Broach ■ Planer ■ Mach<strong>in</strong><strong>in</strong>g Center ■ Other________________<br />
Is a free-stand<strong>in</strong>g shield required? ■ N ■ Y<br />
If Y, what size? ■ 48" x 48" ■ 48" x 60" ■ 48" x 72" ■ 48" x 96"<br />
Is a magnetic-base shield required? ■ N ■ Y<br />
If Y, what size? ■ Sm<strong>all</strong> Flat ■ Medium Flat ■ Large Flat ■ Sm<strong>all</strong> Concave<br />
■ Large Concave ■ With Arm Extension<br />
Is a special shield or guard required? ■ N ■ Y If Y, what style?_________________<br />
2. Control:<br />
A. Is a transformer for 115-V power supply required? ■ N/A ■ N ■ Y<br />
B. Is a red emergency-stop button or cable required? ■ N ■ Y<br />
If Y, check <strong>one</strong>: ■ Sm<strong>all</strong> Button W/Twist Reset ■ Large Button With Latch & Mntg. Box<br />
■ Cable & Switch Assembly PLUS ■ KSC-056 Sign<br />
3. Disconnect:<br />
A. Is an electrical disconnect switch required? ■ N ■ Y If Y, furnish HP, FLA and<br />
Voltage <strong>in</strong> 4A.<br />
B. How is the disconnect to be furnished (if required)? ■ Separate ■ Combo W/Starter<br />
C. Plug lockout? ■ N/A ■ N ■ Y<br />
D. Air lockout valve? ■ N/A ■ N ■ Y If Y: (circle <strong>one</strong>) 1<br />
⁄4" 1<br />
⁄2" 3<br />
⁄4"<br />
4. Starter:<br />
A. Is a magnetic motor starter required? ■ N ■ Y<br />
If Y provide: _______ Horsepower _______ RPM<br />
_______ Full-Load Amps _______ Voltage<br />
_______ Hz ■ 1 Phase ■ 3 Phase<br />
B. How is starter to be furnished (if required)? ■ Separate ■ Combo W/Disconnect<br />
C. What type of ma<strong>in</strong> drive starter is required? Nonrevers<strong>in</strong>g ■ N ■ Y Revers<strong>in</strong>g ■ N ■ Y<br />
D. Is a remote push-button station required? ■ N ■ Y<br />
E. Is the motor two-speed? ■ N ■ Y If Y, provide motor nameplate data.<br />
F. Is the motor jogged or reversed frequently? ■ N ■ Y<br />
G. Is a table motor starter required? ■ N ■ Y<br />
Estimate<br />
Actual<br />
If Y, provide: ________ Horsepower ________<br />
________ Full-Load Amps ________<br />
________ Voltage ________<br />
H. Is a coolant pump motor starter required? ■ N ■ Y<br />
Estimate<br />
Actual<br />
If Y, provide: ________ Horsepower ________ Note: If other motor starters<br />
________ Full-Load Amps ________ are required, please provide<br />
________ Voltage ________<br />
appropriate <strong>in</strong>formation.<br />
5. Cover:<br />
Do any mechanical power-transmission apparatuses need to be covered up to 7 feet<br />
above floor or platform? ■ N ■ Y If Y, what needs to be covered?<br />
Gears ■ N ■ Y Leadscrew ■ N ■ Y Pulley and Belts ■ N ■ Y<br />
Sprockets and Cha<strong>in</strong> ■ N ■ Y Horizontal Shaft ■ N ■ Y Other_________________<br />
Shaft End ■ N ■ Y Vertical Shaft ■ N ■ Y<br />
6. Other Considerations:<br />
A. Does the shield require an electrical <strong>in</strong>terlock switch? ■ N/A ■ N ■ Y<br />
Is a mount<strong>in</strong>g bracket required? ■ N ■ Y<br />
B. Does the <strong>in</strong>terlock require a timer or stop-motion detector? ■ N/A ■ N ■ Y<br />
If Y: ■ Timer ■ Stop-Motion Detector PLUS ■ Proximity Switch Set<br />
C. Is a safety relay required? ■ N ■ Y If Y: ■ 24 V DC ■ 115 V AC<br />
D. Is an electrical power cutoff system w/cha<strong>in</strong> required? ■ N/A ■ N ■ Y<br />
E. Is an electronic motor brake required? ■ N ■ Y<br />
If Y, be sure that <strong>all</strong> of 4A is completed.<br />
Start-Up Time_____sec Coastdown Time_____sec No. of Brak<strong>in</strong>g Stops/Hr______<br />
Does the electronic motor brake require:<br />
■ Zero-Speed Sens<strong>in</strong>g ■ Extended Brak<strong>in</strong>g Time ■ Mechanical Brake Release<br />
■ High Brake Torque ■ Other __________________<br />
Does the mach<strong>in</strong>e have:<br />
■ Manual Brake ■ Variable-Speed Drive ■ Forward/Revers<strong>in</strong>g Starter<br />
■ S<strong>in</strong>gle-Speed Motor ■ High-Inertia Loads ■ Mechanical-Hold<strong>in</strong>g Brake<br />
F. Are danger signs required? ■ N ■ Y<br />
Survey for Cutt<strong>in</strong>g and Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
70 | SAFETY SHIELDS<br />
www.rockfordsystems.com 73
OSHA STANDARDS<br />
OSHA 29 CFR 1910.212 and a portion of 1910.219 are <strong>in</strong>cluded <strong>in</strong> this<br />
catalog for use as a reference when determ<strong>in</strong><strong>in</strong>g safety requirements for<br />
br<strong>in</strong>g<strong>in</strong>g cutt<strong>in</strong>g and turn<strong>in</strong>g mach<strong>in</strong>es <strong>in</strong>to compliance. Please note that<br />
29 CFR 1910.147 (lockout/tagout) is not <strong>in</strong>cluded here but it is an OSHA<br />
standard an employer must comply with for <strong>all</strong> mach<strong>in</strong>es and equipment.<br />
29 CFR 1910.212 GENERAL REQUIREMENTS FOR ALL MACHINES<br />
(a) Mach<strong>in</strong>e guard<strong>in</strong>g — (1) Types of guard<strong>in</strong>g. One or more<br />
methods of mach<strong>in</strong>e guard<strong>in</strong>g sh<strong>all</strong> be provided to protect the operator<br />
and other employees <strong>in</strong> the mach<strong>in</strong>e area from hazards such as those<br />
created by po<strong>in</strong>t of operation, <strong>in</strong>go<strong>in</strong>g nip po<strong>in</strong>ts, rotat<strong>in</strong>g parts, fly<strong>in</strong>g<br />
chips and sparks. Examples of guard<strong>in</strong>g methods are barrier guards,<br />
two-hand tripp<strong>in</strong>g devices, electronic safety devices, etc.<br />
(2) General requirements for mach<strong>in</strong>e guards. Guards sh<strong>all</strong> be<br />
affixed to the mach<strong>in</strong>e where possible and secured elsewhere if for any<br />
reason attachment to the mach<strong>in</strong>e is not possible. The guard sh<strong>all</strong> be<br />
such that it does not offer an accident hazard <strong>in</strong> itself.<br />
(3) Po<strong>in</strong>t of operation guard<strong>in</strong>g. (i) Po<strong>in</strong>t of operation is the<br />
area on the mach<strong>in</strong>e where work is actu<strong>all</strong>y performed upon the material<br />
be<strong>in</strong>g processed.<br />
(ii) The po<strong>in</strong>t of operation of mach<strong>in</strong>es whose operation exposes<br />
an employee to <strong>in</strong>jury, sh<strong>all</strong> be guarded. The guard<strong>in</strong>g device sh<strong>all</strong> be <strong>in</strong><br />
conformity with any appropriate standards therefor; or, <strong>in</strong> the absence of<br />
applicable specific standards, sh<strong>all</strong> be so designed and constructed as to<br />
prevent the operator from hav<strong>in</strong>g any part of his body <strong>in</strong> the danger z<strong>one</strong><br />
dur<strong>in</strong>g the operat<strong>in</strong>g cycle.<br />
(iii) Special hand tools for plac<strong>in</strong>g and remov<strong>in</strong>g material sh<strong>all</strong><br />
be such as to permit easy handl<strong>in</strong>g of material without the operator<br />
plac<strong>in</strong>g a hand <strong>in</strong> the danger z<strong>one</strong>. Such tools sh<strong>all</strong> not be <strong>in</strong> lieu of other<br />
guard<strong>in</strong>g required by this section, but can only be used to supplement<br />
protection provided.<br />
(iv) The follow<strong>in</strong>g are some of the mach<strong>in</strong>es which usu<strong>all</strong>y<br />
require po<strong>in</strong>t-of-operation guard<strong>in</strong>g:<br />
(a) Guillot<strong>in</strong>e cutters.<br />
(b) Shears.<br />
(c) Alligator shears.<br />
(d) Power presses.<br />
(e) Mill<strong>in</strong>g mach<strong>in</strong>es.<br />
(f) Power saws.<br />
(g) Jo<strong>in</strong>ters.<br />
(h) Portable power tools.<br />
(i) Form<strong>in</strong>g rolls and calenders.<br />
(4) Barrels, conta<strong>in</strong>ers, and drums. Revolv<strong>in</strong>g drums, barrels<br />
and conta<strong>in</strong>ers sh<strong>all</strong> be guarded by an enclosure which is <strong>in</strong>terlocked<br />
with the drive mechanism, so that the barrel, drum or conta<strong>in</strong>er cannot<br />
revolve unless the guard enclosure is <strong>in</strong> place.<br />
(5) Exposure of blades. When the periphery of the blades of a<br />
fan is less than seven (7) feet above the floor or work<strong>in</strong>g level, the blades<br />
sh<strong>all</strong> be guarded. The guard sh<strong>all</strong> have open<strong>in</strong>gs no larger then <strong>one</strong>-half<br />
(½) <strong>in</strong>ch.<br />
(b) Anchor<strong>in</strong>g fixed mach<strong>in</strong>ery. Mach<strong>in</strong>es designed for a fixed<br />
location sh<strong>all</strong> be securely anchored to prevent walk<strong>in</strong>g or mov<strong>in</strong>g.<br />
29 CFR 1910.219 MECHANICAL<br />
POWER-TRANSMISSION APPARATUS<br />
(b) Prime-mover guards—(1) Flywheels. Flywheels located so<br />
that any part is seven (7) feet or less above floor or platform sh<strong>all</strong> be<br />
guarded <strong>in</strong> accordance with the requirements of this subparagraph:<br />
(i) With an enclosure of sheet, perforated, or expanded metal,<br />
or woven wire;<br />
(ii) With guard rails placed not less than fifteen (15) <strong>in</strong>ches nor<br />
more than twenty (20) <strong>in</strong>ches from rim. When flywheel extends <strong>in</strong>to pit or<br />
is with<strong>in</strong> 12 <strong>in</strong>ches of floor, a standard toeboard sh<strong>all</strong> also be provided;<br />
(iii) When the upper rim of flywheel protrudes through a<br />
work<strong>in</strong>g floor, it sh<strong>all</strong> be entirely enclosed or surrounded by a guardrail<br />
and toeboard.<br />
(iv) For flywheels with smooth rims five (5) feet or less <strong>in</strong><br />
diameter, where the preced<strong>in</strong>g methods cannot be applied, the follow<strong>in</strong>g<br />
may be used: a disk attached to the flywheel <strong>in</strong> such manner as<br />
to cover the spokes of the wheel on the exposed side and present a<br />
smooth surface and edge, at the same time provid<strong>in</strong>g means for periodic<br />
<strong>in</strong>spection. An open space, not exceed<strong>in</strong>g four (4) <strong>in</strong>ches <strong>in</strong> width, may<br />
be left between the outside edge of the disk and the rim of the wheel<br />
if desired, to facilitate turn<strong>in</strong>g the wheel over. Where a disk is used, the<br />
keys or other dangerous projections not covered by disk sh<strong>all</strong> be cut off<br />
or covered. This subdivision does not apply to flywheels with solid web<br />
centers.<br />
(v) Adjustable guard to be used for start<strong>in</strong>g eng<strong>in</strong>e or for<br />
runn<strong>in</strong>g adjustment may be provided at the flywheel of gas or oil eng<strong>in</strong>es.<br />
A slot open<strong>in</strong>g for jack bar will be permitted.<br />
(vi) Wherever flywheels are above work<strong>in</strong>g areas, guards sh<strong>all</strong><br />
be <strong>in</strong>st<strong>all</strong>ed hav<strong>in</strong>g sufficient strength to hold the weight of the flywheel<br />
<strong>in</strong> the event of a shaft or wheel mount<strong>in</strong>g failure.<br />
Note: This is not the entire content of 29 CFR 1910.219.<br />
This catalog does not cover <strong>all</strong> aspects of a safety program. There are<br />
many publications on the subject of safety. Please see page 4 for a list<strong>in</strong>g<br />
of safety sources.<br />
SAFETY SHIELDS | 71
A<br />
B<br />
C<br />
D<br />
E<br />
F<br />
Adjustable Slide Shields............................................49<br />
All-Purpose Shields ............................................... 49-59<br />
Alum<strong>in</strong>um Drill Press Shields, Heavy-Duty.....................25<br />
ANSI Standards .............................................................4<br />
B<strong>all</strong> & Socket Shields ......................................... 54-56<br />
Band Saw Shields........................................................47<br />
Basic Safety Requirements ........................................ 3-7<br />
Belt Covers, Mill<strong>in</strong>g Mach<strong>in</strong>e.........................................42<br />
Belt Sander Shields .....................................................48<br />
Bench Gr<strong>in</strong>der Safety Gauge ........................................46<br />
Bench Gr<strong>in</strong>der Shields ......................................18, 43-46<br />
Bridgeport Mill<strong>in</strong>g Mach<strong>in</strong>e Shields......................... 38-39<br />
Bridgeport Vertical Mill<strong>in</strong>g Mach<strong>in</strong>e Controls .................39<br />
Broach<strong>in</strong>g Type Mach<strong>in</strong>e Shields...................................21<br />
Chip Shields for Bridgeport Mill<strong>in</strong>gMach<strong>in</strong>es...... 38-39<br />
Chuck Wrenches, Lathe.......................................... 34-35<br />
Clamp Kit, Universal B<strong>all</strong> & Socket Shields.....................53<br />
Crosslide-Travel Lathe Shields ...............................15, 29<br />
Danger Signs and Labels .................................... 67-68<br />
Disc Sander Shield Assemblies ....................................48<br />
Disconnect and Starter Part Number<strong>in</strong>g System Chart ...64<br />
Disconnect Switches, Motor Starters, & Accessories.......63<br />
Double-Wheel Gr<strong>in</strong>der Shields......................................44<br />
Drill Press Shields...............................................8-11, 25<br />
Electrical Interlock Assembly ...................................42<br />
Electrical Power Cutoff System (Interlock)......................60<br />
Electrical Requirements (NFPA 79)..................................4<br />
Electric<strong>all</strong>y Interlocked Crosslide/Carriage Travel<br />
Lathe Shields ..............................................................15<br />
Electric<strong>all</strong>y Interlocked Drill Press Shields ................. 8-11<br />
Electric<strong>all</strong>y Interlocked Gr<strong>in</strong>der & Tool Gr<strong>in</strong>der Shields.....19<br />
Electric<strong>all</strong>y Interlocked Heavy-Duty Shields ............... 8-24<br />
Electric<strong>all</strong>y Interlocked Lathe Shields ...................... 12-14<br />
Electric<strong>all</strong>y Interlocked Mill<strong>in</strong>g Mach<strong>in</strong>e Shields........ 16-18<br />
Electric<strong>all</strong>y Interlocked Slott<strong>in</strong>g and Broach<strong>in</strong>g Type<br />
Mach<strong>in</strong>e Shields..........................................................21<br />
Electric<strong>all</strong>y Interlocked Surface Gr<strong>in</strong>der Shields..............20<br />
Emergency Stop Buttons ...................................... 61-62<br />
Enclosed Transformers ................................................63<br />
Flexible Spr<strong>in</strong>g-Steel Arm Shields ...................... 54-57<br />
Free-Stand<strong>in</strong>g Shield Assembly ....................................59<br />
G<br />
H<br />
I<br />
L<br />
M<br />
O<br />
P<br />
R<br />
Gauge, Bench Gr<strong>in</strong>der Safety.....................................46<br />
Gr<strong>in</strong>der Shields, Surface...............................................20<br />
Gr<strong>in</strong>der & Tool Gr<strong>in</strong>der Shields, Electric<strong>all</strong>y Interlocked....19<br />
Heavy-Duty Alum<strong>in</strong>um Drill Press Shields ................25<br />
Heavy-Duty S<strong>in</strong>gle Buffer Shields..............................45<br />
IEC Fused Disconnect Switches, Magnetic Motor<br />
Starters, and Comb<strong>in</strong>ations ......................................63<br />
Interlock Assembly.......................................................42<br />
Interlocked Shields, Electric<strong>all</strong>y................................. 8-21<br />
Labels, Danger and Warn<strong>in</strong>g ............................... 67-68<br />
Large Steel Lathe Chuck Shields ..................................32<br />
Lathe Chuck Wrenches ......................................... 34-35<br />
Lathe Mount<strong>in</strong>g Brackets .............................................33<br />
Lock-A-Plugs ..............................................................60<br />
Lockout Hasps ............................................................60<br />
Lockouts ....................................................................60<br />
Lockout Valves ............................................................62<br />
Longer Lathe Chuck Wrenches.....................................35<br />
Mach<strong>in</strong>e Safety Requirements ............................... 3-7<br />
Magnetic-Base Shields........................................... 55-58<br />
Mill<strong>in</strong>g Mach<strong>in</strong>e Control, Bridgeport...............................39<br />
Mill<strong>in</strong>g Mach<strong>in</strong>e Belt Covers .........................................42<br />
Motor<br />
Starter, S<strong>in</strong>gle-Phase With E-Stop Button...............61<br />
Starters, Magnetic................................................63<br />
Mount<strong>in</strong>g Brackets, Lathe ............................................33<br />
Mount<strong>in</strong>g Plate, Steel........................................44, 55-58<br />
On/Off Magnetic-Base Shields .................................58<br />
OSHA Standards .........................................................71<br />
Part Number<strong>in</strong>g System Chart<br />
Disconnects and Starters ..................................64<br />
Remote Operator Stations..................................65<br />
Plug Hugger................................................................60<br />
Plug Lockouts..............................................................60<br />
Power Cutoff System....................................................60<br />
Rear Shield Assemblies ............................................41<br />
Remote Operator Station Part Number<strong>in</strong>g<br />
System Chart...............................................................65<br />
Remote Operator Stations ............................................66<br />
Rigid-Arm Magnetic-Base Shields ................................50<br />
<strong>Safeguard<strong>in</strong>g</strong> ........................................................ 8-58<br />
72 | SAFETY SHIELDS
S<br />
Safety Chip Shields .....................................................24<br />
Safety Gauge, Bench Gr<strong>in</strong>der .......................................46<br />
Safety on Band Saws ..................................................47<br />
Safety on Bench Gr<strong>in</strong>ders .................................19, 43-46<br />
Safety on Broach<strong>in</strong>g Type Mach<strong>in</strong>es..............................21<br />
Safety on Disc and Belt Sanders ..................................48<br />
Safety on Drill Presses .................................. 8-11, 22-25<br />
Safety on Gr<strong>in</strong>der and Tool Gr<strong>in</strong>ders..............................19<br />
Safety on Lathes ........................................ 12-14, 26-35<br />
Safety on Mill<strong>in</strong>g Mach<strong>in</strong>es ......................... 16-18, 36-42<br />
Safety on Slott<strong>in</strong>g Type Mach<strong>in</strong>es..................................21<br />
Safety on Surface Gr<strong>in</strong>ders...........................................20<br />
SAFS-200 ..................................................................62<br />
SAFS-300 ..................................................................62<br />
Sens<strong>in</strong>g Saf-Start ® Packages .......................................62<br />
Shields<br />
All-Purpose.................................................... 49-59<br />
Band Saw............................................................47<br />
Belt Sander..........................................................48<br />
Bench Gr<strong>in</strong>der...........................................19, 43-46<br />
Bridgeport, Chip............................................. 38-39<br />
Disc Sander.........................................................48<br />
Drill Press............................................. 8-11, 22-25<br />
Electric<strong>all</strong>y Interlocked...................................... 8-21<br />
Flexible Spr<strong>in</strong>g-Steel Arm................................ 54-57<br />
Free-Stand<strong>in</strong>g......................................................59<br />
Lathe.................................................. 12-14, 26-35<br />
Magnetic Base............................................... 55-58<br />
Mill<strong>in</strong>g Mach<strong>in</strong>e................................... 16-18, 36-42<br />
On/Off Magnetic...................................................58<br />
Rear Assemblies...................................................41<br />
Slide and Sw<strong>in</strong>g-Aside.................................... 40-41<br />
Universal B<strong>all</strong> & Socket................................... 51-53<br />
Signs, Danger........................................................ 67-58<br />
S<strong>in</strong>gle-Phase Disconnect/Starter ..................................61<br />
S<strong>in</strong>gle-Wheel Gr<strong>in</strong>der Shields .......................................44<br />
Slide and Sw<strong>in</strong>g-Aside Shields ............................... 40-41<br />
Slid<strong>in</strong>g Lathe Shields ...................................................28<br />
Sm<strong>all</strong> Steel Lathe Chuck Shields ..................................30<br />
T<br />
U<br />
W<br />
Spr<strong>in</strong>g-Loaded Chuck Wrenches ............................ 34-35<br />
Spr<strong>in</strong>g-Loaded/Self-Eject<strong>in</strong>g Chuck Keys<br />
—Drill Presses............................................................25<br />
Spr<strong>in</strong>g-Steel Arm Shields..............................................56<br />
Standard-Mount Gr<strong>in</strong>der Shields ..................................45<br />
Standard Size Lathe Chuck Wrenches...........................34<br />
Standards, ANSI ............................................................4<br />
Standards, OSHA ........................................................71<br />
Survey for Cutt<strong>in</strong>g and Turn<strong>in</strong>g Mach<strong>in</strong>es ................ 69-70<br />
Tagouts .....................................................................60<br />
Terms and Conditions of Sale .......................................79<br />
Transformers, Enclosed............................................... 63<br />
Transparent Lathe Chuck Shields .................................32<br />
Universal B<strong>all</strong> & Socket Shields .......................... 51-53<br />
Warn<strong>in</strong>g Labels.................................................... 67-68<br />
Wrenches, Lathe Chuck......................................... 34-35<br />
SAFETY SHIELDS | 73
<strong>Safeguard<strong>in</strong>g</strong> Devices<br />
For Industrial Mach<strong>in</strong>es<br />
www.rockfordsystems.com
<strong>Safeguard<strong>in</strong>g</strong> Devices is a comprehensive<br />
catalog that features a wide-range of<br />
safeguard<strong>in</strong>g devices and other safety-related<br />
products for updat<strong>in</strong>g hazardous mach<strong>in</strong>ery<br />
and processes. These devices are designed<br />
for po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g as well<br />
as for auxiliary guard<strong>in</strong>g and large workenvelope<br />
safeguard<strong>in</strong>g.<br />
Some of the products <strong>in</strong> this catalog <strong>in</strong>clude<br />
presence-sens<strong>in</strong>g devices, area scann<strong>in</strong>g<br />
devices, tower light assemblies, Detect-A-<br />
F<strong>in</strong>ger ® drop-probe devices, and pressure<br />
sensitive safety mats. These products can<br />
be used to safeguard fabricat<strong>in</strong>g mach<strong>in</strong>es,<br />
metal-cutt<strong>in</strong>g mach<strong>in</strong>es, material handl<strong>in</strong>g<br />
equipment, woodwork<strong>in</strong>g mach<strong>in</strong>es, and more.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong>
IN GENERAL ....................................................................... 3-5<br />
PRESENCE-SENSING DEVICES.............................................. 6-7<br />
STOP-TIME MEASUREMENT DEVICE..................................... 8-9<br />
QUICK REFERENCE GUIDES.....................................................10<br />
POINT-OF-OPERATION LIGHT CURTAIN SYSTEM............... 11-18<br />
EZ-Screen Light Curta<strong>in</strong> System................................................. 11-14<br />
EZ-Screen Dimensions ...............................................................13<br />
EZ-Screen Response Times.........................................................13<br />
Noncascad<strong>in</strong>g Light Curta<strong>in</strong> Part Number<strong>in</strong>g Chart ......................14<br />
Remote Fixed Blank<strong>in</strong>g Switch ....................................................14<br />
Cascad<strong>in</strong>g Light Curta<strong>in</strong> Part Number<strong>in</strong>g Chart .......................... 15-16<br />
EZ-Screen Interfaces ......................................................................17<br />
Remote Operator Stations ...............................................................18<br />
Laser Alignment Tool.......................................................................18<br />
PERIMETER LIGHT BEAM SYSTEM.................................... 19-24<br />
Perimeter Light Beam System .........................................................19<br />
Perimeter Light Beam Dimensions ..................................................20<br />
Perimeter Light Beam Part Number<strong>in</strong>g Chart ...................................21<br />
Laser Alignment Tool .....................................................................21<br />
Perimeter Light Beam Interfaces .....................................................22<br />
Off/On Remote Operator Station ......................................................22<br />
SINGLE BEAM SYSTEM..................................................... 23-24<br />
S<strong>in</strong>gle Beam System ......................................................................23<br />
S<strong>in</strong>gle Beam Dimensions ................................................................23<br />
S<strong>in</strong>gle Beam Part Number<strong>in</strong>g Chart .................................................24<br />
Off/On Remote Operator Station ......................................................24<br />
Laser Alignment Tool.......................................................................24<br />
S3000 SAFETY LASER SCANNER...................................... 25-28<br />
S3000 Safety Laser Scanner ..........................................................25<br />
S3000 Mount<strong>in</strong>g Kits .....................................................................26<br />
S3000 Floor Stand..........................................................................26<br />
S3000 Dimensions .........................................................................27<br />
S3000 Safety Laser Scanner Part Number<strong>in</strong>g Chart..........................28<br />
ACCESSORIES................................................................... 29-31<br />
Tower Light Assemblies ............................................................ 29-30<br />
No-Go Indicator Light .....................................................................31<br />
Test Rods for Light Curta<strong>in</strong>s.............................................................31<br />
Optional Mount<strong>in</strong>g Brackets for Po<strong>in</strong>t-Of-Operation Light ......................<br />
Curta<strong>in</strong> <strong>Systems</strong>..............................................................................31<br />
SWING-AWAY BRACKETS.................................................. 32-35<br />
STATIONARY BRACKETS.................................................... 36-37<br />
FLOOR STAND.........................................................................37<br />
MIRRORS AND MIRROR BRACKETS.................................. 38-39<br />
TWO-HAND CONTROL....................................................... 40-42<br />
TWO-HAND TRIP............................................................... 43-44<br />
GATE (MOVABLE BARRIER) DEVICES................................. 45-51<br />
Type A Gate ...................................................................................45<br />
Type B Gate ............................................................................. 46-47<br />
Gate Assemblies.............................................................................48<br />
Gate Assembly Measurement Forms.......................................... 49-51<br />
SAFETY BUMPER....................................................................52<br />
PRESSURE-SENSITIVE SAFETY MATS............................... 53-57<br />
DETECT-A-FINGER ® DROP-PROBE DEVICES...................... 58-64<br />
RKC-000 and RCK-001 Series................................................... 58-60<br />
RKC-500 Series........................................................................ 61-62<br />
DAF-100 Series........................................................................ 63-64<br />
REFERENCES 67-72<br />
Function-Test<strong>in</strong>g Checklist for Light Curta<strong>in</strong>s.............................. 65-66<br />
Function-Test<strong>in</strong>g Checklist for Two-Hand Control..............................67<br />
Function-Test<strong>in</strong>g Checklist for Two-Hand Trip...................................68<br />
OSHA and ANSI Guard-Open<strong>in</strong>g Requirements.................................69<br />
OSHA and ANSI Guard-Open<strong>in</strong>g Scales............................................70<br />
Safety Distance Guide.....................................................................70<br />
<strong>Safeguard<strong>in</strong>g</strong> Sem<strong>in</strong>ars ..................................................................71<br />
INDEX ............................................................................... 72-73<br />
The applications described <strong>in</strong> this catalog are for <strong>in</strong>structional and <strong>in</strong>formational purposes only; the photos <strong>in</strong> this catalog are for illustrative purposes<br />
only. They may not represent actual usage. This catalog has been carefully checked for accuracy and is thought to be fully consistent with the<br />
products described here<strong>in</strong>. However, <strong>Rockford</strong> <strong>Systems</strong>, LLC does not assume liability for the contents of this publication or for the use of any<br />
products described here<strong>in</strong>. <strong>Rockford</strong> <strong>Systems</strong>, LLC reserves the right to make changes to the products and documentation without further notice.<br />
This document conta<strong>in</strong>s proprietary <strong>in</strong>formation protected by copyright. No part of this catalog may be reproduced, transmitted, stored <strong>in</strong> a retrieval<br />
system, or translated <strong>in</strong>to any language, <strong>in</strong> any form or by any means without prior written permission from <strong>Rockford</strong> <strong>Systems</strong>, LLC, 5795 Logistics<br />
Parkway, <strong>Rockford</strong>, Ill<strong>in</strong>ois 61109. <strong>Rockford</strong> <strong>Systems</strong> reserves the right to make changes or revisions to the material conta<strong>in</strong>ed <strong>in</strong> this catalog and<br />
cannot be held liable for <strong>in</strong>cidental or consequential damages result<strong>in</strong>g from the furnish<strong>in</strong>g, performance or use of this material.<br />
Copyright © 2019 by <strong>Rockford</strong> <strong>Systems</strong>, LLC. All rights reserved. Not to be reproduced <strong>in</strong> whole or <strong>in</strong> part without written permission. LITHO IN U.S.A.<br />
2 | SAFEGUARDING DEVICES
1. An Act–Public Law 91-596, 91st Congress, S. 2193,<br />
December 29, 1970, Duties, Section 5(a)(1)(2)(b)<br />
2. OSHA 29 CFR sections that an employer (user) must<br />
comply with <strong>in</strong>clude:<br />
3. OSHA 29 CFR 1910.147 The control of hazardous energy<br />
(lockout/tagout).<br />
4. OSHA 29 CFR 1910.301-1910.399 Electrical<br />
ANSI Publications<br />
B11– 2008 General Safety Requirements Common to<br />
ANSI B11 Mach<strong>in</strong>es<br />
B11.1 Mechanical Power Presses<br />
B11.2 Hydraulic Power Presses<br />
B11.3 Power Press Brakes<br />
B11.4 Shears<br />
B11.5 Iron Workers<br />
B11.6 Lathes<br />
B11.7 Cold Headers and Cold Formers<br />
B11.8 Drill<strong>in</strong>g, Mill<strong>in</strong>g, and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.9 Gr<strong>in</strong>d<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.10 Metal Saw<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.11 Gear and Spl<strong>in</strong>e Cutt<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.12 Roll Form<strong>in</strong>g and Roll Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.13 Automatic Screw/Bar and Chuck<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.14 Coil Slitt<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.15 Pipe, Tube, and Shape Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.16 Metal Powder Compact<strong>in</strong>g Presses<br />
B11.17 Horizontal Hydraulic Extrusion Presses<br />
B11.18 Coil Process<strong>in</strong>g <strong>Systems</strong><br />
B11.19 Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong><br />
B11.20 Integrated Manufactur<strong>in</strong>g <strong>Systems</strong><br />
B11.21 Mach<strong>in</strong>e Tools Us<strong>in</strong>g Lasers for Process<strong>in</strong>g<br />
Materials<br />
B11.22 Turn<strong>in</strong>g Centers and CNC Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.23 Mach<strong>in</strong><strong>in</strong>g Centers and CNC Mill<strong>in</strong>g, Drill<strong>in</strong>g,<br />
and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.24 Transfer Mach<strong>in</strong>es<br />
B11.TR1 Ergonomic Guidel<strong>in</strong>es<br />
B11.TR2 Mist Control Considerations<br />
B11.TR3 Risk Assessment and Risk Reduction<br />
B11.TR4 Selection of Programmable Electronic <strong>Systems</strong><br />
(PES/PLC) for Mach<strong>in</strong>e Tools<br />
B11.TR5 Sound Level Measurement Guidel<strong>in</strong>es<br />
B11.TR6 Safety Control <strong>Systems</strong> for Mach<strong>in</strong>e Tools<br />
B11.TR7 Design For Safety and Lean Manufactur<strong>in</strong>g<br />
R15.06 Robotic <strong>Safeguard<strong>in</strong>g</strong><br />
B15.1 Mechanical Power Transmission Apparatus<br />
B65.1 Pr<strong>in</strong>t<strong>in</strong>g Press <strong>Systems</strong><br />
B65.2 B<strong>in</strong>d<strong>in</strong>g and F<strong>in</strong>ish<strong>in</strong>g <strong>Systems</strong><br />
B65.5 Stand-Al<strong>one</strong> Platen Presses<br />
B151.1 Horizontal (Plastic) Injection Mold<strong>in</strong>g Mach<strong>in</strong>es<br />
B152.1 Hydraulic Die Cast<strong>in</strong>g Presses<br />
B154.1 Rivet Sett<strong>in</strong>g Mach<strong>in</strong>es<br />
B155.1 Packag<strong>in</strong>g and Packag<strong>in</strong>g-Related Convert<strong>in</strong>g<br />
Mach<strong>in</strong>ery<br />
01.1 Woodwork<strong>in</strong>g Mach<strong>in</strong>ery<br />
These standards can be purchased by contact<strong>in</strong>g:<br />
ANSI (American National Standards Institute, Inc.)<br />
25 West 43rd Street, 4th Floor<br />
New York, New York 10036<br />
(212) 642-4900 • www.ansi.org<br />
Another good reference for safety on mach<strong>in</strong>e tools is the follow<strong>in</strong>g<br />
publication from the National Safety Council:<br />
<strong>Safeguard<strong>in</strong>g</strong> Concepts Illustrated—7th Edition<br />
This publication can be purchased by contact<strong>in</strong>g:<br />
National Safety Council<br />
1121 Spr<strong>in</strong>g Lake Drive<br />
Itasca, IL 60143-3201<br />
1-800-621-7615 • www.nsc.org<br />
Other sources that can be used for reference <strong>in</strong>clude:<br />
1. NFPA 79, Electrical Standard for Industrial Mach<strong>in</strong>ery<br />
2. NEC (National Electrical Code) Handbook<br />
These can be purchased by contact<strong>in</strong>g:<br />
National Fire Protection Association<br />
1 Batterymarch Park<br />
Qu<strong>in</strong>cy, MA 02169<br />
(617) 770-3000 • www.nfpa.org<br />
3. NEMA (National Electrical Manufacturers Association)<br />
1300 North 17th Street, Suite 1752<br />
Rosslyn, VA 22209<br />
(703) 841-3200 • www.nema.org<br />
For additional safety <strong>in</strong>formation and assistance <strong>in</strong> devis<strong>in</strong>g,<br />
implement<strong>in</strong>g or revis<strong>in</strong>g your safety program, please contact the<br />
mach<strong>in</strong>e manufacturer, your state and local safety councils, <strong>in</strong>surance<br />
carriers, national trade associations, and your state’s occupational<br />
safety and health adm<strong>in</strong>istration.<br />
SAFEGUARDING DEVICES | 3
POINT-OF-OPERATION SAFEGUARDING<br />
<strong>Safeguard<strong>in</strong>g</strong> for metal-fabricat<strong>in</strong>g mach<strong>in</strong>es f<strong>all</strong>s <strong>in</strong>to three categories:<br />
barrier guards, devices, and other safeguard<strong>in</strong>g methods. The only<br />
exception to safeguard<strong>in</strong>g is when the hazardous open<strong>in</strong>g is 1/4” or less<br />
[OSHA 29 CFR 1910.217(c)(ii)].<br />
Some of the guards and devices described here can be used for<br />
auxiliary guard<strong>in</strong>g and for large work-envelope safeguard<strong>in</strong>g. Details<br />
can be found <strong>in</strong> each <strong>in</strong>dividual safeguard<strong>in</strong>g section.<br />
BARRIER GUARDS<br />
Barrier guards are designed to prevent entry of the operator’s hands or<br />
f<strong>in</strong>gers <strong>in</strong>to the po<strong>in</strong>t of operation. There are four types of barrier guards<br />
that can be furnished. They are die enclosure guards, fixed guards,<br />
adjustable guards, and <strong>in</strong>terlocked guards. Each of these guards must<br />
meet specific requirements. Please refer to <strong>Catalog</strong> EX-AL on barrier<br />
and perimeter guard<strong>in</strong>g for more <strong>in</strong>formation.<br />
SAFEGUARDING DEVICES<br />
Accord<strong>in</strong>g to OSHA 29 CFR 1910.217(c)(i), Po<strong>in</strong>t-of-operation devices<br />
sh<strong>all</strong> protect the operator by:<br />
(a) Prevent<strong>in</strong>g and/or stopp<strong>in</strong>g normal strok<strong>in</strong>g of the press if the<br />
operator’s hands are <strong>in</strong>advertently placed <strong>in</strong> the po<strong>in</strong>t of operation<br />
(presence-sens<strong>in</strong>g); or<br />
(b) Prevent<strong>in</strong>g the operator from <strong>in</strong>advertently reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation; or withdraw<strong>in</strong>g his hands, if they are <strong>in</strong>advertently located <strong>in</strong><br />
the po<strong>in</strong>t of operation as the dies close (pullbacks); or<br />
(c) Prevent<strong>in</strong>g the operator from <strong>in</strong>advertently reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation at <strong>all</strong> times (restra<strong>in</strong>ts); or<br />
(d) [Reserved]<br />
(e) Requir<strong>in</strong>g application of both of the operator’s hands to mach<strong>in</strong>e<br />
operat<strong>in</strong>g controls and locat<strong>in</strong>g such controls at such a safety distance<br />
from the po<strong>in</strong>t of operation that the slide completes the downward travel<br />
or stops before the operator can reach <strong>in</strong>to the po<strong>in</strong>t of operation with<br />
his hands (two-hand trip or two-hand control); or<br />
(f) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be <strong>in</strong>itiated,<br />
and ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g this closed condition until the motion of the slide has<br />
ceased (type A gate); or<br />
(g) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be<br />
<strong>in</strong>itiated, so as to prevent an operator from reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation prior to die closure or prior to cessation of slide motion dur<strong>in</strong>g<br />
the downward stroke (type B gate).<br />
These safeguard<strong>in</strong>g devices f<strong>all</strong> <strong>in</strong>to the follow<strong>in</strong>g categories.<br />
1. Presence-Sens<strong>in</strong>g Devices (pp. 6-39)<br />
2. Two-Hand Control (pp. 40-42)<br />
3. Two-Hand Trip (pp. 43-44)<br />
4. Gates (A or B) or<br />
Movable Barrier Device (pp. 45-51)<br />
PRESENCE-SENSING DEVICES<br />
These devices are usu<strong>all</strong>y photoelectric light curta<strong>in</strong>s or RF (radio<br />
frequency) units.<br />
Presence-sens<strong>in</strong>g devices are <strong>one</strong> of the most versatile and positive<br />
means to safeguard many different types of mach<strong>in</strong>es or equipment.<br />
When us<strong>in</strong>g presence-sens<strong>in</strong>g devices, if an object such as an<br />
employee’s hand, arm, or any part of their body enters the plane of light<br />
or light beams, either the cycle will not start or a stop signal will be<br />
given to the mach<strong>in</strong>e to stop the hazardous motion. Proper use of these<br />
devices provides protection not only for operators but also for other<br />
employees <strong>in</strong> the area. They also m<strong>in</strong>imize operator resistance to these<br />
types of safety devices due to their nonrestrictive design.<br />
Presence-sens<strong>in</strong>g devices can be used for many types of applications.<br />
They can be used on power presses, press brakes, around robotic work<br />
envelopes, <strong>in</strong>jection and compression mold<strong>in</strong>g mach<strong>in</strong>es, assembly<br />
systems, transfer l<strong>in</strong>es, automated equipment, flexible manufactur<strong>in</strong>g<br />
systems, assembl<strong>in</strong>g mach<strong>in</strong>es, tube mills, roll formers, and textile<br />
mach<strong>in</strong>ery. These devices can be used on any mach<strong>in</strong>e where the<br />
hazardous motion can stop quickly before an <strong>in</strong>dividual can reach the<br />
hazard.<br />
Presence-sens<strong>in</strong>g devices cannot be used on full- revolution-clutch<br />
presses or on any other mach<strong>in</strong>e that cannot quickly stop the hazardous<br />
motion. At the time of this pr<strong>in</strong>t<strong>in</strong>g, they cannot be used as a tripp<strong>in</strong>g<br />
means (PSDI—presence-sens<strong>in</strong>g device <strong>in</strong>itiation) on mechanical<br />
power presses. However, PSDI can be applied to other mach<strong>in</strong>es, such<br />
as hydraulic power presses and press brakes. Please consult the factory<br />
for details if this is a consideration.<br />
Each mach<strong>in</strong>e safeguard<strong>in</strong>g application can be placed <strong>in</strong> <strong>one</strong> of the<br />
follow<strong>in</strong>g categories:<br />
• Po<strong>in</strong>t of Operation—protects operators from mach<strong>in</strong>e po<strong>in</strong>t-ofoperation<br />
hazards where workpieces or materials are processed.<br />
• Perimeter/Work-Envelope <strong>Safeguard<strong>in</strong>g</strong>—detects entry <strong>in</strong>to a<br />
larger area where hazardous motion occurs.<br />
The products and <strong>in</strong>formation found <strong>in</strong> this catalog cover applications for<br />
these types of safeguard<strong>in</strong>g. Please do not consider us<strong>in</strong>g a perimeter/<br />
work-envelope safeguard<strong>in</strong>g device <strong>in</strong> a po<strong>in</strong>t-of-operation type of<br />
application.<br />
4 | SAFEGUARDING DEVICES
Presence-sens<strong>in</strong>g devices used for po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g<br />
must be <strong>in</strong>st<strong>all</strong>ed on a mach<strong>in</strong>e so that operators’ f<strong>in</strong>gers and hands are<br />
protected from po<strong>in</strong>t-of-operation hazards. Safety standards also state<br />
that “guards sh<strong>all</strong> be used to protect <strong>all</strong> areas of entry to the po<strong>in</strong>t of<br />
operation not protected by the presence-sens<strong>in</strong>g device.”<br />
TWO-HAND CONTROL<br />
Two-hand control can be used as a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g<br />
device as long as the palm buttons are located at the proper safety<br />
distance. This means the palm buttons must be located so that the slide<br />
has traveled far enough on the downstroke, or can stop fast enough to<br />
prevent the operator from gett<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t-of-operation hazard<br />
before the mach<strong>in</strong>e can stop. See pages 40-42 for further <strong>in</strong>formation<br />
on the two-hand control requirements.<br />
TWO-HAND TRIP<br />
Two-hand trip is similar to two-hand control. It can be used on both<br />
part- and full-revolution presses as a po<strong>in</strong>t-of-operation safeguard as<br />
long as the palm buttons are placed at the proper safety distance.<br />
Two-hand trip requires only momentary actuation of the palm buttons.<br />
Once these palm buttons have been depressed, they can be released<br />
quickly and the mach<strong>in</strong>e will make <strong>one</strong> full cycle. Please see pages<br />
43-44 for further details on us<strong>in</strong>g two-hand trip as a po<strong>in</strong>t-of-operation<br />
safeguard.<br />
GATES (A OR B) OR MOVABLE BARRIERS<br />
There are two basic types of gates (movable barriers): an A gate and a<br />
B gate. The A gate is designed to enclose the po<strong>in</strong>t of operation before<br />
the press stroke can be started, and it must rema<strong>in</strong> closed until <strong>all</strong> ram<br />
motion has stopped. The follow<strong>in</strong>g is a typical sequence of operation of<br />
a complete cycle on a press which uses an A gate.<br />
1. Initiate the cycle and as long as there are no obstructions, the gate<br />
will close by gravity.<br />
2. The mach<strong>in</strong>e will make <strong>one</strong> complete cycle and stop.<br />
3. The gate will open, after the cycle has stopped.<br />
The B gate only protects the operator on the downstroke of the press<br />
ram. The follow<strong>in</strong>g is a typical sequence of operation of a complete cycle<br />
on a press which uses a B gate.<br />
1. Initiate the cycle and as long as there are no obstructions, the gate<br />
will close by gravity.<br />
2. Once the mach<strong>in</strong>e reaches the portion of the stroke where the p<strong>in</strong>ch<br />
po<strong>in</strong>t has been elim<strong>in</strong>ated and before the cycle has stopped, the B<br />
gate and the ram go up at the same time.<br />
Accord<strong>in</strong>g to OSHA, an A gate can be used on either part- or fullrevolution-clutch<br />
presses. Best safety practice and the ANSI B11<br />
standard dictate that only the A gate sh<strong>all</strong> be used on full-revolutionclutch<br />
presses. Both A and B gates can be used on part-revolutionclutch<br />
presses and hydraulic presses.<br />
SUMMATION<br />
When operat<strong>in</strong>g, ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g, or sett<strong>in</strong>g up hazardous mach<strong>in</strong>ery,<br />
the hands and body of <strong>all</strong> personnel should never be <strong>in</strong> the po<strong>in</strong>t of<br />
operation or any other hazard area. Employees around mach<strong>in</strong>ery must<br />
be protected at <strong>all</strong> times. Energy isolation lockout procedures must be<br />
practiced and enforced.<br />
This product catalog offers and illustrates a wide range of safeguard<strong>in</strong>g<br />
devices, and other safety-related products for updat<strong>in</strong>g hazardous<br />
mach<strong>in</strong>ery and processes to comply with OSHA (Occupational Safety<br />
and Health Adm<strong>in</strong>istration) regulations, ANSI (American National<br />
Standards Institute) standards, and the NFPA 79 Electrical Standard<br />
for Industrial Mach<strong>in</strong>ery. The devices offered can be used to safeguard<br />
fabricat<strong>in</strong>g mach<strong>in</strong>es, metal-cutt<strong>in</strong>g mach<strong>in</strong>es, robotic cells, packag<strong>in</strong>g<br />
mach<strong>in</strong>es, material handl<strong>in</strong>g equipment, woodwork<strong>in</strong>g mach<strong>in</strong>es, etc.<br />
Before an employer (user) purchases and applies any of the products<br />
offered <strong>in</strong> this catalog, a risk assessment and/or hazard analysis of<br />
the mach<strong>in</strong>ery and processes must take place. This ensures correct<br />
decisions on the proper safeguard<strong>in</strong>g to be used. As a supplier, we<br />
f<strong>in</strong>d that employers can make the best safeguard<strong>in</strong>g choices based<br />
on ma<strong>in</strong>tenance ability, condition of mach<strong>in</strong>es, type of operators,<br />
tra<strong>in</strong><strong>in</strong>g programs, and present and future production requirements.<br />
For guidance, please refer to the ANSI technical report B11.TR3 Risk<br />
Assessment and Risk Reduction, and ANSI B11-2008 General Safety<br />
Requirements Common to ANSI B11 Mach<strong>in</strong>es to learn more about<br />
hazard identification and the risk assessment and risk reduction<br />
process.<br />
Please review this catalog for the numerous choices of safeguard<strong>in</strong>g<br />
devices available to <strong>in</strong>dustry. If you do not f<strong>in</strong>d a product or application that<br />
satisfies your needs, please contact us and expla<strong>in</strong> your requirements.<br />
If you require assistance <strong>in</strong> determ<strong>in</strong><strong>in</strong>g compliance issues with your<br />
mach<strong>in</strong>ery, please contact us to discuss your needs. Our knowledgeable<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g specialists can conduct mach<strong>in</strong>e safeguard<strong>in</strong>g<br />
assessments to determ<strong>in</strong>e current compliance levels of each mach<strong>in</strong>e<br />
and provide a detailed report/proposal which covers the safeguard<strong>in</strong>g<br />
solutions required to meet or exceed the OSHA regulations and ANSI<br />
standards. Integration and <strong>in</strong>st<strong>all</strong>ation services are also available for<br />
complete turnkey safeguard<strong>in</strong>g solutions.<br />
SAFEGUARDING DEVICES | 5
PRESENCE-SENSING DEVICES<br />
Stop-Time<br />
Measurement Device<br />
(pp. 10-11)<br />
Quick Reference Guide<br />
(p. 12)<br />
Po<strong>in</strong>t-Of-Operation<br />
Light Curta<strong>in</strong> System<br />
(pp. 13-18)<br />
Perimeter Light Beam System<br />
(pp. 21-23)<br />
S<strong>in</strong>gle-Beam System<br />
(pp. 25-26)<br />
Safety Laser Scanner<br />
(pp. 27-30)<br />
Accessories<br />
(pp. 31-33)<br />
Sw<strong>in</strong>g-Away and Stationary Brackets<br />
(pp. 34-38)<br />
Floor Stands, Mirrors, and Mirror Brackets<br />
(pp. 36-41)<br />
6 | SAFEGUARDING DEVICES
PRESENCE-SENSING DEVICES<br />
INTRODUCTION<br />
Presence-sens<strong>in</strong>g devices are available as <strong>in</strong>frared po<strong>in</strong>t-of-operation<br />
light curta<strong>in</strong>s, <strong>in</strong>frared perimeter multiple light beam devices, <strong>in</strong>frared<br />
s<strong>in</strong>gle-beam devices, or safety laser scanners. Light curta<strong>in</strong>s used for<br />
po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g have close channel spac<strong>in</strong>g to protect<br />
f<strong>in</strong>gers and hands. Perimeter light curta<strong>in</strong>s have wider channel spac<strong>in</strong>g<br />
to detect larger parts of the body. Perimeter, multi-beam, and s<strong>in</strong>glebeam<br />
devices are designed specific<strong>all</strong>y for perimeter safeguard<strong>in</strong>g.<br />
Safety laser scanners are designed for area, access, and po<strong>in</strong>t-ofoperation<br />
safeguard<strong>in</strong>g.<br />
There are many safety requirements that must be met before light<br />
curta<strong>in</strong>s can be <strong>in</strong>st<strong>all</strong>ed as po<strong>in</strong>t-of-operation safeguards. These<br />
requirements are located <strong>in</strong> OSHA 29 CFR 1910.217 and the ANSI<br />
B11-series safety standards for mach<strong>in</strong>e-tool safety. We have pr<strong>in</strong>ted<br />
the follow<strong>in</strong>g paragraphs for your convenience.<br />
(c)(3)(i) Po<strong>in</strong>t-of-operation devices sh<strong>all</strong> protect the operator by:<br />
(a) Prevent<strong>in</strong>g and/or stopp<strong>in</strong>g normal strok<strong>in</strong>g of the press if the<br />
operator’s hands are <strong>in</strong>advertently placed <strong>in</strong> the po<strong>in</strong>t of operation;<br />
(c)(3)(iii) A presence sens<strong>in</strong>g po<strong>in</strong>t-of-operation device sh<strong>all</strong> protect the<br />
operator as provided <strong>in</strong> paragraph (c)(3)(i)(a) of this section, and sh<strong>all</strong> be<br />
<strong>in</strong>terlocked <strong>in</strong>to the control circuit to prevent or stop slide motion if the<br />
operator’s hand or other part of his body is with<strong>in</strong> the sens<strong>in</strong>g field of<br />
the device dur<strong>in</strong>g the downstroke of the press slide.<br />
(a) The devices may not be used on mach<strong>in</strong>es us<strong>in</strong>g full revolution<br />
clutches.<br />
(b) The devices may not be used as a tripp<strong>in</strong>g means to <strong>in</strong>itiate slide<br />
motion, except when used <strong>in</strong> total conformance with paragraph (h) of<br />
this section. (See OSHA safety standards for details.)<br />
(c) The device sh<strong>all</strong> be constructed so that a failure with<strong>in</strong> the system<br />
does not prevent the normal stopp<strong>in</strong>g action from be<strong>in</strong>g applied to the<br />
press when required, but does prevent the <strong>in</strong>itiation of a successive<br />
stroke until the failure is corrected. The failure sh<strong>all</strong> be <strong>in</strong>dicated by the<br />
system.<br />
(d) Mut<strong>in</strong>g (bypass<strong>in</strong>g of the protective function) of such device dur<strong>in</strong>g<br />
the upstroke of the press slide is permitted for the purpose of parts<br />
ejection, circuit check<strong>in</strong>g, and feed<strong>in</strong>g.<br />
(e) The safety distance (Ds) from the sens<strong>in</strong>g field to the po<strong>in</strong>t of<br />
operation sh<strong>all</strong> be greater than the distance determ<strong>in</strong>ed by the follow<strong>in</strong>g<br />
formula:<br />
Ds = 63 <strong>in</strong>ches/second x Ts where:<br />
Ds = m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
Ts = stopp<strong>in</strong>g time of the press measured at approximately 90°<br />
position of crankshaft rotation (seconds).<br />
(f) Guards sh<strong>all</strong> be used to protect <strong>all</strong> areas of entry to the po<strong>in</strong>t of<br />
operation not protected by the presence-sens<strong>in</strong>g device.<br />
MINIMUM SAFETY DISTANCE<br />
The m<strong>in</strong>imum safety distance, which is <strong>one</strong> of the considerations listed,<br />
is def<strong>in</strong>ed <strong>in</strong> ANSI as the m<strong>in</strong>imum distance from the light curta<strong>in</strong>’s<br />
plane of light to the closest hazard or danger po<strong>in</strong>t where the operator<br />
could reach <strong>in</strong>to the hazard.<br />
This m<strong>in</strong>imum safety distance is based on the stopp<strong>in</strong>g ability of<br />
the mach<strong>in</strong>e and a hand speed constant. When the m<strong>in</strong>imum safety<br />
distance is calculated, several other factors must be taken <strong>in</strong>to account<br />
which are not <strong>in</strong>cluded <strong>in</strong> the OSHA formula. These factors <strong>in</strong>clude the<br />
total system response time <strong>in</strong>clud<strong>in</strong>g the light curta<strong>in</strong>, the m<strong>in</strong>imum<br />
object sensitivity of the presence-sens<strong>in</strong>g device, and the additional<br />
time for brake monitor<strong>in</strong>g. The total system response time <strong>in</strong>cludes the<br />
stopp<strong>in</strong>g time of the mach<strong>in</strong>e under worse case conditions, response<br />
time of the control system, response time of the presence-sens<strong>in</strong>g<br />
device as stated by the manufacturer, the response time of the <strong>in</strong>terface,<br />
and, if applicable, additional time <strong>all</strong>owed for the brake monitor to<br />
compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time.<br />
The depth penetration factor (Dpf), which is based on the light curta<strong>in</strong>’s<br />
MOS (m<strong>in</strong>imum object sensitivity), is part of the formula.<br />
The follow<strong>in</strong>g formula is used to compute the m<strong>in</strong>imum safety distance<br />
(Ds) on mechanical power presses to meet the ANSI (American National<br />
Standards Institute) B11.1 standard for press safety:<br />
D s<br />
= K (Ts + Tc + Tr + Tspm) + Dpf where:<br />
K = 63 <strong>in</strong>ches/second (hand speed constant)<br />
T s<br />
= Stop time of equipment measured at the f<strong>in</strong>al control element<br />
T c<br />
= Response time of the control system<br />
T r<br />
= Response time of the presence-sens<strong>in</strong>g device and its <strong>in</strong>terface<br />
T spm<br />
= Additional time <strong>all</strong>owed for the stopp<strong>in</strong>g performance monitor to<br />
compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time<br />
D pf<br />
= The added distance due to the depth penetration factor.<br />
Note: If the channel blank<strong>in</strong>g feature is used on light curta<strong>in</strong>s, additional<br />
safety distance must be enforced based on the number of channels<br />
blanked.<br />
The follow<strong>in</strong>g is a list of safeguard<strong>in</strong>g devices that could be applied<br />
us<strong>in</strong>g the above safety distance formula. For more details, see ANSI<br />
B11.1-2009.<br />
1. Interlocked barrier guards<br />
2. Two-hand control devices<br />
3. Two-hand trip devices<br />
4. S<strong>in</strong>gle control safeguard<strong>in</strong>g devices<br />
5. Electro-optical presence-sens<strong>in</strong>g devices<br />
6. RF (radio-frequency) presence-sens<strong>in</strong>g devices<br />
7. Safety mat devices<br />
8. Safety edge device<br />
SAFEGUARDING DEVICES | 7
PORTABLE STOP-TIME MEASUREMENT (STM) DEVICE<br />
The stop-time measurement (STM) device measures the time it takes a<br />
mach<strong>in</strong>e to stop after a signal is given. It is ma<strong>in</strong>ly used on reciprocat<strong>in</strong>g<br />
(strok<strong>in</strong>g or cycl<strong>in</strong>g) mach<strong>in</strong>es, such as mechanical or hydraulic presses<br />
and press brakes. With optional accessories, it can also be used on<br />
mach<strong>in</strong>es that rotate, such as lathes, mills, and drills.<br />
Industry uses this type of device to determ<strong>in</strong>e the stopp<strong>in</strong>g time of a<br />
mach<strong>in</strong>e before <strong>in</strong>st<strong>all</strong><strong>in</strong>g safeguard<strong>in</strong>g devices such as a two-hand<br />
control or a presence-sens<strong>in</strong>g device. The stopp<strong>in</strong>g time measured<br />
by the STM device dur<strong>in</strong>g the hazardous portion of the cycle is used<br />
<strong>in</strong> the OSHA (Occupational Safety and Health Adm<strong>in</strong>istration) or ANSI<br />
(American National Standards Institute) formulas to calculate the safety<br />
distance. The safety distance is then used to establish the location of<br />
the safeguard<strong>in</strong>g device <strong>in</strong> relation to the nearest hazard. This device<br />
can also be used to periodic<strong>all</strong>y check the mach<strong>in</strong>e’s stopp<strong>in</strong>g time<br />
to ensure that the current safety distance corresponds to the current<br />
condition of the mach<strong>in</strong>e’s stopp<strong>in</strong>g ability.<br />
FEATURES<br />
• Easy to use <strong>in</strong> the field<br />
• Portable; battery-operated<br />
• Readout <strong>in</strong> stopp<strong>in</strong>g time and<br />
safety distance<br />
• Handy carry<strong>in</strong>g case<br />
• Easy programm<strong>in</strong>g<br />
• Mach<strong>in</strong>e memory<br />
• Preprogrammed light cuta<strong>in</strong> response<br />
time and m<strong>in</strong>imum object sensitivity<br />
• Choice of hand-speed constant<br />
SPECIFICATIONS:<br />
Electronics<br />
Display<br />
Description................................4 digit, 14 segment, 1 ⁄4” red LED<br />
Stop Time..................................................0-9999 milliseconds<br />
Safety Distance................................................. 0-999.9 <strong>in</strong>ches<br />
Automatic Decimal.............................................................. Yes<br />
Lead Zero Blank<strong>in</strong>g.............................................................. Yes<br />
Accuracy............................................................................+1%<br />
Power Source...................................115 V AC or <strong>in</strong>ternal battery<br />
Battery Type.................................................6 V, sealed lead acid<br />
Operat<strong>in</strong>g Time...........................................10 hours (full charge)<br />
Recharge Time................................................................ 8 hours<br />
Battery Charger............................................................Conta<strong>in</strong>ed<br />
Mechanical<br />
Meter<br />
Material.............................. Alum<strong>in</strong>um with baked enamel f<strong>in</strong>ish<br />
Dimensions..................................................11” L x 7” D x 7” H<br />
Weight................................................................................9 lb<br />
Hand-Held Actuator<br />
Material.............................. Alum<strong>in</strong>um with baked enamel f<strong>in</strong>ish<br />
Dimensions........................................................4 1 ⁄2” dia. x 2” H<br />
Weight................................................................................3 lb<br />
Position/Velocity Transducer<br />
Material.............................. Alum<strong>in</strong>um with baked enamel f<strong>in</strong>ish<br />
Dimensions........................................... 5 1 ⁄4” L x 2 3 ⁄4” D x 4 3 ⁄4” H<br />
Weight.............................................................................1.6 lb<br />
Cable stroke........................................................................ 49”<br />
8 | SAFEGUARDING DEVICES
When us<strong>in</strong>g this STM device, the display gives both the stopp<strong>in</strong>g time<br />
of the mach<strong>in</strong>e <strong>in</strong> milliseconds (thousandths of a second), and the<br />
calculated safety distance <strong>in</strong> <strong>in</strong>ches. The safety distance is based on<br />
the hand speed constant of 63 <strong>in</strong>ches (1.6 meters) per second. For<br />
mechanical power presses, the OSHA formula multiplies the hand speed<br />
constant by the stopp<strong>in</strong>g time of the mach<strong>in</strong>e at 90° of crankshaft<br />
rotation. When us<strong>in</strong>g this formula, the reaction time of either ergonomic<br />
(capacitive) palm buttons or a presence-sens<strong>in</strong>g device should be added<br />
to the stopp<strong>in</strong>g time to calculate the proper safety distance. Please refer<br />
to the formula found <strong>in</strong> the ANSI B11.1 standard for mechanical power<br />
presses.<br />
This STM device is also used by federal and state OSHA compliance<br />
officers, <strong>in</strong>surance company loss-control eng<strong>in</strong>eers, and safety tra<strong>in</strong><strong>in</strong>g<br />
personnel to determ<strong>in</strong>e if proper safety distances are be<strong>in</strong>g used for the<br />
exist<strong>in</strong>g safeguard<strong>in</strong>g method.<br />
The portable design makes the STM very easy to use. A programmed<br />
stop signal is provided, which releases or actuates a button or other<br />
operator-controlled device on the mach<strong>in</strong>e dur<strong>in</strong>g the hazardous portion<br />
of the cycle. If a mach<strong>in</strong>e has a presence-sens<strong>in</strong>g device, the plane of<br />
light can be <strong>in</strong>terrupted with the furnished flag, which sends a signal to<br />
stop the mach<strong>in</strong>e.<br />
This device consists of three major comp<strong>one</strong>nts:<br />
1. The meter which is the processor conta<strong>in</strong><strong>in</strong>g the electronics and display.<br />
2. The position/velocity transducer which detects motion and provides<br />
the programmed output signal to stop the mach<strong>in</strong>e.<br />
3. The hand-held actuator which automatic<strong>all</strong>y releases or pushes a button<br />
or other device on the mach<strong>in</strong>e. It is also used to operate the flag when<br />
presence-sens<strong>in</strong>g devices are used as the safeguard<strong>in</strong>g method.<br />
Other STM comp<strong>one</strong>nts provided with this device are the presencesens<strong>in</strong>g<br />
flag, cable extension set, legs, plunger extension, and<br />
<strong>in</strong>struction manual.<br />
ORDERING INFORMATION<br />
Part No. DCL-100—Complete STM <strong>in</strong> a carry<strong>in</strong>g case <strong>in</strong>clud<strong>in</strong>g meter,<br />
transducer, cable extension set, hand-held actuator, presence-sens<strong>in</strong>g<br />
flag, legs, plunger extension, and <strong>in</strong>struction manual.<br />
Optional Accessories<br />
Part No. DCL-101—Remote tachometer assembly<br />
(for reciprocat<strong>in</strong>g mach<strong>in</strong>es that stop beyond bottom or top, and for<br />
mach<strong>in</strong>es with relatively slow rotat<strong>in</strong>g or l<strong>in</strong>eage motion)<br />
Note: Requires DCL-102 (see below)<br />
Part No. DCL-102—One NO manual start switch<br />
FIELD OF<br />
COVERATE<br />
IN INCHES<br />
(mm)<br />
A<br />
INCHES<br />
(mm)<br />
B<br />
INCHES<br />
(mm)<br />
C<br />
INCHES<br />
(mm)<br />
D<br />
INCHES<br />
(mm)<br />
12 (300) 11.8 (300) 14.6 (372) 16.0 (405) 13.7 (347)<br />
18 (450) 17.7 (450) 20.6 (522) 21.9 (555) 19.6 (497)<br />
24 (600) 23.6 (600) 26.4 (671) 27.7 (704) 25.4 (646)<br />
30 (750) 29.5 (750) 32.3 (821) 33.6 (854) 31.3 (796)<br />
35 (900) 35.4 (900) 38.2 (971) 39.5 (1004) 37.2 (946)<br />
41 (1050) 41.3 (1050) 44.1 (1120) 45.4 (1153) 43.1 (1095)<br />
47 (1200) 47.2 (1200) 50.0 (1270) 51.3 (1303) 49.0 (1245)<br />
53 (1350) 53.1 (1350) 55.9 (1420) 57.2 (1453) 54.9 (1395)<br />
59 (1500) 59.1 (1500) 61.8 (1569) 63.1 (1602) 60.8 (1544)<br />
65 (1650) 65.0 (1650) 67.7 (1719) 69.0 (1752) 66.7 (1694)<br />
71 (1800) 70.9 (1800) 73.6 (1869) 74.9 (1902) 72.6 (1844)<br />
SAFEGUARDING DEVICES | 9
Selection Guide for Po<strong>in</strong>t-of-Operation and Perimeter (Work-Envelope) <strong>Safeguard<strong>in</strong>g</strong><br />
This chart has been put together to make select<strong>in</strong>g the proper safeguard<strong>in</strong>g system for your application easy. Beg<strong>in</strong> by determ<strong>in</strong><strong>in</strong>g the type of<br />
application that requires safeguard<strong>in</strong>g. Choose the po<strong>in</strong>t-of-operation system, perimeter system, s<strong>in</strong>gle beam system, or area scann<strong>in</strong>g device that<br />
fits your application. If at any time you have questions, please c<strong>all</strong> us at 1-800-922-7533.<br />
PRESENCE-SENSING DEVICES QUICK REFUERENCE GUIDE SAFETY CATEGORY FOR 4 PRODUCTS<br />
Po<strong>in</strong>t of Operation<br />
EZ-SCREEN<br />
LIGHT CURTAIN<br />
pp. 12-19<br />
PERIMETER<br />
LIGHT BEAM<br />
pp. 20-23<br />
SINGLE BEAM<br />
SYSTEM<br />
pp. 24-25<br />
Perimeter X X X<br />
Entry/Exit<br />
P<strong>all</strong>etiz<strong>in</strong>g<br />
Cables<br />
Max Field of Coverage<br />
Fixed Blank<strong>in</strong>g<br />
Remote Fixed Blank<strong>in</strong>g<br />
Float Blank<strong>in</strong>g/Reducted<br />
Resolution<br />
Cascade Capability<br />
Max Field of Coverage<br />
Max Rage<br />
X<br />
Up to 100’<br />
(30.4 m)<br />
70.9”<br />
(1800 mm)<br />
X<br />
X<br />
X<br />
X<br />
.55” (14 mm) or<br />
1.18” (30 mm)<br />
Up to 59’<br />
(18 m)<br />
Up to 100’<br />
(30.4 m)<br />
35”<br />
(900 mm)<br />
Up to 230’<br />
(70 m )<br />
Up to 100’<br />
(30.4 m)<br />
1 Beam<br />
Up to 230<br />
(70 m)<br />
CONTACT THE<br />
FACTORY<br />
X<br />
X<br />
AREA SCANNING DEVICES QUICK REFERNCE GUIDE SAFETY CATEGORY 3 PRODUCTS<br />
S3000 STANDARD<br />
pp. 26-29<br />
S3000 ADVANCED<br />
pp. 26-29<br />
S3000 PROFESSIONAL<br />
pp. 26-29<br />
Area X X X<br />
Stationary X X X<br />
Protective Field – Max Range 23’ (7 m) 23’ (7m) 23’ (7m)<br />
Warn<strong>in</strong>g Field – Max Range 160’ (49 m) 160’ (49 m) 160’ (49 m)<br />
Number of Z<strong>one</strong>s 1 4 8<br />
Scann<strong>in</strong>g Angle 190° 190° 190°<br />
10 | SAFEGUARDING DEVICES
POINT-OF-OPERATION LIGHT CURTAIN SYSTEMS<br />
EZ-SCREEN LIGHT CURTAIN SYSTEM FEATURES<br />
• Meets <strong>in</strong>dustry OSHA, ANSI, UL, IEC, and EN safety standards 14<br />
and 30 mm resolutions<br />
• Field of coverage from 11.8” to 70.9” (300 mm to 1800 mm)<br />
• Scann<strong>in</strong>g range up to 59’ (18 m)<br />
• 2 solid-state OSSD (output signal switch<strong>in</strong>g device) outputs—24-V<br />
PNP outputs<br />
• Quick response times<br />
• Strobe-light and weld-flash immunity<br />
• Compact light bar hous<strong>in</strong>g—1.78” x 1.42” (45.2 x 36.0 mm)<br />
• Transmitter and receiver cable lengths from 15’ to 100’ (4.5 to 30 m)<br />
• 7-segment alignment and diagnostics display<br />
• Two-piece design with external device monitor<strong>in</strong>g (EDM)<br />
• Cascad<strong>in</strong>g—up to 4 pairs and of different lengths<br />
This photoelectric presence-sens<strong>in</strong>g system (light curta<strong>in</strong>) is designed<br />
to meet safety standards for protect<strong>in</strong>g operat<strong>in</strong>g personnel from po<strong>in</strong>tof-operation<br />
mach<strong>in</strong>e hazards. The EZ-Screen system operates as a<br />
stand-al<strong>one</strong> system to be <strong>in</strong>terfaced <strong>in</strong>to an exist<strong>in</strong>g mach<strong>in</strong>e control, or<br />
a generic <strong>in</strong>terface control is available (see page 17).<br />
The EZ-Screen system consists of a transmitter and receiver. The<br />
transmitter consists of a series of LEDs (light-emitt<strong>in</strong>g diodes) which<br />
transmit modulated <strong>in</strong>frared light to the receiver unit. The receiver<br />
consists of a correspond<strong>in</strong>g array of photo-diodes that are automatic<strong>all</strong>y<br />
synchronized with the transmitter LEDs. The EZ-Screen system can<br />
be mounted vertic<strong>all</strong>y, horizont<strong>all</strong>y, or on any angle depend<strong>in</strong>g on the<br />
application. The only requirement is that the transmitter must align<br />
with the receiver when these units are <strong>in</strong>st<strong>all</strong>ed. This system is also<br />
cascadable up to four systems. The cascadable pairs can be any length,<br />
any number of beams, or have different resolutions as long as each<br />
transmitter matches its own receiver.<br />
The EZ-Screen presence-sens<strong>in</strong>g system provides a protective, durable<br />
plane of light formed by the aligned transmitter and receiver cells. Any<br />
<strong>in</strong>terruption of this plane of light by an object equal to or larger than<br />
the MOS (m<strong>in</strong>imum object sensitivity) <strong>in</strong>itiates an output signal to the<br />
mach<strong>in</strong>e control system. This output causes the mach<strong>in</strong>e to stop or does<br />
not <strong>all</strong>ow a cycle until the blockage is removed.<br />
SAFEGUARDING DEVICES | 11
EZ-SCREEN LIGHT CURTAIN SYSTEM FEATURES (CONTINUED)<br />
The EZ-Screen system is designed <strong>in</strong> a way that if a comp<strong>one</strong>nt<br />
should fail, a total system shutdown results. This is achieved through<br />
redundant self-check<strong>in</strong>g circuitry, which compares the actual<br />
system operation with that of a redundant setup. Upon detection of any<br />
deviation from the expected status, a shutdown condition occurs.<br />
The plane-of-light portion of the system is formed by a series of<br />
high-quality <strong>in</strong>dividual optical lenses on every transmitter and receiver<br />
channel. This assures the optimal signal-to-noise ratio and <strong>all</strong>ows<br />
operation <strong>in</strong> harsh, oily, and dirty environments. Individual channel<br />
lenses create a column of light between each of the active transmitter<br />
and receiver channels. The creation of a column of light between<br />
transmitter and receiver is c<strong>all</strong>ed light collimation. Light collimation is<br />
necessary to ensure that the <strong>in</strong>frared light moves from the transmitter<br />
to the receiver <strong>in</strong> a controlled beam that maximizes its efficiency.<br />
Addition<strong>all</strong>y, the lens on each receiver channel m<strong>in</strong>imizes the possibility<br />
of the <strong>in</strong>frared light bounc<strong>in</strong>g off sh<strong>in</strong>y objects and fool<strong>in</strong>g the receiver.<br />
The light bars are equipped with status <strong>in</strong>dicators—LEDs and a<br />
7-segment display. These status <strong>in</strong>dicators are helpful when align<strong>in</strong>g<br />
the light curta<strong>in</strong> and when determ<strong>in</strong><strong>in</strong>g the cause of an <strong>in</strong>terruption <strong>in</strong><br />
the EZ-Screen system. The LEDs illum<strong>in</strong>ate and the display <strong>in</strong>dicates<br />
alphanumeric error messages when a channel is <strong>in</strong>terrupted, out of<br />
alignment, configured <strong>in</strong>correctly, etc.<br />
The EZ-Screen light curta<strong>in</strong> system modulates each of its LED<br />
light sources <strong>in</strong> a speci<strong>all</strong>y coded manner. This modulation virtu<strong>all</strong>y<br />
elim<strong>in</strong>ates ambient light <strong>in</strong>terference. The light curta<strong>in</strong> electronic<strong>all</strong>y<br />
sequences its <strong>in</strong>dividual LED transmitters and photo-transistor receivers<br />
at a fast rate that prevents any light <strong>in</strong>terference between <strong>in</strong>dividual<br />
transmitter/receiver sections. This also provides maximum stability and<br />
ease of alignment.<br />
EZ-Screen Light Curta<strong>in</strong> System<br />
STATUS INDICATOR LIGHTS<br />
A variety of status <strong>in</strong>dicator lights are clearly visible on the front panel<br />
of each transmitter and receiver. Red, green, and yellow lights display<br />
the operat<strong>in</strong>g status, configuration error codes, and blocked beams.<br />
A diagnostic display <strong>in</strong>dicates alphanumeric error messages when<br />
a channel is <strong>in</strong>terrupted, out of alignment, configured <strong>in</strong>correctly,<br />
blocked, etc.<br />
Transmitter<br />
Receiver<br />
Transmitter<br />
Receiver<br />
Receiver<br />
Emitter<br />
Receiver<br />
Emitter<br />
3-digit<br />
Diagnostic<br />
Display<br />
1-digit<br />
Diagnostic<br />
Display<br />
3-digit<br />
Diagnostic<br />
Display<br />
1-<br />
Di<br />
Di<br />
Z<strong>one</strong>Indicators<br />
(eachshows<br />
statusofapprox.<br />
1/8ofthetotal<br />
beams)<br />
YellowReset<br />
Indicator<br />
Z<strong>one</strong>Indicators<br />
(eachshows<br />
statusofapprox.<br />
1/8ofthetotal<br />
beams)<br />
YellowReset<br />
Indicator<br />
StatusIndicator<br />
(Red/Green)<br />
StatusIndicator<br />
(Red/Green)<br />
StatusIndicator<br />
(Red/Green)<br />
Sta<br />
(Re<br />
Z<strong>one</strong>1Indicator<br />
(<strong>in</strong>dicatesbeamsynchronizationstatus)<br />
Z<strong>one</strong>1Indicator<br />
(<strong>in</strong>dicatesbeamsynchronizationstatus)<br />
12 | SAFEGUARDING DEVICES
DIMENSIONS FOR THE EZ-SCREEN LIGHT CURTAIN SYSTEM<br />
FIELD OF<br />
COVERATE<br />
IN INCHES<br />
(mm)<br />
A<br />
INCHES<br />
(mm)<br />
B<br />
INCHES<br />
(mm)<br />
C<br />
INCHES<br />
(mm)<br />
D<br />
INCHES<br />
(mm)<br />
1.78"<br />
(45.2 mm)<br />
0.47"<br />
(12 mm)<br />
1.42"<br />
(36.0 mm)<br />
12 (300) 11.8 (300) 14.6 (372) 16.0 (405) 13.7 (347)<br />
18 (450) 17.7 (450) 20.6 (522) 21.9 (555) 19.6 (497)<br />
24 (600) 23.6 (600) 26.4 (671) 27.7 (704) 25.4 (646)<br />
30 (750) 29.5 (750) 32.3 (821) 33.6 (854) 31.3 (796)<br />
35 (900) 35.4 (900) 38.2 (971) 39.5 (1004) 37.2 (946)<br />
41 (1050) 41.3 (1050) 44.1 (1120) 45.4 (1153) 43.1 (1095)<br />
47 (1200) 47.2 (1200) 50.0 (1270) 51.3 (1303) 49.0 (1245)<br />
A<br />
B<br />
C<br />
D<br />
53 (1350) 53.1 (1350) 55.9 (1420) 57.2 (1453) 54.9 (1395)<br />
59 (1500) 59.1 (1500) 61.8 (1569) 63.1 (1602) 60.8 (1544)<br />
65 (1650) 65.0 (1650) 67.7 (1719) 69.0 (1752) 66.7 (1694)<br />
71 (1800) 70.9 (1800) 73.6 (1869) 74.9 (1902) 72.6 (1844)<br />
2.20"<br />
(56.0 mm)<br />
0.17"<br />
(4.2 mm)<br />
EZ-SCREEN RESPONSE TIMES<br />
The response time of these light curta<strong>in</strong>s varies depend<strong>in</strong>g on their size (see the chart below). The response time is the length of time that elapses<br />
between the <strong>in</strong>terruption of the light beam and the output signal. Response time <strong>in</strong>cludes the reaction time of the output device(s) (i.e., relays), and<br />
is specified <strong>in</strong> milliseconds.<br />
These light curta<strong>in</strong>s are designed to meet UL and CSA standards and also have full PSDI (presence-sens<strong>in</strong>g-device <strong>in</strong>itiation) capability. This means<br />
that the light curta<strong>in</strong> can be used to start the cycle of the mach<strong>in</strong>e while at the same time it can be safeguard<strong>in</strong>g the mach<strong>in</strong>e. For further <strong>in</strong>formation<br />
on PSDI, please see OSHA 29 CFR 1910.217 (h) and ANSI B11.1, B11.2, B11.3, and B11.19.<br />
Transmitter/Receiver With .55” (14 mm) M<strong>in</strong>imum<br />
Object Sensitivity (Resolution)<br />
FIELD OF<br />
COVERATE<br />
INCHES (mm)<br />
NUMBER OF<br />
BEAMS<br />
RESPONSE<br />
TIME<br />
12 (300) 40 15 ms<br />
18 (450) 60 19 ms<br />
24 (600) 80 23 ms<br />
30 (750) 100 27 ms<br />
35 (900) 120 32 ms<br />
41 (1050) 140 36 ms<br />
47 (1200) 160 40 ms<br />
53 (1350) 180 43 ms<br />
59 (1500) 200 48 ms<br />
65 (1650) 220 52 ms<br />
71 (1800) 240 56 ms<br />
Transmitter/Receiver With 1.18” (30 mm) M<strong>in</strong>imum<br />
Object Sensitivity (Resolution)<br />
FIELD OF<br />
COVERATE<br />
INCHES (mm)<br />
NUMBER OF<br />
BEAMS<br />
RESPONSE<br />
TIME<br />
12 (300) 20 11 ms<br />
18 (450) 30 13 ms<br />
24 (600) 40 15 ms<br />
30 (750) 50 17 ms<br />
35 (900) 60 19 ms<br />
41 (1050) 70 21 ms<br />
47 (1200) 80 23 ms<br />
53 (1350) 90 25 ms<br />
59 (1500) 100 27 ms<br />
65 (1650) 110 30 ms<br />
71 (1800) 120 32 ms<br />
SAFEGUARDING DEVICES | 13
SELECTING A NONCASCADING EZ-SCREEN LIGHT CURTAIN<br />
To determ<strong>in</strong>e the 9-digit configured part number for a noncascad<strong>in</strong>g light curta<strong>in</strong> required, follow the directions and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits for <strong>all</strong> EZ-Screen light curta<strong>in</strong> pairs are LCB.<br />
2. The 4th digit determ<strong>in</strong>es the MOS (m<strong>in</strong>imum object sensitivity) and OPR (operat<strong>in</strong>g range).<br />
3. The 5th and 6th digits determ<strong>in</strong>e the field of coverage.<br />
4. The 7th digit determ<strong>in</strong>es the selection of remote keyed fixed blank<strong>in</strong>g.<br />
5. The 8th digit <strong>in</strong>dicates the length of the transmitter cable.<br />
6. The 9th digit <strong>in</strong>dicates the length of the receiver cable (can be a different length from the transmitter cable).<br />
SAMPLE<br />
1 2 3<br />
4 5 6<br />
L C B - 3 - 2 4 - 1 - 5 - 7<br />
The sample shown, Part No. LCB-3-24-1-5-7, is an EZ-Screen light curta<strong>in</strong> pair with 1.18” (30 mm) m<strong>in</strong>imum object sensitivity, 1-59’ (18 m)<br />
operat<strong>in</strong>g range, 23.6” (600 mm) field of coverage, remote fixed blank<strong>in</strong>g, a 50’ transmitter cable, and a 75’ receiver cable.<br />
MOS (MINIMUM OBJECT SENSITIVITY) AND<br />
OPR (OPERATING RANGE)<br />
MOS<br />
OPR<br />
1 —0.55” (14 mm) 19.68’ (6 m)<br />
3 —1.18” (30 mm) 59’ (18 m)<br />
FIELD OF COVERAGE<br />
12 —11.8” (300 mm)<br />
18 —17.7” (450 mm)<br />
24 —23.6” (600 mm)<br />
30 —29.5” (750 mm)<br />
35 —35.4” (900 mm)<br />
41 —41.3” (1050 mm)<br />
47 —47.2” (1200 mm)<br />
53 —53.1” (1350 mm)<br />
59 —59” (1500 mm)<br />
65 —65” (1650 mm)<br />
71 —70.9” (1800 mm)<br />
NONCASCADING LIGHT CURTAIN PRESENCE-SENSING DEVICE SYSTEM<br />
LCB - X - X X - X - X - X<br />
RECEIVER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
TRANSMITTER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
REMOTE FIXED BLANKING SWITCH<br />
1 —Yes–<strong>in</strong>cludes 1’ (.31 m) connection cable<br />
2 —No<br />
Four (4) end mount swivel brackets are <strong>in</strong>cluded with each light bar pair for mount<strong>in</strong>g.<br />
Two (2) additional center mount<strong>in</strong>g brackets are <strong>in</strong>cluded with each light bar pair with a field of coverage of 47 and up.<br />
REMOTE FIXED BLANKING SWITCH<br />
A remote fixed blank<strong>in</strong>g switch is provided when the remote fixed blank<strong>in</strong>g switch option is chosen <strong>in</strong> the part<br />
number<strong>in</strong>g chart above. This remote blank<strong>in</strong>g switch is used <strong>in</strong> place of the DIP switches on the receiver when<br />
frequent configuration of fixed blank<strong>in</strong>g is needed. A 1’ connection cable, two (2) mount<strong>in</strong>g brackets, and two (2)<br />
keys are supplied with each remote switch.<br />
14 | SAFEGUARDING DEVICES
SELECTING THE FIRST PAIR IN A CASCADING EZ-SCREEN LIGHT CURTAIN SYSTEM<br />
To determ<strong>in</strong>e the 9-digit configured part number for the first pair <strong>in</strong> a cascad<strong>in</strong>g light curta<strong>in</strong> system, follow the directions and use the <strong>in</strong>formation<br />
<strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
1. The first 4 digits for the first pair <strong>in</strong> a cascad<strong>in</strong>g light curta<strong>in</strong> system are LCBC.<br />
2. The 5th digit determ<strong>in</strong>es the MOS (m<strong>in</strong>imum object sensitivity) and OPR (operat<strong>in</strong>g range).<br />
3. The 6th and 7th digits determ<strong>in</strong>e the field of coverage.<br />
4. The 8th digit determ<strong>in</strong>es the length of the transmitter cable. NOTE: This is required for the first pair of cascad<strong>in</strong>g light bar pairs only.<br />
5. The 9th digit determ<strong>in</strong>es the length of the receiver cable (can be a different length from the transmitter cable). NOTE: This is<br />
required for the first pair of cascad<strong>in</strong>g light bar pairs only.<br />
SAMPLE—FIRST IN CASCADE SYSTEM<br />
1 2 3<br />
4 5<br />
L C B C - 3 - 1 8 - 1 - 2<br />
The sample shown, Part No. LCBC-3-18-1-2, is the first pair <strong>in</strong> the cascad<strong>in</strong>g system. It has 1.18” (30 mm) m<strong>in</strong>imum object sensitivity, 1-59’ (18<br />
m) operat<strong>in</strong>g range, 17.7” (450 mm) field of coverage, a 15’ transmitter cable, and a 25’ receiver cable.<br />
MOS (MINIMUM OBJECT SENSITIVITY) AND<br />
OPR (OPERATING RANGE)<br />
MOS<br />
OPR<br />
1 —0.55” (14 mm) 19.68’ (6 m)<br />
3 —1.18” (30 mm) 59’ (18 m)<br />
LENGTH OF BARS<br />
12 —11.8” (300 mm)<br />
18 —17.7” (450 mm)<br />
24 —23.6” (600 mm)<br />
30 —29.5” (750 mm)<br />
35 —35.4” (900 mm)<br />
41 —41.3” (1050 mm)<br />
47 —47.2” (1200 mm)<br />
53 —53.1” (1350 mm)<br />
59 —59” (1500 mm)<br />
65 —65” (1650 mm)<br />
71 —70.9” (1800 mm)<br />
CASCADING LIGHT CURTAIN PRESENCE-SENSING DEVICE SYSTEM<br />
LCBC - X - X X - X - X<br />
RECEIVER CABLE W/PLUG (REQUIRED FOR FIRST IN CASCADE ONLY)<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
TRANSMITTER CABLE W/PLUG (REQUIRED FOR FIRST IN CASCADE ONLY)<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
Four (4) end mount swivel brackets are <strong>in</strong>cluded with each light bar pair for mount<strong>in</strong>g.<br />
Two (2) additional center mount<strong>in</strong>g brackets are <strong>in</strong>cluded with each light bar pair with a field of coverage of 47 and up.<br />
NOTE: Use the chart on the next page to configure an additional part number for each of the 2nd, 3rd, and/or 4th pair <strong>in</strong> the cascad<strong>in</strong>g system.<br />
A maximum of four (4) light bar pairs may be cascaded, and they can be of different lengths.<br />
SAFEGUARDING DEVICES | 15
SELECTING THE 2ND, 3RD, AND/OR 4TH PAIR IN A CASCADING EZ-SCREEN LIGHT CURTAIN SYSTEM<br />
To determ<strong>in</strong>e the 9-digit configured part number for the 2nd, 3rd, and/or 4th pair <strong>in</strong> a cascad<strong>in</strong>g light curta<strong>in</strong> system, follow the directions and use<br />
the <strong>in</strong>formation <strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
1. The first 4 digits for the 2nd, 3rd, and/or 4th pair <strong>in</strong> a cascad<strong>in</strong>g light curta<strong>in</strong> system are LCBC.<br />
2. The 5th digit determ<strong>in</strong>es the MOS (m<strong>in</strong>imum object sensitivity) and OPR (operat<strong>in</strong>g range).<br />
3. The 6th and 7th digits determ<strong>in</strong>e the field of coverage.<br />
4. The 8th digit determ<strong>in</strong>es the length of the connect<strong>in</strong>g cables between the transmitters.<br />
5. The 9th digit determ<strong>in</strong>es the length of the connect<strong>in</strong>g cables between the receivers.<br />
SAMPLE—SECOND IN CASCADE SYSTEM<br />
1 2 3<br />
4 5<br />
L C B C - 3 - 2 4 - C - C<br />
The sample shown, Part No. LCBC-3-24-C-C, is the second pair <strong>in</strong> the cascad<strong>in</strong>g system. It has 1.18” (30 mm) m<strong>in</strong>imum object sensitivity, 1-59’<br />
(18 m) operat<strong>in</strong>g range, 23.6” (600 mm) field of coverage, and a 3’ transmitter connect<strong>in</strong>g cable with a 3’ receiver connect<strong>in</strong>g cable.<br />
MOS (MINIMUM OBJECT SENSITIVITY) AND<br />
OPR (OPERATING RANGE)<br />
MOS<br />
OPR<br />
1 —0.55” (14 mm) 19.68’ (6 m)<br />
3 —1.18” (30 mm) 59’ (18 m)<br />
LENGTH OF BARS<br />
12 —11.8” (300 mm)<br />
18 —17.7” (450 mm)<br />
24 —23.6” (600 mm)<br />
30 —29.5” (750 mm)<br />
35 —35.4” (900 mm)<br />
41 —41.3” (1050 mm)<br />
47 —47.2” (1200 mm)<br />
53 —53.1” (1350 mm)<br />
59 —59” (1500 mm)<br />
65 —65” (1650 mm)<br />
71 —70.9” (1800 mm)<br />
CASCADING LIGHT CURTAIN PRESENCE-SENSING DEVICE SYSTEM<br />
LCBC - X - X X - X - X<br />
CASCADE RECEIVER CABLE LENGTH<br />
A —1’ (.31 m)<br />
B —3’ (.91 m)<br />
C —8’ (2.43 m)<br />
CASCADE TRANSMITTER CABLE LENGTH<br />
A —1’ (.31 m)<br />
B —3’ (.91 m)<br />
C —8’ (2.43 m)<br />
Four (4) end mount swivel brackets are <strong>in</strong>cluded with each light bar pair for mount<strong>in</strong>g.<br />
Two (2) additional center mount<strong>in</strong>g brackets are <strong>in</strong>cluded with each light bar pair with a field of coverage of 47 and up.<br />
NOTE: Use the chart above to configure a part number for EACH additional cascad<strong>in</strong>g light bar pair for the 2nd, 3rd, and/or 4th pair <strong>in</strong> the cascad<strong>in</strong>g<br />
system. A maximum of four (4) light bar pairs may be cascaded, and they can be of different lengths.<br />
16 | SAFEGUARDING DEVICES
EZ-SCREEN LIGHT CURTAIN INTERFACES<br />
The EZ-Screen <strong>in</strong>terfaces are available <strong>in</strong> several variations. They<br />
are available with the comp<strong>one</strong>nts furnished loose, <strong>in</strong> a pla<strong>in</strong> door<br />
enclosure, or <strong>in</strong> an enclosure with the operators on the door. Depend<strong>in</strong>g<br />
on the requirements, comp<strong>one</strong>nt options <strong>in</strong>clude term<strong>in</strong>als, fuses,<br />
a safety monitor<strong>in</strong>g relay, force-guided relays, a light curta<strong>in</strong> off/on<br />
selector switch, a pwer supply, a reset pushbutton, and an enclosure.<br />
Select an EZ-Screen standard light curta<strong>in</strong> <strong>in</strong>terface from the chart on<br />
this page based on your requirements.<br />
EZ-Screen <strong>in</strong>terfaces provide a generic tie-<strong>in</strong> to most control systems.<br />
These <strong>in</strong>terfaces can supply the 24-V DC power needed to operate the<br />
light curta<strong>in</strong>s. The light curta<strong>in</strong>s provide two solid-state OSSD (output<br />
signal switch<strong>in</strong>g device) outputs, and s<strong>in</strong>ce many control systems are<br />
not compatible with this type of output, <strong>in</strong>terfaces are available. These<br />
units <strong>in</strong>corporate a safety monitor<strong>in</strong>g relay to provide a Category 4<br />
<strong>in</strong>terface when properly <strong>in</strong>tegrated with the exist<strong>in</strong>g controls system.<br />
Some control systems require more relay contacts than are available on<br />
a safety monitor<strong>in</strong>g relay, therefore, force-guided relays can be provided<br />
that will work <strong>in</strong> conjunction with the safety monitor<strong>in</strong>g relays. This<br />
provides additional contacts and still ma<strong>in</strong>ta<strong>in</strong>s a Category 4 <strong>in</strong>terface.<br />
A light curta<strong>in</strong> off/on selector swith is also an available option. This<br />
selector switch gives the option to run the mach<strong>in</strong>e <strong>in</strong> the setup mode.<br />
Other safegaurd<strong>in</strong>g methods must be used when the light curta<strong>in</strong><br />
selector switch is <strong>in</strong> the off position.<br />
A light curta<strong>in</strong> reset pushbutton can also be chosen as an option. It<br />
<strong>all</strong>ows easy access for the light curta<strong>in</strong> to be reset.<br />
If necessary, special <strong>in</strong>terfaces can be provided that will show the exact<br />
tie-<strong>in</strong> of the light curta<strong>in</strong>s to your control system. We will need your<br />
exist<strong>in</strong>g electrical control system schematics to verify that it is compliant<br />
and that it is capable of accept<strong>in</strong>g a light curta<strong>in</strong> tie-<strong>in</strong>. Please contact<br />
our factory for more <strong>in</strong>formation.<br />
Inside View of an EZ-Screen Interface<br />
LIGHT CURTAIN INTERFACE FOR EZ-SCREEN LIGHT CURTAINS<br />
LRS-XXXX PART NO.<br />
FEATURES 1012 1013 1014 1015 1016 1017 1018 1019<br />
Term<strong>in</strong>als X X X X X X<br />
Fuses X X X X X X<br />
Safety<br />
Monitor<strong>in</strong>g<br />
Relay<br />
Force-Guided<br />
Relays (2)<br />
Light Curta<strong>in</strong><br />
Off/On Selector<br />
Switch<br />
X X X X X X X X<br />
X X X X X X<br />
X X X<br />
Power Supply X X X X<br />
Enclosure X X X X X X<br />
Reset<br />
Pushbtton<br />
X<br />
SAFEGUARDING DEVICES | 17
REMOTE OPERATOR STATIONS<br />
Remote operator stations are available that can be used <strong>in</strong> conjunction with an <strong>in</strong>terface when a pla<strong>in</strong> door enclosure or loose <strong>in</strong>terface comp<strong>one</strong>nts<br />
are chosen. These remote operator stations are available with an off/on keyed selector switch, a light curta<strong>in</strong> reset button, or an off/on keyed selector<br />
switch and reset button. Each remote operator station is furnished <strong>in</strong> a steel enclosure.<br />
ORDERING INFORMATION<br />
PART NO.<br />
DESCRIPTION<br />
LLD-1236 Light Curta<strong>in</strong> off/on remote operator station<br />
LLD-1237 Light Curta<strong>in</strong> reset remote operator station<br />
LLD-1238 Light Curta<strong>in</strong> on/off with reset remote operator station<br />
LLD-1236<br />
LLD-1237<br />
LLD-1238<br />
LASER ALIGNMENT TOOL—PART NO. LAT-1<br />
A laser alignment tool is available to aid <strong>in</strong> the alignment of any po<strong>in</strong>t-ofoperation<br />
light curta<strong>in</strong> system. It is particularly useful with applications<br />
<strong>in</strong>volv<strong>in</strong>g mirrors.<br />
The laser alignment tool <strong>in</strong>cludes a 9-volt battery, a mount<strong>in</strong>g clip, and<br />
has a built-<strong>in</strong> circular bubble level. This alignment tool is to be used<br />
for set up only.<br />
18 | SAFEGUARDING DEVICES
PERIMETER LIGHT BEAM SYSTEM<br />
The perimeter light beam system is designed to meet safety standards for <strong>one</strong>-sided or multi-sided hazardous area and access protection. It can be<br />
used for safeguard<strong>in</strong>g robotic work cells, automatic mach<strong>in</strong>ery work envelopes, assembly l<strong>in</strong>es, and other manufactur<strong>in</strong>g work cells.<br />
FEATURES<br />
• Meets <strong>in</strong>dustry OSHA, ANSI, UL, IEC, and EN safety standards<br />
• Operat<strong>in</strong>g ranges: Short—2.6’ to 65’ (.8 to 20 m)<br />
Long—49’ to 230’ (15 to 70 m)<br />
• Number of beams—2, 3, or 4<br />
• Beam separation—12” to 23” (300 mm to 584 mm)<br />
• 24 ms response time<br />
• Strobe-light and weld-flash immunity<br />
• Transmitter and receiver cable lengths up to 100’ (30.5 m)<br />
• Restart <strong>in</strong>terlock<br />
• External device monitor<strong>in</strong>g (EDM)<br />
• LED 7-segment alignment and diagnostics display<br />
The perimeter light beam system consists of a transmitter and receiver.<br />
Each is encased <strong>in</strong> a rigid, alum<strong>in</strong>um die-cast hous<strong>in</strong>g which makes<br />
them very durable. Communication between the transmitter and<br />
receiver is accomplished optic<strong>all</strong>y; no external controller is required.<br />
An <strong>in</strong>visible <strong>in</strong>frared beam of light is formed between the transmitter<br />
and receiver. Interruption of this beam of light sends a stop signal to the<br />
mach<strong>in</strong>e’s control. This signal is designed to stop hazardous mach<strong>in</strong>e<br />
motion or prevent the <strong>in</strong>itiation of mach<strong>in</strong>e motion.<br />
Mirrors <strong>in</strong>crease the coverage of the safeguarded area. Two sides of a<br />
hazardous area can be safeguarded with the use of <strong>one</strong> perimeter light<br />
beam system and <strong>one</strong> mirror. Three sides of a hazardous area can be<br />
safeguarded by us<strong>in</strong>g <strong>one</strong> perimeter light beam system and two mirrors.<br />
See pages 38-39 for <strong>in</strong>formation about mirrors.<br />
The perimeter light beam system is delivered ready for operation.<br />
Configuration sett<strong>in</strong>gs are accessible from the front of the beams and<br />
can be changed while the system rema<strong>in</strong>s mounted.<br />
Perimeter Light Curta<strong>in</strong> System Used as Access Protection for an Automatic Mach<strong>in</strong>e Work Envelope<br />
SAFEGUARDING DEVICES | 19
1<br />
2<br />
BEAMS<br />
R<br />
E<br />
S<br />
E<br />
T<br />
S<br />
T<br />
A<br />
T<br />
U<br />
S<br />
1<br />
2<br />
BEAMS<br />
R<br />
E<br />
S<br />
E<br />
T<br />
S<br />
T<br />
A<br />
T<br />
U<br />
S<br />
PERIMETER LIGHT BEAM DIMENSIONS<br />
0.50" (12.5 mm)<br />
M<strong>in</strong>imum Bend Radius<br />
0.66"<br />
(16.7 mm)<br />
3.5"<br />
(89 mm)<br />
1.02"<br />
(26 mm)<br />
4.21"<br />
(107.0 mm)<br />
2.0"<br />
(52 mm)<br />
2.1"<br />
(55 mm)<br />
A<br />
S<br />
B<br />
C<br />
1.0"<br />
(25 mm)<br />
2.36"<br />
(60.0 mm)<br />
2.92"<br />
(74.2 mm)<br />
NUMBER OF<br />
BEAMS<br />
FIELD OF<br />
COVERAGE<br />
INCHES (mm)<br />
S<br />
BEAM<br />
SEPARATION<br />
INCHES (mm)<br />
A<br />
INCHES<br />
(mm)<br />
B<br />
INCHES<br />
(mm)<br />
C<br />
INCHES<br />
(mm)<br />
2 19.7 (500) 19.7 (500) 26.9 (684) 28.2 (717) 25.9 (659)<br />
2 23 (584) 23 (584) 30.8 (768) 31.6 (802) 29.3 (743)<br />
3 31.5 (800) 15.7 (400) 38.7 (984) 40.1 (1017) 37.8 (959)<br />
3 42 (1066) 21 (533) 49.2 (1251) 50.6 (1284) 48.3 (1226)<br />
4 35.4 (900) 11.8 (300) 42.7 (1084) 44 (1117) 41.7 (1059)<br />
20 | SAFEGUARDING DEVICES
SELECTING PERIMETER LIGHT BEAM SYSTEM<br />
To determ<strong>in</strong>e the 8-digit configured part number for the perimeter light beam system required, follow the directions below and use the <strong>in</strong>formation<br />
<strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits determ<strong>in</strong>es the choice of a short range perimeter system or a long range perimeter system.<br />
2. The 4th, 5th, and 6th digits determ<strong>in</strong>e the number of beams and beam separation.<br />
3. The 7th digit determ<strong>in</strong>es the length of the transmitter cable.<br />
4. The 8th digit determ<strong>in</strong>es the length of the receiver cable (can be a different length from the transmitter cable).<br />
SAMPLE<br />
1 2 3<br />
P B S - 342 - 1 - 2<br />
4<br />
The sample shown, Part No. PBS-342-1-2, is a short range perimeter light beam system. It has three beams with 21.0” (533 mm) of beam<br />
separation, 42.0” (1066 mm) field of coverage, with a 15’ (4.5 m) transmitter cable and a 25’ (7.6 m) receiver cable.<br />
PERIMETER LIGHT BEAM SYSTEM TYPE<br />
PBS —Short range: 2.62’ to 65.6’ (0.8 m to 20 m)<br />
PBL —Long range: 49.2’ to 229.6’ (15 m to 70 m)<br />
NUMBER OF BEAMS, BEAM SEPARATION, AND FIELD OF COVERAGE<br />
NO. OF BEAMS SEPARATION FIELD OF COVERAGE<br />
219 — 2 19.7” (500 mm) 19.7” (500 mm)<br />
223 — 2 23.0” (584 mm) 23.0” (584 mm)<br />
331 — 3 15.7” (400 mm) 31.5” (800 mm)<br />
342 — 3 21.0” (533 mm) 42.0” (1066 mm)<br />
435 — 4 11.8” (300 mm) 35.4” (900 mm)<br />
PERIMETER LIGHT BEAM PART NUMBERING SYSTEM CHART<br />
X X X - X X X - X - X<br />
Four (4) end mount swivel brackets are <strong>in</strong>cluded with each perimeter light beam system for mount<strong>in</strong>g.<br />
RECEIVER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
TRANSMITTER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
LASER ALIGNMENT TOOL—PART NO. LAT-1<br />
A laser alignment tool is available to aid <strong>in</strong> the alignment of any perimeter light curta<strong>in</strong> system. It is<br />
particularly useful with applications <strong>in</strong>volv<strong>in</strong>g mirrors.<br />
The laser alignment tool <strong>in</strong>cludes a 9-volt battery, a mount<strong>in</strong>g clip, and has a built-<strong>in</strong> circular bubble<br />
level. This alignment tool is to be used for set up only.<br />
SAFEGUARDING DEVICES | 21
PERIMETER LIGHT BEAM INTERFACE<br />
The perimeter light beam <strong>in</strong>terfaces are available <strong>in</strong> several variations.<br />
They are available with the comp<strong>one</strong>nt furnished loose, <strong>in</strong> a pla<strong>in</strong> door<br />
enclosure, or <strong>in</strong> an enclosure with the operators on the door. Depend<strong>in</strong>g<br />
on the requirements, compent options <strong>in</strong>clude term<strong>in</strong>als, fuses, a safety<br />
mo<strong>in</strong>tor<strong>in</strong>g relay, force-guided relays, a multiple beam off/on selector<br />
switch, a power supply, a reset pushbutton, and an enclosure. Select<br />
a perimeter light beam <strong>in</strong>terface from the chart on this page based on<br />
your requirements.<br />
Perimeter light beam <strong>in</strong>terfaces provide a generic tie-<strong>in</strong> to most control<br />
systems. These <strong>in</strong>terfaces can supply the 24-V DC power needed to<br />
operate the perimeter light beam. The perimeter light beams provide<br />
two solid-state output signal switch<strong>in</strong>g device (OSSD) outputs, and<br />
s<strong>in</strong>ce many control systems are not compatible with this type of output,<br />
<strong>in</strong>terfaces are available. These units <strong>in</strong>corporate a safety monitor<strong>in</strong>g<br />
relay to provide a Category 4 <strong>in</strong>terface when properly <strong>in</strong>tegrated with<br />
the exist<strong>in</strong>g controls system. Some control systems require more relay<br />
contacts than are available on a safety monitor<strong>in</strong>g relay, therefore,<br />
force-guided relays can be provided that will work <strong>in</strong> conjunction with<br />
the safety monitor<strong>in</strong>g relays. This provides additional contacts and still<br />
ma<strong>in</strong>t<strong>in</strong>s a Category 4 <strong>in</strong>terface.<br />
A multiple beam off/on selector switch is also an available option. This<br />
selector switch gives the option to run the mach<strong>in</strong>e <strong>in</strong> the setup mode<br />
without <strong>in</strong>terruption from the perimeter light beam. Other safeguard<strong>in</strong>g<br />
methods must be used when the permeter beam selector switch is <strong>in</strong><br />
the off position.<br />
If necessary, special <strong>in</strong>terfaces can be provided that will show the exact<br />
tie-<strong>in</strong> of the perimeter light beam system to your control system. We<br />
will need your exist<strong>in</strong>g electrical control system schematics to verify<br />
that it is compliant and that it is capable of accept<strong>in</strong>g a perimeter light<br />
beam tie-<strong>in</strong>. Please contact our factory for more <strong>in</strong>formation. Also,<br />
please contact <strong>Rockford</strong> <strong>Systems</strong> to discuss entry/exit applications to<br />
determ<strong>in</strong>e remote mut<strong>in</strong>g, sensor, and <strong>in</strong>terface options.<br />
INTERFACE FOR A PERIMETER LIGHT BEAM SYSTEM<br />
LRS-XXXX PART NO.<br />
FEATURES 1022 1023 1024 1025 1026 1027 1028<br />
Term<strong>in</strong>als X X X X X<br />
Fuses X X X X X<br />
Safety Monitor<strong>in</strong>g<br />
Relay<br />
Force-Guided<br />
Relays (2)<br />
Multiple Beam Off/<br />
On Selector Switch<br />
X X X X X X X<br />
X X X X X<br />
Power Supply X X X<br />
Enclosure X X X X X<br />
Reset Pushbtton<br />
Inside View of a Perimeter<br />
Light Beam Interface<br />
X<br />
X<br />
X<br />
OFF/ON REMOTE OPERATOR STATION—PART NO. LLD-1236<br />
An off/on remote operator station is available that is used <strong>in</strong> conjunction<br />
with an <strong>in</strong>terface when a pla<strong>in</strong> door enclosure or loose <strong>in</strong>terface<br />
comp<strong>one</strong>nts are chosen. This remote operator station <strong>in</strong>cludes an off/<br />
on keyed selector switch <strong>in</strong> a steel 31/2” x 31/4” x 23/4” enclosure.<br />
Perimeter Light Curta<strong>in</strong> Remote Operator Station<br />
22 | SAFEGUARDING DEVICES
1<br />
BEAM<br />
R<br />
E<br />
S<br />
E<br />
T<br />
S<br />
T<br />
A<br />
T<br />
U<br />
S<br />
1<br />
BEAM<br />
R<br />
E<br />
S<br />
E<br />
T<br />
S<br />
T<br />
A<br />
T<br />
U<br />
S<br />
SINGLE BEAM SYSTEM<br />
The s<strong>in</strong>gle beam system is designed specific<strong>all</strong>y for perimeter or auxiliary safeguard<strong>in</strong>g. It can be used for safeguard<strong>in</strong>g hazardous areas around<br />
mach<strong>in</strong>es and processes such as press feed<strong>in</strong>g equipment, robotic work cells, automatic mach<strong>in</strong>ery work envelopes, assembly l<strong>in</strong>es, conveyors,<br />
p<strong>all</strong>etizers, stackers, and plastic-<strong>in</strong>jection mold<strong>in</strong>g mach<strong>in</strong>es.<br />
FEATURES<br />
• Meets <strong>in</strong>dustry OSHA, ANSI, UL, IEC, and EN<br />
safety standards<br />
• Operat<strong>in</strong>g ranges: Short—2.6’ to 65’ (.8 to 20 m)<br />
Long—49’ to 230’ (15 to 70 m)<br />
• Number of beams—1<br />
• Strobe-light and weld-flash immunity<br />
• 24 ms response time<br />
• Diagnostics with 7-segment display<br />
• Optional external device monitor<strong>in</strong>g (EDM)<br />
The s<strong>in</strong>gle beam system consists of a transmitter and a receiver, each<br />
with strong, durable alum<strong>in</strong>um hous<strong>in</strong>g. When aligned and mounted at<br />
the proper safety distance, these sensors transmit an <strong>in</strong>visible beam<br />
of light across the entryway to the hazardous area. Interruption of this<br />
light beam sends a stop signal to the mach<strong>in</strong>e’s control. This signal is<br />
designed to stop hazardous mach<strong>in</strong>e motion or prevent the <strong>in</strong>itiation of<br />
mach<strong>in</strong>e motion. The s<strong>in</strong>gle beam system can be used <strong>in</strong> conjunction<br />
with mirrors to <strong>in</strong>crease the coverage of the safeguarded area.<br />
SINGLE BEAM TRANSMITTER AND RECEIVER DIMENSIONS<br />
0.50" (12.5 mm)<br />
M<strong>in</strong>imum Bend Radius<br />
0.66"<br />
(16.7 mm)<br />
Allow 3.5"<br />
(89 mm)<br />
5.9"<br />
(149 mm)<br />
1.02"<br />
(26 mm)<br />
4.21"<br />
(107.0 mm)<br />
1.0"<br />
(25 mm)<br />
2.0"<br />
(52 mm)<br />
2.1"<br />
(55 mm)<br />
4.9"<br />
(124 mm)<br />
7.2"<br />
(182 mm)<br />
2.36"<br />
(60.0 mm)<br />
2.92"<br />
(74.2 mm)<br />
SAFEGUARDING DEVICES | 23
SELECTING A SINGLE BEAM SYSTEM<br />
To determ<strong>in</strong>e the 6-digit configured part number for the s<strong>in</strong>gle beam system required, follow the directions below and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits determ<strong>in</strong>es the choice of a short range s<strong>in</strong>gle beam system or a long range s<strong>in</strong>gle beam system.<br />
2. The 4th digit determ<strong>in</strong>es the number of beams which will always be <strong>one</strong> (1).<br />
3. The 5th digit determ<strong>in</strong>es the length of the transmitter cable.<br />
4. The 6th digit determ<strong>in</strong>es the length of the receiver cable (can be a different length from the transmitter cable).<br />
SAMPLE<br />
1 2 3<br />
S B L - 1 - 2 - 5<br />
4<br />
The sample shown, Part No. SBL-1-2-5, is a long range s<strong>in</strong>gle beam system with <strong>one</strong> (1) beam. It has a 25’ (7.6 m) transmitter cable and a 50’<br />
(15.2 m) receiver cable.<br />
SINGLE BEAM SYSTEM TYPE<br />
SBS —Short range: 2.62’ to 65.6’ (0.8 m to 20 m)<br />
SBL —Long range: 49.2’ to 229.6’ (15 m to 70 m)<br />
NUMBER OF BEAMS<br />
1 —1<br />
SINGLE BEAM PART NUMBERING SYSTEM CHART<br />
X X X - 1 - X - X<br />
Four (4) end mount swivel brackets are <strong>in</strong>cluded with each s<strong>in</strong>gle beam system for mount<strong>in</strong>g.<br />
RECEIVER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
TRANSMITTER CABLE W/PLUG<br />
0 —No cable<br />
1 —15’ (4.5 m)<br />
2 —25’ (7.6 m)<br />
5 —50’ (15.2 m)<br />
7 —75’ (22.8 m)<br />
9 —100’ (30.4 m)<br />
OFF/ON REMOTE OPERATOR STATION—PART NO. LLD-1236<br />
An off/on remote operator station is available that is used <strong>in</strong> conjunction with an <strong>in</strong>terface when<br />
a pla<strong>in</strong> door enclosure or loose <strong>in</strong>terface comp<strong>one</strong>nts are chosen. This remote operator station<br />
<strong>in</strong>cludes an off/on keyed selector switch <strong>in</strong> a steel 31⁄2” x 31⁄4” x 23⁄4” enclosure.<br />
LASER ALIGNMENT TOOL—PART NO. LAT-1<br />
A laser alignment tool is available to aid <strong>in</strong> the alignment of any s<strong>in</strong>gle beam system. It is<br />
particularly useful with applications <strong>in</strong>volv<strong>in</strong>g mirrors.<br />
The laser alignment tool <strong>in</strong>cludes a 9-volt battery, a mount<strong>in</strong>g clip, and has a built-<strong>in</strong> circular<br />
bubble level. This alignment tool is to be used for set up only.<br />
24 | SAFEGUARDING DEVICES
S3000 SAFETY LASER SCANNER<br />
FEATURES<br />
• Meets <strong>in</strong>dustry OSHA, ANSI, UL, IEC, and EN safety standards<br />
• 3 models to choose from—standard, advanced, and professional<br />
• Selectable resolutions—30 mm (1.18”), 40 mm (1.58”), 50 mm<br />
(1.96”), 70 mm (2.75”), and 150 mm (5.9”)<br />
• 190° scann<strong>in</strong>g angle<br />
• Protective field scann<strong>in</strong>g range radius up to 23’ (7 m)<br />
• Warn<strong>in</strong>g field scann<strong>in</strong>g range radius up to 160’ (49 m)<br />
• M<strong>in</strong>imum response time 60 ms<br />
• Up to 8 programmable protective fields and<br />
8 warn<strong>in</strong>g fields (dependent on the I/O<br />
module and application)<br />
• Operat<strong>in</strong>g modes: restart <strong>in</strong>terlock, restart delay, and reset<br />
• Integrated external device monitor<strong>in</strong>g (EDM)<br />
• Warn<strong>in</strong>g field auxiliary output<br />
• Simultaneous monitor<strong>in</strong>g of two areas<br />
• Multiple sampl<strong>in</strong>g for various ambient conditions<br />
• LED 7-segment alignment and diagnostics display<br />
• 2 solid-state OSSD (output signal switch<strong>in</strong>g device) outputs—24-V<br />
PNP outputs<br />
• Configuration and diagnostic software (CDS)<br />
• Easy <strong>in</strong>st<strong>all</strong>ation<br />
S3000 Safety Laser Scanner Mounted<br />
on a Coil Process<strong>in</strong>g L<strong>in</strong>e<br />
The S3000 scanner is designed to meet <strong>in</strong>dustry safety standards for<br />
<strong>in</strong>door hazardous area and mach<strong>in</strong>ery protection, access protection,<br />
guided vehicle protection, robot stations, and irregular shaped areas.<br />
The scanner is an optical sensor that scans its surround<strong>in</strong>gs <strong>in</strong> two<br />
dimensions us<strong>in</strong>g <strong>in</strong>frared laser beams. It sends out very short pulses<br />
of light and measures the time it takes to reflect back (time of flight<br />
measurement).<br />
The S3000 scanner is encased <strong>in</strong> a yellow, scratch-resistant alum<strong>in</strong>um<br />
die-cast hous<strong>in</strong>g and has a durable polycarbonate front screen. The<br />
safety laser scanner <strong>in</strong>cludes the sensor head, system plug, and<br />
I/O module. The sensor head houses the opto-electronic acquisition<br />
system. The I/O module def<strong>in</strong>es the functionality of the S3000 safety<br />
laser scanner, and the system plug (with the configuration memory)<br />
conta<strong>in</strong>s <strong>all</strong> electrical connections.<br />
Up to eight (8) programmable warn<strong>in</strong>g fields and protective fields are<br />
available, depend<strong>in</strong>g on which scanner model is chosen. Each warn<strong>in</strong>g<br />
field has a non-safety output that can be <strong>in</strong>terfaced to a light, PLC,<br />
display, etc., to warn of impend<strong>in</strong>g encroachment of a protective field.<br />
Any <strong>in</strong>terruption to a protective field will cause the OSSDs to drop and<br />
<strong>in</strong>itiate a stop signal to the mach<strong>in</strong>e control system (mach<strong>in</strong>e primary<br />
control elements–MPCE).<br />
The programmable feature of the scanner elim<strong>in</strong>ates the need to<br />
reprogram the scanner every time someth<strong>in</strong>g changes with<strong>in</strong> the field.<br />
For example, if someth<strong>in</strong>g is regularly moved <strong>in</strong> and out of a field, then<br />
multiple fields can be programmed to accommodate the changes. A<br />
static <strong>in</strong>put <strong>all</strong>ows for a selector switch or PLC to be used to change the<br />
field sets as needed.<br />
S3000 Safety Laser Scanner<br />
SAFEGUARDING DEVICES | 25
MOUNTING OPTIONS<br />
The S3000 safety laser scanner can be mounted vertic<strong>all</strong>y or<br />
horizont<strong>all</strong>y. A mount<strong>in</strong>g kit (sold separately) is required. S3L-MK1<br />
is the base mount<strong>in</strong>g kit—S3L-MK2 adds on to the S3L-MK1, and<br />
S3L-MK3 adds on to S3L-MK1 and S3L-MK2. See the order<strong>in</strong>g<br />
<strong>in</strong>formation below.<br />
S3000 Mount<strong>in</strong>g Kits<br />
ORDERING INFORMATION<br />
PART NO.<br />
S3L-MK1<br />
S3L-MK2<br />
S3L-MK3<br />
DESCRIPTION<br />
Mount<strong>in</strong>g Kit #1 – No Adjustment Capability<br />
Mount<strong>in</strong>g Kit #2 – Provides Vertical Adjustment (an<br />
S3L-MK1 is Required <strong>in</strong> Addition to an S3L-MK2)<br />
Mount<strong>in</strong>g Kit #3 – Provides Horizontal Adjustment<br />
(an S3L-MK1 and S3L-MK2 are Required <strong>in</strong> Addition<br />
to an S3L-MK3)<br />
S3L-MK2<br />
S3L-MK2<br />
9”<br />
S3000 FLOOR STAND<br />
This floor stand is designed specific<strong>all</strong>y for mount<strong>in</strong>g the S3000 safety<br />
laser scanner. The stand is constructed of alum<strong>in</strong>um extrusion on a<br />
steel base plate which can be bolted to the floor.<br />
6.89”<br />
16”<br />
ORDERING INFORMATION<br />
PART NO.<br />
FKT-1093<br />
DESCRIPTION<br />
Floor Stand for S3000 Safety Laser Scanner – 2” x<br />
2” x 16” Extruded Alum<strong>in</strong>um Post on a 6” x 6” Steel<br />
Base Plate<br />
26 | SAFEGUARDING DEVICES
S3000 SAFETY LASER SCANNER DIMENSIONS<br />
Side View<br />
8.31"<br />
(211 mm)<br />
2.17"<br />
(55 mm)<br />
6.30"<br />
(160 mm)<br />
6.10"<br />
(155 mm)<br />
Front View<br />
7.28"<br />
(185 mm)<br />
190° Scann<strong>in</strong>g<br />
Angle<br />
SAFEGUARDING DEVICES | 27
SELECTING AN S3000 SERIES SAFETY LASER SCANNER<br />
To determ<strong>in</strong>e the 6-digit configured part number for the S3000 safety laser scanner required, follow the directions below and use the <strong>in</strong>formation<br />
<strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits for <strong>all</strong> safety laser scanners are S3S- (for standard), S3A- (for advanced), or S3P- (for professional).<br />
2. The 4th and 5th digits determ<strong>in</strong>e the safety z<strong>one</strong> scann<strong>in</strong>g range.<br />
3. The 6th digit determ<strong>in</strong>es the cable length with plug.<br />
4. A configuration cable is required for connection to a PC to enable configuration. See below for Part No S3L-CC6.<br />
SAMPLE<br />
1 2 3<br />
S 3 A - 1 3 2<br />
The sample shown, Part No. S3A-132, is an S3000 advanced safety laser scanner with a 13-foot safety z<strong>one</strong> scann<strong>in</strong>g range and a 10-meter cable<br />
with plug.<br />
LASER SCANNER TYPE<br />
S3S —S3000 Standard<br />
• 1 programmable protection field<br />
• 1 programmable warn<strong>in</strong>g field<br />
• 1 monitor<strong>in</strong>g case<br />
S3A —S3000 Advanced<br />
• 4 programmable protection fields<br />
• 4 programmable warn<strong>in</strong>g fields<br />
• 4 different monitor<strong>in</strong>g cases<br />
• 2 <strong>in</strong>puts for protective field switch<strong>in</strong>g<br />
S3P —S3000 Professional<br />
• 8 programmable protection fields<br />
• 8 programmable warn<strong>in</strong>g fields<br />
• 16 different monitor<strong>in</strong>g cases<br />
• 4 <strong>in</strong>puts for protective field switch<strong>in</strong>g<br />
• 1 <strong>in</strong>cremental encoder <strong>in</strong>put<br />
S3000 SERIES SAFETY LASER SCANNER PART NUMBERING SYSTEM CHART<br />
S 3 X - X X X<br />
SYSTEM PLUG AND CABLE LENGTH<br />
1 —5-meter cable with plug<br />
2 —10-meter cable with plug<br />
3 —20-meter cable with plug<br />
SAFETY ZONE SCANNING RANGE<br />
13 —13’ (4 m)<br />
18 —18’ (5.5 m)<br />
23 —23’ (7 m)<br />
Note: A configuration cable (Part No. S3L-CC6) is required to program<br />
the S3000 safety laser scanner—see <strong>in</strong>formation below.<br />
CONFIGURATION CABLE—PART NO. S3L-CC6<br />
At least <strong>one</strong> configuration cable is required for connect<strong>in</strong>g an S3000 safety laser scanner to a PC to enable configuration. One cable can be used<br />
to configure <strong>one</strong> or more S3000 safety laser scanners.<br />
NOTE: Please contact <strong>Rockford</strong> <strong>Systems</strong> for <strong>in</strong>formation on <strong>in</strong>terface requirements.<br />
28 | SAFEGUARDING DEVICES
TOWER LIGHT ASSEMBLIES<br />
A tower light assembly is designed to be exception<strong>all</strong>y bright with a long, visible <strong>in</strong>dication range. This provides highly visible<br />
operator and supervisor <strong>in</strong>formation as to equipment status. These assemblies are extremely rugged and are built to be used<br />
<strong>in</strong> the toughest <strong>in</strong>dustrial environments. They are available <strong>in</strong> both 24V DC and 120V AC.<br />
Each tower light assembly can be configured for up to five LED colors, or for up to four LED colors with an audible alarm.<br />
Each tower light assembly has a black ABS hous<strong>in</strong>g with polycarbonate LEDs. A standoff pipe (choose between 6” [152<br />
mm] or 12” [304 mm]) houses a 78-<strong>in</strong>ch (2-meter) connection cable that is supplied with each assembly. These tower light<br />
assemblies are completely self-conta<strong>in</strong>ed, or can be used <strong>in</strong> conjunction with a control box (see next page). Each tower<br />
assembly is pre-assembled with no field serviceable parts.<br />
SELECTING A TOWER LIGHT ASSEMBLY<br />
To determ<strong>in</strong>e the configured part number for the tower light assembly required, follow the directions below and use the <strong>in</strong>formation <strong>in</strong> the PART<br />
NUMBERING SYSTEM CHART below.<br />
1. Determ<strong>in</strong>e the voltage of the tower light assemblies—24V DC or 120V AC.<br />
2. Determ<strong>in</strong>e the color, function, and position of the lights (selected from bottom to top) and/or choose an alarm and t<strong>one</strong>. If an<br />
alarm is selected, only four light positions may be chosen s<strong>in</strong>ce the alarm will always occupy the top position.<br />
3. Determ<strong>in</strong>e the standoff pipe extension length.<br />
1 2 3<br />
SAMPLE<br />
T L A - R S G F W S Y T A C - 1 2<br />
The sample shown, Part No. TLA-RSGFWSYTAC-12, is a 24V DC tower light assembly that has <strong>one</strong> red solid light, <strong>one</strong> green flash<strong>in</strong>g light, <strong>one</strong><br />
white solid light, and <strong>one</strong> yellow turn<strong>in</strong>g light (stacked from bottom to top). It also has a cont<strong>in</strong>uous t<strong>one</strong> alarm with a 12” (304 mm) pipe extension.<br />
1 2 3<br />
SAMPLE<br />
T L Z - A P - 0 6<br />
The sample shown, Part No. TLZ-AP-06, is a 120V AC tower light assembly without any lights. It has a pulsed t<strong>one</strong> alarm with a 6” (304 mm) pipe<br />
extension.<br />
TOWER LIGHT ASSEMBLY PART NUMBERING SYSTEM CHART<br />
T L X - X X X X X X X X X X - X X<br />
TOWER LIGHT ASSEMBLY<br />
TLA —24 V DC Tower Light Assembly<br />
TLZ —120 V AC Tower Light Assembly<br />
Pos. 1<br />
Pos. 2<br />
Pos. 3<br />
Pos. 4<br />
Pos. 5*<br />
Choose<br />
Color/Alarm + Function<br />
+<br />
+<br />
+<br />
+<br />
+<br />
R=Red<br />
B=Blue<br />
G=Green<br />
W=White<br />
Y=Yellow<br />
A=Alarm<br />
Blank=Not used<br />
Light Color and Function and/or Alarm<br />
Top<br />
S=On Solid<br />
F=Flash<strong>in</strong>g<br />
T=Turn<strong>in</strong>g (rotat<strong>in</strong>g)<br />
C=Cont<strong>in</strong>uous t<strong>one</strong> alarm<br />
P=Pulsed t<strong>one</strong> alarm<br />
*Up to 5 lights without alarm<br />
Up to 4 lights with alarm–alarm will always occupy top position<br />
Position 5*<br />
Position 4<br />
Position 3<br />
Position 2<br />
Position 1<br />
Bottom<br />
Standoff Pipe<br />
-- —N<strong>one</strong><br />
06 —6” (152 mm) Pipe extension<br />
12 —12” (304 mm) Pipe extension<br />
SAFEGUARDING DEVICES | 29
TOWER LIGHT BRACKET— CMC569M<br />
An optional mount<strong>in</strong>g bracket for self-conta<strong>in</strong>ed tower light assemblies<br />
is available for mount<strong>in</strong>g the tower light <strong>in</strong> a convenient location. The<br />
right angle bracket is made of 12-ga. sta<strong>in</strong>less steel and has curved<br />
mount<strong>in</strong>g slots for versatility and orientation.<br />
TOWER LIGHT ASSEMBLY CONTROL BOX—LLD-1631<br />
The tower light <strong>in</strong>terface box provides a convenient means of mount<strong>in</strong>g and wir<strong>in</strong>g the tower light. The LLD-1631 standard box comes with enough<br />
term<strong>in</strong>als to accommodate five (5) lights or four (4) lights with an alarm <strong>in</strong> the tower light assembly. This control box is approximately 8” x 6” x 6”.<br />
Inside View of Tower Light<br />
Assembly Control Box<br />
30 | SAFEGUARDING DEVICES
NO-GO INDICATOR LIGHT<br />
ORDERING INFORMATION<br />
PART NO.<br />
LLD-141<br />
DESCRIPTION<br />
No-Go Indicator Light Mount<strong>in</strong>g<br />
Box and Lens Projectors<br />
Most po<strong>in</strong>t-of-operation light curta<strong>in</strong>s will not detect workpieces that<br />
present a profile of 1/4” or less. However, if the workpiece profile becomes<br />
bowed enough to be seen <strong>in</strong> the plane of light, it will be detected.<br />
On press brake operations, the mach<strong>in</strong>e will not start a stroke because<br />
the workpiece quite often protrudes through the plane of light and is<br />
detected. This becomes frustrat<strong>in</strong>g for operators because they have to<br />
look to the right or to the left for the red and green <strong>in</strong>dicator lights on<br />
the transmitter or receiver to determ<strong>in</strong>e if the obstruction is detected.<br />
To avoid frustrat<strong>in</strong>g the operator, a large red no-go <strong>in</strong>dicator light can<br />
be <strong>in</strong>st<strong>all</strong>ed on the slide and <strong>in</strong> the peripheral sight of the operator. This<br />
light <strong>all</strong>ows the operator to hold the workpiece <strong>in</strong> the correct position. At<br />
the same time, the no-go light will let them know if their hands or the<br />
workpiece is be<strong>in</strong>g detected by the light curta<strong>in</strong>. In some cases, the red<br />
no-go <strong>in</strong>dicator light can be used to avoid channel blank<strong>in</strong>g.<br />
The red no-go <strong>in</strong>dicator light has a low-profile design. It is protected<br />
from workpieces which bend <strong>in</strong>to the light, and is easily wired <strong>in</strong>to<br />
exist<strong>in</strong>g light curta<strong>in</strong> systems.<br />
The no-go <strong>in</strong>dicator light <strong>in</strong>cludes the light, the mount<strong>in</strong>g box, and<br />
<strong>in</strong>structions on how to wire it <strong>in</strong>to the light curta<strong>in</strong> control system.<br />
TEST RODS FOR EZ-SCREEN LIGHT CURTAINS<br />
A test rod is <strong>in</strong>cluded with each shipment of an EZ-Screen light curta<strong>in</strong><br />
system. When a light curta<strong>in</strong> is used for safeguard<strong>in</strong>g, a test rod<br />
must be used to test the light curta<strong>in</strong> after each setup or after any<br />
ma<strong>in</strong>tenance work performed—refer to pages 65-66 for a sample<br />
function-test<strong>in</strong>g checklist for light curta<strong>in</strong>s.<br />
ORDERING INFORMATION<br />
PART NO.<br />
STP-13<br />
STP-14<br />
STP-3<br />
DIAMETER/MOS<br />
(MIN. OBJECT SENSITIVITY)<br />
0.55” (14 mm)<br />
1.18” (30 mm)<br />
1.75” (45 mm)<br />
OPTIONAL MOUNTING BRACKETS FOR POINT-OF-OPERATION LIGHT CURTAIN SYSTEMS<br />
—PART NO. EZA-MBK-20<br />
These optional mount<strong>in</strong>g brackets are for use with the po<strong>in</strong>t-of-operation<br />
light curta<strong>in</strong> systems on pages 11-16. These brackets are designed to<br />
mount po<strong>in</strong>t-of-operation light curta<strong>in</strong> systems to eng<strong>in</strong>eered/slotted<br />
alum<strong>in</strong>um fram<strong>in</strong>g (for example, <strong>Rockford</strong> <strong>Systems</strong>’ Ex-Al products).<br />
Set of two (2).<br />
SAFEGUARDING DEVICES | 31
SAB-A (SWING-AWAY WITH ADJUSTABLE GUARDS) AND<br />
SAB-NA (SWING-AWAY WITH NONADJUSTABLE GUARDS) MOUNTING BRACKETS<br />
Sw<strong>in</strong>g-away light curta<strong>in</strong> mount<strong>in</strong>g brackets with guards are ideal<br />
for many mach<strong>in</strong>es, <strong>in</strong>clud<strong>in</strong>g gap-frame presses and press brakes,<br />
when the light curta<strong>in</strong> must be swung out of the way for setup, die<br />
changes, or ma<strong>in</strong>tenance. The light curta<strong>in</strong> transmitter and receiver are<br />
easily aligned when they are swung back <strong>in</strong>to the mach<strong>in</strong>e operat<strong>in</strong>g<br />
position. The 2” square extruded-alum<strong>in</strong>um brackets <strong>in</strong>clude side<br />
barrier guards as shown. The nonadjustable portion of these guards<br />
can be constructed of black or yellow mesh (1⁄2” square, 16 gauge), or<br />
clear polycarbonate (3⁄16”). The lower portion of the barrier guard can<br />
be constructed of adjustable, black-oxidized steel hairp<strong>in</strong>s. This <strong>all</strong>ows<br />
for feed<strong>in</strong>g of stock, location of chutes, etc., on the sides of the po<strong>in</strong>t<br />
of operation.<br />
SAB-A MOUNTING BRACKET<br />
These guards <strong>in</strong>corporate a h<strong>in</strong>ge assembly on the corner. This <strong>all</strong>ows<br />
the light curta<strong>in</strong> to be swung out. This assembly can also be used to<br />
adjust the light curta<strong>in</strong> panel forward and backward to adjust for safety<br />
distance. A built-<strong>in</strong> lock<strong>in</strong>g p<strong>in</strong> <strong>in</strong> this assembly holds the panel <strong>in</strong> place.<br />
Sw<strong>in</strong>g-away brackets and barrier guards are built to specifications and<br />
measurements provided. See the next page for the appropriate SAB-A<br />
or SAB-NA measurement form.<br />
SAB-NA MOUNTING BRACKET<br />
Sw<strong>in</strong>g-Away Light Curta<strong>in</strong> Mount<strong>in</strong>g Bracket with<br />
Material Feed<strong>in</strong>g Segment Built Into the Guards<br />
Sw<strong>in</strong>g-Away Light Curta<strong>in</strong> Mount<strong>in</strong>g Bracket<br />
with Nonadjustable Guards<br />
32 | SAFEGUARDING DEVICES
SWING-AWAY MOUNTING BRACKET SPECIFICATIONS<br />
SAB-A<br />
(WITH ADJUSTABLE GUARDS)<br />
SAB-NA<br />
(WITH NONADJUSTABLE GUARDS)<br />
A<br />
B+C<br />
A<br />
B+C<br />
E<br />
D<br />
D<br />
Rear<br />
Panel<br />
Side Panel<br />
Adjustable<br />
Hairp<strong>in</strong>s<br />
Light<br />
Curta<strong>in</strong><br />
Rear<br />
Panel<br />
Side Panel<br />
Light Curta<strong>in</strong><br />
Note: B + C dimension <strong>in</strong>cludes safety distance. Stopp<strong>in</strong>g time of the mach<strong>in</strong>e must be determ<strong>in</strong>ed to establish the safety distance. Please<br />
consult the factory if assistance is needed.<br />
Select the appropriate SAB (sw<strong>in</strong>g-away bracket) for your application. If adjustability is required <strong>in</strong> the lower portion of the barrier guard section,<br />
select the mount<strong>in</strong>g bracket SAB-A. If adjustability is not required, select the mount<strong>in</strong>g bracket SAB-NA.<br />
Please complete <strong>one</strong> of the measurement forms (see page 34 or 35) when order<strong>in</strong>g these brackets. The A, B, C, D, and E dimensions will be<br />
determ<strong>in</strong>ed from the measurements supplied. Check the material type for the sides and rear panels below.<br />
LEFT SIDE OF MACHINE<br />
£SAB-A<br />
RIGHT SIDE OF MACHINE<br />
Side Panel Material Type<br />
£ Black Mesh £ Black Mesh<br />
£ Yellow Mesh £ Yellow Mesh<br />
£ Clear Polycarbonate £ Clear Polycarbonate<br />
Rear Panel Material Type<br />
£ Black Mesh £ Black Mesh<br />
£ Yellow Mesh £ Yellow Mesh<br />
£ Clear Polycarbonate £ Clear Polycarbonate<br />
LEFT SIDE OF MACHINE<br />
£SAB-NA<br />
RIGHT SIDE OF MACHINE<br />
Side Panel Material Type<br />
£ Black Mesh £ Black Mesh<br />
£ Yellow Mesh £ Yellow Mesh<br />
£ Clear Polycarbonate £ Clear Polycarbonate<br />
Rear Panel Material Type<br />
£ Black Mesh £ Black Mesh<br />
£ Yellow Mesh £ Yellow Mesh<br />
£ Clear Polycarbonate £ Clear Polycarbonate<br />
SAFEGUARDING DEVICES | 33
I<br />
MEASUREMENT FORM FOR MODELS SAB-A AND SAB-NA SWING-AWAY BRACKETS<br />
Company___________________________________________________ Address_______________________________________<br />
_________________________________________________________<br />
City_______________________________________________________ State__________________ZIP_____________________<br />
Attention___________________________________________________ Rep.__________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No._____________________________________ Mach<strong>in</strong>e No.____________________________________<br />
Measured By_____________________________________________________________________________________________<br />
Determ<strong>in</strong>e which mount<strong>in</strong>g brackets are required: SAB-A (with adjustable barrier guards) or SAB-NA (with nonadjustable barrier guards).<br />
Check the bracket type required and complete measurements for the mach<strong>in</strong>e where brackets will be applied.<br />
MEASURING INSTRUCTIONS<br />
£ SAB-A*<br />
PRESS APPLICATION<br />
Check type of press:<br />
£ SAB-NA*<br />
Top View<br />
Mechanical Hydraulic Other<br />
ht-Side View<br />
FLYWHEEL COVER<br />
(If Mechanical Press)<br />
G<br />
r Plate<br />
H<br />
C<br />
B<br />
Left<br />
Side<br />
Floor<br />
T<br />
A<br />
(3" m<strong>in</strong>.)<br />
F<br />
E<br />
Right-Side View<br />
FLYWHEEL COVER<br />
G<br />
Bolster Plate<br />
(If Mechanical Press)<br />
H<br />
F<br />
Mach<strong>in</strong>e Frame<br />
Bolster<br />
Plate<br />
Front of Press<br />
Field of Coverage<br />
E<br />
(3" m<strong>in</strong>.)<br />
Roof/Floor Sections<br />
Length<br />
A<br />
F<br />
R<br />
Length<br />
Right<br />
Side<br />
Height<br />
Size of light curta<strong>in</strong>: ___________”<br />
A: Enter dimensions from mount<strong>in</strong>g po<strong>in</strong>t on press frame<br />
to <strong>in</strong>side of sw<strong>in</strong>g-away mount<strong>in</strong>g bracket. (Be sure<br />
bracket extend<strong>in</strong>g forward will clear bolster and any<br />
obstruction on the side of the press frame.)<br />
B: Enter dimension from front side of mach<strong>in</strong>e frame<br />
mount<strong>in</strong>g bracket to front edge of bolster plate<br />
(assum<strong>in</strong>g nearest p<strong>in</strong>ch po<strong>in</strong>t to operator is at the<br />
front edge of bolster).<br />
C: Enter the m<strong>in</strong>imum safety distance determ<strong>in</strong>ed by the<br />
safety distance formula. Stopp<strong>in</strong>g time of the press<br />
must be determ<strong>in</strong>ed to establish safety distance.<br />
D: Enter the panel height for the guard on the left and<br />
right side of mach<strong>in</strong>e.<br />
Left________”<br />
Right________”<br />
Note: The light curta<strong>in</strong> mount<strong>in</strong>g extrusion will be a<br />
m<strong>in</strong>imum of 8” longer than the light curta<strong>in</strong> field<br />
of coverage.<br />
E: If roof section(s) are required, enter E dimension(s)<br />
(height) and provide length of roof section(s):<br />
Left________” Right_ _______”<br />
F: If floor section(s) are required, enter F dimension(s)<br />
(height) and provide length of floor section(s):<br />
Left_______” Front_______” Right_______”<br />
G: If hairp<strong>in</strong>s are required on side panel extend<strong>in</strong>g<br />
upward, enter G dimension (height) above the guard<br />
to the flywheel cover and provide length _ _______”.<br />
H: Height from floor to top of bolster.<br />
I: Maximum feedl<strong>in</strong>e height (used to determ<strong>in</strong>e hairp<strong>in</strong><br />
Floor<br />
Roof/Floor Sections<br />
length if adjustable brackets).<br />
Notes:<br />
Height<br />
* 1⁄2” square black mesh will be furnished <strong>in</strong> the nonadjustable portion of the assembly unless otherwise specified <strong>in</strong> Notes section above.<br />
B<br />
Precautions should be taken when apply<strong>in</strong>g light curta<strong>in</strong>s for po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g. Be sure that some<strong>one</strong> cannot pass through or<br />
stand undetected between the plane of light and the hazard when a light curta<strong>in</strong> is mounted <strong>in</strong> a vertical position. If a light curta<strong>in</strong> must be<br />
mounted <strong>in</strong> this manner due to the safety distance requirements or because of the configuration of the mach<strong>in</strong>e, be sure that supplemental<br />
safeguard<strong>in</strong>g is provided to safeguard this pass-through area. Examples of supplemental safeguard<strong>in</strong>g <strong>in</strong>clude a horizont<strong>all</strong>y mounted light<br />
curta<strong>in</strong>, s<strong>in</strong>gle-beam devices, guards, or pressure-sensitive safety mats on the floor.<br />
C<br />
34 | SAFEGUARDING DEVICES
MEASUREMENT FORM FOR MODELS SAB-A AND SAB-NA SWING-AWAY BRACKETS<br />
Company___________________________________________________ Address_______________________________________<br />
_________________________________________________________<br />
City_______________________________________________________ State__________________ ZIP_____________________<br />
Attention___________________________________________________ Rep._________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No._____________________________________ Mach<strong>in</strong>e No.___________________________________<br />
Measured By________________________________________________<br />
Determ<strong>in</strong>e which mount<strong>in</strong>g brackets are required: SAB-A (with adjustable barrier guards) or SAB-NA (with nonadjustable barrier<br />
guards). Check the bracket type required and complete measurements for the mach<strong>in</strong>e where brackets will be applied.<br />
£ SAB-A*<br />
£ SAB-NA*<br />
Left-Side View<br />
Sw<strong>in</strong>g-Away<br />
Light Curta<strong>in</strong><br />
Mount<strong>in</strong>g Brackets<br />
Notes:<br />
B<br />
C<br />
Left<br />
Side<br />
T<br />
A<br />
(3" m<strong>in</strong>.)<br />
Light<br />
Curta<strong>in</strong><br />
F<br />
PRESS BRAKE APPLICATION<br />
D<br />
Panel Height<br />
(LC FOC + 8")<br />
Height from Floor<br />
to Top of Bed<br />
Top View<br />
E<br />
Press<br />
Brake Frame<br />
Slide<br />
Field of Coverage<br />
Feedl<strong>in</strong>e Height<br />
M<strong>in</strong>. "<br />
Max. "<br />
D<br />
Panel Height<br />
(LC FOC + 8")<br />
Light<br />
Curta<strong>in</strong><br />
F<br />
Height from Floor<br />
to Top of Bed<br />
Right-Side View<br />
Sw<strong>in</strong>g-Away<br />
Light Curta<strong>in</strong><br />
Mount<strong>in</strong>g Brackets<br />
Precautions should be taken when apply<strong>in</strong>g light curta<strong>in</strong>s for po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g. Be<br />
sure that some<strong>one</strong> cannot pass through or stand undetected between the plane of light and the<br />
hazard when a light curta<strong>in</strong> is mounted <strong>in</strong> a vertical position. If a light curta<strong>in</strong> must be mounted<br />
<strong>in</strong> this manner due to the safety distance requirements or because of the configuration of the<br />
mach<strong>in</strong>e, be sure that supplemental safeguard<strong>in</strong>g is provided to safeguard this pass-through area.<br />
Examples of supplemental safeguard<strong>in</strong>g <strong>in</strong>clude a horizont<strong>all</strong>y mounted light curta<strong>in</strong>, s<strong>in</strong>gle-beam<br />
devices, guards, or pressure-sensitive safety mats on the floor.<br />
G<br />
A<br />
(3" m<strong>in</strong>.)<br />
* 1 ⁄2” square black mesh will be furnished <strong>in</strong> the nonadjustable portion of the assembly unless otherwise<br />
specified <strong>in</strong> Notes section above.<br />
Right<br />
Side<br />
R<br />
B<br />
C<br />
MEASURING INSTRUCTIONS<br />
Check type of press brake:<br />
Mechanical<br />
Air Clutch<br />
Other<br />
Size of light curta<strong>in</strong>: ___________”<br />
A: Enter dimensions from mount<strong>in</strong>g po<strong>in</strong>t on<br />
mach<strong>in</strong>e frame to <strong>in</strong>side of sw<strong>in</strong>g-away<br />
bracket. (Be sure bracket extend<strong>in</strong>g forward<br />
will clear slide.)<br />
Note: Left and right side dimensions may be<br />
different due to an extension on <strong>one</strong> end<br />
of the slide.<br />
B: Enter dimension from front side of mach<strong>in</strong>e<br />
frame mount<strong>in</strong>g bracket to front of slide or<br />
bed.<br />
Note: Left and right side dimensions may<br />
be different due to available mount<strong>in</strong>g<br />
surfaces on side of mach<strong>in</strong>e.<br />
C: Enter the m<strong>in</strong>imum safety distance<br />
determ<strong>in</strong>ed by the safety distance formula.<br />
Stopp<strong>in</strong>g time of the mach<strong>in</strong>e must be<br />
determ<strong>in</strong>ed to establish safety distance.<br />
D: Enter the panel height for the guards on the<br />
left and right end of the mach<strong>in</strong>e.<br />
Note: The light curta<strong>in</strong> mount<strong>in</strong>g extrusion will<br />
be a m<strong>in</strong>imum of 8” longer than the light<br />
curta<strong>in</strong> field of coverage.<br />
E: Enter <strong>in</strong>side frame dimension at the rear of<br />
mach<strong>in</strong>e.<br />
F: Enter height from floor to top of bed. Also<br />
provide maximum and m<strong>in</strong>imum feedl<strong>in</strong>e<br />
height.<br />
G: Enter dimension from back of the slide to<br />
rear of mach<strong>in</strong>e.<br />
If floor/roof sections are required, please read<br />
the <strong>in</strong>structions (E & F) on the previous page and<br />
provide dimensions <strong>in</strong> the Notes section above.<br />
SAFEGUARDING DEVICES | 35
STATIONARY MOUNTING BRACKET SPECIFICATIONS FOR MODELS:<br />
SB-2, SB-3 OBI, SB-3 SS, SB-3 SSG, SB-5, AND SB-5 G<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
Company______________________________________________ Address____________________________________________<br />
City__________________________________________________ State___________________ ZIP_________________________<br />
Attention______________________________________________ Rep.______________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No.________________________________ Mach<strong>in</strong>e No._________________________________________<br />
Measured By___________________________________________ ____________________________________________<br />
Check the required stationary bracket. If the standard dimensions specified here do not fit your application, <strong>in</strong>dicate the dimensions required. The A dimension for<br />
<strong>all</strong> brackets should be a m<strong>in</strong>imum of 8” more than the light curta<strong>in</strong> field-of-coverage height.<br />
SB-2<br />
A<br />
B*<br />
2-Section Mount<strong>in</strong>g Bracket<br />
(2-Dimensional)<br />
A<br />
B*<br />
Std<br />
32”<br />
20”<br />
Req’d<br />
SB-3 OBI<br />
A<br />
B*<br />
3-Section<br />
<br />
Mount<strong>in</strong>g Bracket<br />
(3-Dimensional)<br />
C<br />
A<br />
B*<br />
C<br />
Std<br />
32”<br />
24”<br />
12”<br />
Req’d<br />
(3” M<strong>in</strong>.)<br />
SB-3 SS<br />
SB-5<br />
A<br />
A<br />
B*<br />
B*<br />
3-Section Mount<strong>in</strong>g Bracket<br />
(2-Dimensional)<br />
A<br />
B*<br />
Std<br />
44”<br />
12”<br />
Req’d<br />
SB-3 SSG<br />
5-Section Mount<strong>in</strong>g Bracket<br />
SB-5 G <br />
(3-Dimensional)<br />
Guard<strong>in</strong>g Material<br />
Std Req’d<br />
C<br />
A<br />
B*<br />
*B dimension must <strong>in</strong>clude safety distance. Stopp<strong>in</strong>g time of the mach<strong>in</strong>e must<br />
be determ<strong>in</strong>ed to establish the safety distance. Please consult the factory if<br />
assistance is needed.<br />
C<br />
3-Section Mount<strong>in</strong>g Bracket<br />
(2-Dimensional) With Guards<br />
A<br />
B*<br />
Std<br />
44”<br />
12”<br />
Blk<br />
5-Section Mount<strong>in</strong>g Bracket<br />
(2-Dimensional) With Guards<br />
Std<br />
36”<br />
A 36”<br />
A<br />
B* 24”<br />
24”<br />
C 12”<br />
Guard<br />
12” B*<br />
C Blk<br />
Mat’l<br />
(3” M<strong>in</strong>.)<br />
**<br />
A<br />
B*<br />
Guard<strong>in</strong>g<br />
Material<br />
Guard<br />
Mat’l<br />
**<br />
Req’d<br />
Req’d<br />
(3” M<strong>in</strong>.)<br />
**CHOICES OF GUARDING MATERIAL: 1 ⁄2” square or 1” square black (Blk) or<br />
yellow (Y) mesh, or polycarbonate (PC). 1 ⁄2” square black mesh is furnished as<br />
standard guard<strong>in</strong>g material unless otherwise specified.<br />
36 | SAFEGUARDING DEVICES
STATIONARY MOUNTING BRACKETS<br />
These stationary light curta<strong>in</strong> mount<strong>in</strong>g brackets are economical,<br />
heavy-duty, and versatile. Their design <strong>all</strong>ows them to be tailored to<br />
each <strong>in</strong>dividual mach<strong>in</strong>e. They are available <strong>in</strong> two-, three-, or fivesection<br />
assemblies. They are ideal for applications where side barriers<br />
(guards) will be fabricated by the user or provided separately. Two of<br />
the stationary light curta<strong>in</strong> mount<strong>in</strong>g brackets can also be furnished<br />
with <strong>in</strong>tegral guard<strong>in</strong>g material. See the measurement form on the<br />
previous page.<br />
The two-section and three-section (SS) brackets can be used whenever<br />
mount<strong>in</strong>g brackets can be <strong>in</strong>st<strong>all</strong>ed on the front surface of the mach<strong>in</strong>e.<br />
The three-section (OBI) should be used when the brackets must be<br />
mounted to the sides of the mach<strong>in</strong>e (see photo). The five-section can<br />
also be mounted on the sides of the mach<strong>in</strong>e, at both the top and the<br />
bottom for greater stability. All of these brackets are designed for use<br />
on gap-frame presses or press brakes.<br />
These brackets are constructed of 2” square extruded alum<strong>in</strong>um which<br />
attach to the mach<strong>in</strong>e with L-shaped mount<strong>in</strong>g feet. The brackets<br />
are fastened to the mount<strong>in</strong>g feet with T-nuts and cap screws. Each<br />
mount<strong>in</strong>g foot has two holes which are used for mount<strong>in</strong>g the bracket<br />
to the mach<strong>in</strong>e. Fasteners are <strong>in</strong>cluded with each assembly.<br />
3-Section (OBI) Stationary Light Curta<strong>in</strong> Mount<strong>in</strong>g Bracket<br />
(barrier guard has been removed from mach<strong>in</strong>e for photo)<br />
When light bars (transmitter or receiver) cannot be conveniently<br />
mounted to the mach<strong>in</strong>e, a floor stand can be furnished. Floor stands<br />
can also be used when safeguard<strong>in</strong>g large work envelopes or perimeter<br />
areas. Mirrors or s<strong>in</strong>gle-beam devices can be attached to the floor stand<br />
when the application requires multiple-sided safeguard<strong>in</strong>g. Light bars,<br />
s<strong>in</strong>gle-beam devices, or mirrors can easily be adjusted up or down on<br />
any side of the upright extruded-alum<strong>in</strong>um stand.<br />
This floor stand assembly consists of a 6’ length of 2” square extruded<br />
alum<strong>in</strong>um, <strong>one</strong> base, and two right-angle brackets with fasteners. The<br />
base has four holes for permanent attachment to the floor with bolts<br />
(not furnished). Other floor stand sizes are available. Please consult<br />
the factory.<br />
Floor Stand With Light Curta<strong>in</strong> Transmitter<br />
(Light Curta<strong>in</strong> Sold Separately)<br />
Floor Stand With Mirror<br />
(Mirror Sold Separately)<br />
SAFEGUARDING DEVICES | 37
MIRRORS FOR LIGHT CURTAINS<br />
Mirrors can be used with the light curta<strong>in</strong> to protect more than <strong>one</strong><br />
side of the po<strong>in</strong>t of operation or work envelope. The mirrors can help<br />
protect two, three, and even four sides of the po<strong>in</strong>t of operation or<br />
perimeter area (see next page). They are usu<strong>all</strong>y mounted on a 45°<br />
angle at each corner of the area to be safeguarded. Mount<strong>in</strong>g hardware<br />
is provided which can be used with the floor stand illustrated on the<br />
previous page, or with the SAB-LC/M bracket illustrated on page 39.<br />
Shock and vibration isolation mount<strong>in</strong>g fasteners are also provided with<br />
each mirror.<br />
The mirror frame is constructed of 11/2” square alum<strong>in</strong>um extrusion<br />
with a rubber gasket. This gasket protects the mirror from mach<strong>in</strong>e<br />
vibration and shock load.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION OF MIRROR<br />
KTR-226 7” Field of Coverage<br />
KTR-227 12” Field of Coverage<br />
KTR-228 16” Field of Coverage<br />
KTR-229 18” Field of Coverage<br />
KTR-230 21” Field of Coverage<br />
KTR-231 24” Field of Coverage<br />
KTR-232 28” Field of Coverage<br />
KTR-233 35” Field of Coverage<br />
KTR-234 36” Field of Coverage<br />
KTR-235 42” Field of Coverage<br />
KTR-236 48” Field of Coverage<br />
KTR-237 56” Field of Coverage<br />
Special-size mirrors are available upon request.<br />
ADJUSTABLE MIRROR MOUNTING BRACKET<br />
—PART NO. MMB-F<br />
Adjustable mirror mount<strong>in</strong>g brackets are available for mount<strong>in</strong>g mirrors<br />
to floor stands. These brackets are designed to provide easier alignment<br />
between light curta<strong>in</strong>s and mirrors. Each adjustable mirror mount<strong>in</strong>g<br />
bracket consists of two pieces of 1” x 2” extruded alum<strong>in</strong>um (48”<br />
long) connected by a rotat<strong>in</strong>g corner bracket. Please contact <strong>Rockford</strong><br />
<strong>Systems</strong> if the standard dimension does not meet your requirements.<br />
Adjustable Corner Bracket Provides Easy Alignment<br />
38 | SAFEGUARDING DEVICES
LIGHT CURTAIN AND MIRROR SWING-AWAY MOUNTING BRACKETS (PART NO. SAB-LC/M)<br />
These brackets can be used on a variety of mach<strong>in</strong>es which<br />
require two-sided or three-sided light curta<strong>in</strong> protection. One<br />
light curta<strong>in</strong> and <strong>one</strong> mirror provide two-sided protection; <strong>one</strong><br />
light curta<strong>in</strong> and two mirrors provide three-sided protection<br />
(see illustration).<br />
The left and right sides of these brackets have the ability to<br />
adjust <strong>in</strong> both directions. This provides flexibility for different<br />
production runs so the light curta<strong>in</strong> can always be mounted at<br />
the proper safety distance.<br />
The assembly for three-sided protection consists of the<br />
brackets on the left and right side plus the rear barrier guards.<br />
One light curta<strong>in</strong> and two mirrors (see previous page for mirror<br />
part numbers) must be ordered separately.<br />
The assembly for two-sided protection consists of <strong>one</strong> leftside<br />
bracket or <strong>one</strong> right-side bracket. Please specify at time<br />
of order. One light curta<strong>in</strong> and <strong>one</strong> mirror must be ordered<br />
separately. One floor stand or <strong>one</strong> light curta<strong>in</strong> mount<strong>in</strong>g<br />
bracket is also required to mount the other light bar. See pages<br />
32-38 for brackets, floor stands, and mirrors.<br />
Left SAB-LC/M<br />
Light<br />
Curta<strong>in</strong><br />
This draw<strong>in</strong>g is for illustrative purposes only.<br />
Rear Barrier<br />
Guard<br />
Rear Barrier<br />
Guard<br />
Light<br />
Curta<strong>in</strong><br />
Mirrors<br />
Right SAB-LC/M<br />
Three-Sided Application With SAB-LC/M Mount<strong>in</strong>g Brackets<br />
SAFEGUARDING DEVICES | 39
TWO-HAND CONTROL<br />
Two-hand control can be used as a safeguard<strong>in</strong>g device <strong>in</strong> the<br />
s<strong>in</strong>gle-stroke mode of operation on part-revolution clutch presses and<br />
hydraulic press and press brakes.<br />
There are many requirements that must be met before two-hand<br />
control can be used as a po<strong>in</strong>t-of-operation safeguard. These<br />
requirements are located <strong>in</strong> OSHA 29 CFR 1910.217 and ANSI<br />
B11.1, B11.2, B11.3, and B11.19. We have referenced the follow<strong>in</strong>g<br />
paragraphs for your convenience:<br />
OSHA<br />
(c)(3)(i) Po<strong>in</strong>t-of-operation devices sh<strong>all</strong> protect the operator by:<br />
(e) Requir<strong>in</strong>g application of both of the operator’s hands to mach<strong>in</strong>e<br />
operat<strong>in</strong>g controls and locat<strong>in</strong>g such controls at such a safety distance<br />
from the po<strong>in</strong>t of operation that the slide completes the downward<br />
travel or stops before the operator can reach <strong>in</strong>to the po<strong>in</strong>t of operation<br />
with his hands;<br />
(c)(3)(vii) The two-hand control device sh<strong>all</strong> protect the operator as<br />
specified <strong>in</strong> paragraph (c)(3)(i)(e) of this section.<br />
(a) When used <strong>in</strong> press operations requir<strong>in</strong>g more than <strong>one</strong> operator,<br />
separate two-hand controls sh<strong>all</strong> be provided for each operator, and<br />
sh<strong>all</strong> be designed to require concurrent application of <strong>all</strong> operator<br />
controls to activate the slide. The removal of a hand from any control<br />
button sh<strong>all</strong> cause the slide to stop.<br />
(b) Each two-hand control sh<strong>all</strong> meet the construction requirements of<br />
paragraph (b)(7)(v) of this section.<br />
(c)The safety distance (Ds) between each two-hand control device and<br />
the po<strong>in</strong>t of operation sh<strong>all</strong> be greater than the distance determ<strong>in</strong>ed by<br />
the follow<strong>in</strong>g formula:<br />
Ds = 63 <strong>in</strong>ches/second x Ts where:<br />
Ds = m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
Ts = stopp<strong>in</strong>g time of the press measured at approximately 90°<br />
position of crankshaft rotation (seconds).<br />
(d) Two-hand controls sh<strong>all</strong> be fixed <strong>in</strong> position so that only a<br />
supervisor or safety eng<strong>in</strong>eer is capable of relocat<strong>in</strong>g the controls.<br />
(b)(7)(v) Two-hand controls for s<strong>in</strong>gle stroke sh<strong>all</strong> conform to the<br />
follow<strong>in</strong>g requirements:<br />
(a) Each hand control sh<strong>all</strong> be protected aga<strong>in</strong>st un<strong>in</strong>tended operation<br />
and arranged by design, construction, and/or separation so that the<br />
concurrent use of both hands is required to trip the press.<br />
(b) The control system sh<strong>all</strong> be designed to permit an adjustment<br />
which will require concurrent pressure from both hands dur<strong>in</strong>g the die<br />
clos<strong>in</strong>g portion of the stroke.<br />
(c) The control system sh<strong>all</strong> <strong>in</strong>corporate an antirepeat feature.<br />
(d) The control system sh<strong>all</strong> be designed to require release of <strong>all</strong><br />
operator hand controls before an <strong>in</strong>terrupted stroke can be resumed.<br />
ANSI<br />
The follow<strong>in</strong>g formula is used to compute the m<strong>in</strong>imum safety distance<br />
(Ds) on mechanical power presses to meet the ANSI (American National<br />
Standards Institute) B11.1 press safety standard:<br />
Ds = K x (Ts + Tc + Tr + Tspm) where:<br />
K = Hand speed constant (63 <strong>in</strong>ches/second)<br />
Ts =Stop time of equipment measured at the f<strong>in</strong>al control element<br />
Tc = Response time of the control system<br />
Tr = Response time of the two-hand control device and its <strong>in</strong>terface<br />
Tspm = Additional time <strong>all</strong>owed for the stopp<strong>in</strong>g performance monitor<br />
to compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time<br />
Dpf = The added distance due to the depth penetration factor. Note: If<br />
the channel blank<strong>in</strong>g feature is used on light curta<strong>in</strong>s, additional<br />
safety distance must be enforced based on the number of<br />
channels blanked.<br />
When determ<strong>in</strong><strong>in</strong>g the safety distance, a portable or built-<strong>in</strong> stop-time<br />
measur<strong>in</strong>g unit must be used to check the stopp<strong>in</strong>g time (Ts) of the<br />
mach<strong>in</strong>e. Please see pages 8 and 9 for details on a portable STM (stoptime<br />
measurement) device.<br />
The application of any safeguard<strong>in</strong>g device, the requirements of proper mach<strong>in</strong>e <strong>in</strong>terface, as well as the safety distance formulas may be difficult to<br />
understand and apply. When any of these safeguard<strong>in</strong>g devices detailed <strong>in</strong> this section are a consideration, these factors must be evaluated. To help<br />
understand how to apply these devices, we offer monthly safeguard<strong>in</strong>g sem<strong>in</strong>ars to educate the employer/user on the safety requirements.<br />
40 | SAFEGUARDING DEVICES
ALL-IN-ONE TWO-HAND CONTROL<br />
The <strong>all</strong>-<strong>in</strong>-<strong>one</strong> two-hand control is a NEMA 12 control box with a control module, two relays, a term<strong>in</strong>al strip, and two buttons. Everyth<strong>in</strong>g <strong>in</strong> the<br />
control box is prewired and ready for the user to br<strong>in</strong>g wires <strong>in</strong> from the mach<strong>in</strong>e actuator.<br />
FEATURES<br />
• Preset time for concurrent operation of the buttons<br />
• Buttons must be ma<strong>in</strong>ta<strong>in</strong>ed (actuated) dur<strong>in</strong>g hazardous portion<br />
of the cycle<br />
• Nonresumption of an <strong>in</strong>terrupted cycle<br />
• Provides control reliability of the two-hand control portion of the<br />
control system<br />
• Compact design for ease <strong>in</strong> mount<strong>in</strong>g and can be easily applied to<br />
sm<strong>all</strong> mach<strong>in</strong>es or devices<br />
• Choice of control modules or control monitor and actuat<strong>in</strong>g buttons<br />
• Available <strong>in</strong> 24 V DC or 115 V DC<br />
(control monitor available <strong>in</strong> 115 V AC only)<br />
The <strong>all</strong>-<strong>in</strong>-<strong>one</strong> two-hand control can be applied to most any mach<strong>in</strong>e<br />
or device that is pneumatic<strong>all</strong>y, hydraulic<strong>all</strong>y, or electric<strong>all</strong>y operated<br />
that is usu<strong>all</strong>y manu<strong>all</strong>y fed. These mach<strong>in</strong>es or devices <strong>in</strong>clude sm<strong>all</strong><br />
presses, stakers, riveters, and assembly mach<strong>in</strong>es. The <strong>all</strong>-<strong>in</strong>-<strong>one</strong> twohand<br />
control can be used as a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g device<br />
as long as it is located at the proper safety distance. For more<br />
<strong>in</strong>formation on two-hand control or two-hand trip, see pages 40 and<br />
43-44. See the chart on the next page for select<strong>in</strong>g the proper two-hand<br />
control part number.<br />
All-In-One Two-Hand Control With Banner Buttons<br />
All-In-One Two-Hand Control with Allen-Bradley (A-B) Buttons<br />
on Sides and Emergency-Stop Button on Front<br />
For <strong>in</strong>formation on mechanical and hydraulic power press and press brake controls, please c<strong>all</strong> us toll-free at 1-800-922-7533,<br />
or visit our Web site at www.rockfordsystems.com.<br />
SAFEGUARDING DEVICES | 41
SELECTING AN ALL-IN-ONE TWO-HAND CONTROL<br />
To determ<strong>in</strong>e the 6-digit configured part number for the two-hand control required, follow directions 1-5 below and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
1. The first 2 digits for <strong>all</strong> two-hand controls are TH.<br />
2. The 3rd digit determ<strong>in</strong>es the type of two-hand control provided.<br />
3. The 4th digit determ<strong>in</strong>es the type of run button, if provided, on the control enclosure. Zero (0) <strong>in</strong>dicates no run buttons provided.<br />
4. The 5th digit determ<strong>in</strong>es the type of emergency-stop button, if provided. Zero (0) <strong>in</strong>dicates no emergency button provided.<br />
5. The 6th digit is for the operat<strong>in</strong>g voltage exist<strong>in</strong>g at the mach<strong>in</strong>e.<br />
CONTROL<br />
TH —Two-Hand Control<br />
TWO-HAND CONTROL<br />
(RUN BUTTONS ON SIDES OF ENCLOSURE)<br />
A —A-B Control Module<br />
B —Banner Control Module<br />
RUN BUTTON OPERATOR TYPE<br />
0 —Remotely Located<br />
1 —Rees Black Palm Buttons With <strong>Rockford</strong> <strong>Systems</strong> Guards<br />
2 —A-B Articulated Palm Buttons With Guards<br />
3 —IDEC Green Push Button With Guards<br />
4 —A-B Zero-Force Touch Buttons With Guards (90-264 V AC)<br />
5 —Opto-Touch Buttons With Guards (20-30 V AC/DC)<br />
6 —Square D Mushroom Push Buttons With Guards<br />
7 —Rees Chrome Light-Push Palm Buttons With <strong>Rockford</strong> <strong>Systems</strong> Guards<br />
8 —Ergonomic Safeb<strong>all</strong> Palm Button<br />
TWO-HAND CONTROL PART NUMBERING SYSTEM CHART<br />
THX- X X-X<br />
OPERATING VOLTAGE AT MACHINE<br />
0 —115 V AC<br />
1 —24 V DC<br />
2 —L<strong>in</strong>e Voltage—Includes Multi-Tap Transformer<br />
EMERGENCY-STOP TYPE (ON FRONT OF ENCLOSURE)<br />
0 —N<strong>one</strong><br />
1 —Rees Red Palm Button—Latch-Out Type<br />
2 —Red 40 mm Two-Position—Twist-to-Return Type<br />
Rees Black Palm<br />
Button With RSI Guard<br />
A-B Articulated Palm<br />
Button With A-B Guard<br />
IDEC Button With Guard<br />
A-B Zero-Force Touch<br />
Button With Guard<br />
Opto-Touch Button<br />
With Guard<br />
Mushroom Push Button<br />
With Guard (SQ-D)<br />
Rees Chrome Light-Push<br />
Button With RSI Guard<br />
Ergonomic Safeb<strong>all</strong><br />
Palm Button<br />
Rees Red E-Stop<br />
Button—Latch-Out<br />
Red Two-Position E-Stop<br />
—Twist-to-Return<br />
All buttons have 1 NO and 1 NC contact arrangement.<br />
42 | SAFEGUARDING DEVICES
TWO-HAND TRIP<br />
Note: There are two (2) possible applications for two-hand trip on<br />
full-revolution-clutch presses: to <strong>in</strong>itiate a press cycle only,<br />
or as a method of safeguard<strong>in</strong>g the po<strong>in</strong>t of operation for<br />
operators. In both <strong>in</strong>stances, OSHA has established certa<strong>in</strong><br />
requirements. Applicable ANSI standards can also be referenced<br />
for two-hand trip.<br />
(1) TWO-HAND TRIP<br />
—USED AS A METHOD OF INITIATING A PRESS CYCLE ONLY<br />
F(b)(6)<br />
(i) A two-hand trip sh<strong>all</strong> have the <strong>in</strong>dividual operator’s hand controls<br />
protected aga<strong>in</strong>st un<strong>in</strong>tentional operation and have the <strong>in</strong>dividual<br />
operator’s hand controls arranged by design and construction and/or<br />
separation to require the use of both hands to trip the press and use<br />
a control arrangement requir<strong>in</strong>g concurrent operation of the <strong>in</strong>dividual<br />
operator’s hand controls.<br />
(ii) Two-hand trip systems on full-revolution-clutch mach<strong>in</strong>es sh<strong>all</strong><br />
<strong>in</strong>corporate an antirepeat feature.<br />
(iii) If two-hand trip systems are used on multiple- operator presses,<br />
each operator sh<strong>all</strong> have a separate set of controls.<br />
This description covers the use of two-hand trip as an<br />
<strong>in</strong>itiat<strong>in</strong>g means only, to obta<strong>in</strong> a press cycle. It does<br />
not provide any type of po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g.<br />
Some other properly applied and <strong>in</strong>st<strong>all</strong>ed guard or<br />
device must also be provided <strong>in</strong> accordance with OSHA<br />
29 CFR 1910.217(c).<br />
(2) TWO-HAND TRIP—USED AS A METHOD OF SAFEGUARDING<br />
THE POINT OF OPERATION.<br />
TWO-HAND TRIP<br />
(c)(3)(i) Po<strong>in</strong>t-of-operation devices sh<strong>all</strong> protect the operator by:<br />
(e) Requir<strong>in</strong>g application of both of the operator’s hands to mach<strong>in</strong>e<br />
operat<strong>in</strong>g controls and locat<strong>in</strong>g such controls at such a safety<br />
distance from the po<strong>in</strong>t of operation that the slide completes the<br />
downward travel or stops before the operator can reach <strong>in</strong>to the po<strong>in</strong>t<br />
of operation with his hands;<br />
(c)(3)(viii) The two-hand trip device sh<strong>all</strong> protect the operator as<br />
specified <strong>in</strong> paragraph (c)(3)(i)(e) of this section.<br />
(a) When used <strong>in</strong> press operations requir<strong>in</strong>g more than <strong>one</strong> operator,<br />
separate two-hand trips sh<strong>all</strong> be provided for each operator, and sh<strong>all</strong><br />
be designed to require concurrent application of <strong>all</strong> operator controls<br />
to activate the slide.<br />
(b) Each two-hand trip sh<strong>all</strong> meet the construction<br />
requirements of paragraph (b)(6) of this section.<br />
(c) The safety distance (Dm) between the two-hand trip<br />
and the po<strong>in</strong>t of operation sh<strong>all</strong> be greater than the<br />
distance determ<strong>in</strong>ed by the follow<strong>in</strong>g formula:<br />
D m<br />
= 63 <strong>in</strong>ches/second x Tm where:<br />
D m<br />
= m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
T m<br />
= the maximum time the press takes for the die closure after it<br />
has been tripped (seconds). For full-revolution-clutch presses with<br />
only <strong>one</strong> engag<strong>in</strong>g po<strong>in</strong>t, Tm is equal to the time necessary for<br />
<strong>one</strong>-and-<strong>one</strong>-half revolutions of the crankshaft. For full-revolutionclutch<br />
presses with more than <strong>one</strong> engag<strong>in</strong>g po<strong>in</strong>t, Tm sh<strong>all</strong> be<br />
calculated as follows:<br />
T m<br />
= 1/2 + 1 x<br />
Number of engag<strong>in</strong>g<br />
po<strong>in</strong>ts per revolution<br />
time necessary to complete<br />
<strong>one</strong> revolution of the<br />
crankshaft (seconds)<br />
Note: See chart (next page) for easy reference when apply<strong>in</strong>g two-hand<br />
trip on full-revolution presses.<br />
(d) Two-hand trips sh<strong>all</strong> be fixed <strong>in</strong> position so that only a supervisor<br />
or safety eng<strong>in</strong>eer is capable of relocat<strong>in</strong>g the controls.<br />
When apply<strong>in</strong>g two-hand trip to meet the<br />
requirements for a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g<br />
device, make sure the buttons are located on the<br />
press so they are at least the m<strong>in</strong>imum safety<br />
distance required by the preced<strong>in</strong>g OSHA formula.<br />
Refer to the chart on the next page.<br />
This means the palm buttons must be located far<br />
enough away so that after the press is tripped and<br />
the operator releases <strong>one</strong> or both palm buttons,<br />
the operator cannot “beat the ram” or reach <strong>in</strong>to<br />
the po<strong>in</strong>t of operation or other p<strong>in</strong>ch po<strong>in</strong>ts before<br />
the dies close.<br />
SAFEGUARDING DEVICES | 43
To establish the proper safety distance for two-hand trip on full-revolution-clutch presses, determ<strong>in</strong>e the speed of the press <strong>in</strong> SPM (strokes per m<strong>in</strong>ute) when<br />
runn<strong>in</strong>g <strong>in</strong> the cont<strong>in</strong>uous mode and the number of engagement po<strong>in</strong>ts <strong>in</strong> the clutch mechanism. Then determ<strong>in</strong>e the Safety Distance from the follow<strong>in</strong>g<br />
chart.<br />
I<br />
N<br />
TWO-HAND TRIP SAFETY DISTANCE CHART<br />
SPEED OF PRESS (IN STROKES PER MINUTE)<br />
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10<br />
10<br />
10<br />
20<br />
20<br />
30<br />
40<br />
50<br />
60<br />
70<br />
80<br />
30<br />
40<br />
50<br />
60<br />
70<br />
80<br />
14 Engagement Po<strong>in</strong>ts<br />
4 Engagement Po<strong>in</strong>ts<br />
3 Engagement Po<strong>in</strong>ts<br />
2 Engagement Po<strong>in</strong>ts<br />
1 Engagement Po<strong>in</strong>t<br />
90<br />
90<br />
100<br />
100<br />
Each square is equal to 2” of safety distance.<br />
1, 2, 3, 4, and 14 engagements po<strong>in</strong>ts <strong>in</strong> the clutch mechanism are the most common. Mach<strong>in</strong>es with other engagement po<strong>in</strong>ts may exist.<br />
MINIMUM INCHES FROM POINT OF OPERATION<br />
(each square is equal to 2")<br />
S<br />
A<br />
F<br />
E<br />
T<br />
Y<br />
D<br />
M<br />
E<br />
S<br />
F<br />
R<br />
O<br />
M<br />
P<br />
O<br />
I<br />
M<br />
U<br />
M<br />
I<br />
N<br />
C<br />
H<br />
I<br />
N<br />
T<br />
O<br />
F<br />
O<br />
P<br />
E<br />
R<br />
A<br />
T<br />
I<br />
O<br />
N<br />
I<br />
S<br />
T<br />
A<br />
N<br />
C<br />
E<br />
44 | SAFEGUARDING DEVICES
GATE OR MOVABLE BARRIER DEVICE<br />
The second is a type B gate. It protects the operator dur<strong>in</strong>g the<br />
downstroke only. The gate can open after the hazardous portion<br />
of the cycle has passed. Both type A and B gates can be used on<br />
part-revolution-clutch mach<strong>in</strong>es, hydraulic presses, and other cyclic<br />
mach<strong>in</strong>es where material is be<strong>in</strong>g manu<strong>all</strong>y fed.<br />
Example of a Type A Gate Package<br />
INTRODUCTION<br />
Why use a gate device? Accord<strong>in</strong>g to the OSHA and ANSI standards,<br />
“operators must be prevented from <strong>in</strong>advertently plac<strong>in</strong>g their hands<br />
or any other body parts <strong>in</strong> the po<strong>in</strong>t of operation dur<strong>in</strong>g the die-clos<strong>in</strong>g<br />
portion of the press stroke.” The movable gate device uses a proven<br />
method of plac<strong>in</strong>g a physical barrier between the operator and the<br />
po<strong>in</strong>t-of-operation hazard dur<strong>in</strong>g the die-clos<strong>in</strong>g portion of the press<br />
stroke.<br />
Other advantages of gate devices <strong>in</strong>clude the follow<strong>in</strong>g:<br />
1. Operators are not physic<strong>all</strong>y attached with wristlets to the mach<strong>in</strong>e<br />
as they are when us<strong>in</strong>g a pullback or restra<strong>in</strong>t device. This means<br />
operator resistance is m<strong>in</strong>imized because of the nonrestrictive<br />
design <strong>all</strong>ow<strong>in</strong>g more freedom of movement.<br />
2. These devices protect other employees <strong>in</strong> the mach<strong>in</strong>e area.<br />
3. A foot switch can be used to actuate the press. This m<strong>in</strong>imizes<br />
stress to the hands and arms which can be caused by palm<br />
buttons.<br />
Two types of gates are available. The first is a type A gate. It protects the<br />
operator dur<strong>in</strong>g the entire mach<strong>in</strong>e cycle. This means the gate will not<br />
open until after the mach<strong>in</strong>e’s cycle is complete and stopped (usu<strong>all</strong>y <strong>in</strong><br />
the up position). Type A gates are the only gates that should be used on<br />
full-revolution-clutch presses.<br />
TYPE A GATE SEQUENCE OF OPERATION<br />
When the actuat<strong>in</strong>g means (palm buttons or foot switch) is operated,<br />
air pressure is released from the bottom of the gate-operat<strong>in</strong>g cyl<strong>in</strong>der.<br />
This <strong>all</strong>ows the gate to descend by gravity. Once the gate is fully down,<br />
a gate-down proximity switch senses this and the mach<strong>in</strong>e is <strong>all</strong>owed<br />
to make a cycle. If the gate cannot complete its downward travel, this<br />
gate-down proximity switch will not sense the gate and will prevent a<br />
mach<strong>in</strong>e cycle.<br />
If the actuat<strong>in</strong>g means is released before the mach<strong>in</strong>e starts its cycle,<br />
the gate returns to the full open position with a type A gate. When the<br />
mach<strong>in</strong>e is actu<strong>all</strong>y mak<strong>in</strong>g a cycle, air pressure is applied to the top<br />
of the gate-operat<strong>in</strong>g cyl<strong>in</strong>der which holds the gate down and prevents<br />
it from be<strong>in</strong>g raised until the mach<strong>in</strong>e has completed its cycle. If the<br />
mach<strong>in</strong>e malfunctions and does not stop at the end of a normal cycle,<br />
the gate rema<strong>in</strong>s <strong>in</strong> the closed position.<br />
Accord<strong>in</strong>g to ANSI (see next page), the gate must open after every<br />
cycle <strong>in</strong> order to reset the antirepeat system. If this does not happen,<br />
the mach<strong>in</strong>e will not make another stroke. To accomplish this, the gate<br />
control requires a signal from the mach<strong>in</strong>e at the open position. This<br />
signal is norm<strong>all</strong>y obta<strong>in</strong>ed from a photo-sensor or limit switch operated<br />
by a cam. Actuation of the limit switch is accomplished by the rotation of<br />
the crankshaft or any other member of the mach<strong>in</strong>e which makes <strong>one</strong><br />
cycle or oscillates along <strong>one</strong> axis every stroke.<br />
When a type A gate package is furnished for a full-revolution-clutch<br />
mach<strong>in</strong>e, the top-dead-center signal is provided by a limit switch<br />
assembly.<br />
TYPE B GATE SEQUENCE OF OPERATION<br />
The type B gate operates <strong>in</strong> a similar manner as the type A gate. When<br />
the actuat<strong>in</strong>g means (palm buttons or foot switch) is operated, air<br />
pressure is released from the bottom of the gate-operat<strong>in</strong>g cyl<strong>in</strong>der.<br />
This <strong>all</strong>ows the gate to descend by gravity. Once the gate is fully down,<br />
a gate-down proximity switch senses this and the mach<strong>in</strong>e is <strong>all</strong>owed<br />
to beg<strong>in</strong> the cycle. If the gate cannot complete its downward travel, this<br />
gate-down proximity switch will not sense the gate and will prevent a<br />
mach<strong>in</strong>e cycle.<br />
SAFEGUARDING DEVICES | 45
TYPE B GATE SEQUENCE OF OPERATION (CONTINUED)<br />
If the actuat<strong>in</strong>g means is released before the mach<strong>in</strong>e starts its cycle,<br />
the gate returns to the full open position. When the mach<strong>in</strong>e is actu<strong>all</strong>y<br />
mak<strong>in</strong>g a cycle, air pressure is applied to the top of the gate-operat<strong>in</strong>g<br />
cyl<strong>in</strong>der which holds the gate down and prevents it from be<strong>in</strong>g raised<br />
until the hazardous portion of the cycle has passed.<br />
The gate must open every cycle <strong>in</strong> order to reset the antirepeat system.<br />
The sequence for this is the same as for the A gate described on the<br />
previous page.<br />
OSHA AND ANSI REQUIREMENTS FOR POWER PRESSES<br />
The OSHA requirements for gate or movable barrier devices are located<br />
<strong>in</strong> 29 CFR 1910.217(c)(3)(i) as follows:<br />
(c)(3)(i) Po<strong>in</strong>t-of-operation devices sh<strong>all</strong> protect the operator by:<br />
(f) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be<br />
<strong>in</strong>itiated, and ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g this closed condition until the motion of<br />
the slide has ceased; or<br />
(g) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be<br />
<strong>in</strong>itiated, so as to prevent an operator from reach<strong>in</strong>g <strong>in</strong>to the<br />
po<strong>in</strong>t of operation prior to die closure or prior to cessation of slide<br />
motion dur<strong>in</strong>g the downward stroke.<br />
(c)(3)(ii) A gate or movable barrier device sh<strong>all</strong> protect the operator as<br />
follows:<br />
(a) A Type A gate or movable barrier device sh<strong>all</strong> protect the operator<br />
<strong>in</strong> the manner specified <strong>in</strong> paragraph (c)(3)(i)(f) (above) of this<br />
section, and<br />
(b) A Type B gate or movable barrier device sh<strong>all</strong> protect the<br />
operator <strong>in</strong> the manner specified <strong>in</strong> paragraph (c)(3)(i)(g) (above)<br />
of this section.<br />
Note: OSHA states that the gate must enclose the po<strong>in</strong>t of operation.<br />
The gates illustrated are furnished as a s<strong>in</strong>gle panel only, <strong>all</strong>ow<strong>in</strong>g<br />
access to the po<strong>in</strong>t of operation. Other guard<strong>in</strong>g material is<br />
required to safeguard the sides and back of the po<strong>in</strong>t of operation.<br />
Complete the proper measurement form (page 50, 52, or 53) if<br />
these need to be supplied with the gate.<br />
The ANSI requirements for gates or movable barrier devices are located<br />
<strong>in</strong> 8.6.6 of ANSI B11.1.<br />
8.6.6 Movable Barrier Device<br />
1) A movable barrier device, when used, sh<strong>all</strong> enclose the po<strong>in</strong>t of<br />
operation before a press cycle (stroke) can be <strong>in</strong>itiated.<br />
2) The device sh<strong>all</strong> prevent the <strong>in</strong>dividual from reach<strong>in</strong>g the hazards<br />
associated with the po<strong>in</strong>t of operation by reach<strong>in</strong>g over, under,<br />
around, or through the device when <strong>in</strong> the closed position.<br />
3) In conjunction with the press control, the device sh<strong>all</strong> actuate the<br />
clutch and <strong>in</strong>itiate the press cycle (stroke).<br />
4) The barrier sh<strong>all</strong> be capable of be<strong>in</strong>g returned to the open<br />
position should it encounter an obstruction prior to enclos<strong>in</strong>g the<br />
po<strong>in</strong>t of operation.<br />
5) The device sh<strong>all</strong> require open<strong>in</strong>g of the barrier to reset the<br />
antirepeat system of the press production system every time the<br />
press stops before a successive cycle (stroke) can be <strong>in</strong>itiated.<br />
6) The device sh<strong>all</strong> be <strong>in</strong> compliance with 6.11 and 8.8.<br />
7) The device sh<strong>all</strong> provide visibility to the po<strong>in</strong>t of operation when<br />
necessary for safe operation of the press production system.<br />
8) The device <strong>in</strong> and of itself sh<strong>all</strong> not create a hazard to the operator<br />
or others.<br />
8.6.6.1 Type A movable barrier device<br />
1) A type A movable barrier device, when used, sh<strong>all</strong> protect the<br />
<strong>in</strong>dividuals as specified <strong>in</strong> 8.6.1 (e).<br />
2) The type A movable barrier device sh<strong>all</strong>, <strong>in</strong> normal s<strong>in</strong>gle-cycle<br />
operation, be designed to hold <strong>in</strong> the closed position until the<br />
slide has completed its cycle (stroke) and has stopped at top of<br />
cycle (stroke).<br />
8.6.6.2 Type B movable barrier device<br />
1) A type B movable barrier device sh<strong>all</strong> protect the <strong>in</strong>dividuals as<br />
specified <strong>in</strong> 8.6.1 (f).<br />
2) The device sh<strong>all</strong> not be used on full-revolution-clutch presses.<br />
3) The device sh<strong>all</strong>, <strong>in</strong> normal, s<strong>in</strong>gle-stroke operation, be designed<br />
to hold <strong>in</strong> a closed position dur<strong>in</strong>g the clos<strong>in</strong>g portion of the cycle<br />
(stroke), or until cessation of slide motion dur<strong>in</strong>g the clos<strong>in</strong>g<br />
portion of the cycle (stroke).<br />
4) When the protection of the operator is dependent upon the<br />
stopp<strong>in</strong>g action of the press, a stopp<strong>in</strong>g-performance monitor sh<strong>all</strong><br />
be required <strong>in</strong> conformance with 6.12.<br />
46 | SAFEGUARDING DEVICES
GATE ASSEMBLIES<br />
The gate assembly can be furnished with side guards. The gate and side<br />
panel can be swung open to the left when chang<strong>in</strong>g dies. A dead-bolt<br />
latch is located on the right extrusion. When side guards are furnished,<br />
this latch releases the gate so it can be swung completely open.<br />
These gates are easily mounted on the bolster of the mach<strong>in</strong>e or on a<br />
special plate or bracket on the front of the mach<strong>in</strong>e.<br />
The gate assemblies listed are designed for a variety of mach<strong>in</strong>es,<br />
<strong>in</strong>clud<strong>in</strong>g full-revolution-clutch presses. Side guards are also required<br />
when us<strong>in</strong>g a gate. Gates are made accord<strong>in</strong>g to the measurements<br />
submitted. Please complete the appropriate measurement form on page<br />
52, 54, or 55 for a complete assembly.<br />
Basic Gate Assembly (Without Side<br />
or Rear <strong>Safeguard<strong>in</strong>g</strong>)<br />
GATE CONSTRUCTION<br />
The panel framework of these gates is constructed of 1” x 2”<br />
extruded alum<strong>in</strong>um which slides up and down on roller bear<strong>in</strong>gs <strong>in</strong><br />
a rail extrusion. The panel of the gate is furnished with either clear<br />
polycarbonate (3/16”-thick) or an adjustable lower section.<br />
The standard gate assembly is furnished with h<strong>in</strong>ges <strong>all</strong>ow<strong>in</strong>g it to<br />
sw<strong>in</strong>g open. A button-head cap screw on a lock<strong>in</strong>g plate holds the gate<br />
<strong>in</strong> place. This feature is useful when chang<strong>in</strong>g dies or work<strong>in</strong>g on dies<br />
<strong>in</strong> the mach<strong>in</strong>e.<br />
GATE ASSEMBLY COMPONENTS<br />
• Gate frame assembly<br />
• Gate panel<br />
• Proximity switch (24 V DC only) or limit switch<br />
• Air cyl<strong>in</strong>der(s)<br />
• Quick dump valves<br />
• Air flow control valves<br />
• Solenoid air valve assemblies<br />
• 1/8” air regulator gauge and mount<strong>in</strong>g bracket<br />
• Extrusion, h<strong>in</strong>ge assembly, and<br />
mount<strong>in</strong>g hardware<br />
PRICING/ORDERING INFORMATION<br />
The follow<strong>in</strong>g <strong>in</strong>formation is required to order or price a gate assembly:<br />
1. Choose a gate lift height of either 12”* or 18”*<br />
2. Provide gate’s outside dimensions <strong>in</strong> height and width<br />
Provide gate’s <strong>in</strong>side open<strong>in</strong>g dimensions <strong>in</strong> height and width<br />
OR<br />
*Other lift heights are available. Please complete the measurement form on page 48, 50, or 52.<br />
For full-revolution-clutch presses, part-revolution-clutch presses, or hydraulic presses with a gate <strong>in</strong>terface, please consult the factory.<br />
SAFEGUARDING DEVICES | 47
GATE ASSEMBLY & BARRIER GUARD MEASUREMENT FOR STRAIGHT-SIDE, HYDRAULIC,<br />
OR COLUMN-TYPE MACHINES<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
1 Company________________________________________ Address______________________________________________<br />
City____________________________________________ State_________________________ ZIP_____________________<br />
Attention________________________________________ Rep._________________________________________________<br />
Mach. Mfr. & Model No._____________________________ Mach. No._____________________ Measured By______________<br />
Check Type of Mach<strong>in</strong>e:<br />
Straight Side (SSG) Hydraulic (HG) Column (CG)<br />
8<br />
2<br />
Outside Mount<br />
Inside Mount<br />
Air Cyl<strong>in</strong>der<br />
Heights with:<br />
12" Lift = 22"<br />
18" Lift = 28"<br />
Upper Gate Limit<br />
8<br />
7" m<strong>in</strong>.<br />
7" m<strong>in</strong>.<br />
7 7<br />
6<br />
Lift<br />
Height<br />
5<br />
Top of<br />
Bolster<br />
Top of<br />
Bolster<br />
8<br />
Left Side<br />
1/2" M<strong>in</strong>.<br />
1/2"<br />
4 4<br />
7<br />
Gate Ht.<br />
Gate Frame Type<br />
7<br />
NAP or AP3<br />
6<br />
Typical<br />
7" m<strong>in</strong>. Inside Mt.<br />
Nonadjustable Area Const. 4<br />
7" m<strong>in</strong>.<br />
Typical<br />
Outside Mt.<br />
1/2" Sq. Mesh Black<br />
Yellow<br />
1" Sq. Mesh Black Yellow<br />
Polycarbonate<br />
Note: Gate open<strong>in</strong>g will be 7" less than dimension 3 .<br />
3<br />
or<br />
Lower Mount Limit<br />
(Enter limits only<br />
if restricted)<br />
8<br />
Right Side<br />
5 GATE LIFT HEIGHT<br />
12"<br />
18" Other "<br />
MEASURING INSTRUCTIONS<br />
The gate assembly measurement form is designed to be used for the XL-1SSG, XL-1HG, or the XL-1CG.<br />
8 MOUNTS: FMG EMG<br />
9<br />
SIDE GUARDS<br />
H<br />
Gate<br />
L<br />
Left Side<br />
Right Side<br />
10 FLOOR SECTION<br />
H<br />
11 HINGED GATE<br />
H<br />
No Yes–Type of Interlock:<br />
Lock<strong>in</strong>g Nonlock<strong>in</strong>g<br />
12 CHOOSE ONE<br />
Proximity Switch (24 V DC only)<br />
Limit Switch<br />
L<br />
L<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated.<br />
2. Check whether an Outside or Inside<br />
mount is required. (See lower left side of<br />
front view draw<strong>in</strong>g for examples.)<br />
3. Enter center mount<strong>in</strong>g dimension. The gate<br />
open<strong>in</strong>g will be approximately 7” sm<strong>all</strong>er<br />
than this dimension.<br />
4. Enter gate height, frame type, and construction<br />
of nonadjustable area.<br />
5. Enter gate lift height: 12”, 18”, or other.<br />
6. Enter upper and lower gate mount limits,<br />
if any.<br />
7. If outside mounted, enter the appropriate<br />
location of upper and lower mount<strong>in</strong>g po<strong>in</strong>t<br />
for each mount.<br />
8. Enter the desired length and type of mount<br />
supports; either FMG for direct or EMG for<br />
extended. Allow for any obstructions (7” m<strong>in</strong>imum).<br />
9. Enter dimensions for side guards if required.<br />
10. Indicate if floor section is required for the<br />
gate frame. Provide height and length.<br />
11. Indicate if h<strong>in</strong>ged gate is required. If yes,<br />
<strong>in</strong>dicate the type of <strong>in</strong>terlock switch required.<br />
12. Choose a proximity switch (for 24 V DC only)<br />
or a limit switch.<br />
48 | SAFEGUARDING DEVICES
MEASURING INSTRUCTIONS FOR GATE ASSEMBLY MODELS XL-2G THROUGH XL-6G<br />
The follow<strong>in</strong>g <strong>in</strong>structions are for measur<strong>in</strong>g XL-2G through XL-6G<br />
gate assemblies and barrier guards. The basic <strong>in</strong>formation necessary<br />
to quote or fabricate any of the listed gates and barrier guards is the<br />
size of the gate, the frame type, nonadjustable area construction,<br />
height of panel(s), panel segments (if required), and mounts to attach<br />
the gate and guards to the mach<strong>in</strong>e. The length of <strong>all</strong> panels will be<br />
determ<strong>in</strong>ed by <strong>Rockford</strong> <strong>Systems</strong>.<br />
The follow<strong>in</strong>g <strong>in</strong>structions are purposely kept as simple as possible to<br />
avoid long explanations of the many variations available.<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated.<br />
2. Check appropriate gate model number.<br />
XL-2G = 2 panel and gate<br />
XL-3G = 3 panel and gate<br />
XL-4G = 4 panel and gate<br />
XL-5G = 5 panel and gate<br />
XL-6G = 6 panel and gate<br />
(If any panels are not required, cross them out <strong>in</strong> the panel chart.)<br />
3. Measure and record the bolster width and depth.<br />
4. Measure web width of frame, if the barrier guard is to be mounted to<br />
the front of the frame beh<strong>in</strong>d the bolster plate.<br />
5. Measure and record the distance from the mount<strong>in</strong>g po<strong>in</strong>t of the<br />
guard on the frame of the mach<strong>in</strong>e to the rear of the bolster. Measure<br />
and record the outside width of the press frame beh<strong>in</strong>d the bolster plate.<br />
6. Indicate desired position of L and R panels and gate relative<br />
to the bolster. Draw<strong>in</strong>g shows panels and gate outbound of the<br />
bolster. If panels or gate should be <strong>in</strong>bound, enter m<strong>in</strong>us (-) dimensions,<br />
or on the bolster, enter zero.<br />
7. Enter the m<strong>in</strong>imum and maximum feedl<strong>in</strong>e heights. Enter distance<br />
from the bottom of the gate to bolster (usu<strong>all</strong>y 0 <strong>in</strong>ches). If below bolster,<br />
enter <strong>in</strong>ches.<br />
8. Measure and record the clearance from the flywheel cover or<br />
obstruction to the top of the bolster. This dimension could affect the<br />
panel height if the panel is to be swung underneath. Indicate if view is<br />
from left or right side of the mach<strong>in</strong>e.<br />
When measur<strong>in</strong>g, be sure the gate will lift completely<br />
without hitt<strong>in</strong>g any obstruction.<br />
9. Measure and record the feedl<strong>in</strong>e depth.<br />
10. Indicate the gate lift height required, norm<strong>all</strong>y 12” or 18” is sufficient.<br />
11. Indicate mounts required for LR, L, R, or RR panels.<br />
SFM Side Frame Mount<br />
SFM-7 Side Frame Mount (3”, 5”, or 7”)<br />
SFM-24 Side Frame Mount up to 24”<br />
FFM Front Frame Mount<br />
Note: The panel will beg<strong>in</strong> approximately 2½” from the mount<strong>in</strong>g po<strong>in</strong>t<br />
with the SFM, SFM-7, or SFM-24 mount. The panel will beg<strong>in</strong><br />
approximately 1” from the mount<strong>in</strong>g po<strong>in</strong>t with the FFM mount.<br />
12. Indicate frame type for each panel and gate.<br />
NAP<br />
AP1<br />
AP2<br />
AP3<br />
AP4<br />
AP5<br />
API<br />
Nonadjustable Panel<br />
Adjustable Panel (1/2 frame)<br />
Adjustable Panel (5/8 frame)<br />
Adjustable Panel (3/4 frame)<br />
Adjustable Panel (Center—Full frame)<br />
Adjustable Panel (Lower—Full frame)<br />
Adjustable Panel (Incl<strong>in</strong>able)<br />
The gate can ONLY be NAP or AP3.<br />
13. Indicate the construction of the nonadjustable area for each panel.<br />
B<br />
B1<br />
Y<br />
Y1<br />
PC<br />
1/2” Sq. Black Mesh (16 gauge)<br />
1” Sq. Black Mesh (12 gauge)<br />
1/2” Sq. Yellow Mesh (16 gauge)<br />
1” Sq. Yellow Mesh (12 gauge)<br />
Polycarbonate (3/16” thick)<br />
The gate is norm<strong>all</strong>y polycarbonate.<br />
14. Indicate height of each panel.<br />
15. Indicate length of each panel. <strong>Rockford</strong> <strong>Systems</strong> will determ<strong>in</strong>e<br />
length(s) based on other dimensions provided.<br />
16. Indicate panel segment type, height, length, and if h<strong>in</strong>ged or<br />
nonh<strong>in</strong>ged, if required.<br />
FS<br />
AS<br />
PCS<br />
ES<br />
Feeder Segment<br />
Adjustable Segment<br />
Polycarbonate Segment<br />
Empty Segment<br />
17. Indicate if L, LF, Gate, RF, or R panels require an <strong>in</strong>terlock switch<br />
and choose lock<strong>in</strong>g or nonlock<strong>in</strong>g.<br />
18. Indicate if L, LF, Gate, RF, or R panel needs to be h<strong>in</strong>ged (L or R).<br />
The gate ALWAYS h<strong>in</strong>ges left.<br />
19. Indicate if hairp<strong>in</strong>s are required <strong>in</strong> place of LR or RR panel. The<br />
number of hairp<strong>in</strong>s supplied will be determ<strong>in</strong>ed by the height of the L or<br />
R panel. Indicate the height of hairp<strong>in</strong>s required <strong>in</strong> the box.<br />
20. Indicate if roof section(s) are required. Provide height and length.<br />
21. Indicate if floor section(s) are required. Provide height and length.<br />
22. Choose proximity switch (for 24 V DC only) or limit switch.<br />
SAFEGUARDING DEVICES | 49
GATE ASSEMBLY & BARRIER GUARD MEASUREMENT FORM—GAP OR C-FRAME MACHINES<br />
GATE ASSEMBLY WITH MULTI-PANEL GUARDS—XL-2G, XL-3G, XL-4G, XL-5G, XL-6G<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
(See previous page for <strong>in</strong>structions.)<br />
1<br />
Company________________________________________ Address______________________________________________<br />
City____________________________________________ State_________________________ ZIP_____________________<br />
Attention________________________________________ Rep._________________________________________________<br />
Mach. Mfr. & Model No._____________________________ Mach. No._____________________ Measured By______________<br />
5 LR<br />
REAR<br />
5<br />
RR<br />
4<br />
5<br />
OBSTRUCTION<br />
OR<br />
FLYWHEEL COVER<br />
8<br />
9<br />
7<br />
Max. Feedl<strong>in</strong>e Ht.<br />
M<strong>in</strong>. Feedl<strong>in</strong>e Ht.<br />
Notes:<br />
Bolster<br />
Bed<br />
Left Side<br />
"<br />
"<br />
7<br />
7<br />
7<br />
Bottom of<br />
gate to bolster<br />
(usu<strong>all</strong>y 0 <strong>in</strong>ches);<br />
if below bolster,<br />
enter <strong>in</strong>ches<br />
6<br />
Panel<br />
L<br />
LF<br />
3 3<br />
Gate<br />
See Below<br />
6 FRONT<br />
RF<br />
R<br />
Panel<br />
6<br />
8<br />
Feed Depth<br />
Bolster<br />
Bed<br />
Left Side<br />
Right Side (shown)<br />
2<br />
10<br />
11<br />
17<br />
22<br />
XL-2G<br />
XL-4G<br />
XL-6G<br />
MODEL<br />
XL-3G<br />
XL-5G<br />
GATE LIFT HEIGHT<br />
12"<br />
18"<br />
MOUNTS<br />
SFM SFM-3, -5, -7<br />
SFM-24<br />
Other<br />
"<br />
(Circle <strong>one</strong>)<br />
FFM<br />
ELEC. INTERLOCK<br />
Lock<strong>in</strong>g<br />
Nonlock<strong>in</strong>g<br />
CHOOSE ONE<br />
Proximity Switch (24 V DC only)<br />
Limit Switch<br />
PANEL CHART<br />
Panel LR L LF Gate RF R RR<br />
Frame Type<br />
NAP, AP1, AP2, AP3,<br />
AP4, AP5, API<br />
Nonadjust. Area Const.<br />
B, B1, Y, Y1, PC<br />
L<br />
(Length)<br />
H<br />
(Height)<br />
RSI To<br />
Complete<br />
Panel Segment Type<br />
FS, AS, PCS, ES<br />
H<br />
(Height)<br />
L<br />
(Length)<br />
H (H<strong>in</strong>ged)<br />
NH (Nonh<strong>in</strong>ged)<br />
Electrical Interlock<br />
Y (Yes) N (No)<br />
H<strong>in</strong>ged L or R<br />
Hairp<strong>in</strong>s<br />
(In place of LR or RR)<br />
20 ROOF SECTION<br />
Panel H L<br />
L<br />
*<br />
LF<br />
Gate<br />
RF<br />
R<br />
*<br />
12<br />
13<br />
14<br />
15<br />
16<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
19 19<br />
L<br />
(Length)<br />
*Indicate <strong>in</strong> the Notes section above if a vertical section of hairp<strong>in</strong>s is required above the L or R panel.<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
Y<br />
L<br />
12<br />
13<br />
14<br />
15<br />
18 18 18 18<br />
21 FLOOR SECTION<br />
H Panel H L<br />
(Height) L<br />
LF<br />
Gate<br />
RF<br />
R<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
12<br />
13<br />
14<br />
15<br />
16<br />
50 | SAFEGUARDING DEVICES
SWING-AWAY GATE ASSEMBLY & BARRIER GUARD MEASUREMENT FOR STRAIGHT-SIDE, HYDRAULIC,<br />
OR COLUMN-TYPE MACHINES<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
1 Company________________________________________ Address______________________________________________<br />
City____________________________________________ State_________________________ ZIP_____________________<br />
Attention________________________________________ Rep._________________________________________________<br />
Mach. Mfr. & Model No._____________________________ Mach. No._____________________ Measured By______________<br />
FRONT VIEW<br />
SIDE VIEW<br />
Air Cyl<strong>in</strong>der<br />
Either 22" With<br />
12" Lift Height or<br />
28" With 18"<br />
Lift Height<br />
2"<br />
2<br />
Gate Height<br />
(<strong>in</strong> <strong>in</strong>ches)<br />
INSTRUCTIONS<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
4"<br />
25⁄8"<br />
Provide complete <strong>in</strong>formation.<br />
Determ<strong>in</strong>e gate height required.<br />
Determ<strong>in</strong>e gate open<strong>in</strong>g required.<br />
Determ<strong>in</strong>e gate lift height required.<br />
Choose gate panel construction required.<br />
Choose proximity switch or limit switch.<br />
Choose type of <strong>in</strong>terlock switch.<br />
GATE ASSEMBLY COMPONENTS<br />
Gate frame assembly<br />
Gate panel<br />
Proximity switch (24 V DC only) or limit switch<br />
Air cyl<strong>in</strong>der(s)<br />
Air flow control valves<br />
Quick dump valves<br />
Solenoid air valve assemblies<br />
1<br />
⁄8” air regulator gauge and mount<strong>in</strong>g bracket<br />
Extrusion, h<strong>in</strong>ge assembly, and mount<strong>in</strong>g hardware<br />
Gate Open<strong>in</strong>g (<strong>in</strong> <strong>in</strong>ches)<br />
3<br />
4<br />
5<br />
25⁄8" 3½"<br />
Check box 1 or 2 below:<br />
1.<br />
2.<br />
GATE LIFT HEIGHT<br />
c 12” c 18” c Other ______________”<br />
GATE PANEL CONSTRUCTION<br />
NAP (Nonadjustable Panel)—Choose from the follow<strong>in</strong>g:<br />
Nonadjustable Area<br />
c Polycarbonate OR<br />
c Wire Mesh<br />
c 1 ⁄2” Square or c 1” Square<br />
c Black or c Yellow<br />
AP3 (Adjustable Panel)—Choose from the follow<strong>in</strong>g:<br />
Nonadjustable Area<br />
c Polycarbonate OR<br />
c Wire Mesh<br />
Polycarbonate<br />
or<br />
Mesh<br />
c 1 ⁄2” Square or c 1” Square<br />
c Black or c Yellow<br />
Adjustable Area—Hairp<strong>in</strong> will be 4” maximum.<br />
6<br />
7<br />
c Proximity Switch (24 V DC only) c Limit Switch<br />
c Lock<strong>in</strong>g Interlock<br />
c Nonlock<strong>in</strong>g Interlock<br />
Polycarbonate<br />
or<br />
Mesh<br />
Gate Panel<br />
Polycarbonate<br />
or<br />
Mesh<br />
Gate Panel<br />
Polycarbonate<br />
or<br />
Mesh<br />
SAFEGUARDING DEVICES | 51
SAFETY BUMPER<br />
TYPICAL APPLICATIONS<br />
• Automated manufactur<strong>in</strong>g<br />
• Packag<strong>in</strong>g and material handl<strong>in</strong>g<br />
• Mov<strong>in</strong>g conveyor systems<br />
• Mov<strong>in</strong>g platforms and lifts<br />
• Automated guided vehicles<br />
Has excellent side activation properties!<br />
This safety bumper system is designed to protect some<strong>one</strong> or someth<strong>in</strong>g from hazardous mach<strong>in</strong>e conditions. A safety bumper and a safety <strong>in</strong>terface<br />
control provides a Category 3 safety system. The safety bumper is an <strong>in</strong>dustrial grade, pressure-sensitive safety device with a built-<strong>in</strong> sensor, and is<br />
supplied with wir<strong>in</strong>g. When a person or object comes <strong>in</strong> contact with the safety bumper, a signal is sent to stop the mach<strong>in</strong>e. Each safety bumper<br />
has two 6’ cables, an alum<strong>in</strong>um mount<strong>in</strong>g channel, and is resistant to water, oil, hydraulic fluids, and coolants.<br />
An RKR-164 <strong>in</strong>terface control consists of a safety controller, power supply, force-guided relays, term<strong>in</strong>als, and fuses <strong>all</strong> <strong>in</strong>side an enclosure. An on/<br />
off selector switch and a lighted reset push button are on the front of the enclosure. If the safety bumper is pressed and stops mach<strong>in</strong>e motion,<br />
then the reset button must be pushed to <strong>all</strong>ow a restart of the mach<strong>in</strong>e. Connection of the safety bumper and <strong>in</strong>terface provides a Category 3 safety<br />
system when properly <strong>in</strong>tegrated with the exist<strong>in</strong>g control system.<br />
If an RKR-164 <strong>in</strong>terface is not required, a DIN-rail mounted safety relay control module (RKR-139) is available. Each 24-V DC DIN-rail module has<br />
4 NO dry contacts and can be mounted <strong>in</strong>to an exist<strong>in</strong>g control.<br />
RFT-139 Safety Relay Control Module<br />
RKR-164 Interface Control<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
BMP-1 1’ Safety Bumper<br />
BMP-2 2’ Safety Bumper<br />
BMP-3 3’ Safety Bumper<br />
BMP-4 4’ Safety Bumper<br />
BMP-5 5’ Safety Bumper<br />
BMP-6 6’ Safety Bumper<br />
RKR-164 Interface Control<br />
RFT-139 DIN-Rail Mounted Safety Relay Control Module<br />
52 | SAFEGUARDING DEVICES
PRESSURE-SENSITIVE SAFETY MATS<br />
Safety mats are <strong>in</strong>tended to be used as auxiliary or additional<br />
safeguard<strong>in</strong>g equipment to protect operators and other employees <strong>in</strong><br />
the mach<strong>in</strong>e area. They must not be used as the primary method of<br />
safeguard<strong>in</strong>g except when <strong>all</strong> other means are not applicable.<br />
These mats can safeguard many types of mach<strong>in</strong>es. Consider the<br />
follow<strong>in</strong>g when choos<strong>in</strong>g mats:<br />
1) How is the mat to be <strong>in</strong>terfaced to the exist<strong>in</strong>g motor control or<br />
equipment? Does a new control or starter need to be added?<br />
2) Can the motion of the mach<strong>in</strong>e that is creat<strong>in</strong>g the po<strong>in</strong>t-ofoperation<br />
hazard be stopped quickly? If it can, what k<strong>in</strong>d of clutch<br />
and brake arrangement does it have? Is the mach<strong>in</strong>e hydraulic<strong>all</strong>y<br />
or pneumatic<strong>all</strong>y operated? Is it operated by any other means?<br />
Before apply<strong>in</strong>g a safety mat to any mach<strong>in</strong>e, make sure it will be<br />
<strong>in</strong>terfaced correctly with the mach<strong>in</strong>e control and make sure it does<br />
not <strong>in</strong>terfere with productivity. The whole mach<strong>in</strong>e system must be<br />
considered, <strong>in</strong>clud<strong>in</strong>g safeguard<strong>in</strong>g, mach<strong>in</strong>e control, disconnects,<br />
starters, covers for rotat<strong>in</strong>g parts, auxiliary parts, feed<strong>in</strong>g and retriev<strong>in</strong>g<br />
of workpieces, etc.<br />
The pressure-sensitive, heavy-duty safety mats described on these<br />
pages are highly resistant to wear, oils, grease, acids and most<br />
common chemicals.<br />
These mats function <strong>in</strong> two different ways. One way is that the mach<strong>in</strong>e<br />
will not start if some<strong>one</strong> or some object is on the mat. Another way is<br />
that if the mach<strong>in</strong>e is already operat<strong>in</strong>g or cycl<strong>in</strong>g, it will stop if some<strong>one</strong><br />
steps onto the mat. In this case, the mach<strong>in</strong>e needs to be restarted once<br />
the mat has been cleared.<br />
The mat(s) must be located so an operator or other employee, when<br />
stepp<strong>in</strong>g onto the mat, cannot reach <strong>in</strong>to the po<strong>in</strong>t-of-operation hazard<br />
prior to the mach<strong>in</strong>e’s hazardous motion com<strong>in</strong>g to a stop. See ANSI/<br />
RIA R15.06 robot safety standard for detailed guidel<strong>in</strong>es on mat safety<br />
distance. Also see the ANSI B11.19 for guidel<strong>in</strong>es on mat control<br />
system reliability.<br />
MATS CAN BE APPLIED TO MANY DIFFERENT MACHINES AND AUXILIARY EQUIPMENT FOR PROTECTION.<br />
Control<br />
Station<br />
Mach<strong>in</strong>e<br />
Guard<br />
Safety<br />
Mat<br />
Parts<br />
Chute<br />
Robot<br />
Parts<br />
B<strong>in</strong><br />
Light<br />
Curta<strong>in</strong><br />
Receiver<br />
Guard<br />
Light<br />
Curta<strong>in</strong><br />
Transmitter<br />
Mirror<br />
Drill<strong>in</strong>g, Mill<strong>in</strong>g, and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
Assembly Mach<strong>in</strong>es<br />
Control<br />
Station<br />
Robots and Auxiliary Equipment<br />
Mach<strong>in</strong>e<br />
G<br />
Safety<br />
Mat<br />
SAFEGUARDING DEVICES | 53<br />
Robot
PRESSURE-SENSITIVE SAFETY MATS (CONTINUED)<br />
The heavy-duty pressure-sensitive safety mats offered have been<br />
successfully used to provide auxiliary safeguard<strong>in</strong>g for the hazard areas<br />
that exist <strong>in</strong> many <strong>in</strong>dustrial environments. Some of these <strong>in</strong>clude:<br />
• Robotic weld<strong>in</strong>g<br />
• Laser weld<strong>in</strong>g/cutt<strong>in</strong>g<br />
• Water jet mach<strong>in</strong>es<br />
• Pick-and-place robots<br />
• Plastics mold<strong>in</strong>g mach<strong>in</strong>es<br />
• Assembly mach<strong>in</strong>es<br />
• Automated material handl<strong>in</strong>g<br />
• Packag<strong>in</strong>g mach<strong>in</strong>ery<br />
• Textile mach<strong>in</strong>ery<br />
• Conveyors<br />
• Paper convert<strong>in</strong>g mach<strong>in</strong>ery<br />
• CNC punches and tube benders<br />
The s<strong>in</strong>gle-piece molded construction of these safety mats means these<br />
mats will not delam<strong>in</strong>ate. The mats encase conductive plates which<br />
provide stop/restart signals when pressure is applied or released. Each<br />
mat top surface has a rib pattern runn<strong>in</strong>g par<strong>all</strong>el with the mat length<br />
which helps prevent slipp<strong>in</strong>g, yet is easy to clean.<br />
All mats are supplied with a 20’ s<strong>in</strong>gle-jacketed, four-wire cord exit<strong>in</strong>g<br />
from the width end of the mat. The outside edge of each mat has a lip<br />
to attach either an alum<strong>in</strong>um ramp or a blunt edge. The lip can also<br />
be removed when jo<strong>in</strong><strong>in</strong>g two mats with a mat connector. The mat<br />
dimensions provided are for the active area of the mat.<br />
These mats can be supplied <strong>in</strong>dividu<strong>all</strong>y or <strong>in</strong> multiple configurations.<br />
They are available <strong>in</strong> various sizes and can be tied together (electric<strong>all</strong>y)<br />
<strong>in</strong> series.<br />
The part numbers listed <strong>in</strong> the chart on the next page do not <strong>in</strong>clude<br />
any ramps, blunt edges, or connectors. Follow the <strong>in</strong>structions below<br />
the chart to add ramp edg<strong>in</strong>g.<br />
Note: A mat control box Part No. RKR-162, or Z<strong>one</strong> Monitor<br />
Part No. RKR-103 or RKR-107 must be used with the mats.<br />
See pages 56-57.<br />
MAT SPECIFICATIONS<br />
Operat<strong>in</strong>g Temperature........................................-35° to 120°F<br />
............................................................................(-37° to 49°C)<br />
Individual Mat Sizes................................ 12” x 12” to 48” x 72”<br />
Activation Force........................... 3 to 5 ft/lb (normal foot traffic)<br />
Mat Cover Material.......................................................... Molded v<strong>in</strong>yl<br />
Shore A Hardness.......................................................... 72 ± 2<br />
Mat Cable Length.............................................................. 20 ft<br />
Load Capacity.......................................................................3,000 psi<br />
Applicable Standards....Designed to meet or exceed ANSI B11.19,<br />
.....................................OSHA 1910.212, and ANSI/RIA R15.06<br />
ELECTRODE ASSEMBLY:<br />
• Norm<strong>all</strong>y open switch<br />
• High-durability 24-gauge steel<br />
• 18-gauge, 4-wire, s<strong>in</strong>gle-jacketed lead wires and optional application-specific<br />
wir<strong>in</strong>g options<br />
• Hermetic<strong>all</strong>y encapsulated switch and lead wires<br />
• Designed to meet IP67 and NEMA 6<br />
• Water-tight and tot<strong>all</strong>y submersible<br />
For a complete chemical resistance chart, contact the factory.<br />
54 | SAFEGUARDING DEVICES
STANDARD MATS<br />
These heavy-duty pressure-sensitive safety mats are constructed of<br />
molded v<strong>in</strong>yl material. The mold<strong>in</strong>g encases two separated par<strong>all</strong>el steel<br />
plates. These plates make contact when the mat is stepped on. They<br />
have a black, ribbed pattern top surface to help prevent slipp<strong>in</strong>g and<br />
are easy to clean.<br />
The mats are active over the entire surface, except the narrow border.<br />
They are designed for low-voltage (24-V DC) control circuits.<br />
All standard size safety mats can be modified, i.e., with notches,<br />
cutouts, angles, or holes. Various configured layouts of any dimension<br />
can be supplied. Various colors, sizes, and shapes of mats are available<br />
along with different wir<strong>in</strong>g options to meet your requirements. To obta<strong>in</strong><br />
a proposal to meet your needs, submit a layout draw<strong>in</strong>g complete with<br />
<strong>all</strong> dimensions and a list of your specific requirements.<br />
Part No. PSM-2436-1<br />
Safety Mat (Includes EDG-1000 Series Ramp Edg<strong>in</strong>g)<br />
The pressure-sensitive safety mat <strong>in</strong>formation <strong>in</strong> the chart is for mats<br />
without EDG-1000 Series ramp edg<strong>in</strong>g. To <strong>in</strong>clude mitered ramp edg<strong>in</strong>g<br />
on <strong>all</strong> four sides of the mat, add a -1 to the part number and add 4” to<br />
both the width and length provided <strong>in</strong> the chart.<br />
All mats are furnished with a 20’ four-wire cord that exits the mat at<br />
the width end.<br />
STANDARD MAT SIZES<br />
PRESSURE-SENSITIVE MATS CHART<br />
PART NO. WIDTH LENGTH<br />
PSM-1212 12” 12”<br />
PSM-1224 12” 24”<br />
PSM-1236 12” 36”<br />
PSM-1248 12” 48”<br />
PSM-1260 12” 60”<br />
PSM-1272 12” 72”<br />
PSM-1636 16” 36”<br />
PSM-1824 18” 24”<br />
PSM-1836 18” 26”<br />
PSM-1848 18” 48”<br />
PSM-1860 18” 60”<br />
PSM-1872 18” 72”<br />
PSM-2420 24” 20”<br />
PSM-2424 24” 24”<br />
PSM-2430 24” 30”<br />
PSM-2436 24” 36”<br />
PSM-2442 24” 42”<br />
PSM-2448 24” 48”<br />
PSM-2456 24” 56”<br />
PSM-2460 24” 60”<br />
PSM-2472 24” 72”<br />
PSM-2828 27-1/2” 27-1/2”<br />
PSM-2833 27-1/2” 32-1/2”<br />
PSM-2843 27-1/2” 43”<br />
PSM-2856 27-1/2” 56”<br />
PSM-3030 30” 30”<br />
PSM-3036 30” 36”<br />
PSM-3042 30” 42”<br />
PSM-3048 30” 48”<br />
PSM-3060 30” 60”<br />
PSM-3072 30” 72”<br />
PSM-3432 33-1/2” 32”<br />
PSM-3444 33-1/2” 44”<br />
PSM-3456 33-1/2” 56”<br />
PSM-3636 36” 36”<br />
PSM-3642 36” 42”<br />
PSM-3648 36” 48”<br />
PSM-3660 36” 60”<br />
PSM-3672 36” 72”<br />
PSM-4132 40-7/8” 31-3/16”<br />
PSM-4144 40-7/8” 43-3/16”<br />
PSM-4156 40-7/8” 55-3/16”<br />
PSM-4848 48” 48”<br />
PSM-4860 48” 60”<br />
PSM-4872 48” 72”<br />
SAFEGUARDING DEVICES | 55
RAMP EDGING, BLUNT EDGING, AND MAT CONNECTORS<br />
An alum<strong>in</strong>um ramp-edged mat system can be customized to fit any shape or size area. Custom-made<br />
mats can fit most areas and even provide cutouts for mach<strong>in</strong>e legs, posts, or other obstructions.<br />
Send us a layout draw<strong>in</strong>g with complete dimensions of the area the mats need to cover, and we will<br />
provide a proposal for the required mats and accessories.<br />
BLUNT EDGING—EDG-2000 SERIES<br />
Recessed <strong>in</strong>st<strong>all</strong>ations: for flush edges<br />
aga<strong>in</strong>st thresholds, w<strong>all</strong>s, and mach<strong>in</strong>es.<br />
Part No. EDG-2052-N ( 3 ⁄4” W x 52” L)<br />
Part No. EDG-2096-N ( 3 ⁄4” W x 96” L)<br />
RAMP EDGING<br />
EDG-1000 SERIES<br />
Surface <strong>in</strong>st<strong>all</strong>ations: for easy rollon<br />
of carts, trucks, and walk on.<br />
Part No. EDG-1052-N<br />
(2” W x 52” L)<br />
Part No. EDG-1096-N<br />
(2” W x 96” L)<br />
MAT CONNECTORS—CON-1000 SERIES<br />
Jo<strong>in</strong>s mats together: permits add-on mats for large-area <strong>in</strong>st<strong>all</strong>ations.<br />
Part No. CON-1052-N (52” L)<br />
Part No. CON-1096-N (96” L)<br />
THE MAT EDGE STYLE & MAT MEASUREMENT<br />
The lip edge is the most common and widely used edge style for mats for s<strong>in</strong>gle mat applications. The lip can be removed to create the square<br />
edge for use with the CON-1000 series mat connector.<br />
* Width * *<br />
Length<br />
*<br />
1<br />
⁄2”<br />
MAT CONTROLS<br />
*This dimension is not <strong>in</strong>cluded <strong>in</strong> the mat widths and lengths. Do not <strong>in</strong>clude this <strong>in</strong> your measurements.<br />
MAT CONTROL BOX—PART NO. RKR-162<br />
This mat control box provides an <strong>in</strong>terface for the safety mats to the exist<strong>in</strong>g mach<strong>in</strong>e control. If<br />
some<strong>one</strong> steps on the mat while the mach<strong>in</strong>e is operat<strong>in</strong>g or cycl<strong>in</strong>g, the control is designed to<br />
provide a stop signal; or, if some<strong>one</strong> is on the mat(s), the stop signal will not <strong>all</strong>ow the mach<strong>in</strong>e to<br />
start a cycle. If special applications of this control are required, please consult the factory.<br />
This mat control is furnished <strong>in</strong> a dust- and oil-tight NEMA 12 enclosure and <strong>in</strong>cludes a selectable<br />
latch-out feature. When the latch-out feature is turned on, the mach<strong>in</strong>e will not automatic<strong>all</strong>y be able<br />
to restart until the latch-out has been cleared. This is accomplished with the use of the key-operated<br />
selector switch. When the latch-out feature is turned off, the mach<strong>in</strong>e can be restarted when the mat<br />
is cleared.<br />
CONTROL BOX SPECIFICATIONS<br />
Voltage............................................................................................................... 115 V AC, 60 Hz<br />
Output-Relay Contacts Rat<strong>in</strong>g...................................................................10 A, 115 V AC Resistive<br />
56 | SAFEGUARDING DEVICES
MAT CONTROLS (CONTINUED)<br />
If the mat control box Part No. RKR-162 is not required, a DIN-rail<br />
mounted control module is available. Each control module has 4 NO<br />
safety contacts and 1 NC auxiliary contact. The control module <strong>all</strong>ows<br />
operation <strong>in</strong> either automatic or manual reset modes.<br />
ORDERING INFORMATION<br />
PART NO.<br />
RFT-139<br />
DESCRIPTION<br />
120 V AC, 24-V DC Control Module<br />
Part No. RFT-139<br />
This DIN-rail mount control module can<br />
be mounted <strong>in</strong>to an exist<strong>in</strong>g enclosure.<br />
MAT JUNCTION BOXES<br />
If multiple mats are grouped together to provide auxiliary or perimeter<br />
(work-envelope) safeguard<strong>in</strong>g, junction boxes may be required to<br />
facilitate the <strong>in</strong>st<strong>all</strong>ation.<br />
Use either mat junction box with either the mat control box RKR-162<br />
(previous page) or a DIN-rail mount control module from above. Each<br />
mat junction box <strong>in</strong>cludes 20’ of four-wire cord.<br />
ORDERING INFORMATION<br />
PART NO.<br />
RKR-020<br />
RKR-021<br />
DESCRIPTION<br />
Mat Junction Box to Accommodate<br />
From 2-5 Safety Mats<br />
Mat Junction Box to Accommodate<br />
From 2-10 Safety Mats<br />
Part No. RKR-021<br />
This mat junction box can provide wir<strong>in</strong>g for up to 10 mats<br />
for easy tie-<strong>in</strong> to the mat control.<br />
(Cover has been removed for photo.)<br />
ZONE MONITOR<br />
For applications where multiple safety mats are needed, a z<strong>one</strong> monitor<br />
can be used. It acts as a control box, while elim<strong>in</strong>at<strong>in</strong>g the need for a<br />
junction box for multiple safety mat <strong>in</strong>st<strong>all</strong>ations. Addition<strong>all</strong>y, it has a<br />
diagnostic feature to determ<strong>in</strong>e which mat or mats have been tripped.<br />
The z<strong>one</strong> monitor is available <strong>in</strong> two models: <strong>one</strong> which monitors 1-4<br />
safety mats, and another which monitors 1-8 safety mats.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
RKR-103 Z<strong>one</strong> Monitor for 1-4 Safety Mats<br />
RKR-107 Z<strong>one</strong> Monitor for 1-8 Safety Mats<br />
Z<strong>one</strong> Monitor<br />
If the diagnostics of an entire perimeter safeguard<strong>in</strong>g system are required, a latch-out/reset z<strong>one</strong>-control unit may be required.<br />
Please consult the factory.<br />
SAFEGUARDING DEVICES | 57
DETECT-A-FINGER ® DROP-PROBE DEVICES<br />
INTRODUCTION<br />
The RKC series Detect-A-F<strong>in</strong>ger ® drop-probe devices are used on<br />
sm<strong>all</strong> mach<strong>in</strong>es to protect the operator’s f<strong>in</strong>gers from po<strong>in</strong>t-ofoperation<br />
hazards. The alum<strong>in</strong>um probe is shaped by the user to fit<br />
each application. Additional material, such as acrylic or polycarbonate<br />
clear plastic pieces or tube-type materials can be added to the probe<br />
to provide adequate protection. When do<strong>in</strong>g this, care should be taken<br />
not to add too much additional weight to the probe. Light materials<br />
should be used.<br />
These devices are designed to drop by gravity. If a f<strong>in</strong>ger or workpiece<br />
is <strong>in</strong> the way of the probe and the probe is not <strong>all</strong>owed to complete<br />
its downward travel, the mach<strong>in</strong>e will not start a cycle or stroke. The<br />
rotary solenoid is <strong>in</strong> the control box and when energized, after <strong>in</strong>itiation<br />
of the cycle, it <strong>all</strong>ows the probe to drop. A spr<strong>in</strong>g returns the probe to<br />
its start<strong>in</strong>g or up position.<br />
On mach<strong>in</strong>es that are mechanic<strong>all</strong>y operated, an air cyl<strong>in</strong>der or electric<br />
solenoid may have to be added to the operat<strong>in</strong>g l<strong>in</strong>kage to trip the<br />
mach<strong>in</strong>e. On mach<strong>in</strong>es that are hydraulic<strong>all</strong>y or pneumatic<strong>all</strong>y operated,<br />
the drop-probe control can usu<strong>all</strong>y be <strong>in</strong>terfaced with the exist<strong>in</strong>g<br />
control system.<br />
When updat<strong>in</strong>g mach<strong>in</strong>es to meet safety standards, please make sure<br />
that each mach<strong>in</strong>e is looked at as an <strong>in</strong>dividual system that <strong>in</strong>cludes,<br />
but is not limited to, safeguard<strong>in</strong>g (drop-probe device), mach<strong>in</strong>e control,<br />
disconnect switch, motor starter, covers for rotat<strong>in</strong>g comp<strong>one</strong>nts,<br />
auxiliary parts, lockout/tagout equipment, and feed<strong>in</strong>g and retriev<strong>in</strong>g<br />
of workpieces.<br />
RKC-000 AND RKC-001 SERIES<br />
FOR SAFEGUARDING RIVETERS, EYELETTERS, STAKERS, STAPLERS,<br />
CRIMPERS, FASTENING AND ASSEMBLY MACHINES<br />
Many mach<strong>in</strong>es can easily be safeguarded with Detect-A-F<strong>in</strong>ger ® dropprobe<br />
device.<br />
The RKC series Detect-A-F<strong>in</strong>ger ® drop-probe devices are furnished <strong>in</strong><br />
two models. Part No. RKC-000 is for mount<strong>in</strong>g on the right side of a<br />
mach<strong>in</strong>e, and Part No. RKC-001 is for mount<strong>in</strong>g on the left side of a<br />
mach<strong>in</strong>e.<br />
The RKC models consist of a control box with the probe arm, rotary<br />
electric solenoid, relay, limit switch, basic circuit with term<strong>in</strong>als and<br />
other mechanical mechanisms.<br />
Two 18” alum<strong>in</strong>um drop-probe rods are furnished with each control<br />
box. These rods are shaped by the user to the workpiece or assembly<br />
requirements (see below).<br />
Inside View of RKC-000 and RKC-001 Series Detect-A-<br />
F<strong>in</strong>ger ®<br />
Drop-Probe Device Control Box<br />
Examples of How the Drop-Probe Rods Can Be Shaped<br />
58 | SAFEGUARDING DEVICES
RKC-OOO AND RKC-001 SERIES (CONTINUED)<br />
SEQUENCE OF OPERATION<br />
Select the RKC series Detect-A-F<strong>in</strong>ger ® device (right- or left-side mount) that <strong>all</strong>ows the sens<strong>in</strong>g probe to enter the po<strong>in</strong>t of operation without<br />
obstruct<strong>in</strong>g the work area, and provides for as short and rigid of a sens<strong>in</strong>g probe design as possible. The drop probe stroke is adjustable from 0” to<br />
15⁄8”. Also, select a foot switch, if needed (see next page).<br />
The operator <strong>in</strong>itiates the cycle of the mach<strong>in</strong>e usu<strong>all</strong>y by an overt action on the foot switch. This energizes the rotary solenoid <strong>in</strong> the control box,<br />
which <strong>all</strong>ows the drop probe to descend until it makes contact with a limit switch. If an obstruction, such as a f<strong>in</strong>ger, gets <strong>in</strong> the way of the probe,<br />
the limit switch is not contacted and the mach<strong>in</strong>e does not start its cycle. If noth<strong>in</strong>g obstructs the probe and the limit switch is operated, a relay will<br />
signal the mach<strong>in</strong>e to start its cycle or cause it to trip. Next, the relay drops out, deenergiz<strong>in</strong>g the control box solenoid, <strong>all</strong>ow<strong>in</strong>g the probe to move up<br />
and out of the way. At this time, the mach<strong>in</strong>e completes its cycle and stops. The foot switch must be released and re<strong>in</strong>itiated to beg<strong>in</strong> another cycle.<br />
TYPICAL APPLICATIONS<br />
Electric<strong>all</strong>y or Electropneumatic<strong>all</strong>y Tripped Mach<strong>in</strong>es<br />
(Incorporat<strong>in</strong>g Mechanical Full-Revolution Clutch Typical on<br />
Rivet<strong>in</strong>g, Eyelett<strong>in</strong>g and Stak<strong>in</strong>g Mach<strong>in</strong>es)<br />
Electropneumatic or Electrohydraulic Mach<strong>in</strong>es<br />
All mechanic<strong>all</strong>y operated full-revolution-clutch mach<strong>in</strong>es should <strong>in</strong>corporate s<strong>in</strong>gle-stroke capability (mechanism).<br />
Refer to the comp<strong>one</strong>nt section on the next page for mach<strong>in</strong>es requir<strong>in</strong>g s<strong>in</strong>gle-stroke packages.<br />
SAFEGUARDING DEVICES | 59
RKC-OOO AND RKC-001 SERIES (CONTINUED)<br />
ADDITIONAL COMPONENTS<br />
If the mach<strong>in</strong>e that is be<strong>in</strong>g safeguarded with an RKC- or DAF-series<br />
drop-probe device has s<strong>in</strong>gle-stroke capability, additional comp<strong>one</strong>nts<br />
may be required to trip or cycle the mach<strong>in</strong>e.<br />
ADDITIONAL COMPONENTS<br />
PART NO.<br />
RCL-001<br />
RCL-002<br />
RCL-003<br />
RCD-140<br />
RCL-043<br />
RCD-071<br />
CTD-011<br />
DESCRIPTION<br />
50 lb Pull Air Cyl<strong>in</strong>der – 1-1/8” Bore x 1” Stroke<br />
100 lb Pull Air Cyl<strong>in</strong>der – 1-1/2” Bore x 1” Stroke<br />
200 lb Pull Air Cyl<strong>in</strong>der – 2” Bore x 2” Stroke<br />
1/4” Monitored Dual-Solenoid Air Valve Assembly<br />
1/4” Filter-Regulator-Lubricator Assembly<br />
1/4” Air Lockout Valve<br />
Foot Switch – H<strong>in</strong>ged Flap<br />
RCL-001<br />
RCL-002<br />
RCL-003<br />
Note: For push-type or longer stroke air cyl<strong>in</strong>ders, please consult the factory.<br />
SINGLE-STROKE TRIP-CONTROL SYSTEM<br />
If the mach<strong>in</strong>e that is be<strong>in</strong>g safeguarded with an RKC- or DAF- series<br />
drop-probe device obta<strong>in</strong>s its force from a flywheel but does not have a<br />
s<strong>in</strong>gle-stroke mechanism, a comp<strong>one</strong>nt package can be furnished. For<br />
best safety practices, choose the control box and comp<strong>one</strong>nt package<br />
plus an appropriate sized air cyl<strong>in</strong>der from above.<br />
CONTROL BOX NO. FPF-000-F PLUS<br />
COMPONENT PACKAGE NO. FNF-011 CONSISTING OF:<br />
PART NO.<br />
RCD-140<br />
RCL-043<br />
CTD-062<br />
CML-002<br />
CMK-103<br />
CTD-011<br />
HOS-4000<br />
DESCRIPTION<br />
1/4” Dual-Solenoid Air Valve<br />
1/4” Filter-Regulator-Lubricator Assembly<br />
Air Pressure Switch<br />
Cam and Strap Assembly<br />
Limit Switch Assembly<br />
Foot Switch<br />
Self-Latch<strong>in</strong>g Emergency Stop Palm Button<br />
RCD-140<br />
RCD-071<br />
RCL-043<br />
CTD-011<br />
CMK-103<br />
For fused disconnect switches or magnetic motor starters, please refer<br />
to <strong>Catalog</strong> SFM. C<strong>all</strong> us toll-free at 1-800-922-7533 or visit our Web<br />
site at www.rockfordsystems.com for the latest catalog.<br />
FPF-000-F<br />
CML-002<br />
60 | SAFEGUARDING DEVICES<br />
CTD-062<br />
HOS-4000
RKC-500 SERIES<br />
FOR SAFEGUARDING RESISTANCE-TYPE SPOT WELDERS<br />
The RKC-500 series Detect-A-F<strong>in</strong>ger ® drop-probe device reduces<br />
accidents at the po<strong>in</strong>t of operation where an operator’s f<strong>in</strong>gers can<br />
enter. The key comp<strong>one</strong>nts of this device are a sens<strong>in</strong>g probe module<br />
with the rod shaped to fit over or around the workpiece, and a control<br />
module. When the operator <strong>in</strong>itiates a mach<strong>in</strong>e cycle, the sens<strong>in</strong>g probe<br />
is released and drops by gravity over or around the workpiece. If the<br />
operator’s f<strong>in</strong>gers are still <strong>in</strong> the hazard area, the sens<strong>in</strong>g probe will not<br />
reach its preset position and will not <strong>all</strong>ow the spot welder to start its<br />
cycle. If there are no obstructions to prevent the sens<strong>in</strong>g probe from<br />
dropp<strong>in</strong>g, when it reaches its preset position, the control unit will <strong>all</strong>ow<br />
the mach<strong>in</strong>e to cycle.<br />
The compact design of the sens<strong>in</strong>g probe module <strong>all</strong>ows it to be<br />
attached to the welder arm. The drop-probe stroke is 15/8”.<br />
Rocker-Arm Welder<br />
Air-Operated Welder<br />
Press-Type Resistance Welder<br />
TYPICAL APPLICATIONS<br />
Rocker-Arm-Type Resistance Welder<br />
Detect-A-F<strong>in</strong>ger ®<br />
Sens<strong>in</strong>g Probe<br />
Assembly<br />
Ma<strong>in</strong><br />
Power<br />
Disconnect<br />
Switch<br />
Detect-A-F<strong>in</strong>ger ® Sens<strong>in</strong>g- Probe<br />
Assembly<br />
To Welder<br />
Controller<br />
Sens<strong>in</strong>g Probe<br />
Sens<strong>in</strong>g<br />
Probe<br />
Transformer<br />
(if required)<br />
To<br />
Power<br />
115 V AC<br />
Detect-A-F<strong>in</strong>ger ®<br />
Control Box<br />
Foot Switch<br />
To Welder<br />
Controller Detect-A-F<strong>in</strong>ger ®<br />
Control Box<br />
Foot Switch<br />
This Detect-A-F<strong>in</strong>ger ® drop-probe assembly may be mounted either to<br />
the mov<strong>in</strong>g member of a welder (upper arm), like the rocker-arm type<br />
illustrated above, or may be mounted to a fixed part of a welder, like the<br />
press-type illustrated above. Depend<strong>in</strong>g on the type of welder, a s<strong>in</strong>glestage<br />
or a two-stage foot switch may be required.<br />
The Detect-A-F<strong>in</strong>ger ® may also be applied to mechanical foot pedaltype<br />
welders. To convert from a mechanical operation, the mechanical<br />
pedal must be removed and replaced with an air cyl<strong>in</strong>der to operate<br />
the arm and foot switch. The cyl<strong>in</strong>der bore and stroke (push- or pulltype)<br />
can be determ<strong>in</strong>ed from actual mach<strong>in</strong>e measurements, and<br />
the method and location of attachment to the welder l<strong>in</strong>kage. The air<br />
cyl<strong>in</strong>der can be controlled by a three-way norm<strong>all</strong>y closed 115-V AC<br />
solenoid air valve. Adjustable flow control valves may be employed to<br />
smooth the welder arm movement, and an air filter-regulator-lubricator<br />
assembly may also be required. See the previous page for these<br />
comp<strong>one</strong>nts.<br />
SAFEGUARDING DEVICES | 61
RKC-500 SERIES (CONTINUED)<br />
COMPONENTS<br />
The RKC-500 Detect-A-F<strong>in</strong>ger ® device for spot welders consists of two<br />
comp<strong>one</strong>nts: the control box (mounted on the frame of the welder) and<br />
the drop-probe assembly (mounted on the upper arm).<br />
The control box provides <strong>in</strong>terface of the Detect-A-F<strong>in</strong>ger ® device to the<br />
spot welder’s control system.<br />
In addition to the control box, each unit is furnished with two pla<strong>in</strong><br />
18” alum<strong>in</strong>um drop-probe rods. These rods are to be shaped by the<br />
user to specific requirements. To prevent weld<strong>in</strong>g splash, additional<br />
lightweight clear plastic shield<strong>in</strong>g can be attached to the rod.<br />
Complete <strong>in</strong>st<strong>all</strong>ation <strong>in</strong>structions and a ma<strong>in</strong>tenance manual are<br />
provided with each assembly. Insulated mount<strong>in</strong>g hardware for the<br />
probe unit is also <strong>in</strong>cluded.<br />
A s<strong>in</strong>gle-stage foot switch with a fully guarded top and sides is also<br />
available, if required. Foot switch Part No. CTD-011 has a die-cast cover<br />
that protects the top and sides, and the front is protected by a h<strong>in</strong>ged<br />
flap. These features protect from un<strong>in</strong>tentional operation. (If a two-stage<br />
foot switch is required, please consult the factory).<br />
Control<br />
Box<br />
Foot Switch<br />
CTD-011<br />
Drop-Probe<br />
Assembly<br />
DANGER SIGNS FURNISHED WITH ALL DETECT-A-FINGER UNITS<br />
Operator safety precautions and a danger sign are furnished (<strong>in</strong> English unless otherwise<br />
requested) with each drop-probe device.<br />
DO NOT REMOVE OR COVER THIS SIGN - SEE BACK FOR MOUNTING<br />
PART No. KSC-0 5<br />
Part No. KSC-000<br />
Danger—Clos<strong>in</strong>g Ram and Die<br />
Size is 5” x 6” x .055” thick<br />
Part No. KSC-055 (English)<br />
Part No. KSC-055S (Spanish)<br />
Part No. KSC-000 (English)<br />
Part No. KSC-000S (Spanish)<br />
Operator Safety Precautions for Metal<br />
Form<strong>in</strong>g Mach<strong>in</strong>ery<br />
Size is 81⁄2” x 11”. A hole is provided <strong>in</strong><br />
the upper corner for attach<strong>in</strong>g purposes.<br />
62 | SAFEGUARDING DEVICES
DAF-100 SERIES<br />
ADJUSTABLE STROKE DETECT-A-FINGER ® DROP-PROBE DEVICE FOR SAFEGUARDING RIVETERS, SPOT WELDERS, EYELETTERS, STAKERS,<br />
STAPLERS, CRIMPERS, FASTENING AND ASSEMBLY MACHINES<br />
Drop-Probe<br />
Assembly<br />
PVC Insulator<br />
Block<br />
Sens<strong>in</strong>g<br />
Probe<br />
Control<br />
Box<br />
DAF-100 Detect-A-F<strong>in</strong>ger ® Mounted on a Rivet<strong>in</strong>g Mach<strong>in</strong>e<br />
The DAF-100 Detect-A-F<strong>in</strong>ger ® drop-probe device is an electricair<br />
system that consists of two ma<strong>in</strong> comp<strong>one</strong>nts: the drop-probe<br />
assembly and the control box. The standard unit can provide a stroke<br />
of up to 4” and can be mounted on the left or right side of the mach<strong>in</strong>e.<br />
Location of the DAF-100 should be determ<strong>in</strong>ed by the availability of<br />
the mount<strong>in</strong>g surface, the size or shape of the workpiece, and the<br />
throat depth of the mach<strong>in</strong>e.<br />
The drop-probe assembly functions by <strong>all</strong>ow<strong>in</strong>g the sens<strong>in</strong>g probe<br />
to drop around the po<strong>in</strong>t-of-operation hazard prior to each <strong>in</strong>tended<br />
mach<strong>in</strong>e cycle. If the sens<strong>in</strong>g probe encounters the operator’s f<strong>in</strong>gers<br />
and fails to drop to a preset position, the mach<strong>in</strong>e cycle will not be<br />
<strong>in</strong>itiated. If there are no obstructions to prevent the sens<strong>in</strong>g probe from<br />
dropp<strong>in</strong>g, then the control unit will <strong>all</strong>ow the mach<strong>in</strong>e to cycle when the<br />
sens<strong>in</strong>g probe reaches the preset position.<br />
SAFEGUARDING DEVICES | 63
DAF-100 SERIES (CONTINUED)<br />
COMPONENTS<br />
The DAF-100 system consists of two ma<strong>in</strong> comp<strong>one</strong>nts: the drop-probe assembly and the control box. The drop-probe assembly consists of an air<br />
cyl<strong>in</strong>der and solenoid operated air valve with an adjustable down stop lock<strong>in</strong>g collar, limit switch, magnetic proximity switch, and a PVC <strong>in</strong>sulator<br />
block. The control box consists of a control circuit board, safety relays, and p<strong>in</strong>-type plug-<strong>in</strong> term<strong>in</strong>als.<br />
Each DAF-100 system is furnished with <strong>one</strong> m<strong>in</strong>i air filter, two m<strong>in</strong>i air regulators, 25’ of 5⁄32” PVC tub<strong>in</strong>g, 4’ of 1” x 2” extruded alum<strong>in</strong>um for<br />
mount<strong>in</strong>g, and two pla<strong>in</strong> 18” alum<strong>in</strong>um sens<strong>in</strong>g probes. These sens<strong>in</strong>g probes are shaped by the user to the workpiece or assembly requirements.<br />
Complete <strong>in</strong>st<strong>all</strong>ation <strong>in</strong>structions and a ma<strong>in</strong>tenance manual are provided with each assembly.<br />
ADDITIONAL COMPONENTS<br />
Additional comp<strong>one</strong>nts may be required to trip or cycle the mach<strong>in</strong>e that is be<strong>in</strong>g safeguarded with the DAF-100 drop-probe device. See page 60<br />
for these additional comp<strong>one</strong>nts.<br />
Drop-Probe<br />
Assembly<br />
Alum<strong>in</strong>um Extrusion for<br />
Mount<strong>in</strong>g<br />
PVC Insulator<br />
Block<br />
Sens<strong>in</strong>g Probe<br />
Inside View of Drop-Probe<br />
Assembly (Cover has been<br />
removed for photo)<br />
Inside View of<br />
Control Box<br />
Control<br />
Box<br />
Foot Switch<br />
(Sold separately)<br />
M<strong>in</strong>i Air Filter and<br />
Air Regulators<br />
DAF-100 Detect-A-F<strong>in</strong>ger ® Mounted on a Spot Welder<br />
64 | SAFEGUARDING DEVICES
FUNCTION-TESTING CHECKLIST FOR LIGHT CURTAINS<br />
This is a generic function-test<strong>in</strong>g checklist. Your two-hand control may have other features that require<br />
different tests. Please refer to your two-hand control <strong>in</strong>st<strong>all</strong>ation manual.<br />
DANGER<br />
Make sure that the two-hand control has been <strong>in</strong>terfaced properly to the mach<strong>in</strong>e’s control system to<br />
provide control reliability.<br />
Never place your hands or any part of your body <strong>in</strong> the hazard area while perform<strong>in</strong>g these tests.<br />
Always perform these tests at every setup, operator, and shift change, as well as every time after<br />
ma<strong>in</strong>tenance is performed.<br />
1. Make sure that the light curta<strong>in</strong> is mounted at the proper safety distance <strong>in</strong> accordance with the ANSI safety-distance equation. (See the next<br />
page for the safety-distance equation.)<br />
2. Verify that some<strong>one</strong> cannot reach over, under, or around the sens<strong>in</strong>g field of the light curta<strong>in</strong> to reach the hazard. Additional guards or safeguard<strong>in</strong>g<br />
devices, if necessary, must protect these areas.<br />
3. Turn on the mach<strong>in</strong>e and the light curta<strong>in</strong>. The green status-<strong>in</strong>dicator light on the transmitter should be on and the red status-<strong>in</strong>dicator light should<br />
be off. If the light curta<strong>in</strong> has a float-blank<strong>in</strong>g feature, make sure that it is turned off. If fixed blank<strong>in</strong>g is provided and used, this feature can rema<strong>in</strong><br />
on, and the blanked area should be occupied with an object that fills this entire space across the sens<strong>in</strong>g field.<br />
4. Use a test rod or other object sized accord<strong>in</strong>g to the light curta<strong>in</strong>’s m<strong>in</strong>imum object<br />
sensitivity (sometimes referred to as the resolution) to confirm that <strong>all</strong> the channels<br />
<strong>in</strong> the sens<strong>in</strong>g field are work<strong>in</strong>g properly. To do this, move the test rod through the<br />
sens<strong>in</strong>g field <strong>in</strong> a pattern as illustrated to the right. The red status-<strong>in</strong>dicator light on the<br />
transmitter should stay on dur<strong>in</strong>g the entire test.<br />
5. With the mach<strong>in</strong>e on and ready to be cycled <strong>in</strong> a production mode of operation, hold<br />
the test rod <strong>in</strong> the sens<strong>in</strong>g field and attempt to cycle the mach<strong>in</strong>e. The mach<strong>in</strong>e should<br />
not cycle.<br />
6. Cycle the mach<strong>in</strong>e and then quickly <strong>in</strong>sert the test rod <strong>in</strong> the sens<strong>in</strong>g field. The mach<strong>in</strong>e<br />
should stop immediately.<br />
Note: On some mach<strong>in</strong>es, the light curta<strong>in</strong> is muted dur<strong>in</strong>g the nonhazardous portion of<br />
the mach<strong>in</strong>e cycle. If the test rod is <strong>in</strong>serted <strong>in</strong> the sens<strong>in</strong>g field while the light curta<strong>in</strong><br />
is muted, the mach<strong>in</strong>e will not stop. Therefore, be sure to <strong>in</strong>sert the test rod dur<strong>in</strong>g the<br />
hazardous portion of the cycle when perform<strong>in</strong>g this test.<br />
START STOP<br />
7. Confirm that when the test rod is removed from the sens<strong>in</strong>g field, the mach<strong>in</strong>e does not restart automatic<strong>all</strong>y.<br />
8. Verify that <strong>in</strong> order to start another cycle (or cont<strong>in</strong>ue a cycle that was <strong>in</strong>terrupted), the normal actuat<strong>in</strong>g means must be re<strong>in</strong>itiated; or, if some<strong>one</strong><br />
can pass through the sens<strong>in</strong>g field and stand <strong>in</strong>side the safeguarded area, verify that the light curta<strong>in</strong> or mach<strong>in</strong>e control must be manu<strong>all</strong>y reset<br />
before re<strong>in</strong>itiation of the normal actuat<strong>in</strong>g means. The reset device must be located outside of the safeguarded area (so it cannot be reached from<br />
with<strong>in</strong>) and with<strong>in</strong> view so the operator can verify that no <strong>one</strong> is <strong>in</strong>side the safeguarded area.<br />
9. If any of these function tests fail, take corrective action before runn<strong>in</strong>g production. If <strong>all</strong> tests pass, remove <strong>all</strong> keys from the selector switches<br />
before runn<strong>in</strong>g production.<br />
SAFETY DISTANCE FOR LIGHT CURTAINS<br />
Test Pattern<br />
Sens<strong>in</strong>g<br />
Field<br />
The safety-distance equation from Annex D of ANSI B11.19-2010, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>, is as follows:<br />
Ds = K(Ts + Tc + Tr + Tspm) + Dpf<br />
Where:<br />
Ds = safety distance<br />
K = maximum speed that an <strong>in</strong>dividual can approach the hazard (63 <strong>in</strong>ches/second is commonly used)<br />
Ts = stopp<strong>in</strong>g time of the mach<strong>in</strong>e measured at the f<strong>in</strong>al control element<br />
Tc = reaction time of the control system<br />
Tr = reaction time of the light curta<strong>in</strong> and its <strong>in</strong>terface<br />
Tspm = additional time <strong>all</strong>owed for the stopp<strong>in</strong>g-performance monitor to compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time<br />
Dpf = amount of penetration <strong>all</strong>owed by the light curta<strong>in</strong> <strong>in</strong>to its sens<strong>in</strong>g field before some<strong>one</strong> is detected<br />
The value of Dpf can be found us<strong>in</strong>g <strong>one</strong> of the follow<strong>in</strong>g figures, and it can then be used <strong>in</strong> the safety-distance equation above.<br />
Test<br />
Rod<br />
SAFEGUARDING DEVICES | 65
Figure 1: D pf<br />
for light curta<strong>in</strong>s used <strong>in</strong> a vertical application with object sensitivity less than or equal to 2.5 <strong>in</strong>ches (64 millimeters)<br />
Dpf, the distance added to the safety distance due to the penetration factor,<br />
compensates for vary<strong>in</strong>g object sensitivities of light curta<strong>in</strong>s.<br />
When blank<strong>in</strong>g features are used and when the blanked area is not completely filled<br />
by the workpiece or by mechanical guard<strong>in</strong>g, the object sensitivity can be calculated<br />
as follows:<br />
Object sensitivity = size of the blanked area plus m<strong>in</strong>imum object sensitivity<br />
without blank<strong>in</strong>g.<br />
Once this value is found, then determ<strong>in</strong>e Dpf.<br />
If the entire blanked area is filled with mechanical guard<strong>in</strong>g or other fixed material or<br />
guards, use the light curta<strong>in</strong>’s object sensitivity to determ<strong>in</strong>e Dpf.<br />
Figure 2: D pf<br />
for light curta<strong>in</strong>s used <strong>in</strong> a vertical application with object sensitivity greater than 2.5 <strong>in</strong>ches (64 millimeters)<br />
For light curta<strong>in</strong>s us<strong>in</strong>g large blanked areas, or if an <strong>in</strong>dividual can otherwise reach through or over the sens<strong>in</strong>g field and not be detected, the distance<br />
between any two adjacent detection po<strong>in</strong>ts sh<strong>all</strong> not be greater than 24 <strong>in</strong> (600 mm), i.e., from <strong>one</strong> active po<strong>in</strong>t to the next active po<strong>in</strong>t above.<br />
If the <strong>in</strong>dividual cannot reach over<br />
the top of the sens<strong>in</strong>g field and the<br />
bottom of the sens<strong>in</strong>g field (A) is no<br />
more than 12 <strong>in</strong> (300 mm) above<br />
the floor.<br />
The top of the sens<strong>in</strong>g field (B) is<br />
between 36 and 48 <strong>in</strong> (900 and 1200<br />
mm) above the floor. The bottom of the<br />
sens<strong>in</strong>g field (A) is no more than 12 <strong>in</strong><br />
(300 mm) above the floor.<br />
Reach Through<br />
D pf<br />
= 36 <strong>in</strong> (900 mm) for<br />
reach-through applications<br />
Reach Over<br />
D pf<br />
= 48 <strong>in</strong> (1200 mm) for<br />
reach-over applications<br />
Note: Where <strong>in</strong>dividuals can place themselves between the safeguard<strong>in</strong>g device and the hazard z<strong>one</strong> and rema<strong>in</strong> undetected, additional measures must be taken.<br />
Figure 3: D pf<br />
for light curta<strong>in</strong>s used <strong>in</strong> a horizontal application (30° or less) that can be reached over<br />
Reach Over<br />
D pf<br />
= 48 <strong>in</strong> (1200 mm) for horizontal sens<strong>in</strong>g-field<br />
applications without vertical sens<strong>in</strong>g.<br />
Allowable Sens<strong>in</strong>g-Field Heights <strong>in</strong> Inches (Millimeters)<br />
Object Sensitivity (S)<br />
Mount<strong>in</strong>g Height (h)<br />
M<strong>in</strong>imum<br />
Maximum<br />
< 2 (50) 0 39 (990)<br />
2.5 (64) 7.5 (190) 39 (990)<br />
3 (76) 15 (380) 39 (990)<br />
3.5 (89) 22.5 (570) 39 (990)<br />
4 (102) 30 (760) 39 (990)<br />
4.25 (108) 33.75 (860) 39 (990)<br />
4.6 (117) 39 (990) 39 (990)<br />
M<strong>in</strong>imum mount<strong>in</strong>g height (h) can also be determ<strong>in</strong>ed by the follow<strong>in</strong>g:<br />
h = 15 (S – 2) <strong>in</strong><br />
h = (S – 50) mm<br />
where S is the object sensitivity.<br />
Note: The light curta<strong>in</strong>’s horizontal coverage must be enough to h<strong>in</strong>der an <strong>in</strong>dividual from stepp<strong>in</strong>g over its sens<strong>in</strong>g field. This m<strong>in</strong>imum distance is 36 <strong>in</strong> (900 mm) if supplemental safeguard<strong>in</strong>g<br />
or physical barriers are used such that an <strong>in</strong>dividual cannot step over and clear the sens<strong>in</strong>g field, and 48 <strong>in</strong> (1200 mm) if no supplemental safeguard<strong>in</strong>g or physical barriers are used.<br />
66 | SAFEGUARDING DEVICES
FUNCTION-TESTING CHECKLIST FOR TWO-HAND CONTROL<br />
This is a generic function-test<strong>in</strong>g checklist. Your two-hand control may have other features that require<br />
different tests. Please refer to your two-hand control <strong>in</strong>st<strong>all</strong>ation manual.<br />
DANGER<br />
Make sure that the two-hand control has been <strong>in</strong>terfaced properly to the mach<strong>in</strong>e’s control system to<br />
provide control reliability.<br />
Never place your hands or any part of your body <strong>in</strong> the hazard area while perform<strong>in</strong>g these tests.<br />
1. Before turn<strong>in</strong>g the mach<strong>in</strong>e on, verify that:<br />
Always perform these tests at every setup, operator, and shift change, as well as every time after<br />
ma<strong>in</strong>tenance is performed.<br />
a. The hand controls are protected aga<strong>in</strong>st un<strong>in</strong>tended or <strong>in</strong>advertent operation. This is usu<strong>all</strong>y d<strong>one</strong> with r<strong>in</strong>g guards or fabricated shields.<br />
(If the hand controls are nonmechanical such as capacitive or optical touch buttons, make sure that only an operator’s hands can<br />
actuate them and not other parts of his or her body.)<br />
b. The hand controls are separated by enough distance or configured to require the use of both hands.<br />
c. The hand controls are fixed <strong>in</strong> position at the proper safety distance. (See the safety-distance equation below.)<br />
d. Two <strong>in</strong>dividual hand controls are provided for each operator that is to be safeguarded by two-hand control. When there are<br />
multiple two-hand control stations, there must be an <strong>in</strong>dicator at each station to <strong>in</strong>dicate whether the station is on or off (usu<strong>all</strong>y<br />
accomplished with an <strong>in</strong>dicator light), and the means of turn<strong>in</strong>g the station on and off must be supervisable (usu<strong>all</strong>y d<strong>one</strong> with a<br />
key-operated selector switch).<br />
2. With the mach<strong>in</strong>e on and ready to be cycled <strong>in</strong> the s<strong>in</strong>gle-cycle mode of operation, perform the follow<strong>in</strong>g tests.<br />
a. Actuate both hand controls and keep them actuated. The mach<strong>in</strong>e should make <strong>one</strong> complete cycle<br />
and then it should stop, even though the hand controls are still be<strong>in</strong>g actuated.<br />
b. Actuate both hand controls and release them while the mach<strong>in</strong>e is still <strong>in</strong> the hazardous portion of<br />
its cycle. The mach<strong>in</strong>e should stop. Both hand controls must be cont<strong>in</strong>uously actuated dur<strong>in</strong>g the<br />
hazardous portion of the cycle.<br />
c. Actuate both hand controls and release only <strong>one</strong> control dur<strong>in</strong>g the hazardous portion of the cycle.<br />
The hazardous motion of the mach<strong>in</strong>e should stop. Reactuate the hand control that was released.<br />
The mach<strong>in</strong>e should not f<strong>in</strong>ish the cycle. Repeat this with the other hand control. Aga<strong>in</strong>, the<br />
mach<strong>in</strong>e should not f<strong>in</strong>ish the cycle. Both hand controls must be released and reactuated before<br />
the mach<strong>in</strong>e can f<strong>in</strong>ish the cycle.<br />
d. If the two-hand control has a concurrent timer: Actuate <strong>one</strong> hand control, wait until the concurrent time limit has expired, and then<br />
actuate the other hand control. The mach<strong>in</strong>e should not cycle. The hand controls must be actuated concurrently with<strong>in</strong> a certa<strong>in</strong> time<br />
limit (usu<strong>all</strong>y 0.5 seconds or less) before a mach<strong>in</strong>e cycle can be <strong>in</strong>itiated.<br />
e. If the mach<strong>in</strong>e is equipped with multiple two-hand control stations, turn off <strong>all</strong> stations and make sure that the mach<strong>in</strong>e does not cycle.<br />
Also perform the above tests at each two-hand control station.<br />
3. If any of these function tests fail, take corrective action before runn<strong>in</strong>g production. If <strong>all</strong> tests pass, remove <strong>all</strong> keys from the selector switches<br />
before runn<strong>in</strong>g production.<br />
The safety-distance equation for two-hand control from Annex D of ANSI B11.19-2010, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>, is as follows:<br />
Ds = K(Ts + Tc + Tr + Tspm)<br />
Where:<br />
Ds = safety distance<br />
K = maximum speed that an <strong>in</strong>dividual can approach the hazard (63 <strong>in</strong>ches/second is commonly used)<br />
Ts = stopp<strong>in</strong>g time of the mach<strong>in</strong>e measured at the f<strong>in</strong>al control element<br />
Tc = reaction time of the control system<br />
Tr = reaction time of the two-hand control and its <strong>in</strong>terface<br />
Tspm = additional time <strong>all</strong>owed for the stopp<strong>in</strong>g-performance monitor to compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time<br />
SAFEGUARDING DEVICES | 67
FUNCTION-TESTING CHECKLIST FOR TWO-HAND TRIP<br />
This is a generic function-test<strong>in</strong>g checklist. Your two-hand control may have other features that require<br />
different tests. Please refer to your two-hand control <strong>in</strong>st<strong>all</strong>ation manual.<br />
DANGER<br />
Make sure that the two-hand control has been <strong>in</strong>terfaced properly to the mach<strong>in</strong>e’s control system to provide<br />
control reliability.<br />
Never place your hands or any part of your body <strong>in</strong> the hazard area while perform<strong>in</strong>g these tests.<br />
Always perform these tests at every setup, operator, and shift change, as well as every time after<br />
ma<strong>in</strong>tenance is performed.<br />
1. Before turn<strong>in</strong>g the mach<strong>in</strong>e on, verify that:<br />
a. The hand controls are protected aga<strong>in</strong>st un<strong>in</strong>tended or <strong>in</strong>advertent operation. This is usu<strong>all</strong>y d<strong>one</strong> with r<strong>in</strong>g guards or fabricated shields.<br />
(If the hand controls are nonmechanical such as capacitive or optical touch buttons, make sure that only an operator’s hands can actuate<br />
them and not other parts of his or her body.)<br />
b. The hand controls are separated by enough distance or configured to require the use of both hands.<br />
c. The hand controls are fixed <strong>in</strong> position at the proper safety distance. (See the safety-distance equations below.)<br />
d. Two <strong>in</strong>dividual hand controls are provided for each operator that is to be safeguarded by two-hand trip. When there are multiple twohand<br />
trip stations, there must be an <strong>in</strong>dicator at each station to <strong>in</strong>dicate whether the station is on or off (usu<strong>all</strong>y accomplished with an<br />
<strong>in</strong>dicator light), and the means of turn<strong>in</strong>g the station on and off must be supervisable (usu<strong>all</strong>y d<strong>one</strong> with a key-operated selector switch).<br />
2. With the mach<strong>in</strong>e on and ready to be tripped <strong>in</strong> the s<strong>in</strong>gle-cycle mode of operation, perform the follow<strong>in</strong>g tests.<br />
a. Actuate both hand controls and keep them actuated. The mach<strong>in</strong>e should make <strong>one</strong> complete cycle and then it should stop, even though<br />
the hand controls are still be<strong>in</strong>g actuated.<br />
b. If the two-hand trip has a concurrent timer: Actuate <strong>one</strong> hand control, wait until the concurrent time limit has expired, and then actuate<br />
the other hand control. The mach<strong>in</strong>e should not cycle. The hand controls must be actuated concurrently with<strong>in</strong> a certa<strong>in</strong> time limit<br />
(usu<strong>all</strong>y 0.5 seconds or less) before a mach<strong>in</strong>e cycle can be <strong>in</strong>itiated.<br />
c. If the mach<strong>in</strong>e is equipped with multiple two-hand trip stations, turn off <strong>all</strong> stations and make sure that the mach<strong>in</strong>e does not cycle.<br />
Also perform the above tests at each two-hand trip station.<br />
3. If any of these function tests fail, take corrective action before runn<strong>in</strong>g production. If <strong>all</strong> tests pass, remove <strong>all</strong> keys from the selector switches<br />
before runn<strong>in</strong>g production.<br />
The safety-distance equations for two-hand trip from Annex D of ANSI B11.19-2010, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>, are as follows:<br />
For mach<strong>in</strong>es with full-revolution clutches that have <strong>one</strong> or more clutch-engagement po<strong>in</strong>ts:<br />
<br />
Where:<br />
Ds = KTmc (1/2 + 1/N)<br />
Ds<br />
K<br />
Tmc<br />
N<br />
= safety distance<br />
= maximum speed that an <strong>in</strong>dividual can approach the hazard (63 <strong>in</strong>ches/second is commonly used)<br />
= time it takes to complete a mach<strong>in</strong>e cycle<br />
= number of engagement po<strong>in</strong>ts on the flywheel<br />
For other mach<strong>in</strong>es that are tripped to <strong>in</strong>itiate a cycle that cannot be stopped until the completion of the cycle:<br />
Where:<br />
Ds = KThm<br />
Ds<br />
K<br />
Thm<br />
= safety distance<br />
= maximum speed that an <strong>in</strong>dividual can approach the hazard (63 <strong>in</strong>ches/second is commonly used)<br />
= the time, after <strong>in</strong>itiation of motion, until hazardous motion is completed<br />
68 | SAFEGUARDING DEVICES
OSHA GUARD-OPENING REQUIREMENTS<br />
Table 0-10 details the maximum permissible open<strong>in</strong>gs for guards as required by OSHA 29 CFR 1910.217 for mechanical power presses. A guardopen<strong>in</strong>g<br />
sign is available that can be used by eng<strong>in</strong>eer<strong>in</strong>g, ma<strong>in</strong>tenance, etc., for reference when design<strong>in</strong>g or fabricat<strong>in</strong>g guards. This 10” x 12”<br />
sign is made of .055”-thick semi-rigid plastic and can be mounted with nails, screws, nylon lock-strips, etc.<br />
Part No. KSC-012<br />
OSHA Guard-Open<strong>in</strong>g Requirements Sign<br />
ANSI GUARD-OPENING REQUIREMENTS<br />
The maximum permissible open<strong>in</strong>g for guards as required by Annex D of ANSI B11.19-2010, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>, is as follows:<br />
As a function of gap size <strong>in</strong> millimeters (<strong>in</strong>ches)<br />
As a function of distance <strong>in</strong> millimeters (<strong>in</strong>ches)<br />
Known Gap M<strong>in</strong>imum Distance Known Distance Maximum Gap<br />
0–6 (0–0.24) 13 (0.5) < 13 (< 0.5) Not permitted<br />
6.1–11 (0.25–0.375) 64 (2.5) 13–63.9 (0.5–2.49) 6 (0.250)<br />
11.1–16 (0.376–0.625) 89 (3.5) 64–88.9 (2.5–3.49) 11 (0.375)<br />
16.1–32 (0.626–1.250) 166 (6.5) 89–165.9 (3.5–6.49) 16 (0.625)<br />
32.1–49 (1.251–1.875) 445 (17.5) 166–444.9 (6.5–17.49) 32 (1.250)<br />
49.1–132 (1.876–5.000) 915 (36.0) 445–914.9 (17.5–35.99) 49 (1.875)<br />
> 132 (> 5.0) Not permitted > 915 (> 36.0) 132 (5.000)<br />
SAFEGUARDING DEVICES | 69
GUARD-OPENING SCALES<br />
An OSHA or ANSI guard-open<strong>in</strong>g scale can be used dur<strong>in</strong>g the design, <strong>in</strong>st<strong>all</strong>ation, and <strong>in</strong>spection of barrier guards to make sure they comply<br />
with the OSHA and ANSI guard-open<strong>in</strong>g requirements. These engraved, acrylic copolymer guard-open<strong>in</strong>g scales are available onl<strong>in</strong>e at www.<br />
rockfordsystems.com.<br />
OSHA GUARD-OPENING SCALE—PART NO. KSC-097<br />
This fold<strong>in</strong>g guard-open<strong>in</strong>g scale is based on Table O-10 of OSHA 29 CFR 1910.217 for mechanical power presses, which shows the distances<br />
that guards sh<strong>all</strong> be positi<strong>one</strong>d from the po<strong>in</strong>t of operation based on open<strong>in</strong>g size. It is constructed of acrylic copolymer and has permanent<br />
etched mark<strong>in</strong>gs.<br />
OSHA Guard-Open<strong>in</strong>g Scale Part No.<br />
KSC-097<br />
ANSI GUARD-OPENING SCALE—PART NO. KSC-098<br />
This fold<strong>in</strong>g guard-open<strong>in</strong>g scale is based on “A Review of Mach<strong>in</strong>e-Guard<strong>in</strong>g Recommendations” by Donald R. Vaillancourt and Stover H. Snook<br />
of the Liberty Mutual Research Center for Safety and Health. The ANSI/RIA R15.06 safety standard for <strong>in</strong>dustrial robots and robot systems, as well<br />
as recently revised ANSI B11–series safety standards for mach<strong>in</strong>e tools, use the guard-open<strong>in</strong>g data from this study. The Canadian power press<br />
standard, CSA Z142-02, also uses the data from this study. One side of the scale shows English units; the other side shows metric units. It is<br />
constructed of acrylic copolymer and has permanent etched mark<strong>in</strong>gs<br />
ANSI Guard-Open<strong>in</strong>g Scale Part No.<br />
KSC-098<br />
SAFETY DISTANCE GUIDE<br />
Many OSHA and ANSI safety requirements must be met before <strong>in</strong>st<strong>all</strong><strong>in</strong>g two-hand control or a presence-sens<strong>in</strong>g device as a po<strong>in</strong>t-of-operation<br />
safeguard. One requirement is that the control or device must be located at a m<strong>in</strong>imum safety distance from the po<strong>in</strong>t of operation. This safety<br />
distance guide slide chart can be used to calculate the safety distance for these devices. The m<strong>in</strong>imum safety distance is based on the stopp<strong>in</strong>g<br />
ability of the mach<strong>in</strong>e and a hand-speed constant, <strong>in</strong> addition to other factors.<br />
Safety Distance Guide Slide<br />
Chart<br />
Part No. LLL-050<br />
70 | SAFEGUARDING DEVICES
MACHINE SAFEGUARDING SEMINARS INTRODUCTION<br />
Accord<strong>in</strong>g to safety standards, when a mach<strong>in</strong>e creates a hazard<br />
to operators and other employees <strong>in</strong> the mach<strong>in</strong>e area, it must be<br />
safeguarded. We offer this mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ar to educate<br />
people <strong>in</strong> positions of responsibility how to properly safeguard the po<strong>in</strong>t<br />
of operation and other mach<strong>in</strong>e hazards to meet OSHA regulations and<br />
current <strong>in</strong>dustry standards.<br />
This comprehensive 21/2-day sem<strong>in</strong>ar provides knowledgeable<br />
<strong>in</strong>terpretations of the performance language of both OSHA (Occupational<br />
Safety and Health Adm<strong>in</strong>istration) and ANSI (American National<br />
Standards Institute) standards. Twenty-four ANSI B11-series safety<br />
standards and other related standards are covered.<br />
Classroom discussions are comb<strong>in</strong>ed with a PowerPo<strong>in</strong>t presentation<br />
and live demonstrations of mach<strong>in</strong>es to help attendees understand<br />
when and where safeguard<strong>in</strong>g is required and how various safeguard<strong>in</strong>g<br />
works. The teach<strong>in</strong>g methods used and the material covered dur<strong>in</strong>g the<br />
21/2 days will help attendees determ<strong>in</strong>e compliance issues with their<br />
mach<strong>in</strong>ery and processes.<br />
The metal-turn<strong>in</strong>g portion of this sem<strong>in</strong>ar primarily focuses on the ANSI<br />
requirements for chuck shields and chip/coolant shields on manu<strong>all</strong>y<br />
operated mach<strong>in</strong>es. <strong>Safeguard<strong>in</strong>g</strong> by distance and location are also<br />
covered, as well as awareness barriers and devices, pressure-sensitive<br />
mats, emergency-stop devices, drop-probe devices, color-cod<strong>in</strong>g,<br />
warn<strong>in</strong>g signs, and tra<strong>in</strong><strong>in</strong>g requirements.<br />
Us<strong>in</strong>g ANSI/RIA R15.06 as a guidel<strong>in</strong>e, safeguard<strong>in</strong>g methods for robots are<br />
discussed. This section <strong>in</strong>cludes the newly <strong>in</strong>corporated risk assessment/<br />
hazard analysis. An overview and <strong>in</strong>terpretation of OSHA 1910.147<br />
Lockout/Tagout and STD 1-7.3 are also <strong>in</strong>cluded.<br />
TRAINING CENTER<br />
Our tra<strong>in</strong><strong>in</strong>g center conta<strong>in</strong>s a number of mach<strong>in</strong>es <strong>in</strong>clud<strong>in</strong>g mechanical<br />
and hydraulic power presses, press brakes, an eng<strong>in</strong>e lathe, a vertical<br />
mill, a drill press, a pedestal gr<strong>in</strong>der, a spot welder, and riveter. These<br />
mach<strong>in</strong>es are under power for demonstration purposes. Most of the<br />
demonstration mach<strong>in</strong>es are equipped with multiple types of safeguards<br />
to show how different guards and devices can be applied and used.<br />
Hands-on opportunities abound!<br />
TRAINING INSTRUCTORS<br />
Our <strong>in</strong>structors are well qualified, hav<strong>in</strong>g many years of exposure to the<br />
mach<strong>in</strong>e-tool <strong>in</strong>dustry. Their experience comes from work<strong>in</strong>g <strong>in</strong> the field<br />
with plant eng<strong>in</strong>eers, safety directors, and plant managers. Instructors<br />
are also <strong>in</strong>volved <strong>in</strong> the observance of the various draft stages of ANSI<br />
B11-series safety standards for mach<strong>in</strong>e tools.<br />
SEMINAR MATERIALS<br />
Each person attend<strong>in</strong>g the sem<strong>in</strong>ar receives a variety of <strong>in</strong>formation<br />
regard<strong>in</strong>g mach<strong>in</strong>e safeguard<strong>in</strong>g which <strong>in</strong>cludes the follow<strong>in</strong>g:<br />
• OSHA 29 CFR 1910.211, 1910.212, 1910.217, and 1910.219<br />
• OSHA 29 CFR 1910.147, Lockout/Tagout<br />
• Pert<strong>in</strong>ent ANSI B11 standards<br />
• Charts and graphs for future reference<br />
• <strong>Safeguard<strong>in</strong>g</strong> product catalogs<br />
• U.S. Department of Labor memorandums<br />
• Mechanical power press safety <strong>in</strong>formation card<br />
• Safety distance guide slide chart<br />
• Fold<strong>in</strong>g OSHA and ANSI guard-open<strong>in</strong>g scales<br />
• Lam<strong>in</strong>ated function-test<strong>in</strong>g checklists for safeguards<br />
REGISTRATION INFORMATION<br />
Please consult the factory or our Web site for the registration fee. This<br />
fee <strong>in</strong>cludes the sem<strong>in</strong>ar presentation and demonstrations, sem<strong>in</strong>ar<br />
materials <strong>in</strong>clud<strong>in</strong>g a safety distance guide, guard-open<strong>in</strong>g scales,<br />
food and beverages dur<strong>in</strong>g breaks, lunch on the first two days, and a<br />
certificate of completion. The registration fee does not <strong>in</strong>clude other<br />
meals, lodg<strong>in</strong>g, or transportation.<br />
To enroll, c<strong>all</strong> 1-800-922-7533, or register onl<strong>in</strong>e at<br />
www.rockfordsystems.com.<br />
SEMINAR SCHEDULE<br />
The mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ar is usu<strong>all</strong>y held on the third Tuesday,<br />
Wednesday, and Thursday of each month. (Thursday’s session ends<br />
midmorn<strong>in</strong>g.) All sem<strong>in</strong>ar dates and times are subject to change. Please<br />
c<strong>all</strong> the sem<strong>in</strong>ar registrar to confirm sem<strong>in</strong>ar dates before mak<strong>in</strong>g travel<br />
arrangements.<br />
CONFIRMATION<br />
Each attendee will receive a package of detailed <strong>in</strong>formation prior to<br />
attend<strong>in</strong>g. Maps and a list of over 15 hotels are provided for students to<br />
make their own hotel reservations.<br />
LOCATION<br />
The sem<strong>in</strong>ar is held at our <strong>Rockford</strong>, Ill<strong>in</strong>ois, plant, which is located 65<br />
miles northwest of Chicago O’Hare Airport.<br />
ON-SITE AND SPECIAL GROUP SEMINARS<br />
Mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ars can be presented at your company and<br />
tailored to the types of mach<strong>in</strong>es <strong>in</strong> your plant. We can also conduct<br />
special sem<strong>in</strong>ars at our facility for your group or company. Please<br />
contact our tra<strong>in</strong><strong>in</strong>g department for details.<br />
SAFEGUARDING DEVICES | 71
A<br />
A Gates.................................................................. 45-47<br />
Adjustable Mirror Mount<strong>in</strong>g Bracket................................38<br />
G<br />
Gate Assemblies..........................................................48<br />
Gate (Movable Barrier) Devices................................. 45-51<br />
All-In-One Two-Hand Control.................................... 40-43<br />
ANSI Guard-Open<strong>in</strong>g Requirements................................69<br />
ANSI Guard-Open<strong>in</strong>g Scale.............................................70<br />
I<br />
Guard-Open<strong>in</strong>g Scales...................................................70<br />
Interfaces<br />
EZ Screen Light Curta<strong>in</strong> Interfaces..............................17<br />
B<br />
C<br />
ANSI Publications List......................................................3<br />
B Gates.................................................................. 46-47<br />
Brackets, Light Curta<strong>in</strong> Mount<strong>in</strong>g.............................. 31-37<br />
Brackets, Mirror....................................................... 38-39<br />
Brackets, Tower Light Assembly.....................................30<br />
Bumper, Safety..............................................................52<br />
Checklists, Function-Test<strong>in</strong>g................................. 61-64<br />
Light Curta<strong>in</strong>s...................................................... 65-66<br />
L<br />
M<br />
Perimeter Light Beam.................................................22<br />
Safety Bumper...........................................................52<br />
Laser Alignment Tool.......................................18, 21, 24<br />
Laser Safety Scanner, S3000................................... 25-28<br />
Mat Controls.......................................................... 56-57<br />
Mats, Pressure-Sensitive Safety............................... 53-58<br />
Measurement Forms<br />
Gate Assembly..................................................... 48-51<br />
Two-Hand Control......................................................67<br />
SAB-A/SAB-NA, Press................................................34<br />
Two-Hand Trip...........................................................68<br />
SAB-A/SAB-NA, Press Brake......................................35<br />
Controls<br />
Mirror Brackets........................................................ 38-39<br />
All-In-One Two-Hand Control................................ 40-42<br />
Mirrors, Light Curta<strong>in</strong>.....................................................38<br />
Remote Operator-Style Controls......................18, 22, 24<br />
Mount<strong>in</strong>g Brackets, Light Curta<strong>in</strong>s............................ 31-39<br />
Safety Mat Control............................................... 56-57<br />
Mount<strong>in</strong>g Kits, S3000 Safety Laser Scanner...................26<br />
D<br />
E<br />
F<br />
Tower Light Assembly Controls...................................30<br />
Danger Signs...............................................................62<br />
Detect-A-F<strong>in</strong>ger ® Drop-Probe Devices<br />
DAF-100 Series................................................... 63-64<br />
RKC-000 and RCK-001 Series.............................. 58-60<br />
RKC-500 Series................................................... 61-62<br />
EZ Screen Light Curta<strong>in</strong> System, Po<strong>in</strong>t-of-Operation<br />
.............................................................................. 11-18<br />
Floor Stands<br />
Light Curta<strong>in</strong>..............................................................67<br />
S3000 Safety Laser Scanner................................ 25-28<br />
Function-Test<strong>in</strong>g Checklists<br />
Light Curta<strong>in</strong>s...................................................... 65-66<br />
Two-Hand Control......................................................67<br />
Two-Hand Trip...........................................................68<br />
N<br />
O<br />
P<br />
No-Go Indicator Light..................................................31<br />
Optional Mount<strong>in</strong>g Brackets for P.O.O. Light Curta<strong>in</strong>s....<br />
....................................................................................31<br />
OSHA Guard-Open<strong>in</strong>g Requirements...............................69<br />
OSHA Guard-Open<strong>in</strong>g Scale...........................................70<br />
Part Number<strong>in</strong>g Chart<br />
Cascad<strong>in</strong>g Light Curta<strong>in</strong> Presence-Sens<strong>in</strong>g............ 15-16<br />
Noncascad<strong>in</strong>g Light Curta<strong>in</strong> Presence-Sens<strong>in</strong>g............14<br />
Perimeter Light Beam.................................................21<br />
S3000 Safety Laser Scanner .....................................28<br />
S<strong>in</strong>gle Beam..............................................................24<br />
Tower Light Assembly................................................29<br />
Two-Hand Control......................................................42<br />
Perimeter Light Beam System.................................. 19-22<br />
Portable Stop-Time Measurement Device.................... 18-9<br />
Po<strong>in</strong>t-Of-Operation Light Curta<strong>in</strong> System................... 11-18<br />
Presence-Sens<strong>in</strong>g Devices......................................... 16-7<br />
72 | SAFEGUARDING DEVICES
Q<br />
R<br />
S<br />
T<br />
Pressure-Sensitive Safety Mats................................ 53-57<br />
Quick Reference Guides..............................................10<br />
References............................................................ 65-70<br />
Remote Fixed Blank<strong>in</strong>g Switch........................................14<br />
Remote Operator Stations..................................18, 22, 24<br />
S3000 Safety Laser Scanner................................. 25-28<br />
SAB-A Mount<strong>in</strong>g Brackets........................................ 32-31<br />
SAB-NA Mount<strong>in</strong>g Brackets...................................... 32-35<br />
<strong>Safeguard<strong>in</strong>g</strong> Sem<strong>in</strong>ar.............................................. 71-72<br />
Safety Bumper...............................................................52<br />
Safety Distance Chart, Two-Hand Trip.............................44<br />
Safety Distance Guide....................................................70<br />
Safety Mats............................................................. 53-57<br />
S<strong>in</strong>gle-Beam System................................................ 23-24<br />
Stationary Brackets.................................................. 36-37<br />
STM (Stop-Time Measurement) Device......................... 8-9<br />
Sw<strong>in</strong>g-Away Mount<strong>in</strong>g Brackets............................... 32-35<br />
Test Rods for Light Curta<strong>in</strong>s........................................31<br />
Tower Light Assemblies........................................... 29-30<br />
Two-Hand Control.................................................... 40-42<br />
Two-Hand Trip......................................................... 43-44<br />
Type A Gate..................................................................45<br />
Type B Gate............................................................ 46-47<br />
SAFEGUARDING DEVICES | 73
EX-AL Barrier &<br />
Perimeter Guard<strong>in</strong>g<br />
For Industrial Mach<strong>in</strong>es<br />
www.rockfordsystems.com<br />
2 | EX-AL BARRIER & PERIMETER GUARDING
EX-AL Barrier & Perimeter Guard<strong>in</strong>g is a<br />
comprehensive catalog that features a complete<br />
l<strong>in</strong>e of products to safeguard mach<strong>in</strong>e operators<br />
at the po<strong>in</strong>t of operation us<strong>in</strong>g barrier guard<strong>in</strong>g<br />
systems. Each guard<strong>in</strong>g system is custom<br />
designed and built for each application.<br />
Perimeter safeguard<strong>in</strong>g systems are also<br />
featured <strong>in</strong> this catalog designed to protect<br />
<strong>in</strong>dividuals that work <strong>in</strong> or around large<br />
work areas. These systems can be used <strong>in</strong><br />
numerous applications <strong>in</strong> manufactur<strong>in</strong>g—<br />
around robots and robot systems, assembly<br />
mach<strong>in</strong>es, packag<strong>in</strong>g mach<strong>in</strong>es, transfer l<strong>in</strong>es,<br />
cut-to-length l<strong>in</strong>es, slitt<strong>in</strong>g l<strong>in</strong>es, etc.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong>
TABLE OF CONTENTS<br />
BARRIER GUARDING SYSTEMS........................................... 3-22<br />
<br />
Portable Demonstration Unit...........................................................4<br />
Introduction to Barrier Guard<strong>in</strong>g <strong>Systems</strong>........................................4<br />
OSHA Guard Requirements............................................................5<br />
OSHA and ANSI Guard-Open<strong>in</strong>g Scales..........................................6<br />
General Instructions for Apply<strong>in</strong>g Barrier Guard...............................6<br />
Panels.................................................................................... 7-22<br />
Panel Frame Construction.................................................. 7-8<br />
Panel Segments........................................................................8<br />
Mounts............................................................................... 9-10<br />
Multi-Panel XL-2 Through XL-6.......................................... 11-12<br />
Measur<strong>in</strong>g Instructions for Multi-Panel<br />
Models XL-2 Through XL-6.............................................13<br />
Measurement Form for Multi-Panel<br />
Models XL-2 Through XL-6.............................................14<br />
Front Mount XL-1 Through XL-7..............................................15<br />
Measurement Form for Front Mount<br />
Models XL-1 FM Through XL-7 FM..................................16<br />
Measur<strong>in</strong>g Instructions for Front-Mount<br />
Models XL-1 FM Through XL-7 FM..................................17<br />
S<strong>in</strong>gle Panel Model XL-1 or Double Panel Model XL-2..............18<br />
Measurement Form for S<strong>in</strong>gle Panel<br />
Model XL-1 or Double Panel XL-2....................................19<br />
Spr<strong>in</strong>g Lift XL-1 SL or Air Lift XL-1 AL................................ 20-21<br />
Measurement Form for Spr<strong>in</strong>g-Lift Model<br />
XL-1 SL and Air-Lift Model XL-1 AL.................................22<br />
PERIMETER GUARDING SYSTEMS..................................... 23-33<br />
Introduction.................................................................................23<br />
Measur<strong>in</strong>g Perimeter Guards........................................................24<br />
Alum<strong>in</strong>um Panels, Doors and Posts..............................................25<br />
Hardware ........................................................................... 26-28<br />
Panel-to-Post Connector......................................................26<br />
H<strong>in</strong>ge for Alum<strong>in</strong>um Door....................................................26<br />
Door Stop for Alum<strong>in</strong>um Door..............................................26<br />
Interlock<strong>in</strong>g Door Bolts........................................................26<br />
Extrusions .................................................................................27<br />
Mesh..........................................................................................28<br />
PERIMETER GUARDING SYSTEMS (CONT.)........................ 28-33<br />
Panel Reta<strong>in</strong>er.............................................................................28<br />
Polycarbonate.............................................................................28<br />
Rubber Gasket for Polycarbonate Panel........................................28<br />
T-Slot Covers..............................................................................28<br />
T-Nuts and End Fasteners............................................................29<br />
Hairp<strong>in</strong>s and Fasteners.......................................................... 29-30<br />
Roller Bear<strong>in</strong>g Assembly..............................................................30<br />
H<strong>in</strong>ges........................................................................................30<br />
Sw<strong>in</strong>g-Away H<strong>in</strong>ge Assembly.......................................................30<br />
Deadbolt Latch............................................................................31<br />
Door Handle................................................................................31<br />
End Caps .................................................................................31<br />
T-Handle Hex Wrenches..............................................................31<br />
Brackets for Interlock Switches....................................................31<br />
Brackets and Plates............................................................... 32-33<br />
FLOOR AND CONTROL BOX STANDS.......................................34<br />
Floor Stand.................................................................................34<br />
Control Box Stands......................................................................34<br />
REFERENCES ................................................................... 35-38<br />
Function-Test<strong>in</strong>g Checklist for Perimeter Barrier Guards.......... 35-36<br />
ANSI/RIA and CSA Guard-Open<strong>in</strong>g Requirements..........................36<br />
Safety Distance For Nonlock<strong>in</strong>g Interlocked Barrier Guards............36<br />
Function-Test<strong>in</strong>g Checklist for Po<strong>in</strong>t-of-Operation Barrier Guards......37<br />
OSHA and ANSI Guard-Open<strong>in</strong>g Requirements,<br />
OSHA and ANSI Guard-Open<strong>in</strong>g Scales........................................38<br />
Safety Distance for Nonlock<strong>in</strong>g Interlocked Barrier Guards.............38<br />
EXAMPLE OF SPECIAL PERIMETER AND<br />
POINT-OF-OPERATION BARRIER GUARDS...............................39<br />
The applications described <strong>in</strong> this catalog are for <strong>in</strong>structional and <strong>in</strong>formational purposes only; the photos <strong>in</strong> this catalog are for illustrative purposes<br />
only. They may not represent actual usage. This catalog has been carefully checked for accuracy and is thought to be fully consistent with the<br />
products described here<strong>in</strong>. However, <strong>Rockford</strong> <strong>Systems</strong>, LLC does not assume liability for the contents of this publication or for the use of any<br />
products described here<strong>in</strong>. <strong>Rockford</strong> <strong>Systems</strong>, LLC reserves the right to make changes to the products and documentation without further notice.<br />
This document conta<strong>in</strong>s proprietary <strong>in</strong>formation protected by copyright. No part of this catalog may be reproduced, transmitted, stored <strong>in</strong> a retrieval<br />
system, or translated <strong>in</strong>to any language, <strong>in</strong> any form or by any means without prior written permission from <strong>Rockford</strong> <strong>Systems</strong>, LLC, 5795 Logistics<br />
Parkway, <strong>Rockford</strong>, Ill<strong>in</strong>ois 61109-2695. <strong>Rockford</strong> <strong>Systems</strong> reserves the right to make changes or revisions to the material conta<strong>in</strong>ed <strong>in</strong> this catalog<br />
and cannot be held liable for <strong>in</strong>cidental or consequential damages result<strong>in</strong>g from the furnish<strong>in</strong>g, performance or use of this material.<br />
Copyright © 2019 by <strong>Rockford</strong> <strong>Systems</strong>, LLC. All rights reserved. Not to be reproduced <strong>in</strong> whole or <strong>in</strong> part without written permission. LITHO IN U.S.A.<br />
2 | EX-AL BARRIER & PERIMETER GUARDING
Light Curta<strong>in</strong> Mount<strong>in</strong>g Bracket and Guard Comb<strong>in</strong>ation<br />
Around Assembly Mach<strong>in</strong>e<br />
Po<strong>in</strong>t-of-Operation Guard on OBI Press<br />
Mill<strong>in</strong>g Mach<strong>in</strong>e Shield With Slid<strong>in</strong>g Front Door<br />
Air-Lift Guard on Press<br />
Guard Mounted to Conveyor System and Mach<strong>in</strong>e<br />
Po<strong>in</strong>t-of-Operation Light Curta<strong>in</strong>s on a Press<br />
EX-AL BARRIER & PERIMETER GUARDING | 3
PORTABLE DEMONSTRATION UNIT<br />
We offer custom guards that can be designed and built to fit most<br />
mach<strong>in</strong>es. Our product development and eng<strong>in</strong>eer<strong>in</strong>g personnel can<br />
design guards that are unique to your mach<strong>in</strong>es. These guards comply<br />
with OSHA (Occupational Safety and Health Adm<strong>in</strong>istration) and ANSI<br />
(American National Standards Institute) safety standards.<br />
A portable demonstration unit is available. This unit features various<br />
materials that are used to construct a shield or guard<strong>in</strong>g system. This<br />
portable demonstration unit is ideal as a quick reference or as a visual aid<br />
for safety specialists, loss-control eng<strong>in</strong>eers, etc.<br />
Please use Part No. FFD-000263 when order<strong>in</strong>g.<br />
Portable Demonstration Unit<br />
INTRODUCTION TO BARRIER GUARDING SYSTEMS<br />
Barrier guards are usu<strong>all</strong>y the first po<strong>in</strong>t-of-operation safeguard<br />
considered for mach<strong>in</strong>es. The guards detailed <strong>in</strong> this catalog<br />
are <strong>in</strong>tended and designed to meet the requirements of OSHA<br />
(Occupational Safety and Health Adm<strong>in</strong>istration) and ANSI (American<br />
National Standards Institute) safety standards.<br />
The OSHA 29 CFR 1910.217 requirements on the next page are<br />
specific<strong>all</strong>y for guards on mechanical power presses; however, the<br />
same requirements apply for any other mach<strong>in</strong>ery used <strong>in</strong> <strong>in</strong>dustry.<br />
When review<strong>in</strong>g this catalog, please note guards are mounted on<br />
many different types of mach<strong>in</strong>es. These guards are not limited to<br />
fabricat<strong>in</strong>g equipment; they can be applied to any mach<strong>in</strong>e that<br />
requires po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g.<br />
The EX-AL guard<strong>in</strong>g systems can be used as a barrier (not guard) to<br />
protect the sides and rear of the mach<strong>in</strong>e when other safeguard<strong>in</strong>g is<br />
used such as presence-sens<strong>in</strong>g devices, two-hand control, pullbacks,<br />
and restra<strong>in</strong>ts.<br />
An EX-AL guard<strong>in</strong>g system can also be applied as shields on<br />
metal-cutt<strong>in</strong>g mach<strong>in</strong>es such as lathes, mill<strong>in</strong>g mach<strong>in</strong>es, and drill<br />
presses. This system is ideal for applications which require shield<strong>in</strong>g<br />
from chips and coolant. At the same time, the shield provides a barrier<br />
between the po<strong>in</strong>t-of-operation hazard and the operator for added<br />
protection.<br />
When operat<strong>in</strong>g any mach<strong>in</strong>e, personal protective equipment,<br />
<strong>in</strong>clud<strong>in</strong>g safety glasses, must be worn by the operator. All parts of<br />
the operator’s body must be kept out of the po<strong>in</strong>t-of-operation hazard<br />
and the operator must not wear jewelry. Long hair must be restra<strong>in</strong>ed<br />
and loose cloth<strong>in</strong>g should be avoided.<br />
Each EX-AL guard<strong>in</strong>g system offered <strong>in</strong> this catalog is custom<br />
designed and built for each application. Frame extrusions are cut<br />
and assembled from detailed dimensions furnished to the factory on<br />
measurement forms, pr<strong>in</strong>ts, or sketches. Delivery varies from stock<br />
(<strong>in</strong>ventoried brackets, fasteners, etc.) to four weeks based on the<br />
quantity and complexity of the guards required.<br />
An <strong>in</strong>struction manual, danger signs, and a CAD-generated draw<strong>in</strong>g<br />
are <strong>in</strong>cluded with each EX-AL shipment. This <strong>in</strong>formation is helpful<br />
when mount<strong>in</strong>g the guard to the mach<strong>in</strong>e. When a measurement form<br />
has been provided for the design and fabrication of the guard<strong>in</strong>g<br />
system, a copy of it will be <strong>in</strong>cluded with the shipment of the guard<strong>in</strong>g<br />
system.<br />
Before measur<strong>in</strong>g your mach<strong>in</strong>e for barrier guards, please refer to the<br />
follow<strong>in</strong>g pages to select the proper guard. Take <strong>in</strong>to consideration the<br />
safety and productivity requirements of each mach<strong>in</strong>e.<br />
Barrier guards basic<strong>all</strong>y consist of three comp<strong>one</strong>nts:<br />
1. Panels<br />
2. Panel segments<br />
3. Mounts<br />
Once the decision has been made on these three comp<strong>one</strong>nts and<br />
the OSHA requirements have been read and understood (see next<br />
page), some<strong>one</strong> can measure the mach<strong>in</strong>e(s) for the appropriate type<br />
of guard.<br />
4 | EX-AL BARRIER & PERIMETER GUARDING
OSHA GUARD REQUIREMENTS TAKEN FROM 29 CFR 1910.217<br />
FOR MECHANICAL POWER PRESSES<br />
(c)(2) Po<strong>in</strong>t-of-Operation Guards:<br />
(i) Every po<strong>in</strong>t-of-operation guard sh<strong>all</strong> meet the follow<strong>in</strong>g design,<br />
construction, application, and adjustment requirements:<br />
(a) It sh<strong>all</strong> prevent entry of hands or f<strong>in</strong>gers <strong>in</strong>to the po<strong>in</strong>t of<br />
operation by reach<strong>in</strong>g through, over, under or around the guard;<br />
(b) It sh<strong>all</strong> conform to the maximum permissible open<strong>in</strong>gs of Table<br />
O-10;<br />
(c) It sh<strong>all</strong>, <strong>in</strong> itself, create no p<strong>in</strong>ch po<strong>in</strong>t between the guard and<br />
mov<strong>in</strong>g mach<strong>in</strong>e parts;<br />
(d) It sh<strong>all</strong> utilize fasteners not readily removable by operator, so as<br />
to m<strong>in</strong>imize the possibility of misuse or removal of essential parts;<br />
(e) It sh<strong>all</strong> facilitate its <strong>in</strong>spection, and<br />
(f) It sh<strong>all</strong> offer maximum visibility of the po<strong>in</strong>t of operation consistent<br />
with the other requirements.<br />
(ii) A die enclosure guard sh<strong>all</strong> be attached to the die shoe or stripper<br />
<strong>in</strong> a fixed position.<br />
(iii) A fixed barrier guard sh<strong>all</strong> be attached securely to the frame of the<br />
press or to the bolster plate.<br />
(iv) An <strong>in</strong>terlocked press barrier guard sh<strong>all</strong> be attached to the press<br />
frame or bolster and sh<strong>all</strong> be <strong>in</strong>terlocked <strong>in</strong>to the press clutch control<br />
so that the clutch cannot be activated unless the guard itself, or the<br />
h<strong>in</strong>ged or movable sections of the guard are <strong>in</strong> position to conform to<br />
the requirements of Table O-10.<br />
(v) The h<strong>in</strong>ged or movable sections of an <strong>in</strong>terlocked press barrier<br />
guard sh<strong>all</strong> not be used for manual feed<strong>in</strong>g. The guard sh<strong>all</strong> prevent<br />
open<strong>in</strong>g of the <strong>in</strong>terlocked section and reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation prior to die closure or prior to the cessation of slide motion.<br />
See paragraph (c)(3)(ii) of this section regard<strong>in</strong>g manual feed<strong>in</strong>g through<br />
<strong>in</strong>terlocked press barrier devices.<br />
(vi) The adjustable barrier guard sh<strong>all</strong> be securely attached to the press<br />
bed, bolster plate, or die shoe, and sh<strong>all</strong> be adjusted and operated <strong>in</strong><br />
conformity with Table O-10 and the requirements of this subparagraph.<br />
Adjustments sh<strong>all</strong> be made only by authorized personnel whose<br />
qualifications <strong>in</strong>clude a knowledge of the provisions of Table<br />
O-10 and this subparagraph.<br />
1"<br />
4<br />
1"<br />
2<br />
DANGER LINE<br />
CLEARANCE LINE<br />
MINIMUM GUARDING LINE<br />
3"<br />
8<br />
1"<br />
2<br />
5"<br />
8<br />
3"<br />
4<br />
7"<br />
8<br />
TYPICAL<br />
GUARD<br />
LOCATIONS<br />
1"<br />
14<br />
TABLE O-10<br />
Distance of open<strong>in</strong>g<br />
from po<strong>in</strong>t-of-operation<br />
hazard (<strong>in</strong>ches)<br />
GUARD MUST EXTEND FROM SOME POINT ON<br />
CLEARANCE LINE TO SOME POINT ON OPENING<br />
LINE<br />
1"<br />
1 1" 1" 2" 1" 1" 5" 3" 2" 14"<br />
2<br />
17 1"<br />
2<br />
Explanation of above diagram:<br />
TABLE 0-10<br />
Guard Open<strong>in</strong>gs<br />
Maximum width<br />
of open<strong>in</strong>g (<strong>in</strong>ches)<br />
1<br />
⁄2 to 1 1 ⁄2........................................................ 1 ⁄4<br />
1 1 ⁄2 to 2 1 ⁄2...................................................... 3 ⁄8<br />
2 1 ⁄2 to 3 1 ⁄2...................................................... 1 ⁄2<br />
3 1 ⁄2 to 5 1 ⁄2...................................................... 5 ⁄8<br />
5 1 ⁄2 to 6 1 ⁄2...................................................... 3 ⁄4<br />
6 1 ⁄2 to 7 1 ⁄2...................................................... 7 ⁄8<br />
7 1 ⁄2 to 12 1 ⁄2.................................................. 1 1 ⁄4<br />
12 1 ⁄2 to 15 1 ⁄2................................................1 1 ⁄2<br />
15 1 ⁄2 to 17 1 ⁄2................................................1 7 ⁄8<br />
17 1 ⁄2 to 31 1 ⁄2................................................2 1 ⁄8<br />
1"<br />
12<br />
6"<br />
MAXIMUM<br />
AT<br />
DISTANCES<br />
OVER 31- 1 /2"<br />
USE 6" AS<br />
MAXIMUM<br />
OPENING<br />
Note: The standard panel is furnished with 1 /4” diameter rods or<br />
hairp<strong>in</strong>s that are on 3 /4” centers; therefore, they will be 1 /2 “ apart.<br />
2 1 /2 “ is the m<strong>in</strong>imum distance the panels can be mounted from the<br />
po<strong>in</strong>t of operation. The same 2 1 /2 “ distance applies to the standard<br />
1<br />
/2” square mesh.<br />
7"<br />
18<br />
1"<br />
2 8<br />
STOCK TRAVEL LINE<br />
This diagram shows the accepted safe open<strong>in</strong>gs between the bottom<br />
edge of a guard and feed table at various distances from the danger<br />
l<strong>in</strong>e (po<strong>in</strong>t of operation). A guard-open<strong>in</strong>g scale can be used to check<br />
the open<strong>in</strong>gs <strong>in</strong> a guard after <strong>in</strong>st<strong>all</strong>ation (see next page).<br />
The clearance l<strong>in</strong>e marks the distance required to prevent contact between<br />
the guard and mov<strong>in</strong>g parts.<br />
The m<strong>in</strong>imum guard<strong>in</strong>g l<strong>in</strong>e is the distance between the <strong>in</strong>feed side of the<br />
guard and the danger l<strong>in</strong>e which is <strong>one</strong>-half <strong>in</strong>ch from the clearance l<strong>in</strong>e.<br />
The various open<strong>in</strong>gs (based on a woman’s size 6 glove) are designed<br />
to prevent the operator’s f<strong>in</strong>gers from reach<strong>in</strong>g the po<strong>in</strong>t of operation.<br />
After <strong>in</strong>st<strong>all</strong>ation of po<strong>in</strong>t-of-operation guards and before a mach<strong>in</strong>e is<br />
released for production, a check should be made to verify that the guard will<br />
prevent the operator’s hands from reach<strong>in</strong>g the po<strong>in</strong>t of operation.<br />
Table O-10 shows the distances that guards sh<strong>all</strong> be positi<strong>one</strong>d from<br />
the danger l<strong>in</strong>e <strong>in</strong> accordance with the required open<strong>in</strong>gs.<br />
EX-AL BARRIER & PERIMETER GUARDING | 5
OSHA AND ANSI GUARD-OPENING SCALES<br />
OSHA<br />
Guard-Open<strong>in</strong>g Scale<br />
Part No. KSC-097<br />
ANSI<br />
Guard-Open<strong>in</strong>g Scale<br />
Part No. KSC-098<br />
These guard-open<strong>in</strong>g scales are used to check the open<strong>in</strong>gs <strong>in</strong> a guard once it has been <strong>in</strong>st<strong>all</strong>ed.<br />
GENERAL INSTRUCTIONS FOR APPLYING BARRIER GUARDS<br />
A barrier guard consists basic<strong>all</strong>y of three comp<strong>one</strong>nts: PANELS,<br />
PANEL SEGMENTS (if required), and MOUNTS.<br />
PANELS<br />
1. Beg<strong>in</strong> by determ<strong>in</strong><strong>in</strong>g what type of panel construction is required.<br />
Choices <strong>in</strong>clude a nonadjustable panel (NAP), or a variety of<br />
adjustable panels (AP1, AP2, AP3, AP4, AP5, and API).<br />
2. Next, us<strong>in</strong>g a pla<strong>in</strong> piece of paper or the measurement forms<br />
provided, measure accurately and record the sizes of each panel<br />
required. Important: All dimensions and <strong>in</strong>formation requested<br />
on each measurement form must be filled <strong>in</strong> and answered<br />
completely. Be sure to read the measur<strong>in</strong>g <strong>in</strong>structions for each<br />
type of guard before writ<strong>in</strong>g down the dimensions.<br />
PANEL SEGMENTS<br />
3. Determ<strong>in</strong>e if a segment <strong>in</strong>side the panel is required. If it is, decide<br />
which segment type.<br />
4. Measure the segment size required and provide its location<br />
<strong>in</strong> the panel.<br />
5. On some sm<strong>all</strong>er guards, the segment could be the<br />
entire panel.<br />
MOUNTS<br />
There are various mounts available for attach<strong>in</strong>g the guard to the<br />
mach<strong>in</strong>e. Select the mount that best fits the application.<br />
For price quotes or order<strong>in</strong>g, remember to:<br />
1. Complete <strong>all</strong> dimensions for each barrier guard.<br />
2. Measure accurately and complete <strong>all</strong> dimensions. Important: All<br />
dimensions and <strong>in</strong>formation requested on each measurement form<br />
must be filled <strong>in</strong> and answered completely. Note any mach<strong>in</strong>e<br />
obstructions, such as flywheel covers, knockout rods, feeds, and mov<strong>in</strong>g<br />
mach<strong>in</strong>e comp<strong>one</strong>nts on the measurement form and provide specific<br />
dimensions of these obstructions <strong>in</strong> the Notes section.<br />
3. Send the completed <strong>in</strong>formation to <strong>Rockford</strong> for pric<strong>in</strong>g.<br />
4. When ordered, a complete barrier guard, ready for <strong>in</strong>st<strong>all</strong>ation, will<br />
be furnished.<br />
Note: The barrier guards and/or mount<strong>in</strong>g brackets/stands <strong>in</strong> this<br />
catalog will be fabricated to with<strong>in</strong> ± 1/8” of the measurements<br />
provided. M<strong>in</strong>or modification or additional material may be needed at<br />
the time of <strong>in</strong>st<strong>all</strong>ation for proper fit to the mach<strong>in</strong>e or equipment.<br />
6 | EX-AL BARRIER & PERIMETER GUARDING
PANELS<br />
The standard panel frame is constructed of 1” x 2” extruded alum<strong>in</strong>um.<br />
The nonadjustable area of the panel is made of black or yellow mesh<br />
( 1 /2” sq. 16-gauge or 1” sq. 12-gauge), or 3 /16”-thick clear polycarbonate<br />
which is fastened <strong>in</strong> place for a permanent assembly. A panel can also<br />
be furnished with adjustable 1 /4” diameter, black-oxidized steel hairp<strong>in</strong>s<br />
<strong>in</strong> any portion of the panel. This provides adjustability for strip or coil<br />
feed<strong>in</strong>g, or for obstructions on the mach<strong>in</strong>e. The hairp<strong>in</strong>s are secured to<br />
the panel frame with clips, T-nuts, and socket-head cap screws.<br />
Various types of panel segments can also be furnished <strong>in</strong> the<br />
nonadjustable area of the panel to accommodate required features. A<br />
panel with adjustable hairp<strong>in</strong>s does not have a panel segment unless<br />
the operator requires visibility <strong>in</strong>to the po<strong>in</strong>t of operation. Panels can<br />
be attached to the mach<strong>in</strong>e us<strong>in</strong>g the mounts shown on pages 9 and 10.<br />
AP—ADJUSTABLE PANELS<br />
AP1–Lower Section ( 1 ⁄2 Frame)<br />
The AP1 panel has a sturdy frame around the top half of the<br />
nonadjustable panel area. Steel hairp<strong>in</strong>s are on the lower portion of the<br />
panel to <strong>all</strong>ow for adjustability.<br />
PANEL FRAME CONSTRUCTION<br />
NAP—NONADJUSTABLE PANELS<br />
The NAP panel is fastened <strong>in</strong> place for a permanent assembly. It<br />
can be furnished with 1 /2” or 1” black or yellow mesh, or 3 /16”-thick<br />
clear polycarbonate.<br />
1⁄2” MESH PANEL<br />
AP2–LOWER SECTION (5⁄8 FRAME)<br />
The AP2 panel has adjustability on the lower section, with <strong>one</strong> side<br />
of the frame extend<strong>in</strong>g to the bottom of the panel for an extended<br />
mount<strong>in</strong>g surface.<br />
POLYCARBONATE PANEL<br />
AP3–LOWER SECTION (3⁄4 FRAME)<br />
The AP3 panel has adjustability on the lower section, with both sides<br />
of the frame extend<strong>in</strong>g to the bottom of the panel for an extended<br />
mount<strong>in</strong>g surface on both sides.<br />
EX-AL BARRIER & PERIMETER GUARDING | 7
PANEL FRAME CONSTRUCTION (CONTINUED)<br />
AP4–INTERIOR SECTION (FULL FRAME)<br />
The AP4 panel has steel hairp<strong>in</strong>s located <strong>in</strong> the <strong>in</strong>terior section of<br />
the panel for adjustability. This can be used when the material is fed<br />
through the center portion of the panel.<br />
PANEL SEGMENTS<br />
Various types of panel segments can be positi<strong>one</strong>d <strong>in</strong>to the nonadjustable<br />
area of the framed panel to accommodate required features. A<br />
standard panel with adjustable hairp<strong>in</strong>s does not have a panel segment<br />
unless the operator requires visibility <strong>in</strong>to the po<strong>in</strong>t of operation.<br />
FEEDING (FS)<br />
The feed<strong>in</strong>g segment is used for<br />
strip or coil feed<strong>in</strong>g through a<br />
nonadjustable area of the panel.<br />
This segment can accommodate<br />
various feedl<strong>in</strong>e heights.<br />
AP5–LOWER SECTION FULL FRAME<br />
The AP5 panel has adjustability on the lower section, with full-frame<br />
availability for mount<strong>in</strong>g.<br />
ADJUSTABLE (AS)<br />
The adjustable segment is<br />
used for strip or coil feed<strong>in</strong>g<br />
through an adjustable area. This<br />
segment can accommodate<br />
various feedl<strong>in</strong>e heights. When<br />
us<strong>in</strong>g this adjustable segment,<br />
refer to the requirements of<br />
Table O-10 (see page 5).<br />
API–LOWER SECTION (INCLINABLE)<br />
The API panel has <strong>in</strong>cl<strong>in</strong>able steel hairp<strong>in</strong>s located <strong>in</strong> the lower section.<br />
The <strong>in</strong>cl<strong>in</strong>able section slants the hairp<strong>in</strong>s <strong>in</strong>ward for effective feed<strong>in</strong>g of<br />
material and accommodation of various size dies while provid<strong>in</strong>g po<strong>in</strong>tof-operation<br />
safeguard<strong>in</strong>g. When <strong>in</strong>cl<strong>in</strong><strong>in</strong>g these guards, refer to the<br />
requirements of Table O-10 (see page 5) for the proper size open<strong>in</strong>g.<br />
POLYCARBONATE (PCS)<br />
EMPTY (ES)<br />
Polycarbonate (3/16”-thick)<br />
segments are furnished when<br />
greater visibility <strong>in</strong>to the po<strong>in</strong>t of<br />
operation is required.<br />
An empty segment can be<br />
furnished to <strong>all</strong>ow the user to<br />
exchange custom-built panel<br />
segments based on production<br />
requirements. When us<strong>in</strong>g this<br />
type of segment, refer to the<br />
requirements of Table O-10<br />
(see page 5).<br />
8 | EX-AL BARRIER & PERIMETER GUARDING
MOUNTS<br />
Various mounts are available which attach the barrier guards to the mach<strong>in</strong>e. (Please see illustrations throughout this catalog.) The mounts are<br />
furnished with <strong>all</strong> required comp<strong>one</strong>nts to mount and fasten the barrier guard to the mach<strong>in</strong>e.<br />
SINGLE-PANEL BARRIER GUARD MOUNTS<br />
DFM (Direct Frame Mount) Assembly<br />
Part No. FKT-683 (Black Steel) - Mount)<br />
Park No. FKT-656 (Alum<strong>in</strong>um) - Guard or Post Mount)<br />
The DFM (direct frame mount)<br />
assembly (set of four with fasteners)<br />
attaches a guard panel to a flat<br />
surface on the mach<strong>in</strong>e. The slotted<br />
hook-mount <strong>all</strong>ows the guard panel<br />
to be lifted off the mach<strong>in</strong>e without<br />
remov<strong>in</strong>g the fastener.<br />
IFM (Inside Frame Mount) Assembly<br />
Part No. FKT-684–Two-Hole<br />
Part No. FKT-690–Four-Hole<br />
The IFM (<strong>in</strong>side frame mount) assembly (set of four with fasteners)<br />
has a right angle bracket that fastens a guard panel to the <strong>in</strong>side<br />
column or frame of the mach<strong>in</strong>e. The IFM assembly is used when<br />
there are obstructions on the outside frame (face) of the mach<strong>in</strong>e, or<br />
for conveniently locat<strong>in</strong>g the guard between the mach<strong>in</strong>e frame, closer<br />
to the hazard. Depend<strong>in</strong>g on the size of the panel, either a two-hole<br />
(under 10” square) or four-hole (over 10” square) IFM assembly will<br />
be provided.<br />
EM (Extended Mount) Assembly<br />
Part No. FKT-608–3”<br />
Part No. FKT-609–5”<br />
Part No. FKT-610–7”<br />
EM-24 (Extended Mount) Assembly<br />
Part No. FKT-695<br />
The EM (extended mount) assembly<br />
(set of four with fasteners) connects<br />
a panel up to 3”, 5”, or 7” out from<br />
the mach<strong>in</strong>e frame. The extended<br />
mount is ideal for mach<strong>in</strong>es that<br />
have obstructions, an irregular<br />
mount<strong>in</strong>g surface, or requirements<br />
for the panel to be mounted at a<br />
specific location.<br />
This assembly consists of a set of<br />
four with fasteners. It connects a<br />
panel 8” to 24” out from the mach<strong>in</strong>e<br />
frame. The EM-24 mount is ideal for<br />
mount<strong>in</strong>g a panel to mach<strong>in</strong>es with<br />
obstructions that require a panel to<br />
be mounted at a greater distance<br />
than the EM described above. DFM<br />
(direct frame mounts) are <strong>in</strong>cluded<br />
with this assembly.<br />
Two-Hole<br />
Assembly<br />
HM (H<strong>in</strong>ged Mount) Assembly<br />
Part No. FKT-686<br />
Four-Hole<br />
Assembly<br />
The HM (h<strong>in</strong>ged mount) assembly consists of two h<strong>in</strong>ges, <strong>one</strong> latch, two<br />
1” x 1” pieces of extrusion (length determ<strong>in</strong>ed by dimensions furnished),<br />
and fasteners. DFM (direct frame mount), IFM (<strong>in</strong>side frame mount), or<br />
EM (extended mount) assemblies must be used with this assembly to<br />
connect the h<strong>in</strong>ged hardware and panel to the frame of a mach<strong>in</strong>e.<br />
EX-AL BARRIER & PERIMETER GUARDING | 9
MOUNTS (CONTINUED)<br />
MOUNTS FOR MULTI-PANEL BARRIER GUARDS<br />
The follow<strong>in</strong>g assemblies are usu<strong>all</strong>y applied to gap-type mach<strong>in</strong>es. They are used when the side panels of XL-2 through XL-6 guards need to be<br />
h<strong>in</strong>ged to the left and right. This h<strong>in</strong>ged feature may be necessary when chang<strong>in</strong>g dies, mak<strong>in</strong>g tool<strong>in</strong>g adjustments, or free<strong>in</strong>g jammed workpieces.<br />
Side Frame Mount (SFM) Assembly<br />
Part No. FKT-682<br />
The SFM (side frame mount) assembly <strong>in</strong>cludes four right-angle<br />
brackets (either two-hole or four-hole brackets depend<strong>in</strong>g on the size<br />
of the panel) that connect a guard to a smooth, upright surface of a<br />
mach<strong>in</strong>e. Additional parts for the assembly <strong>in</strong>clude four h<strong>in</strong>ges, two 1”<br />
x 2” extrusions, and other hardware.<br />
SFM-3, -5, or -7 (Side Frame Mount) Assembly<br />
Part No. FKT-677 SFM-3<br />
Part No. FKT-678 SFM-5<br />
Part No. FKT-679 SFM-7<br />
The SFM-3, -5 or -7 (side frame mount) assembly <strong>in</strong>cludes four<br />
extended mount assemblies that can be 3”, 5”, or 7” long. This<br />
mount is ideal for mount<strong>in</strong>g a guard to a mach<strong>in</strong>e with an irregular<br />
surface, or to avoid obstructions at the mount<strong>in</strong>g po<strong>in</strong>t. Additional<br />
parts for the assembly <strong>in</strong>clude four h<strong>in</strong>ges, two 1” x 2” extrusions,<br />
and other hardware.<br />
SFM-24 (Side Frame Mount) Assembly<br />
Part No. FKT-680<br />
The SFM-24 (side frame mount) assembly connects a barrier guard 8”<br />
to 24” out from the sides of the mach<strong>in</strong>e. This SFM-24 mount is ideal<br />
for mount<strong>in</strong>g a guard to a mach<strong>in</strong>e when the guard must extend out<br />
from the mach<strong>in</strong>e frame. Additional parts for the assembly <strong>in</strong>clude four<br />
h<strong>in</strong>ges, two 1” x 2” extrusions, and other hardware.<br />
FFM (Front Frame Mount) Assembly<br />
Part No. FKT-681<br />
The FFM (front frame mount) assembly connects a barrier guard to<br />
the throat portion of a C-frame mach<strong>in</strong>e us<strong>in</strong>g right angle brackets.<br />
This mount is applied when a multi-panel guard cannot be attached to<br />
the side of the mach<strong>in</strong>e us<strong>in</strong>g the SFM, SFM-3, -5, or -7, or the SFM-<br />
24 mounts described on this page. Additional parts for the assembly<br />
<strong>in</strong>clude four h<strong>in</strong>ges, two 1” x 2” extrusions, and other hardware.<br />
10 | EX-AL BARRIER & PERIMETER GUARDING
MULTI-PANEL XL-2 THROUGH XL-6<br />
Example of a Multi-Panel Barrier Guard on a Power Press<br />
Multi-panel barrier guards can be furnished for various mach<strong>in</strong>es<br />
<strong>in</strong>clud<strong>in</strong>g gap or C-frame presses that require barrier guards as the<br />
method of safeguard<strong>in</strong>g. Ideal applications <strong>in</strong>clude manual strip-feed<strong>in</strong>g<br />
operations <strong>in</strong> s<strong>in</strong>gle stroke or for automatic-feed<strong>in</strong>g operations <strong>in</strong> the<br />
cont<strong>in</strong>uous or automatic s<strong>in</strong>gle stroke modes of operation. The guards<br />
are custom-designed for each application to meet the requirements<br />
of OSHA (Occupational Safety and Health Adm<strong>in</strong>istration) and ANSI<br />
(American National Standards Institute). Each guard consists of three<br />
comp<strong>one</strong>nts: panels, panel segments (if required), and mounts.<br />
The panels of these barrier guards are available <strong>in</strong> nonadjustable<br />
(NAP) and adjustable (AP1, AP2, AP3, AP4, AP5, and API) frame<br />
construction. Various panel segments can be positi<strong>one</strong>d <strong>in</strong>to a<br />
nonadjustable panel to meet specific requirements. Please see page<br />
8 for details on panel segments.<br />
Norm<strong>all</strong>y, panels with adjustable hairp<strong>in</strong>s do not have panel segments<br />
unless the operator requires visibility <strong>in</strong>to the po<strong>in</strong>t of operation.Mounts<br />
are used to attach guards to the mach<strong>in</strong>e.<br />
Norm<strong>all</strong>y, the framework of the panels is constructed of 1” x 2” square<br />
extruded alum<strong>in</strong>um. Larger frame extrusions are available (see page<br />
27 for choices). Standard panels can be furnished with black or yellow<br />
mesh (1/2” sq. 16-gauge or 1” sq. 12-gauge), or 3⁄/16”-thick clear<br />
polycarbonate. Panels are available with adjustable, black-oxidized<br />
steel hairp<strong>in</strong>s <strong>in</strong> the lower portion of the panel. These hairp<strong>in</strong>s provide<br />
adjustability for strip or coil feed<strong>in</strong>g, or for go<strong>in</strong>g around obstructions on<br />
the mach<strong>in</strong>e. The adjustable hairp<strong>in</strong>s are secured to the panel frame<br />
with clips, T-nuts, and socket-head cap screws.<br />
EX-AL BARRIER & PERIMETER GUARDING | 11
MULTI-PANEL XL-2 THROUGH XL-6 (CONTINUED)<br />
This page illustrates guards that are usu<strong>all</strong>y applied to C-frame mach<strong>in</strong>es. The two-panel and four-panel barrier guards cannot be considered a<br />
safeguard. They are to be used with safeguard<strong>in</strong>g devices such as two-hand trip or control, presence-sens<strong>in</strong>g devices, pullbacks, or restra<strong>in</strong>ts. They<br />
are designed to protect the sides of the po<strong>in</strong>t of operation while the front is open for feed<strong>in</strong>g and remov<strong>in</strong>g of workpieces.<br />
The three- and five-panel barrier guards are designed to meet the requirements of a po<strong>in</strong>t-of-operation guard as detailed on pages 5 and 6 of this<br />
catalog. The rear of the mach<strong>in</strong>e must also be guarded when apply<strong>in</strong>g front and side guards. A roof and/or floor section is required if the guard is<br />
designed and applied where some<strong>one</strong> could reach over or under it.<br />
Model XL-2—This two-panel guard can be constructed from any of<br />
the panels shown on pages 7 and 8. The mounts can be furnished<br />
as illustrated on pages 9 and 10. The barrier shown has two panels<br />
constructed of mesh and hairp<strong>in</strong>s with SFM-5 mounts.<br />
Model XL-3—This three-panel guard shows the same two panels as<br />
the XL-2 with the addition of a front panel made of polycarbonate and<br />
adjustable hairp<strong>in</strong>s.<br />
Model XL-4—This four-panel barrier guard is similar to the XL-2<br />
shown above with the addition of right rear and left rear panels. The<br />
XL-4 barrier guard is used when the guard must extend out from the<br />
mach<strong>in</strong>e frame to provide clearance for the mach<strong>in</strong>e bed or tool<strong>in</strong>g. This<br />
guard is constructed of polycarbonate and mesh panels and <strong>in</strong>cludes<br />
feed<strong>in</strong>g and adjustable segments. SFM-24 and FFM mounts are shown.<br />
Model XL-5—This five-panel guard shows the same four panels as the<br />
XL-4 with the addition of a front panel. This panel is made of mesh and<br />
<strong>in</strong>cludes a polycarbonate segment.<br />
Note: Model XL-6 (not shown) consists of two XL-3 barrier guards placed<br />
on top of each other with a gap <strong>in</strong> between them to <strong>all</strong>ow for large sheet<br />
metal feed<strong>in</strong>g.<br />
12 | EX-AL BARRIER & PERIMETER GUARDING
MEASURING INSTRUCTIONS FOR MULTI-PANEL MODELS XL-2 THROUGH XL-6 USED ON<br />
MECHANICAL OR HYDRAULIC POWER PRESSES WITH C-FRAME CONSTRUCTION<br />
The follow<strong>in</strong>g <strong>in</strong>structions are for measur<strong>in</strong>g XL-2 through XL-6 barrier<br />
guards. The basic <strong>in</strong>formation necessary to quote or fabricate any of<br />
the listed guards is the frame type, nonadjustable area construction,<br />
height and length of panel(s), panel segments (if required), and mounts<br />
to attach the guards to the mach<strong>in</strong>e.<br />
The follow<strong>in</strong>g <strong>in</strong>structions are purposely kept as simple as possible to<br />
avoid long explanations of the many variations available.<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated.<br />
2. Check appropriate guard model number.<br />
XL-2 = 2 panel<br />
XL-3 = 3 panel<br />
XL-4 = 4 panel<br />
XL-5 = 5 panel<br />
XL-6 = 6 panel (gap style)<br />
(If any panels are not required, cross them out <strong>in</strong> the<br />
panel chart.)<br />
3. Measure and record the bolster width and depth.<br />
4. Measure web width of frame, if the barrier guard is to be<br />
mounted to the front of the frame beh<strong>in</strong>d the bolster plate.<br />
5. Measure and record the outside width of the press frame<br />
beh<strong>in</strong>d the bolster plate.<br />
6. Indicate desired position of each panel relative to the bolster.<br />
Draw<strong>in</strong>g shows panels extended from the bolster. If panels<br />
should be <strong>in</strong>bound, enter m<strong>in</strong>us (-) dimensions, or on the<br />
bolster, enter zero.<br />
7. Measure and record the distance from the mount<strong>in</strong>g po<strong>in</strong>t of<br />
the guard on the mach<strong>in</strong>e to the rear of the bolster, or back<br />
of press throat if us<strong>in</strong>g FFM mounts.<br />
8. Measure and record the clearance from the flywheel cover to<br />
the top of the bolster. This dimension could affect the panel<br />
height if the panel is to be swung under the flywheel cover.<br />
9. Measure and record the feedl<strong>in</strong>e depth if apply<strong>in</strong>g a gap type<br />
guard (XL-6).<br />
10. Enter the m<strong>in</strong>imum and maximum feedl<strong>in</strong>e height if apply<strong>in</strong>g<br />
adjustable hairp<strong>in</strong>s or <strong>in</strong>cl<strong>in</strong>able panels.<br />
11. Indicate mounts required.<br />
SFM Side Frame Mount<br />
SFM-7 Side Frame Mount up to 7”<br />
SFM-24 Side Frame Mount up to 24”<br />
FFM Front Frame Mount<br />
12. Indicate frame type for each panel.<br />
NAP Nonadjustable Panel<br />
AP1 Adjustable Panel (1/2 frame)<br />
AP2 Adjustable Panel (5/8 frame)<br />
AP3 Adjustable Panel (3/4 frame)<br />
AP4 Adjustable Panel (Full frame)<br />
AP5 Adjustable Panel (Full frame)<br />
API Adjustable Panel (Incl<strong>in</strong>able)<br />
If adjustability is not required at the left and right front corners of the<br />
barrier guard, use AP3 panels for L and R, and AP1 panel for F for<br />
quicker removal of F panel.<br />
If adjustability is required at the left and right front corners of the barrier<br />
guard, use AP2 panels for L and R, and AP1 panel for F and <strong>in</strong>dicate <strong>in</strong><br />
Notes section on the form. All panels (L, F, R) should have the same size<br />
nonadjustable area and it should be <strong>in</strong> the same position on <strong>all</strong> panels.<br />
13. Indicate the construction of the nonadjustable area for<br />
each panel.<br />
B<br />
B1<br />
Y<br />
Y1<br />
PC<br />
1/2” Sq. Black Mesh (16 gauge)<br />
1” Sq. Black Mesh (12 gauge)<br />
1/2” Sq. Yellow Mesh (16 gauge)<br />
1” Sq. Yellow Mesh (12 gauge)<br />
Polycarbonate (3/16”-thick)<br />
14. Indicate height of each panel.<br />
15. Indicate length of each panel.<br />
16. Indicate panel Segment type, height, length, and if<br />
h<strong>in</strong>ged or nonh<strong>in</strong>ged.<br />
FS<br />
AS<br />
PCS<br />
ES<br />
Feed<strong>in</strong>g Segment<br />
Adjustable Segment<br />
Polycarbonate Segment<br />
Empty Segment<br />
17. Indicate which panel(s) require an <strong>in</strong>terlock switch and if<br />
switch is lock<strong>in</strong>g or nonlock<strong>in</strong>g.<br />
18. Indicate if F panel needs to be h<strong>in</strong>ged (L or R).<br />
19. Indicate if hairp<strong>in</strong>s are required <strong>in</strong> place of RR or LR<br />
panel. The number of hairp<strong>in</strong>s supplied will be<br />
determ<strong>in</strong>ed by the height of the L or R panel.<br />
20. Indicate if roof section(s) are required. Provide height<br />
and length.<br />
21. Indicate if floor section(s) are required. Provide height<br />
and length.<br />
EX-AL BARRIER & PERIMETER GUARDING | 13
MEASUREMENT FORM FOR MULTI-PANEL MODELS XL-2 THROUGH XL-6<br />
5795 Logistics Parkway • <strong>Rockford</strong>, IL 61109<br />
Toll-Free: 1-800-922-7533 • Ph<strong>one</strong>: 815-874-7891 • Fax: 815-874-6144<br />
Web site: www.rockfordsystems.com • E-mail: sales@rockfordsystems.com<br />
Multi-panel guards—XL-2, XL-3, XL-4, XL-5, XL-6<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
(See previous page for <strong>in</strong>structions.)<br />
Company______________________________________________ Address___________________________________________<br />
City__________________________________________________ State___________________ Zip________________________<br />
Attention______________________________________________ Rep._____________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No.________________________________ Mach<strong>in</strong>e No.________________________________________<br />
Measured By:____________________________________________________________________________________________<br />
Note: If rear of mach<strong>in</strong>e requires guard<strong>in</strong>g, use S<strong>in</strong>gle-Panel Model XL-1 measurement form on page 19.<br />
4<br />
LR<br />
REAR<br />
5<br />
RR<br />
FLYWHEEL<br />
COVER<br />
9<br />
7<br />
7<br />
8<br />
10<br />
Bolster<br />
Panel<br />
L<br />
3 3<br />
R<br />
Panel<br />
Feed Depth<br />
Bolster<br />
Bed<br />
6<br />
Bed<br />
Max. Feedl<strong>in</strong>e Ht.<br />
M<strong>in</strong>. Feedl<strong>in</strong>e Ht.<br />
Notes:<br />
2<br />
11<br />
17<br />
Left Side<br />
XL-2<br />
XL-4<br />
" 10<br />
" 10<br />
MODEL<br />
XL-3<br />
XL-5<br />
MOUNTS<br />
6<br />
6<br />
Bottom of Panel<br />
to Bolster (usu<strong>all</strong>y<br />
ʻ0ʼ <strong>in</strong>ches); if below<br />
bolster, enter <strong>in</strong>ches<br />
SFM<br />
SFM-3, -5, or -7<br />
(Circle <strong>one</strong>)<br />
SFM-24<br />
FFM<br />
XL-6<br />
ELEC. INTERLOCK<br />
Lock<strong>in</strong>g<br />
Nonlock<strong>in</strong>g<br />
L<br />
(Length)<br />
H<br />
(Height)<br />
ROOF SECTION<br />
Panel H L<br />
L<br />
F<br />
R<br />
Right Side<br />
PANEL CHART<br />
Panel LR L F R RR<br />
Frame Type—NAP, AP1,<br />
AP2, AP3, AP4, AP5, or API<br />
Nonadjust. Area Const.<br />
B, B1, Y, Y1, PC<br />
H<br />
(Height)<br />
L<br />
(Length)<br />
Panel Segment Type<br />
FS, AS, PCS, or ES<br />
H<br />
(Height)<br />
L<br />
(Length)<br />
H (H<strong>in</strong>ged)<br />
NH (Nonh<strong>in</strong>ged)<br />
Electrical Interlock<br />
Y (Yes) N (No)<br />
F Panel Only<br />
H<strong>in</strong>ged L or R<br />
6<br />
Hairp<strong>in</strong>s<br />
(In place of LR or RR)<br />
F<br />
Panel<br />
FRONT<br />
20<br />
12 12 12 12 12<br />
13 13 13 13 13<br />
14 14 14 14 14<br />
15 15 15 15 15<br />
16 16 16 16 16<br />
19<br />
17 17 17<br />
18<br />
21<br />
19<br />
FLOOR SECTION<br />
Panel H L<br />
L<br />
F<br />
R<br />
14 | EX-AL BARRIER & PERIMETER GUARDING
FRONT MOUNT XL-1 THROUGH XL-7<br />
Extended Mount<br />
Assembly<br />
Roof Section<br />
Front Mount<br />
Adjustable Lower Section<br />
of Panel<br />
Front Frame Mount<br />
Nonadjustable Panel<br />
With H<strong>in</strong>ged and Latched<br />
Polycarbonate Door<br />
Floor Section<br />
Example of a Seven-Panel Guard (XL-7) on a Gap-Type Mach<strong>in</strong>e<br />
The front-mount guard<strong>in</strong>g system is applied to mach<strong>in</strong>es that usu<strong>all</strong>y<br />
have a gap-type construction with comp<strong>one</strong>nts that extend to the right<br />
or left of the po<strong>in</strong>t of operation. These comp<strong>one</strong>nts can be dies, tool<strong>in</strong>g,<br />
feeds, scrap choppers, etc. The front-mount extrusion provides support<br />
for the guard across the front of the mach<strong>in</strong>e. The front portion of the<br />
mach<strong>in</strong>e can be safeguarded with <strong>one</strong>, two, or three panels (see the<br />
measurement form on page 17 for the LF, F, and RF panels).<br />
If panels need to be removed or h<strong>in</strong>ged, please <strong>in</strong>dicate how they<br />
should be attached. When measur<strong>in</strong>g for a front-mount guard and the<br />
construction of the panel is determ<strong>in</strong>ed, a roof and/or floor section is<br />
required if some<strong>one</strong> can reach over or under the guard.<br />
The panel length will be determ<strong>in</strong>ed at the factory based on the<br />
<strong>in</strong>formation provided on the measurement form.<br />
EX-AL BARRIER & PERIMETER GUARDING | 15
MEASURING INSTRUCTIONS FOR FRONT-MOUNT MODELS XL-1 FM THROUGH XL-7 FM<br />
The follow<strong>in</strong>g <strong>in</strong>structions are for measur<strong>in</strong>g XL-1 through XL-7 front<br />
mount barrier guards. The basic <strong>in</strong>formation necessary to quote or<br />
fabricate any of the listed guards is the frame type, nonadjustable<br />
area construction, height of panel(s), panel segments (if required), and<br />
mounts to attach the guards to the mach<strong>in</strong>e. The length of <strong>all</strong> panels<br />
will be determ<strong>in</strong>ed by <strong>Rockford</strong> <strong>Systems</strong>.<br />
The follow<strong>in</strong>g <strong>in</strong>structions are purposely kept as simple as possible to<br />
avoid long explanations of the many variations available.<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated.<br />
2. Check appropriate guard model number.<br />
XL-1 = 1 panel XL-5 = 5 panel<br />
XL-2 = 2 panel XL-6 = 6 panel<br />
XL-3 = 3 panel XL-7 = 7 panel<br />
XL-4 = 4 panel<br />
(If any panels are not required, cross them out <strong>in</strong> the panel<br />
chart.) Indicate how front mount will be attached to the<br />
press: direct, extended, or tie-bar boss.<br />
3. Measure and record the bolster width and depth.<br />
4. Measure and record the distance from the edge of the<br />
bolster to the outside of the frame of the mach<strong>in</strong>e<br />
on both sides.<br />
5. Measure and record the distance from the mount<strong>in</strong>g po<strong>in</strong>t<br />
of the guard on the frame of the mach<strong>in</strong>e to the rear of the<br />
bolster.<br />
6. Indicate desired position of L, F, and R panels relative<br />
to the bolster. Draw<strong>in</strong>g shows panels outbound of the<br />
bolster. If panels should be <strong>in</strong>bound, enter m<strong>in</strong>us (-)<br />
dimensions, or on the bolster, enter zero.<br />
7. Indicate the distance of the LR and RR panels to the<br />
mount<strong>in</strong>g po<strong>in</strong>t on the frame of the mach<strong>in</strong>e.<br />
8. Enter the center to center distance of tie-bar bosses or<br />
extended mount locations and distance from the right<br />
edge of the bolster to the center of the right tie-bar<br />
boss or right extended mount.<br />
9. Measure and record the distance from the edge of the bolster<br />
to the right edge of the LF panel and the left edge of the<br />
RF panel. If the edge of the panel(s) is on the bolster, enter<br />
zero. If there is no LF or RF panel(s), put an “X” <strong>in</strong> the square.<br />
10. Enter the m<strong>in</strong>imum and maximum feedl<strong>in</strong>e heights.<br />
11. Indicate mounts required for LR, L, R, or RR panels.<br />
SFM Side Frame Mount<br />
SFM-7 Side Frame Mount up to 7”<br />
SFM-24 Side Frame Mount up to 24”<br />
FFM Front Frame Mount<br />
12. Measure and record the distance from the top of the Front<br />
Mount to the top of the bolster.<br />
13. Enter the distance between the bottom of the front panel(s)<br />
to the top of the Front Mount.<br />
14. Indicate frame type for each panel.<br />
NAP Nonadjustable Panel<br />
AP1 Adjustable Panel ( 1 /2 frame)<br />
AP2 Adjustable Panel ( 5 /8 frame)<br />
AP3 Adjustable Panel ( 3 /4 frame)<br />
AP4 Adjustable Panel (Full frame)<br />
AP5 Adjustable Panel (Full frame)<br />
API Adjustable Panel (Incl<strong>in</strong>able)<br />
15. Indicate the construction of the nonadjustable area for<br />
each panel.<br />
B 1 /2” Sq. Black Mesh (16 gauge)<br />
B1 1” Sq. Black Mesh (12 gauge)<br />
Y 1 /2” Sq. Yellow Mesh (16 gauge)<br />
Y1 1” Sq. Yellow Mesh (12 gauge)<br />
PC Polycarbonate ( 3 /16”-thick)<br />
16. Indicate height of each panel.<br />
17. Indicate length of each panel. <strong>Rockford</strong> <strong>Systems</strong> will<br />
determ<strong>in</strong>e length(s) based on other dimensions<br />
provided.<br />
18. Indicate panel segment type, height, length, and if h<strong>in</strong>ged<br />
or nonh<strong>in</strong>ged, if required.<br />
FS Feed<strong>in</strong>g Segment<br />
AS Adjustable Segment<br />
PCS Polycarbonate Segment<br />
ES Empty Segment<br />
19. Indicate which panel(s) require an <strong>in</strong>terlock switch and if<br />
switch is lock<strong>in</strong>g or nonlock<strong>in</strong>g.<br />
20. Indicate if L, LF, F, RF, or R panels need to be h<strong>in</strong>ged<br />
(L or R).<br />
21. Indicate if hairp<strong>in</strong>s are required <strong>in</strong> place of LR or RR panel.<br />
The number of hairp<strong>in</strong>s supplied will be determ<strong>in</strong>ed<br />
by the height of the L or R panel.<br />
22. Indicate if roof section(s) are required.<br />
Provide height and length.<br />
23. Indicate if floor section(s) are required.<br />
Provide height and length.<br />
16 | EX-AL BARRIER & PERIMETER GUARDING
MEASUREMENT FORM FOR FRONT MOUNT MODELS XL-1 FM THROUGH XL-7 FM<br />
7<br />
5795 Logistics Parkway • <strong>Rockford</strong>, IL 61109<br />
Toll-Free: 1-800-922-7533 • Ph<strong>one</strong>: 815-874-7891 • Fax: 815-874-6144<br />
Web site: www.rockfordsystems.com • E-mail: sales@rockfordsystems.com<br />
FRONT MOUNT MODELS—XL-1, XL-2, XL-3, XL-4, XL-5, XL-6, XL-7<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
(See previous page for <strong>in</strong>structions.)<br />
Company______________________________________________ Address___________________________________________<br />
City__________________________________________________ State___________________ Zip________________________<br />
Attention______________________________________________ Rep._____________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No.________________________________ Mach<strong>in</strong>e No.________________________________________<br />
Measured By:____________________________________________________________________________________________<br />
Note: If rear of mach<strong>in</strong>e requires guard<strong>in</strong>g, use S<strong>in</strong>gle-Panel Model XL-1 measurement form on page 19.<br />
7<br />
LR<br />
PANEL<br />
RR<br />
PANEL<br />
Notes:<br />
2<br />
2<br />
11<br />
L<br />
1<br />
PANEL<br />
Direct<br />
Extended<br />
MOUNTS<br />
FOR LR, L, R, RR<br />
SFM<br />
SFM-3, -5, or -7<br />
SFM-24<br />
FFM<br />
4 4<br />
5 5<br />
6<br />
3<br />
6<br />
9 8<br />
9<br />
“X” out if no LF<br />
panel<br />
LF F RF<br />
PANEL<br />
MODEL XL-__ FM<br />
2<br />
5 6<br />
3<br />
FRONT-MOUNT TYPE<br />
(Circle One)<br />
7<br />
Tie-Bar<br />
Boss<br />
19 ELEC. INTERLOCK<br />
Lock<strong>in</strong>g<br />
Nonlock<strong>in</strong>g<br />
3<br />
4<br />
6<br />
PANEL<br />
L<br />
(Length)<br />
H<br />
(Height)<br />
PANEL CHART<br />
Max. Feedl<strong>in</strong>e Ht.<br />
M<strong>in</strong>. Feedl<strong>in</strong>e Ht.<br />
Panel LR L LF F RF R RR<br />
Frame Type NAP, AP1<br />
AP2, AP3, AP4, AP5, or API<br />
Nonadjust. Area Const.<br />
B, B1, Y, Y1, PC<br />
L<br />
(Length)<br />
8<br />
H<br />
(Height)<br />
RSI To<br />
Complete<br />
Panel Segment Type<br />
FS, AS, PCS, or ES<br />
H<br />
(Height)<br />
L<br />
(Length)<br />
H (H<strong>in</strong>ged)<br />
NH (Nonh<strong>in</strong>ged)<br />
Electrical Interlock<br />
Y (Yes) N (No)<br />
H<strong>in</strong>ged L or R<br />
Hairp<strong>in</strong>s<br />
(In place of LR or RR)<br />
PANEL<br />
PANEL<br />
“X” out if no RF<br />
panel<br />
14<br />
15<br />
16<br />
17<br />
18<br />
R<br />
12<br />
BOLSTER<br />
PRESS<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
PANEL<br />
FRONT<br />
MOUNT<br />
ROOF SECTION<br />
Panel H L<br />
L<br />
LF<br />
F<br />
RF<br />
R<br />
13<br />
TOP OF<br />
FRONT<br />
MOUNT<br />
20 20 20 20 20<br />
10<br />
10<br />
SLIDE<br />
BOLSTER<br />
BED<br />
21 21<br />
22 23<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
DIE<br />
FLOOR SECTION<br />
Panel H L<br />
L<br />
LF<br />
F<br />
RF<br />
R<br />
"<br />
"<br />
10<br />
10<br />
14<br />
15<br />
16<br />
17<br />
18<br />
EX-AL BARRIER & PERIMETER GUARDING | 17
SINGLE PANEL MODEL XL-1 OR DOUBLE PANEL MODEL XL-2<br />
The s<strong>in</strong>gle-panel barrier guard can be furnished for any mach<strong>in</strong>e that<br />
requires simple, <strong>one</strong>-sided guard<strong>in</strong>g. The panel can be custom designed<br />
for each application. In some applications, it is more convenient to have<br />
a double panel (split guard) with two panels <strong>in</strong> l<strong>in</strong>e with each other that<br />
are h<strong>in</strong>ged and latched. Applications <strong>in</strong>clude areas of the mach<strong>in</strong>e not<br />
protected by a light curta<strong>in</strong>—front, rear, sides of the mach<strong>in</strong>e, or for<br />
auxiliary guard<strong>in</strong>g.<br />
The framework of the panel is typic<strong>all</strong>y constructed of 1” x 2” square<br />
extruded alum<strong>in</strong>um. The fixed area of the panel is made of black or<br />
yellow mesh ( 1 /2” sq. 16-gauge or 1” sq. 12-gauge), or 3 /16”-thick clear<br />
polycarbonate. It is fastened <strong>in</strong> place for a permanent assembly.<br />
Adjustable, black-oxidized steel hairp<strong>in</strong>s are available for the lower<br />
portion of the panel. These hairp<strong>in</strong>s provide adjustability for strip or<br />
coil feed<strong>in</strong>g, or for go<strong>in</strong>g around obstructions on the mach<strong>in</strong>e. The<br />
adjustable hairp<strong>in</strong>s are secured to the panel frame with hairp<strong>in</strong> clips,<br />
T-nuts, and socket-head cap screws. Various panel segments can also<br />
be positi<strong>one</strong>d <strong>in</strong>to a framed panel to meet specific requirements. Panels<br />
with adjustable hairp<strong>in</strong>s norm<strong>all</strong>y do not have a panel segment unless<br />
the operator requires visibility <strong>in</strong>to the po<strong>in</strong>t of operation.<br />
A s<strong>in</strong>gle panel can be attached to the mach<strong>in</strong>e us<strong>in</strong>g any of the mounts<br />
described on the next page.<br />
S<strong>in</strong>gle-Panel Barrier Guard With Notched Upper Left<br />
Corner Mounted on Back of a Mach<strong>in</strong>e<br />
Double Panel Model XL-2 With Black Mesh,<br />
Heavy H<strong>in</strong>ge Assembly and Door Handles<br />
S<strong>in</strong>gle Panel Model XL-1 With Black<br />
Mesh and Direct Frame Mounts<br />
18 | EX-AL BARRIER & PERIMETER GUARDING
MEASUREMENT FORM FOR SINGLE PANEL MODEL XL-1 OR DOUBLE PANEL XL-2<br />
5795 Logistics Parkway • <strong>Rockford</strong>, IL 61109<br />
Toll-Free: 1-800-922-7533 • Ph<strong>one</strong>: 815-874-7891 • Fax: 815-874-6144<br />
sales@rockfordsystems.com • www.rockfordsystems.com<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
Company______________________________________________ Address___________________________________________<br />
City__________________________________________________ State___________________ Zip________________________<br />
Attention______________________________________________ Rep._____________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No.________________________________ Mach<strong>in</strong>e No.________________________________________<br />
Measured By:____________________________________________________________________________________________<br />
DFM (Direct Frame Mount) Assembly<br />
Mount<strong>in</strong>g center distance will be approximately 2”<br />
greater than the over<strong>all</strong> panel length.<br />
IFM (Inside Frame) Mount Assembly<br />
Panel length will be approximately the <strong>in</strong>side<br />
mach<strong>in</strong>e frame dimension.<br />
EM (Extended Mount) Assembly<br />
Mount<strong>in</strong>g center distance will be approximately 1”<br />
greater than the over<strong>all</strong> panel length.<br />
HM (H<strong>in</strong>ged Mount) Assembly<br />
If h<strong>in</strong>g<strong>in</strong>g is required, order this HM (h<strong>in</strong>ge mount)<br />
assembly along with <strong>one</strong> of the follow<strong>in</strong>g: DFM,<br />
IFM, or EM.<br />
If Direct Frame H<strong>in</strong>ged Mounts are used, the mount<strong>in</strong>g center<br />
distance will be approximately 4” greater than the over<strong>all</strong> panel length.<br />
If Inside Frame H<strong>in</strong>ged Mounts are used, the panel length will be<br />
approximately 2” less than the <strong>in</strong>side mach<strong>in</strong>e frame dimension.<br />
If Extended H<strong>in</strong>ged Mounts are used, the mount<strong>in</strong>g center distance<br />
will be approximately 3” greater than the over<strong>all</strong> panel length.<br />
Identify, dimension and locate desired panel segments or panel cutouts, if<br />
required, by sketch<strong>in</strong>g on blank panel draw<strong>in</strong>g below.<br />
6<br />
Bolster<br />
Level<br />
6<br />
Panel Ht.<br />
2<br />
Note: If the guard will be divided <strong>in</strong>to two h<strong>in</strong>ged and latched panels, <strong>in</strong>dicate<br />
above so the proper XL-2 barrier guard is furnished.<br />
7<br />
Mount<strong>in</strong>g Center<br />
3<br />
Distance (MCD)<br />
6<br />
6<br />
MEASURING INSTRUCTIONS<br />
This s<strong>in</strong>gle panel Model XL-1 or double panel Model XL-2 measurement<br />
form <strong>in</strong>cludes draw<strong>in</strong>gs of mount<strong>in</strong>g situations. By enter<strong>in</strong>g<br />
dimensions and select<strong>in</strong>g the appropriate mounts, the barrier guard<br />
will mount easily to the mach<strong>in</strong>e.<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated above.<br />
2. Enter the MCD (mount<strong>in</strong>g center distance).<br />
3. Enter height and panel frame construction.<br />
4. Enter panel construction for nonadjustable area.<br />
5. Select appropriate mounts and check box(es) provided.<br />
If extended mounts are selected, check the distance the panel<br />
must be out from the mount<strong>in</strong>g surface. Hollow studs will<br />
accommodate up to 7 <strong>in</strong>ches.<br />
6. Enter appropriate location of <strong>all</strong> mounts, especi<strong>all</strong>y if above and<br />
below the panel.<br />
7. Enter panel segment location <strong>in</strong> panel (if applicable) and select<br />
type of segment.<br />
8. Check type of electrical <strong>in</strong>terlock switch, if any.<br />
3. Panel Frame Construction (select <strong>one</strong>)<br />
Nonadjustable (NAP)<br />
Adjustable (Full Frame)AP4<br />
Adjustable ( 1 ⁄2 Frame) AP1 Adjustable (Full Frame)AP5<br />
Adjustable ( 5 ⁄8 Frame) AP2 Adjustable (Incl<strong>in</strong>able) API<br />
Adjustable ( 3 ⁄4 Frame) AP3<br />
4. Nonadjustable Area Construction (select <strong>one</strong>)<br />
1<br />
⁄2” Black Mesh 1<br />
⁄2” Yellow Mesh Polycarbonate<br />
1” Black Mesh 1” Yellow Mesh<br />
5. Mounts and Connectors<br />
• Select and enter the appropriate <strong>in</strong>formation<br />
Direct Frame Mount (DFM)<br />
Inside Frame Mount (IFM)<br />
Hollow Studs (check <strong>one</strong>) 3” 5” 7”<br />
H<strong>in</strong>ged Mounts (HM): (plus either DFM, IFM, or EM)<br />
H<strong>in</strong>ged Right (HR) H<strong>in</strong>ged Left (HL)<br />
7. Panel Segment Type<br />
Feed<strong>in</strong>g (FS)<br />
Polycarbonate (PCS)<br />
Adjustable (AS) Empty (ES)<br />
8. Electrical Interlock Switch and Bracket<br />
Lock<strong>in</strong>g Nonlock<strong>in</strong>g N<strong>one</strong><br />
EX-AL BARRIER & PERIMETER GUARDING | 19
SPRING LIFT XL-1 SL OR AIR LIFT XL-1 AL<br />
Solenoids<br />
Rail Extrusion<br />
Air Cyl<strong>in</strong>ders<br />
Nonadjustable Portion of Panel<br />
With Black Mesh<br />
Adjustable Hairp<strong>in</strong>s<br />
Key-Operated<br />
Control Station<br />
Air-Lift Guard XL-1 AL on a Power Press With 1 ⁄2” Square Black Mesh and Hairp<strong>in</strong>s<br />
Lift-type guards, either spr<strong>in</strong>g lift or air lift, can be furnished on<br />
mach<strong>in</strong>es where guards need to be quickly and easily positi<strong>one</strong>d up<br />
out of the way for die setup and ma<strong>in</strong>tenance. These lift-type guards<br />
are custom designed for each application to meet the requirements<br />
of OSHA (Occupational Safety and Health Adm<strong>in</strong>istration) and ANSI<br />
(American National Standards Institute) safety standards.<br />
These barrier guards are available with non-adjustable panels (NAP), or<br />
a variety of adjustable panels (AP3, AP4, AP5, and API). Various panel<br />
segments can be located <strong>in</strong> the nonadjustable area of the panel to<br />
meet specific requirements. Panels with adjustable hairp<strong>in</strong>s do not have<br />
panel segments unless the operator requires visibility <strong>in</strong>to the po<strong>in</strong>t of<br />
operation. The lift-type barrier guards are attached to the mach<strong>in</strong>e by<br />
mount<strong>in</strong>g the rails directly to the mach<strong>in</strong>e frame.<br />
Usu<strong>all</strong>y, the panel framework of the guard is constructed<br />
of a rail and carriage assembly. The nonadjustable portion<br />
of the panel can be furnished with black or yellow mesh ( 1 /2” sq.<br />
16-gauge or 1” sq. 12-gauge), or 3 /16”-thick clear polycarbonate.<br />
A panel can be furnished with adjustable steel hairp<strong>in</strong>s. The hairp<strong>in</strong>s<br />
provide adjustability for strip or coil feed<strong>in</strong>g, or for obstructions on the<br />
mach<strong>in</strong>e. The adjustable hairp<strong>in</strong>s are secured to the panel frame with<br />
clips, T-nuts and socket-head cap screws.<br />
This style of guard can also be furnished for horizontal operation rather<br />
than vertical operation as illustrated. Please contact the factory for<br />
details on horizontal applications.<br />
20 | EX-AL BARRIER & PERIMETER GUARDING
SPRING LIFT XL-1 SL OR AIR LIFT XL-1 AL (CONTINUED)<br />
Spr<strong>in</strong>g-Lift Guard XL-1 SL With 1 ⁄2”<br />
Square Black Mesh, Hairp<strong>in</strong>s, and<br />
Polycarbonate H<strong>in</strong>ged Segment<br />
Mechanical Motor Spr<strong>in</strong>g<br />
Helps Counterbalance the<br />
Spr<strong>in</strong>g-Lift Guard<br />
The spr<strong>in</strong>g-lift and air-lift guards are usu<strong>all</strong>y applied to a mach<strong>in</strong>e that has straight vertical sides with a po<strong>in</strong>t of operation that needs to be guarded.<br />
The mechanical motor spr<strong>in</strong>gs on the spr<strong>in</strong>g-lift guard provide a counterbalance for the weight of the guard. This <strong>all</strong>ows the guard to move upward<br />
from the guarded position to access the po<strong>in</strong>t of operation.<br />
The air-lift guard is usu<strong>all</strong>y applied to larger mach<strong>in</strong>es. With this system, the guards are raised and lowered by air<br />
cyl<strong>in</strong>ders (2) and operat<strong>in</strong>g cables that are attached to the guard.<br />
A separate key-operated selector switch station controls the movement of the guard. This selector switch operates<br />
a solenoid which controls the air cyl<strong>in</strong>ders. The solenoid has a built-<strong>in</strong> check valve to keep the guard from dropp<strong>in</strong>g<br />
if air pressure is lost.<br />
Part No. LLD-240<br />
Key-Operated Selector Switch<br />
Station for Air-Lift Guard<br />
(Included <strong>in</strong> Air-Lift Assembly)<br />
The spr<strong>in</strong>g-lift and air-lift guards are not designed for manual feed<strong>in</strong>g operations. For manual feed<strong>in</strong>g<br />
operations us<strong>in</strong>g gates, please consult the factory.<br />
MOTOR SPRING*<br />
PART NO.<br />
FKT-673<br />
FKT-674<br />
FKT-675<br />
FKT-676<br />
LIFT CAPACITY<br />
20 LB<br />
30 LB<br />
40 LB<br />
50 LB<br />
AIR CYLINDER<br />
PART NO. DESCRIPTION LIFT CAPACITY<br />
FKT-795 24” Lift Air Cyl<strong>in</strong>der 174 lb<br />
FKT-796 36” Lift Air Cyl<strong>in</strong>der 174 lb<br />
FKT-797 48” Lift Air Cyl<strong>in</strong>der 174 lb<br />
*Different spr<strong>in</strong>gs are available <strong>in</strong> sets of two or four to accommodate a variety of panel weights (a m<strong>in</strong>imum of two spr<strong>in</strong>gs required for each panel). Please consult the factory.<br />
EX-AL BARRIER & PERIMETER GUARDING | 21
MEASUREMENT FORM FOR SPRING-LIFT MODEL XL-1 SL AND AIR-LIFT MODEL XL-1 AL<br />
If more than <strong>one</strong> mach<strong>in</strong>e is to be measured, please make copies of this page.<br />
9<br />
7" m<strong>in</strong>.<br />
(AL<br />
only)<br />
Spr<strong>in</strong>g Lift<br />
(SL)<br />
Air Lift<br />
(AL)<br />
5795 Logistics Parkway • <strong>Rockford</strong>, IL 61109<br />
Toll-Free: 1-800-922-7533 • Ph<strong>one</strong>: 815-874-7891 • Fax: 815-874-6144<br />
sales@rockfordsystems.com • www.rockfordsystems.com<br />
Company___________________________________________________ Address ______________________________________<br />
City_______________________________________________________ State______________ Zip _______________________<br />
Attention___________________________________________________ Rep. ________________________________________<br />
Mach<strong>in</strong>e Mfr. and Model No._____________________________________ Mach<strong>in</strong>e No. __________________________________<br />
Measured By: ___________________________________________________________________________________________<br />
Outside Mount<br />
Inside Mount<br />
(see below left)<br />
Identify, dimension & locate any<br />
desired panel segments or panel cutouts<br />
by sketch<strong>in</strong>g on blank panel draw<strong>in</strong>g.<br />
2<br />
Upper Rail Limit<br />
7" m<strong>in</strong>.<br />
(AL<br />
only)<br />
9<br />
8 8<br />
7<br />
Top of<br />
Bolster<br />
6<br />
Lift<br />
Ht.<br />
10<br />
Top of<br />
Bolster<br />
1/2" M<strong>in</strong>. L.<br />
4 Panel Ht.<br />
5<br />
9<br />
Left Side<br />
Notes:<br />
Notes:<br />
H<br />
7" m<strong>in</strong>.<br />
(AL<br />
only)<br />
SIDE GUARDS:<br />
L<br />
10<br />
Left Side<br />
8<br />
Typical<br />
Inside Mt.<br />
Typical<br />
Outside Mt.<br />
Right Side<br />
11 ELECTRICAL INTERLOCK<br />
Lock<strong>in</strong>g<br />
Nonlock<strong>in</strong>g<br />
N<strong>one</strong><br />
H<br />
1/2"<br />
L<br />
Panel Frame Type<br />
NAP, AP3, AP4, AP5, API<br />
Nonadjustable Area Const.<br />
1/2" Sq. Mesh Black Yellow<br />
or<br />
1" Sq. Mesh Black Yellow<br />
If panel length is given, the Rail Support center<br />
distance will be approx. 6" greater than the panel<br />
length. If outside dim. of rails is given, the panel<br />
will be approx. 5" shorter.<br />
MEASURING INSTRUCTIONS<br />
The lift guard measurement form<br />
is designed to be used for the<br />
XL-1 SL and XL-1 AL guards.<br />
1. Fill <strong>in</strong> the complete head<strong>in</strong>g as <strong>in</strong>dicated.<br />
2. Check whether an Outside or Inside<br />
mount is required. (See lower left side of<br />
front view draw<strong>in</strong>g for examples.)<br />
3. Enter outside rail dimension;<br />
or<br />
4. Enter panel length. If outside<br />
rail dimension is specified, it will dictate<br />
the panel length and vice versa.<br />
(See note.)<br />
5. Enter panel height, frame type, and<br />
construction of nonadjustable area.<br />
5<br />
3<br />
5<br />
Polycarbonate<br />
7<br />
Lower Rail Limit<br />
(Enter rail limits<br />
only if restricted)<br />
6. Enter lift height. This will usu<strong>all</strong>y<br />
be the same as panel height.<br />
8<br />
7" m<strong>in</strong>.<br />
(AL<br />
only)<br />
7. Enter upper and lower rail limits, if any.<br />
9<br />
Right Side<br />
8. If outside mounted, enter the appropriate<br />
location of upper and lower mount<strong>in</strong>g<br />
po<strong>in</strong>t for each rail. These dimensions<br />
plus the panel height and lift height will<br />
help determ<strong>in</strong>e the length of the rails.<br />
9. Enter the desired length of the four rail<br />
supports. Allow for any obstructions<br />
(7” m<strong>in</strong>. for air lift only).<br />
10. Enter dimensions and <strong>in</strong>formation for<br />
panel segments and/or side guards as<br />
required.<br />
11. Check type of electrical <strong>in</strong>terlock switch,<br />
if any.<br />
22 | EX-AL BARRIER & PERIMETER GUARDING
INTRODUCTION TO PERIMETER GUARDING SYSTEMS<br />
Perimeter safeguard<strong>in</strong>g is used <strong>in</strong> numerous applications <strong>in</strong><br />
manufactur<strong>in</strong>g: around robots and robot systems, assembly mach<strong>in</strong>es,<br />
packag<strong>in</strong>g mach<strong>in</strong>es, transfer l<strong>in</strong>es, cut-to-length l<strong>in</strong>es, slitt<strong>in</strong>g l<strong>in</strong>es,<br />
etc. It is also applied <strong>in</strong> a diverse number of <strong>in</strong>dustries such as pr<strong>in</strong>t<strong>in</strong>g,<br />
bottl<strong>in</strong>g, food process<strong>in</strong>g, textiles, and petroleum products.<br />
When safeguard<strong>in</strong>g the perimeter area around a mach<strong>in</strong>e or process,<br />
the safeguard<strong>in</strong>g must prevent access to the hazard or cause the<br />
hazard to cease. To protect <strong>in</strong>dividuals that work <strong>in</strong> or around large<br />
work areas, several choices of primary safeguard<strong>in</strong>g are available<br />
under these categories:<br />
1. Barrier guards are physical barriers that prevent access to the hazard.<br />
2. Presence-sens<strong>in</strong>g devices, such as light curta<strong>in</strong>s, s<strong>in</strong>gle- or<br />
multiple-beam devices, area scanners, radio-frequency devices,<br />
and pressure-sensitive mats, detect the presence of a person and<br />
stop the hazardous motion of the robot or mach<strong>in</strong>e.<br />
3. Hostage controls can be applied where an application requires<br />
that a control be held actuated while the mach<strong>in</strong>e is runn<strong>in</strong>g.<br />
Two-hand controls, or a s<strong>in</strong>gle-hand or foot control, can be used<br />
for this. A hostage control must be fixed <strong>in</strong> position at the proper<br />
safety distance to keep the operator at a safe distance from the<br />
hazard. However, hostage controls only protect the <strong>in</strong>dividuals<br />
us<strong>in</strong>g them, so other safeguard<strong>in</strong>g must be provided for other<br />
personnel that are exposed to the hazard.<br />
Additional supplemental safeguard<strong>in</strong>g can be applied with the use of<br />
awareness barriers, awareness signals (audible or visual), warn<strong>in</strong>g<br />
signs, and color-cod<strong>in</strong>g. Safety procedures and personal protective<br />
equipment can also play a role <strong>in</strong> protect<strong>in</strong>g <strong>in</strong>dividuals.<br />
Risk assessment and hazard analysis should be d<strong>one</strong> before apply<strong>in</strong>g<br />
safeguards to a perimeter application. First, identify the hazards;<br />
second, identify the risk that <strong>in</strong>dividuals will be exposed to around<br />
the mach<strong>in</strong>e and equipment. Lastly, decisions must be made as to<br />
what tolerable risk rema<strong>in</strong>s when runn<strong>in</strong>g production, sett<strong>in</strong>g up, and<br />
ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g the mach<strong>in</strong>e and equipment.<br />
Two safety standards <strong>in</strong> North America are usu<strong>all</strong>y referenced when<br />
apply<strong>in</strong>g perimeter safeguard<strong>in</strong>g:<br />
1. ANSI/RIA* R15.06-1999, American National Standard for Industrial<br />
Robots and Robot <strong>Systems</strong>—Safety Requirements<br />
2. CSA† Z434-03, Industrial Robots and Robot <strong>Systems</strong>—General<br />
Safety Requirements.<br />
Both standards require that safeguards are designed, constructed,<br />
attached, and ma<strong>in</strong>ta<strong>in</strong>ed so that personnel cannot reach over, under,<br />
around, or through the guard or device undetected and reach the hazard.<br />
Barrier guards must prevent access to a hazard. They must be constructed<br />
with materials (such as steel or alum<strong>in</strong>um) that will hold up to the<br />
environment and application, and must not themselves create a hazard.<br />
If open<strong>in</strong>gs are needed <strong>in</strong> a guard, the open<strong>in</strong>gs must comply with the<br />
guard-open<strong>in</strong>g table <strong>in</strong> the standards. Any fixed portion of a guard must<br />
require the use of tools to be adjusted or removed. If the possibility<br />
exists that some object, workpiece, etc., can be ejected from the hazard<br />
area, the barrier guard must conta<strong>in</strong> these objects.<br />
The requirements for barrier guards are the same <strong>in</strong> both the ANSI/RIA and<br />
CSA standards. The only difference is <strong>in</strong> the m<strong>in</strong>imum height requirements<br />
of the bottom and top of the guard above adjacent walk<strong>in</strong>g surfaces.<br />
ANSI/RIA R15.06 requires that the bottom of the guard be no more<br />
than 12 <strong>in</strong>ches above adjacent walk<strong>in</strong>g surfaces and that the top of<br />
the guard be no lower than 60 <strong>in</strong>ches above adjacent walk<strong>in</strong>g surfaces<br />
unless additional safeguard<strong>in</strong>g devices are <strong>in</strong>st<strong>all</strong>ed to prevent or detect<br />
access to the hazard.<br />
CSA Z434 has the same language except the dimensions are 6 <strong>in</strong>ches<br />
for the bottom of the guard and 72 <strong>in</strong>ches for the top of the guard above<br />
adjacent walk<strong>in</strong>g surfaces.<br />
When barrier guards have <strong>in</strong>terlocked sections, each section must<br />
provide two sets of contacts unless the risk assessment determ<strong>in</strong>es <strong>one</strong><br />
set of contacts is acceptable. If magnetic switches are used, they must<br />
be magnetic<strong>all</strong>y coded to reduce the possibility of defeat or <strong>in</strong>terference.<br />
Switches designed with a positive open<strong>in</strong>g operation must be mounted<br />
<strong>in</strong> a positive mode so that when the actuator is disengaged, the motion<br />
forces a nonresilient l<strong>in</strong>kage to open the closed contact(s) tied <strong>in</strong> to the<br />
safety-stop circuit.<br />
Switches other than positive-open<strong>in</strong>g switches must be automatic<strong>all</strong>y<br />
monitored to detect faults with the switches or their <strong>in</strong>st<strong>all</strong>ation. The<br />
<strong>in</strong>terlock<strong>in</strong>g device must not be used as an end-of-travel stop. It must<br />
be tamper-resistant and unable to be defeated without tools, and it must<br />
be capable of be<strong>in</strong>g easily unlocked from the <strong>in</strong>side of the safeguarded<br />
area with or without power available (when the possibility of full body<br />
access exists). The device must be <strong>in</strong>terfaced to the safety-stop circuit<br />
so that the robot or mach<strong>in</strong>e cannot be placed <strong>in</strong> automatic operation<br />
until the <strong>in</strong>terlocked guard is closed. When the guard is opened, a stop<br />
signal must be given by the device, and clos<strong>in</strong>g of the guard must not,<br />
by itself, restart automatic operation—automatic operation must require<br />
a deliberate action outside the safeguarded area.<br />
To ensure that an <strong>in</strong>dividual is out of the hazard area so that automatic<br />
operation cannot be accident<strong>all</strong>y restarted by some<strong>one</strong> else, the<br />
<strong>in</strong>terlock<strong>in</strong>g system should require a key, password or security code<br />
from that <strong>in</strong>dividual before permitt<strong>in</strong>g restart. For special <strong>in</strong>terlock<br />
controls, please consult the factory for details.<br />
*American National Standards Institute/Robotic Industries Association<br />
†Canadian Standards Association<br />
EX-AL BARRIER & PERIMETER GUARDING | 23
MEASURING PERIMETER GUARDS<br />
The alum<strong>in</strong>um perimeter guard<strong>in</strong>g systems offered <strong>in</strong> this catalog consist of alum<strong>in</strong>um panels and posts. The mount<strong>in</strong>g hardware and distances<br />
between comp<strong>one</strong>nts are shown below. Please refer to the follow<strong>in</strong>g draw<strong>in</strong>gs when measur<strong>in</strong>g.<br />
2”<br />
6”<br />
2”<br />
2”<br />
All Posts and<br />
Door Frames<br />
Are 2” Square<br />
Panel<br />
Post<br />
Panel<br />
Door Assembly<br />
Panel<br />
2”<br />
Post<br />
W<strong>all</strong><br />
or Other<br />
Obstruction<br />
Post<br />
Panel<br />
Panel<br />
6” Square<br />
Floor Plate<br />
The standard panels are furnished <strong>in</strong> widths of 18”, 24”, 30”, and<br />
36”. Standard doors are either 30” or 36” wide. Special panels and<br />
doors are available upon request; please consult the factory.<br />
The L-shaped panel-to-post connector shown on page 26 will<br />
<strong>all</strong>ow the panel to be positi<strong>one</strong>d anywhere with<strong>in</strong> 180° of the<br />
post. This <strong>all</strong>ows the panel to be at an angle from the post, which<br />
makes <strong>in</strong>st<strong>all</strong>ation easy at corners.<br />
24 | EX-AL BARRIER & PERIMETER GUARDING
ALUMINUM PANELS, DOORS AND POSTS<br />
The alum<strong>in</strong>um panels are constructed of 1” square alum<strong>in</strong>um frames<br />
with a T-slot on <strong>all</strong> four sides. The material <strong>in</strong> the center portion of the<br />
panel can be 1” or 2” square black mesh, 1” square yellow mesh, or<br />
3<br />
/16”-thick clear polycarbonate.<br />
The mesh is held <strong>in</strong> the frame with clamps and the polycarbonate is held <strong>in</strong><br />
place with a rubber gasket.<br />
The standard panels are furnished <strong>in</strong> widths of 18”, 24”, 30”, and 36”.<br />
Standard heights are 48” (60” height from the floor) and 66” (72”<br />
height from the floor). This provides a 6” sweep under the 66” high<br />
panel and a 6” sweep under the 72” high panel. Other center materials<br />
and special-size panels are available upon request.<br />
24” Panel<br />
18” Panel<br />
30” Door<br />
With Right-Hand H<strong>in</strong>ge,<br />
Interlock<strong>in</strong>g Door Bolt, and<br />
Safety Interlock Switch<br />
The outside door frame is constructed of 2” square alum<strong>in</strong>um with two<br />
T-slots on each side. The frame sits <strong>in</strong> the same foot described above<br />
and the door posts are fastened together at the top for stability. The<br />
height under the door frame is 84”.<br />
The door is constructed of a 1” x 2” alum<strong>in</strong>um frame. The center portion<br />
is available <strong>in</strong> 1” or 2” square black mesh, 1” square yellow mesh, or<br />
3<br />
/16”-thick clear polycarbonate. Special doors and center material are<br />
available upon request.<br />
The alum<strong>in</strong>um posts are constructed of 2” square alum<strong>in</strong>um with two<br />
T-slots on each side. The standard posts are 60” or 72” high. Specialheight<br />
posts are available upon request.<br />
The foot for the post is 6” square with four holes on 4 1 /2” centers. The foot<br />
is constructed of steel.<br />
For more <strong>in</strong>formation about our customized perimeter guard<strong>in</strong>g sytems,<br />
please contact a mach<strong>in</strong>e safeguard<strong>in</strong>g specialist.<br />
Post<br />
EX-AL BARRIER & PERIMETER GUARDING | 25
HARDWARE<br />
PANEL-TO-POST CONNECTOR<br />
HINGE FOR ALUMINUM DOOR<br />
Part No. FKT-584 H<strong>in</strong>ge<br />
This steel h<strong>in</strong>ge measures 2” x 2”.<br />
Four h<strong>in</strong>ges are furnished on each door.<br />
DOOR STOP FOR ALUMINUM DOOR<br />
Part No. STL-013 Panel-to-Post Connector<br />
The connector assembly for attach<strong>in</strong>g a panel to a post consists of two<br />
right-angle steel brackets. One bracket has an elongated slot and the<br />
other has a tapped hole. A fastener with nut is <strong>in</strong>cluded.<br />
Part No. FKT-595 Door Stop<br />
The door stop is made of alum<strong>in</strong>um.<br />
Two are furnished for each door.<br />
INTERLOCKING DOOR BOLTS<br />
Closed<br />
Interlock<strong>in</strong>g door bolts are made of steel and alum<strong>in</strong>um comp<strong>one</strong>nts. The<br />
slid<strong>in</strong>g type slides back and forth to latch the door closed and provides<br />
a guide for the <strong>in</strong>terlock switch. The back side of the assembly has a<br />
knob to slide the bolt open if some<strong>one</strong> is <strong>in</strong>side the guard and the bolt<br />
is latched. It is available for both h<strong>in</strong>ged and lift-off doors. The fixed<br />
type is available for slid<strong>in</strong>g doors. Special latch hardware for other<br />
<strong>in</strong>terlock switches is available upon request.<br />
Note: These <strong>in</strong>terlock<strong>in</strong>g door bolts do not <strong>in</strong>clude a safety <strong>in</strong>terlock<br />
switch. Refer to <strong>Catalog</strong> SS which can be downloaded at:<br />
http://www.rockfordsystems.com/catalogs.html or c<strong>all</strong><br />
<strong>Rockford</strong> <strong>Systems</strong> at 1-800-922-7533 and request <strong>Catalog</strong> SS.<br />
For Use With Safety Switches 6025060, 6022580, 6025067,<br />
and 6025073<br />
PART NO.<br />
FKT-1014<br />
FKIT-1017<br />
FKIT-1019<br />
FKIT-1020<br />
DESCRIPTION<br />
Open<br />
Slid<strong>in</strong>g Type for a H<strong>in</strong>ged-Left or Lift-Off Door<br />
Slid<strong>in</strong>g Type for a H<strong>in</strong>ged-Right or Lift-Off Door<br />
Fixed Type for a Slid<strong>in</strong>g Door that Opens Left<br />
to Right<br />
Fixed Type for a Slid<strong>in</strong>g Door that Opens Right<br />
to Left<br />
For Use With Safety Switch<br />
Part No. 6025059<br />
PART NO.<br />
FKT-1025<br />
FKIT-1026<br />
FKIT-1027<br />
FKIT-1028<br />
DESCRIPTION<br />
Slid<strong>in</strong>g Type for a H<strong>in</strong>ged-Left or<br />
Lift-Off Door<br />
Slid<strong>in</strong>g Type for a H<strong>in</strong>ged-Right or<br />
Lift-Off Door<br />
Fixed Type for a Slid<strong>in</strong>g Door that<br />
Opens Left to Right<br />
Fixed Type for a Slid<strong>in</strong>g Door that<br />
Opens Right to Left<br />
26 | EX-AL BARRIER & PERIMETER GUARDING
EXTRUSIONS<br />
This page illustrates cross sections of the various extruded alum<strong>in</strong>um sizes that are available. Most of the guards and barriers offered <strong>in</strong> this catalog use the<br />
1” square, 1” x 2”, 1 1 /2” square, or 2” square sizes. Larger sizes are available for guards, fixtures, mount<strong>in</strong>g brackets, mach<strong>in</strong>e bases, furniture, or anyth<strong>in</strong>g that<br />
requires this type of material for its design and construction. Extrusions are <strong>in</strong> stock <strong>in</strong> 12-foot lengths; however, longer lengths are available up to 20 feet. The<br />
extrusions are made of strong, lightweight 6105-T5, clear anodized, #204-R1 alum<strong>in</strong>um.<br />
MATERIAL SPECIFICATIONS<br />
• Yield strength 35,000 lb/<strong>in</strong> 2 m<strong>in</strong>imum<br />
• Tensile strength 38,000 lb/<strong>in</strong> 2 m<strong>in</strong>imum<br />
• Elongation A5 m<strong>in</strong>imum 10%<br />
• Elongation A10 m<strong>in</strong>imum 8%<br />
• Rockwell hardness approximately E-88<br />
• Extrusion conform<strong>in</strong>g to DIN 17 615 specifications<br />
• Twist per foot of length not to exceed .25 degree and total twist over<br />
20 feet of length not to exceed 1.5 degrees<br />
• Flatness .004” per <strong>in</strong>ch of width<br />
• Straightness 0.0125” per foot of length, not to exceed .120” over 20<br />
feet of length<br />
• All extrusions have etch and clear (204-R1) anodiz<strong>in</strong>g with depth of<br />
.004” and surface hardness of approximately 250 HV<br />
Part No. FKT-526<br />
(per <strong>in</strong>ch)<br />
Part No. FKT-1036<br />
(per 12’ length)<br />
1” x 1”<br />
Part No. FKT-527<br />
(per <strong>in</strong>ch)<br />
Part No. FKT-1037<br />
(per 12’ length)<br />
1” x 2”<br />
Part No. FKT-537<br />
1 1 ⁄2” x Quarter Round<br />
Part No. FKT-528<br />
1” x 3”<br />
Part No. FKT-532<br />
1 1 ⁄2” x 3”<br />
Part No. FKT-531<br />
1 1 ⁄2” x 1 1 ⁄2” Light<br />
Part No. FKT-529<br />
(per <strong>in</strong>ch)<br />
Part No. FKT-1038<br />
(per 12’ length)<br />
2” x 2”<br />
Part No. FKT-534<br />
3” x 3”<br />
Part No. FKT-535<br />
3” x 6”<br />
Part No.<br />
FKT-772<br />
Panel/<br />
Bear<strong>in</strong>g<br />
Rail<br />
Part No. FKT-533<br />
1 1 ⁄2” x 4 1 ⁄2”<br />
Part No. FKT-773<br />
Rail Extrusion<br />
EX-AL BARRIER & PERIMETER GUARDING | 27
MESH<br />
The nonadjustable area of a panel can be constructed of black or yellow mesh<br />
( 1 /2” square 16 gauge, 1” square 12- gauge, or 2” square 16-gauge). Usu<strong>all</strong>y, the<br />
1<br />
/2” square mesh is used for po<strong>in</strong>t-of-operation guards and the 1” or 2” square<br />
mesh is used for large work envelope (perimeter) safeguard<strong>in</strong>g. The mesh is<br />
made of PVC-coated carbon steel which is rust resistant. Black mesh provides<br />
better visibility <strong>in</strong>to the po<strong>in</strong>t of operation. Mesh can be ordered <strong>in</strong> any size up to<br />
48 x 96 <strong>in</strong>ches. Please provide dimensions when order<strong>in</strong>g.<br />
H” Square<br />
Black or Yellow Mesh<br />
1” Square<br />
Black or Yellow Mesh<br />
2” Square<br />
Black Mesh<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION SIZE<br />
FKT- 567 Black 1/2” square Per <strong>in</strong> 2<br />
FKT- 1049 Black 1/2” square Per 4’ x 8’<br />
FKT- 568 Black 1” square Per <strong>in</strong> 2<br />
FKT- 1031 Black 1” square Per 4’ x 8’<br />
FKT- 1015 Black 2” square Per <strong>in</strong> 2<br />
FKT- 1033 Black 2” square Per 4’ x 8’<br />
FKT- 569 Yellow 1/2” square Per <strong>in</strong> 2<br />
FKT- 1050 Yellow 1/2” square Per 4’ x 8’<br />
FKT- 570 Yellow 1” square Per <strong>in</strong> 2<br />
FKT- 1032 Yellow 1” square Per 4’ x 8’<br />
PANEL RETAINER<br />
PART NO. FKT-560<br />
The panel reta<strong>in</strong>er holds mesh <strong>in</strong> the extruded-alum<strong>in</strong>um framework of<br />
the guard. This reta<strong>in</strong>er prevents panel push out and is the strongest<br />
way to hold panels <strong>in</strong> place.<br />
Front View of Panel<br />
Reta<strong>in</strong>er<br />
Rear View of Panel<br />
Reta<strong>in</strong>er<br />
POLYCARBONATE<br />
PART NO. FKT-617 (PER SQ. INCH)<br />
PART NO. FKT-1035 (4’ X 8’)<br />
The nonadjustable area of a panel can be constructed of clear polycarbonate. Polycarbonate is ideal when<br />
high visibility is required. It is also useful for conta<strong>in</strong><strong>in</strong>g chips, sparks, and coolant.<br />
The polycarbonate is 3/16”-thick and can be mounted <strong>in</strong> extruded-alum<strong>in</strong>um frames with rubber gaskets<br />
(see below). Please provide dimensions when order<strong>in</strong>g; sizes available up to 48 x 96 <strong>in</strong>ches.<br />
3<br />
⁄16”-Thick Polycarbonate<br />
RUBBER GASKET FOR<br />
POLYCARBONATE PANEL<br />
PART NO. FKT-590<br />
The rubber gasket tightly holds the polycarbonate panels <strong>in</strong><br />
the T-slot of the extruded alum<strong>in</strong>um. This gasket is made of<br />
high-grip rubber and is easily <strong>in</strong>serted <strong>in</strong>to the T-slot after<br />
the panel is assembled <strong>in</strong> the frame. Polycarbonate panels<br />
( 3 /16”-thick) are secured with the gasket on <strong>one</strong> side of the<br />
panel. The gasket material can be ordered by the <strong>in</strong>ch.<br />
Rubber Gasket<br />
Gasket Shown<br />
Inserted Into<br />
T-Slot With<br />
Polycarbonate<br />
Panel<br />
T-SLOT COVERS<br />
These T-slot covers snap <strong>in</strong>to the T-slots of the extruded<br />
alum<strong>in</strong>um. They keep dust and dirt out and wires <strong>in</strong> place.<br />
FKT-726<br />
Gray T-Slot Cover<br />
FKT-839<br />
Yellow T-Slot Cover<br />
28 | EX-AL BARRIER & PERIMETER GUARDING
T-NUTS<br />
T-nuts <strong>all</strong>ow jo<strong>in</strong><strong>in</strong>g plates, panels, h<strong>in</strong>ges and other accessories to be bolted <strong>in</strong>to the T-slot of any of the extrusions. They are made of hardened<br />
steel and are coated with corrosion-resistant black oxide. Standard T-nuts slide <strong>in</strong>to the T-slot from the end.<br />
The drop-<strong>in</strong> style <strong>all</strong>ows the T-nut to be dropped <strong>in</strong>to the slot after the extrusions have already been fastened together. T-nuts are usu<strong>all</strong>y<br />
fastened to button-head cap screws.<br />
ORDERING INFORMATION<br />
PART NO.<br />
DESCRIPTION<br />
FSY-028<br />
End-Load T-nut<br />
FST-586 Drop-In Style T-nut<br />
FSC-072 Button-Head Cap Screw (1/4-20 x 1/2”)<br />
End-Load T-nut<br />
Drop-In-Style T-nut<br />
Button-Head<br />
Cap Screw<br />
END FASTENERS<br />
The end fastener provides a concealed method for connect<strong>in</strong>g<br />
extrusions at 90º° without external jo<strong>in</strong><strong>in</strong>g plates. The end fastener<br />
creates a tight, square jo<strong>in</strong>t. These fasteners consist of a stamp<strong>in</strong>g<br />
that aligns the T-slots and a button-head cap screw that threads <strong>in</strong>to<br />
the tapped extrusion end. The end fastener is ideal for tight space<br />
restrictions. When loosened, connected extrusions glide smoothly<br />
over end fasteners. When connect<strong>in</strong>g extrusions, 1/4” drilled access<br />
holes are required to <strong>all</strong>ow a hex wrench to reach the button-head cap<br />
screws. Access holes are drilled 1/2” from the end of the extrusion.<br />
Additional holes are drilled at 1” centers from the first hole.<br />
ORDERING INFORMATION<br />
PART NO.<br />
FKT-562<br />
FKT-613<br />
DESCRIPTION<br />
End Fastener<br />
Double End Fastener<br />
FSC-072 Button-Head Cap Screw (1/4-20 x 1/2”)<br />
Part No. FKT-562 End<br />
Fastener With Button-<br />
Head Screw for 1”<br />
Square Extrusions<br />
Part No. FKT-613 Double<br />
End Fastener With Button-<br />
Head Screw for 1” x 2”<br />
and 2” x 2” Extrusions<br />
Access Hole<br />
Cross Section of End Fastener<br />
Connect<strong>in</strong>g Extrusions at 90°<br />
HAIRPINS AND FASTENERS<br />
The adjustable area of a panel consists of <strong>in</strong>dividual black-oxidized steel<br />
hairp<strong>in</strong>s. These hairp<strong>in</strong>s are 1/4” round rods on 3/4” centers (1” wide from<br />
outside to outside) which create a 1/2” open<strong>in</strong>g between hairp<strong>in</strong>s. Hairp<strong>in</strong>s<br />
provide adjustability of the guard for go<strong>in</strong>g around conveyors, chutes, or<br />
other obstructions on the mach<strong>in</strong>e or robot.<br />
The clip that secures the hairp<strong>in</strong> <strong>in</strong> place uses 1” of the total hairp<strong>in</strong> length,<br />
and the rounded tip uses 1/2”. For this reason, add 11/2” to the adjustability<br />
required on the hairp<strong>in</strong> to obta<strong>in</strong> the proper hairp<strong>in</strong> length. Example: An 11”<br />
hairp<strong>in</strong> will have 91/2” of adjustability; a 20” hairp<strong>in</strong> will have 181/2” of<br />
adjustability, etc.<br />
Part No. FKT-753 Hairp<strong>in</strong><br />
Clip Assembly<br />
Clips and Fasteners<br />
Each hairp<strong>in</strong> is secured to the panel frame with <strong>one</strong> clip, <strong>one</strong> socket-head<br />
cap screw, and <strong>one</strong> T-nut.<br />
EX-AL BARRIER & PERIMETER GUARDING | 29
HAIRPINS AND FASTENERS (CONTINUED)<br />
ORDERING INFORMATION<br />
LENGTH PART NO. LENGTH PART NO. LENGTH PART NO.<br />
3” FKT- 701 13” FKT- 625 22” FKT- 712<br />
4” FKT- 702 14” FKT- 708 23” FKT- 713<br />
5” FKT- 703 15” FKT- 626 24” FKT- 714<br />
6” FKT- 704 16” FKT- 709 25” FKT- 715<br />
7” FKT- 623 17” FKT- 627 26” FKT- 716<br />
8” FKT- 705 18” FKT- 710 27” FKT- 717<br />
9” FKT- 624 19” FKT- 628 28” FKT- 718<br />
10” FKT- 706 20” FKT- 566 29” FKT- 719<br />
11” FKT- 565 21” FKT- 711 30” FKT- 629<br />
12” FKT- 707<br />
ROLLER BEARING ASSEMBLY<br />
PART NO. FKT-837<br />
The roller bear<strong>in</strong>g assembly is used on the spr<strong>in</strong>g- and air-lift guards<br />
shown on pages 20 and 21 of this catalog, and on gate assemblies.<br />
These bear<strong>in</strong>gs are available for guid<strong>in</strong>g guards up and down or back<br />
and forth. The roller bear<strong>in</strong>g assembly consists of a roller bear<strong>in</strong>g,<br />
bear<strong>in</strong>g plate, collar, and necessary hardware.<br />
Roller Bear<strong>in</strong>g<br />
Assembly<br />
Roller Bear<strong>in</strong>g<br />
Enter<strong>in</strong>g Extrusion<br />
HINGES<br />
PART NO. FKT-687 (STANDARD)<br />
PART NO. FKT-671 (LIFT-OFF RIGHT)<br />
PART NO. FKT-670 (LIFT-OFF LEFT)<br />
H<strong>in</strong>ges are used to sw<strong>in</strong>g guard panels and<br />
segments to the right or left. They are attached<br />
to the alum<strong>in</strong>um extrusion anywhere along<br />
the T-slot with button-head or socket-head<br />
cap screws and T-nuts (furnished). Standard<br />
alum<strong>in</strong>um h<strong>in</strong>ges and lift-off h<strong>in</strong>ges are available.<br />
Sw<strong>in</strong>g-Away H<strong>in</strong>ge Assembly<br />
PART NO. FKT-655<br />
This speci<strong>all</strong>y designed h<strong>in</strong>ge assembly is used on the light curta<strong>in</strong><br />
sw<strong>in</strong>g-away mount<strong>in</strong>g brackets. The assembly consists of two plates<br />
with fasteners for the top and bottom of the sw<strong>in</strong>g-away bracket.<br />
The top plate has a b<strong>all</strong> lock p<strong>in</strong> that holds the side guard <strong>in</strong> position.<br />
These h<strong>in</strong>ges are designed to <strong>all</strong>ow the side panel to move forward or<br />
backward for light curta<strong>in</strong> safety distance adjustment. Please use Part<br />
No. FKT-655 for order<strong>in</strong>g <strong>one</strong> right or left sw<strong>in</strong>g-away h<strong>in</strong>ge assembly.<br />
Top Plate<br />
B<strong>all</strong> Lock P<strong>in</strong> With Cable<br />
Part No. FKT-687 One<br />
(1) Standard H<strong>in</strong>ge<br />
With Fasteners<br />
Part No. FKT-671<br />
Lift-Off Assembly (Right)<br />
Part No. FKT-670<br />
Lift-Off Assembly (Left)<br />
Note: Both lift-off assemblies consist of<br />
five h<strong>in</strong>ge parts plus fasteners.<br />
30 | EX-AL BARRIER & PERIMETER GUARDING
DEADBOLT LATCH<br />
PART NO. FKT-620<br />
A deadbolt latch is ideal for hold<strong>in</strong>g guard doors closed. This spr<strong>in</strong>gloaded<br />
deadbolt is made of anodized alum<strong>in</strong>um. A socket-head<br />
lock<strong>in</strong>g set-screw located towards the end of the latch requires the<br />
use of a tool to open the guard. This feature complies with OSHA 29<br />
CFR 1910.217 (c)(2)(d). This deadbolt with side latch <strong>in</strong>cludes <strong>all</strong><br />
mount<strong>in</strong>g hardware.<br />
Socket-Head Lock<strong>in</strong>g Set-Screw<br />
DOOR HANDLE<br />
PART NO. TXS-101<br />
This plastic door handle is ideal for T-slot frame doors on guards or<br />
shields. Handles bolt directly to doors and panels us<strong>in</strong>g two 1/4-20<br />
screws and two T-nuts (sold separately, see chart). The handle is made<br />
of high-strength black polycarbonate and is corrosion resistant.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
TXS-101 Door Handle<br />
FSC-072 1/4-20 x 1/2” Screw<br />
FSY-028 T-Nut<br />
END CAPS<br />
End caps are made of black high-impact styrene. They fit easily onto<br />
the end of extrusions to present a f<strong>in</strong>ished look Push <strong>in</strong> fasteners (sold<br />
separately) are used to secure the end caps to the extrusion. Other sizes<br />
are available–please consult the factory.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
FKT-615 1” x 1” End Cap<br />
FKT-600 1” x 2” End Cap<br />
FKT-551 2” x 2” End Cap<br />
FKT-653 Push-In Fastener<br />
T-HANDLE HEX WRENCHES<br />
The T-handle hex wrench is an ideal way to tighten and loosen buttonhead<br />
cap screws and socket-head cap screws. The handle has a<br />
cushion grip and the long arm provides access to hard to reach areas.<br />
The end of the hex wrench is b<strong>all</strong>-shaped which <strong>all</strong>ows for angle entry<br />
up to 25º. Two sizes are available.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
FKT-658 3/16” Hex Wrench<br />
FKT-657 5/32” Hex Wrench<br />
BRACKETS FOR INTERLOCK SWITCHES<br />
Interlock switches 6025067 and 6025060 can be mounted on<br />
extrusions with the appropriate bracket.<br />
These switches are used with Part No. FKT-618 to mount on spr<strong>in</strong>gor<br />
air-lift guards. Part No. FKT-621 can be used with these switches<br />
to mount on multi-panels. They are ideal for larger guard applications.<br />
Part No. FKT-618<br />
Part No. FKT-621<br />
EX-AL BARRIER & PERIMETER GUARDING | 31
BRACKETS AND PLATES<br />
A variety of brackets, plates, clamps, bolts, bear<strong>in</strong>gs, rollers, etc., are available for attach<strong>in</strong>g guards to mach<strong>in</strong>es and for guard assemblies. Jo<strong>in</strong><strong>in</strong>g<br />
plates are used to connect extruded panels without additional mach<strong>in</strong><strong>in</strong>g.<br />
Part No. FKT-560<br />
Mesh Clamp Assembly<br />
Part No. FKT-604<br />
1” Mesh Clamp<br />
Part No. FKT-647<br />
2” Mesh Clamp<br />
Part No. FKT-562<br />
S<strong>in</strong>gle End Fastener<br />
Part No. FKT-613<br />
Double End Fastener<br />
Part No. FKT-586<br />
1<br />
⁄4-20 Drop-In T-Nut<br />
Part No. FKT-587<br />
1<br />
⁄4-20 Drop-In T-Nut W/Set Screw<br />
Part No. FKT-630<br />
Channel Guide<br />
Part No. FKT-589<br />
Roller Wheel<br />
Part No. FKT-837<br />
Roller Bear<strong>in</strong>g Assembly<br />
Part No. FKT-636<br />
L<strong>in</strong>ear Bear<strong>in</strong>g<br />
Part No. FKT-649<br />
Double-Wide L<strong>in</strong>ear Bear<strong>in</strong>g<br />
Part No. FKT-585<br />
Stripper Bolt Assembly<br />
Part No. FSC-081<br />
3<br />
⁄4” 1 ⁄4-20 Carriage Bolt<br />
Part No. FSC-082<br />
1 1 ⁄2” 1 ⁄4-20 Carriage Bolt<br />
Part No. FSC-086<br />
3<br />
⁄4” 1 ⁄4-20 Flanged<br />
Button Cap Screw<br />
Part No. FST-005<br />
& FSY-002 1 ⁄4” Z<strong>in</strong>c<br />
Washer & Nut<br />
Part No. FSY-028<br />
1<br />
⁄4-20 Standard T-Nut<br />
Part No. FSC-072<br />
Button-Head Cap<br />
Screw ( 1 ⁄4-20 x 1 ⁄2”)<br />
Part No. FKT-753<br />
Hairp<strong>in</strong> Clip Assembly<br />
Part No. FKT-754<br />
End Cap for Hairp<strong>in</strong>s<br />
Part No. FKT-558<br />
90° SAB H<strong>in</strong>ge Nub<br />
Part No. FKT-606<br />
180° Liv<strong>in</strong>g Nub<br />
Part No. FKT-555<br />
L-Bracket W/Brass Insert<br />
Part No. FKT-559<br />
Flat Pivot Arm W/Brass<br />
Insert<br />
Part No. FKT-656<br />
Inside Bay<strong>one</strong>t Connector<br />
Part No. FKT-591<br />
Lock<strong>in</strong>g Plate<br />
Part No. FKT-654<br />
SAB Top<br />
Lock<strong>in</strong>g Plate<br />
32 | EX-AL BARRIER & PERIMETER GUARDING
BRACKETS AND PLATES (CONTINUED)<br />
Part No. FKT-563<br />
Bay<strong>one</strong>t Plate<br />
Part No. FKT-572<br />
Jo<strong>in</strong><strong>in</strong>g Strip<br />
Part No. FKT-588<br />
Jo<strong>in</strong><strong>in</strong>g Strip<br />
Part No. FKT-573<br />
Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-574<br />
Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-645<br />
8-Hole Flat Jo<strong>in</strong><strong>in</strong>g Bracket<br />
Part No. FKT-554<br />
90° Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-575<br />
90° Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-576<br />
90° Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-577<br />
Tee Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-578<br />
Tee Jo<strong>in</strong><strong>in</strong>g Plate<br />
Part No. FKT-596<br />
Inside Corner Bracket<br />
Part No. FKT-597<br />
Slotted Corner Bracket<br />
Part No. FKT-598<br />
S<strong>in</strong>gle Floor-Mount Bracket<br />
Part No. FKT-557<br />
Double Floor-Mount Bracket<br />
Part No. FKT-607<br />
3<br />
⁄16” Inside Corner Bracket<br />
Part No. FKT-642<br />
Inside Corner Bracket<br />
Part No. FKT-561<br />
Inside Corner Bracket<br />
Part No. FKT-619<br />
Inside Corner Bracket<br />
Part No. FKT-700<br />
SSA Mount<strong>in</strong>g Bracket<br />
Part No. FKT-616<br />
Inside Corner Gusset<br />
Part No. FKT- 631<br />
90° Rotat<strong>in</strong>g Corner Bracket (Left)<br />
Part No. FKT-632<br />
90° Rotat<strong>in</strong>g Corner Bracket (Right)<br />
Part No. FKT-691<br />
45° Heavy-Duty Bracket<br />
Part No. FKT-1021<br />
B<strong>all</strong> Lock P<strong>in</strong> With Cable<br />
EX-AL BARRIER & PERIMETER GUARDING | 33
FLOOR STAND<br />
PART NO. KTR-077<br />
When light bars (transmitter or receiver) cannot be conveniently mounted<br />
to the mach<strong>in</strong>e, a floor stand can be furnished. Floor stands can also be<br />
used when safeguard<strong>in</strong>g large work envelopes or perimeter areas. Mirrors<br />
or s<strong>in</strong>gle-beam devices can be attached to the floor stand when the<br />
application requires multiple-sided safeguard<strong>in</strong>g. Light bars, s<strong>in</strong>gle-beam<br />
devices, or mirrors can easily be adjusted up or down on any side of the<br />
upright extruded-alum<strong>in</strong>um stand.<br />
This floor stand assembly consists of a 6’ length of 2” square extruded<br />
alum<strong>in</strong>um, <strong>one</strong> base, and two right-angle brackets with fasteners. The<br />
base has four holes for permanent attachment to the floor with bolts (not<br />
furnished). Other floor stand sizes are available. Please consult the factory.<br />
Floor Stand With Light<br />
Curta<strong>in</strong> Transmitter<br />
CONTROL BOX STANDS<br />
When a control box cannot be conveniently mounted to the mach<strong>in</strong>e or<br />
the mach<strong>in</strong>e has excess vibration, rigid and adjustable control box stands<br />
are available. These stands are made of extruded alum<strong>in</strong>um and have<br />
base plates to permanently attach to the floor with bolts (not furnished).<br />
Adjustable stands are available <strong>in</strong> models with height adjustment, and<br />
are also available <strong>in</strong> models with tilt adjustment for operator comfort.<br />
ORDERING INFORMATION<br />
PART NO. DESCRIPTION<br />
KCL-017 Vertical Adjustable Stand<br />
KCL-062 24” Wide Control Box Stand<br />
KCL-063 36” Wide Control Box Stand<br />
78”<br />
High<br />
Adjustable<br />
From 28” to<br />
47” Above the<br />
Floor<br />
Vertical Adjustable Stand<br />
34 | EX-AL BARRIER & PERIMETER GUARDING<br />
Tilt Adjustable Stand*<br />
*Consult the factory for custom tilt stands.<br />
Control Box Stand With Control Box<br />
and Comb<strong>in</strong>ation Starter/Disconnect
FUNCTION-TESTING CHECKLIST FOR PERIMETER BARRIER GUARDS<br />
This is a generic function-test<strong>in</strong>g checklist. Your barrier guard may have other features that require different tests. Please<br />
refer to your barrier guard <strong>in</strong>st<strong>all</strong>ation manual.<br />
If the barrier guard is <strong>in</strong>terlocked, make sure that the <strong>in</strong>terlock device has been <strong>in</strong>terfaced properly to the<br />
mach<strong>in</strong>e’s control system to provide control reliability (if required, based on the risk assessment).<br />
DANGER<br />
Never place your hands or any part of your body <strong>in</strong> the hazard area while perform<strong>in</strong>g these tests.<br />
Always perform these tests at every setup, operator, and shift change, as well as every time after<br />
ma<strong>in</strong>tenance is performed.<br />
1. Make sure that the barrier guard is designed and constructed so that some<strong>one</strong> cannot reach over, under,<br />
around, or through the barrier guard and reach the hazard. Additional guards or safeguard<strong>in</strong>g devices must<br />
protect <strong>all</strong> areas not protected by the barrier guard.<br />
2. If there are open<strong>in</strong>gs <strong>in</strong> the barrier guard, check the open<strong>in</strong>gs for compliance with the ANSI/RIA* and CSA † guardopen<strong>in</strong>g<br />
requirements. (See next page.)<br />
3. Verify that the barrier guard is designed and constructed of materials substantial for the application to protect<br />
<strong>in</strong>dividuals from identified hazards. If the possibility exists that some object, workpiece, etc., can be ejected<br />
from the hazard area, confirm that the barrier guard will conta<strong>in</strong> these objects.<br />
4. Make sure that any fixed portion of the barrier guard must require the use of tools to be adjusted or removed.<br />
5. Confirm that the barrier guard is fixed <strong>in</strong> position.<br />
6. Check that the barrier guard is free of sharp edges and projections that may cause <strong>in</strong>jury to <strong>in</strong>dividuals when handl<strong>in</strong>g, remov<strong>in</strong>g, or us<strong>in</strong>g the<br />
barrier guard.<br />
7. Make sure that the barrier guard is <strong>in</strong>st<strong>all</strong>ed, ma<strong>in</strong>ta<strong>in</strong>ed, and operated such that it does not create any p<strong>in</strong>ch po<strong>in</strong>ts between itself and mov<strong>in</strong>g<br />
parts of the mach<strong>in</strong>e or robot.<br />
8. Verify that the barrier guard provides adequate visibility to the po<strong>in</strong>t of operation, if required, with material such as perforated metal, wire mesh, or transparent<br />
polycarbonate. If visibility is provided through perforations or slots, the color of the material should be darker than the area observed to enhance visibility.<br />
9. Check that the bottom of the guard is no more than 12 <strong>in</strong>ches above adjacent walk<strong>in</strong>g surfaces and the top of the guard is no lower than 60 <strong>in</strong>ches<br />
above adjacent walk<strong>in</strong>g surfaces.<br />
Note: CSA Z434-03 uses dimensions of 6 <strong>in</strong>ches for the bottom of the guard and 72 <strong>in</strong>ches for the top of the guard.<br />
10. If the barrier guard has <strong>one</strong> or more <strong>in</strong>terlocked sections, perform the follow<strong>in</strong>g tests for each <strong>in</strong>terlocked section.<br />
a. Check that the <strong>in</strong>terlocked section opens later<strong>all</strong>y or away from the hazard, and not <strong>in</strong>to the safeguarded space, and cannot close by itself<br />
and activate the <strong>in</strong>terlock<strong>in</strong>g circuitry.<br />
b. With the mach<strong>in</strong>e on and ready to be cycled <strong>in</strong> a production mode of operation, open an <strong>in</strong>terlocked section of the barrier guard and attempt<br />
to cycle the mach<strong>in</strong>e. The mach<strong>in</strong>e should not cycle.<br />
c. An <strong>in</strong>terlocked section must either (1) prevent open<strong>in</strong>g until hazardous motion has stopped (with a lock<strong>in</strong>g <strong>in</strong>terlock device), or (2) be located at the<br />
proper safety distance so that when it is opened, an <strong>in</strong>dividual cannot reach the hazard before hazardous motion has stopped (with a nonlock<strong>in</strong>g<br />
<strong>in</strong>terlock device).<br />
(1) Lock<strong>in</strong>g: With <strong>all</strong> <strong>in</strong>terlocked sections of the barrier guard closed while the mach<strong>in</strong>e is cycl<strong>in</strong>g, attempt to open an <strong>in</strong>terlocked section.<br />
The <strong>in</strong>terlocked section should not open. A lock<strong>in</strong>g <strong>in</strong>terlocked section must open only when the hazardous motion of the mach<strong>in</strong>e has<br />
stopped after a normal stop command.<br />
(2) Nonlock<strong>in</strong>g: With <strong>all</strong> <strong>in</strong>terlocked sections of the barrier guard closed while the mach<strong>in</strong>e is cycl<strong>in</strong>g, open an <strong>in</strong>terlocked section. The<br />
mach<strong>in</strong>e should stop before some<strong>one</strong> can reach the hazard.<br />
*American National Standards Institute/Robotic Industries Association<br />
†<br />
Canadian Standards Association<br />
ANSI guard-open<strong>in</strong>g scale be<strong>in</strong>g used<br />
to check open<strong>in</strong>gs for compliance<br />
EX-AL BARRIER & PERIMETER GUARDING | 35
FUNCTION-TESTING CHECKLIST FOR PERIMETER BARRIER GUARDS (CONTINUED)<br />
d. Verify that reclos<strong>in</strong>g of an open <strong>in</strong>terlocked section does not, by itself, cause any hazardous motion of the mach<strong>in</strong>e. Restart<strong>in</strong>g of the<br />
mach<strong>in</strong>e must require a deliberate action outside the safeguarded area. To ensure that an <strong>in</strong>dividual is out of the hazard area so that<br />
automatic operation cannot be accident<strong>all</strong>y restarted by some<strong>one</strong> else, the <strong>in</strong>terlock<strong>in</strong>g system should require a key or a unique password<br />
or security code from that <strong>in</strong>dividual before permitt<strong>in</strong>g restart.<br />
e. Verify that the <strong>in</strong>terlock device will not be adversely affected by the environmental conditions.<br />
f. Make sure that the <strong>in</strong>terlock device is tamper-resistant and unable to be defeated without tools.<br />
g. Confirm that the <strong>in</strong>terlock device is not used as and end-of-travel stop for the <strong>in</strong>terlocked section of the barrier guard.<br />
h. Verify that the <strong>in</strong>terlock device has two sets of contacts (unless the risk assessment determ<strong>in</strong>ed that <strong>one</strong> set of contacts was acceptable).<br />
If the <strong>in</strong>terlock device is a magnetic switch, make sure that it is magnetic<strong>all</strong>y coded to reduce the possibility of defeat or <strong>in</strong>terference.<br />
Confirm that if the <strong>in</strong>terlock device is a switch designed with a positive open<strong>in</strong>g operation (cam-operated switch<strong>in</strong>g element), it is mounted<br />
<strong>in</strong> a positive mode so that when the actuator is disengaged, the motion forces a l<strong>in</strong>kage to open the closed safety contact(s). If the <strong>in</strong>terlock<br />
device is a switch other than a positive-open<strong>in</strong>g switch (magnetic switch, limit switch, etc.), check that it is automatic<strong>all</strong>y monitored to<br />
detect faults with the switch or its <strong>in</strong>st<strong>all</strong>ation.<br />
i. Confirm that the <strong>in</strong>terlock device is capable of be<strong>in</strong>g easily unlocked from the <strong>in</strong>side of the safeguarded area with or without power available<br />
(when the possibility of full body access exists).<br />
j. Make sure that spare keys and actuat<strong>in</strong>g devices are supervisory-controlled and not readily available for the purpose of defeat<strong>in</strong>g the safeguard.<br />
11. If any of these function tests fail, take corrective action before runn<strong>in</strong>g production. If <strong>all</strong> tests pass, remove <strong>all</strong> keys from the selector switches<br />
before runn<strong>in</strong>g production.<br />
ANSI/RIA AND CSA GUARD-OPENING REQUIREMENTS<br />
The m<strong>in</strong>imum distance from the hazard as a function of barrier open<strong>in</strong>g size as required by Table 5 of ANSI/RIA R15.06-1999, Industrial Robots<br />
and Robot <strong>Systems</strong>—Safety Requirements, and by Table 5 of CSA Z434-03, Industrial Robots and Robot <strong>Systems</strong>—General Safety Requirements,<br />
is as follows:<br />
SAFETY DISTANCE FOR NONLOCKING INTERLOCKED BARRIER GUARDS<br />
The safety equation for nonlock<strong>in</strong>g <strong>in</strong>terlocked barrier guards from Table 6 of ANSI/RIA R15.06-1999, Industrial Robots and Robot <strong>Systems</strong>—Safety<br />
Requirements, and from 10.4.3b of CSA Z434-03, Industrial Robots and Robot <strong>Systems</strong>—General Safety Requirements, is as follows:<br />
Where:<br />
D s<br />
= K(T s<br />
+ T c<br />
+ T r<br />
)<br />
D s<br />
= safety distance that the <strong>in</strong>terlocked section of the barrier guard<br />
must be located from the hazard<br />
K = maximum speed that an <strong>in</strong>dividual can approach the hazard<br />
(63 <strong>in</strong>ches/second [1.6 meters/second] is commonly used)<br />
T s<br />
= worst stopp<strong>in</strong>g time of the mach<strong>in</strong>e/equipment<br />
T c<br />
= worst stopp<strong>in</strong>g time of the control system<br />
T r<br />
= reaction time of the <strong>in</strong>terlock device and its <strong>in</strong>terface<br />
36 | EX-AL BARRIER & PERIMETER GUARDING<br />
Barrier Open<strong>in</strong>g Size (Sm<strong>all</strong>est Dimension)<br />
M<strong>in</strong>imum Distance From Hazard<br />
mm <strong>in</strong>ches Slotted open<strong>in</strong>g Square open<strong>in</strong>g<br />
0.0–6.0 0.000–0.250 > 13.0 mm* [0.5 <strong>in</strong>] > 13.0 mm* [0.5 <strong>in</strong>]<br />
6.1–11.0 0.251–0.375 > 64.0 mm [2.5 <strong>in</strong>] > 48 mm [1.9 <strong>in</strong>]<br />
11.1–16.0 0.376–0.625 > 89.0 mm [3.5 <strong>in</strong>] > 66 mm [2.6 <strong>in</strong>]<br />
16.1–32.0 0.626–1.250 > 166.0 mm [6.5 <strong>in</strong>] > 166.0 mm [6.5 <strong>in</strong>]<br />
32.1–49.0 1.251–1.875 > 445.0 mm [17.5 <strong>in</strong>] > 445.0 mm [17.5 <strong>in</strong>]<br />
49.1–132.0 † 1.876–5.000 † > 915.0 mm [36.0 <strong>in</strong>] > 915.0 mm [36.0 <strong>in</strong>]<br />
*Barriers sh<strong>all</strong> not be located less than 13.0 mm (0.5 <strong>in</strong>ches) from the hazard.<br />
†Barrier open<strong>in</strong>gs sh<strong>all</strong> not be greater than 132.0 mm (5.0 <strong>in</strong>ches) unless a risk assessment is performed.
FUNCTION-TESTING CHECKLIST FOR POINT-OF-OPERATION BARRIER GUARDS<br />
This is a generic function-test<strong>in</strong>g checklist. Your barrier guard may have other features that require different<br />
tests. Please refer to your barrier guard <strong>in</strong>st<strong>all</strong>ation manual.<br />
DANGER<br />
If the barrier guard is <strong>in</strong>terlocked, make sure that the <strong>in</strong>terlock device has been <strong>in</strong>terfaced properly to the mach<strong>in</strong>e’s<br />
control system to provide control reliability.<br />
Never place your hands or any part of your body <strong>in</strong> the hazard area while perform<strong>in</strong>g these tests.<br />
Always perform these tests at every setup, operator, and shift change, as well as every time after<br />
ma<strong>in</strong>tenance is performed.<br />
1. Make sure that the barrier guard is designed and constructed so that some<strong>one</strong> cannot reach over, under,<br />
around, or through the barrier guard and reach the hazard. Additional guards or safeguard<strong>in</strong>g devices must<br />
protect <strong>all</strong> areas not protected by the barrier guard.<br />
2. If there are open<strong>in</strong>gs <strong>in</strong> the barrier guard, check the open<strong>in</strong>gs for compliance with the OSHA or ANSI<br />
guard-open<strong>in</strong>g requirements. (See next page.)<br />
3. Verify that the barrier guard is designed and constructed of materials substantial for the application to protect<br />
<strong>in</strong>dividuals from identified hazards.<br />
4. Make sure that the barrier guard is designed, constructed, and ma<strong>in</strong>ta<strong>in</strong>ed with fasteners not readily removable to<br />
protect aga<strong>in</strong>st unauthorized adjustment or circumvention. Examples of fasteners that should not be used are slotted<br />
or Phillips head screws, w<strong>in</strong>g nuts, magnets, latches and hasps, and hooks and eyes.<br />
5. Confirm that the barrier guard is designed and constructed to ensure ease of use. If the barrier guard is overly large or cumbersome, it may<br />
discourage proper use.<br />
6. Check that the barrier guard is free of sharp edges, burrs, slag welds, etc., that may cause <strong>in</strong>jury to <strong>in</strong>dividuals when handl<strong>in</strong>g, remov<strong>in</strong>g, or<br />
us<strong>in</strong>g the barrier guard.<br />
7. Make sure that the barrier guard is <strong>in</strong>st<strong>all</strong>ed, ma<strong>in</strong>ta<strong>in</strong>ed, and operated such that it does not create any p<strong>in</strong>ch po<strong>in</strong>ts between itself and mov<strong>in</strong>g<br />
parts of the mach<strong>in</strong>e.<br />
8. Verify that the barrier guard provides adequate visibility to the po<strong>in</strong>t of operation, if required, with material such as perforated metal, wire mesh, or<br />
transparent polycarbonate. If visibility is provided through perforations or slots, the color of the material should be darker than the area observed to<br />
enhance visibility.<br />
9. If the barrier guard has <strong>one</strong> or more <strong>in</strong>terlocked sections, perform the follow<strong>in</strong>g tests for each <strong>in</strong>terlocked section.<br />
Guard-open<strong>in</strong>g scale be<strong>in</strong>g used to check<br />
open<strong>in</strong>gs for compliance<br />
a. With the mach<strong>in</strong>e on and ready to be cycled <strong>in</strong> a production mode of operation, open an <strong>in</strong>terlocked section of the barrier guard and attempt<br />
to cycle the mach<strong>in</strong>e. The mach<strong>in</strong>e should not cycle.<br />
b. An <strong>in</strong>terlocked section must either (1) prevent open<strong>in</strong>g until hazardous motion has stopped (with a lock<strong>in</strong>g <strong>in</strong>terlock device), or (2) be located<br />
at the proper safety distance so that an <strong>in</strong>dividual cannot reach the hazard before hazardous motion has stopped when it is opened (with<br />
a nonlock<strong>in</strong>g <strong>in</strong>terlock device; see next page for the ANSI safety-distance equation).<br />
(1) Lock<strong>in</strong>g: With <strong>all</strong> <strong>in</strong>terlocked sections of the barrier guard closed while the mach<strong>in</strong>e is cycl<strong>in</strong>g, attempt to open an <strong>in</strong>terlocked section. The<br />
<strong>in</strong>terlocked section should not open. A lock<strong>in</strong>g <strong>in</strong>terlocked section must open only when the hazardous motion of the mach<strong>in</strong>e has stopped<br />
after a normal stop command.<br />
(2) Nonlock<strong>in</strong>g: With <strong>all</strong> <strong>in</strong>terlocked sections of the barrier guard closed while the mach<strong>in</strong>e is cycl<strong>in</strong>g, open an <strong>in</strong>terlocked section. The<br />
mach<strong>in</strong>e should stop.<br />
c. Verify that reclos<strong>in</strong>g of an open <strong>in</strong>terlocked section does not, by itself, cause any hazardous motion of the mach<strong>in</strong>e. Restart<strong>in</strong>g of the mach<strong>in</strong>e<br />
must require a deliberate action, such as reactuat<strong>in</strong>g the normal actuat<strong>in</strong>g means.<br />
10. If any of these function tests fail, take corrective action before runn<strong>in</strong>g production. If <strong>all</strong> tests pass, remove <strong>all</strong> keys from the selector switches<br />
before runn<strong>in</strong>g production.<br />
EX-AL BARRIER & PERIMETER GUARDING | 37
OSHA GUARD-OPENING REQUIREMENTS<br />
The maximum permissible open<strong>in</strong>g for guards as required by OSHA 29 CFR 1910.217 for mechanical power presses is as follows:<br />
Distance of open<strong>in</strong>g<br />
from po<strong>in</strong>t-of-operation<br />
hazard (<strong>in</strong>ches)<br />
ANSI GUARD-OPENING REQUIREMENTS<br />
TABLE O-10<br />
Maximum width<br />
of open<strong>in</strong>g<br />
(<strong>in</strong>ches)<br />
1<br />
/2 to 1 1 /2 ...................................... 1 /4<br />
1 1 /2 to 2 1 /2 ...................................... 3 /8<br />
2 1 /2 to 3 1 /2 ...................................... 1 /2<br />
3 1 /2 to 5 1 /2 ...................................... 5 /8<br />
5 1 /2 to 6 1 /2 ...................................... 3 /4<br />
6 1 /2 to 7 1 /2 ...................................... 7 /8<br />
7 1 /2 to 12 1 /2 ....................................1 1 /4<br />
12 1 /2 to 15 1 /2 ....................................1 1 /2<br />
15 1 /2 to 17 1 /2 ....................................1 7 /8<br />
17 1 /2 to 31 1 /2 ....................................2 1 /8<br />
The maximum permissible open<strong>in</strong>g for guards as required by Annex D of ANSI B11.19-2003, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>, is as follows:<br />
As a function of gap size <strong>in</strong> millimeters (<strong>in</strong>ches)<br />
As a function of distance <strong>in</strong> millimeters (<strong>in</strong>ches)<br />
Known Gap M<strong>in</strong>imum Distance Known Distance Maximum Gap<br />
0–6 (0–0.24) 13 (0.5) < 13 (< 0.5) Not permitted<br />
6.1–11 (0.25–0.375) 64 (2.5) 13–63.9 (0.5–2.49) 6 (0.250)<br />
11.1–16 (0.376–0.625) 89 (3.5) 64–88.9 (2.5–3.49) 11 (0.375)<br />
16.1–32 (0.626–1.250) 166 (6.5) 89–165.9 (3.5–6.49) 16 (0.625)<br />
32.1–49 (1.251–1.875) 445 (17.5) 166–444.9 (6.5–17.49) 32 (1.250)<br />
49.1–132 (1.876–5.000) 915 (36.0) 445–914.9 (17.5–35.99) 49 (1.875)<br />
> 132 (> 5.0) Not permitted > 915 (> 36.0) 132 (5.000)<br />
OSHA AND ANSI GUARD-OPENING SCALES<br />
OSHA guard-open<strong>in</strong>g scale part<br />
No. KSC-097<br />
ANSI guard-open<strong>in</strong>g scale part<br />
No. KSC-098<br />
An OSHA or ANSI guard-open<strong>in</strong>g scale can be used dur<strong>in</strong>g the design, <strong>in</strong>st<strong>all</strong>ation, and <strong>in</strong>spection of barrier guards to make sure they comply with the<br />
OSHA and ANSI guard-open<strong>in</strong>g requirements. These sta<strong>in</strong>less-steel guard-open<strong>in</strong>g scales are available onl<strong>in</strong>e at www.rockfordsystems.com.<br />
SAFETY DISTANCE FOR NONLOCKING INTERLOCKED BARRIER GUARDS<br />
The safety-distance equation for nonlock<strong>in</strong>g <strong>in</strong>terlocked barrier guards from Annex D of ANSI B11.19-2003, Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong>,<br />
is as follows:<br />
D s<br />
= K(T s<br />
+ T c<br />
+ T r<br />
+ T spm<br />
)<br />
Where:<br />
D s<br />
= safety distance that the <strong>in</strong>terlocked section of the barrier guard must be located from the po<strong>in</strong>t-of-operation hazard<br />
K = maximum speed that an <strong>in</strong>dividual can approach the hazard (63 <strong>in</strong>ches/second is commonly used)<br />
T s<br />
= stopp<strong>in</strong>g time of the mach<strong>in</strong>e measured at the f<strong>in</strong>al control element<br />
T c<br />
= reaction time of the control system<br />
T r<br />
= reaction time of the <strong>in</strong>terlock device and its <strong>in</strong>terface<br />
= additional time <strong>all</strong>owed for the stopp<strong>in</strong>g-performance monitor to compensate for variations <strong>in</strong> normal stopp<strong>in</strong>g time (if applicable)<br />
T spm<br />
38 | EX-AL BARRIER & PERIMETER GUARDING
EXAMPLES OF SPECIAL PERIMETER AND POINT-OF-OPERATION BARRIER GUARDS<br />
Guard on a Straightener<br />
Guard on a Package Roller<br />
Spr<strong>in</strong>g-Lift Guard on a Straight-Side Press<br />
With Adjustable Side Guards<br />
Perimeter Guard<br />
Around a Transfer L<strong>in</strong>e<br />
EX-AL BARRIER & PERIMETER GUARDING | 39
Hand Feed<strong>in</strong>g Tools<br />
For Industrial Mach<strong>in</strong>es<br />
www.rockfordsystems.com<br />
2 | HAND FEEDING TOOLS
Hand Feed<strong>in</strong>g Tools is a comprehensive catalog<br />
that features a wide variety of pliers, tongs,<br />
positi<strong>one</strong>rs, and vacu-tongs.<br />
These tools are used to keep hands out of the<br />
po<strong>in</strong>t of operation while feed<strong>in</strong>g or remov<strong>in</strong>g<br />
parts from the mach<strong>in</strong>e.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
Most of the tools are constructed of soft <strong>all</strong>oy<br />
materials, eng<strong>in</strong>eered to easily crush if caught<br />
between dies or parts of the mach<strong>in</strong>e. Vacuum<br />
lifters and magnetic tools are also featured <strong>in</strong><br />
the catalog.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong><br />
HAND FEEDING TOOLS | 3
HAND-FEEDING AND RETRIEVAL TOOLS (PLIERS, POSITIONERS, TONGS, AND VACU-TONGS)<br />
A wide variety of hand-feed<strong>in</strong>g tools are available. They are used to keep<br />
hands out of the po<strong>in</strong>t of operation while feed<strong>in</strong>g or remov<strong>in</strong>g parts from<br />
the mach<strong>in</strong>e. Although they are not considered to be guards or devices<br />
by themselves, hand tools do offer additional protection. In addition to<br />
numerous pliers and tongs, hand tools are available with either suction<br />
cups or magnetic pick-ups. Most of the tools are constructed of soft<br />
<strong>all</strong>oy materials, eng<strong>in</strong>eered to easily crush if caught between dies or<br />
parts of the mach<strong>in</strong>e. Many of today’s hand tools are designed with<br />
ergonomics <strong>in</strong> m<strong>in</strong>d. This provides the operator with maximum comfort<br />
and m<strong>in</strong>imum fatigue.<br />
Part No. CYF-550<br />
Lightweight duckbill<br />
spr<strong>in</strong>g-opened pliers.<br />
Jaw Length – 2-1/2”<br />
Total Length – 7”<br />
Weight – 2 oz<br />
Part No. CYF-551<br />
Pliers with long tapered jaws—<br />
ideal for sm<strong>all</strong> parts.<br />
Jaw Length – 3”<br />
Total Length – 7-1/2”<br />
Weight – 2-1/4 oz<br />
Part No. CYF-552<br />
Pliers with a right-angle<br />
hook nose for gripp<strong>in</strong>g.<br />
Jaw Length – 2-1/2”<br />
Total Length – 7”<br />
Weight – 2 oz<br />
Part No. CYF-553<br />
1 -1/2” wide duckbill for<br />
rigid support.<br />
Jaw Length – 3”<br />
Total Length – 7-1/8”<br />
Weight – 3-1/2 oz<br />
Part No. CYF-554<br />
Heavy-duty pliers similar<br />
to CYF-552.<br />
Jaw Length – 2-3/4”<br />
Total Length – 7-1/2”<br />
Weight – 4 oz<br />
Part No. CYF-555<br />
Heavy-duty rugged plier.<br />
Jaw Length – 2-3/4”<br />
Total Length – 8-1/4”<br />
Weight – 4 oz<br />
Part No. CYF-556<br />
Similar to CYF-551<br />
with vacuum cup.<br />
Jaw Length – 3”<br />
Total Length – 7-1/2”<br />
Weight – 4 oz<br />
Part No. CYF-557<br />
Heavy-duty duckbill pliers.<br />
Jaw Length – 3”<br />
Total Length – 8-1/4”<br />
Weight – 5-3/4 oz<br />
Part No. CYF-558<br />
Similar to CYF-557 with thumb<br />
loop for operator comfort.<br />
Jaw Length – 2-7/8”<br />
Total Length – 8-5/8”<br />
Weight – 5-1/2 oz<br />
Part No. CYF-559<br />
Sm<strong>all</strong>, heavy-duty stubby<br />
pliers with good gripp<strong>in</strong>g<br />
capability.<br />
Jaw Length – 1-1/2”<br />
Total Length – 6-1/8”<br />
Weight – 4 oz<br />
Part No. CYF-560<br />
Medium-duty, spr<strong>in</strong>g-opened<br />
pliers with long nose.<br />
Jaw Length – 4-1/2”<br />
Total Length – 9-3/4”<br />
Weight – 6 oz<br />
Part No. CYF-562<br />
Ergonomic pliers<br />
with 45° bend.<br />
Jaw Length – 3”<br />
Total Length – 7”<br />
Weight – 2-1/4 oz<br />
Part No. CYF-563<br />
Medium-duty, spr<strong>in</strong>g-opened<br />
pliers with offset design.<br />
Jaw Length – 4-1/2”<br />
Total Length – 10-1/4”<br />
Weight – 5-1/2 oz<br />
Offset – 1-3/4”<br />
Part No. CYF-564<br />
Popular long-handled<br />
lightweight tongs.<br />
Jaw Length – 3-1/8”<br />
Total Length – 11-1/2”<br />
Weight – 5 oz<br />
Part No. CYF-565<br />
Similar to CYF-564 with<br />
torsion spr<strong>in</strong>g.<br />
Jaw Length – 3”<br />
Total Length – 11-1/2”<br />
Weight – 59/10 oz<br />
Part No. CYF-566<br />
Similar to CYF-564 with<br />
vacuum cup.<br />
Jaw Length – 3”<br />
Total Length – 11”<br />
Weight – 7 oz<br />
Part No. CYF-567<br />
Heavy-duty straighthandled<br />
tongs for two-handed<br />
use.<br />
Jaw Length – 3”<br />
Total Length – 11-1/2”<br />
Weight – 4 oz<br />
Part No. CYF-568<br />
Medium-duty tongs with<br />
f<strong>in</strong>ger loops on both handles.<br />
Jaw Length – 3”<br />
Total Length – 10-1/2”<br />
Weight – 6 oz<br />
Part No. CYF-569<br />
Popular ergonomic tongs with<br />
30° bend and thumb loop.<br />
Jaw Length – 2-7/8”<br />
Total Length – 10”<br />
Weight – 7 oz<br />
Part No. CYF-570<br />
Ergonomic tong with 60° bend<br />
and two large loops. These tongs<br />
can be used <strong>in</strong> either direction.<br />
Jaw Length – 2-1/2”<br />
Total Length – 12”<br />
Weight – 10 oz<br />
Part No. CYF-571<br />
Heavy-duty straight-handled<br />
tongs to handle<br />
parts up to 20 oz.<br />
Jaw Length – 3”<br />
Total Length – 10-5/8”<br />
Weight – 6-1/2 oz<br />
Part No. CYF-572<br />
Versatile heavy-duty tongs<br />
with thumb loop.<br />
Jaw Length – 3”<br />
Total Length – 10-1/2”<br />
Weight – 7-1/2 oz<br />
Part No. CYF-573<br />
Similar to CYF-572 with<br />
vacuum cup.<br />
Jaw Length – 3”<br />
Total Length – 10-1/2”<br />
Weight – 9-1/2 oz<br />
Part No. CYF-574<br />
Heavy-duty tongs with f<strong>in</strong>ger<br />
loops on both handles.<br />
Jaw Length – 3”<br />
Total Length – 10-5/8”<br />
Weight – 8 oz<br />
Part No. CYF-575<br />
Rugged tongs for heavy<br />
parts up to 5 lb.<br />
Jaw Length – 3”<br />
Total Length – 12”<br />
Weight – 10 oz<br />
2 | HAND FEEDING TOOLS
HAND-FEEDING AND RETRIEVAL TOOLS (CONTINUED)<br />
Part No. CYF-576<br />
Similar to CYF-575<br />
with adjustable set<br />
screw <strong>in</strong> jaw for extra<br />
gripp<strong>in</strong>g power or sheet pull<strong>in</strong>g.<br />
Jaw Length – 3”<br />
Total Length – 12”<br />
Weight – 11 oz<br />
Part No. CYF-577<br />
Tong with short 1” jaw<br />
ruggedly designed for<br />
good gripp<strong>in</strong>g; gapped<br />
3/16” for thick plate.<br />
Total Length – 10”<br />
Weight – 8 oz<br />
Part No. CYF-578<br />
Most versatile of <strong>all</strong> handfeed<strong>in</strong>g<br />
tools. Will handle<br />
up to 10 lb easily.<br />
Jaw Length – 4-1/2”<br />
Total Length – 15”<br />
Weight – 15 oz<br />
Part No. CYF-579<br />
Tongs with th<strong>in</strong> tapered<br />
jaw. Extremely light-weight<br />
for their size.<br />
Jaw Length – 2”<br />
Total Length – 10-1/2”<br />
Weight – 8 oz<br />
Part No. CYF-580<br />
Popular right-angle-jaw tongs<br />
for handl<strong>in</strong>g flanged or cupshaped<br />
workpieces.<br />
Jaw Length – 5/8”<br />
Total Length – 10-3/8”<br />
Weight – 9 oz<br />
Part No. CYF-581<br />
Reverse-angle grip to be held<br />
with jaws up or down; ideal for<br />
flanges and cupped operations.<br />
Total Length – 10-5/8”<br />
Weight – 11 oz<br />
Part No. CYF-583<br />
Straight-handled tongs.<br />
Jaw Length – 3”<br />
Total Length – 12-1/2”<br />
Weight – 6 oz<br />
Part No. CYF-584<br />
Tongs designed to hold<br />
3-1/2” diameter objects.<br />
Total Length – 14”<br />
Weight – 12 oz<br />
Part No. CYF-585<br />
Stubby–nose tongs with f<strong>in</strong>ger<br />
loops on both handles.<br />
Jaw Length – 2”<br />
Total Length – 13”<br />
Weight – 9 oz<br />
Part No. CYF-586<br />
Extra long lightweight tongs.<br />
Jaw Length – 3”<br />
Total Length – 16-1/4”<br />
Weight – 8-1/2 oz<br />
Part No. CYF-587<br />
Needle–nose tongs designed<br />
to be held <strong>in</strong> the hand and<br />
closed by thumb pressure;<br />
ideal for sm<strong>all</strong> parts.<br />
Jaw Depth – 2-7/8”<br />
Total Length – 13-1/2”<br />
Weight – 5-1/2 oz<br />
Part No. CYF-<br />
588<br />
Similar to CYF-587<br />
with jaw<br />
tips formed down<br />
1/2”.<br />
Total Length – 13-1/2”<br />
Weight – 5-1/2 oz<br />
Part No. CYF-589<br />
Similar to CYF-580 with<br />
right-angle po<strong>in</strong>t<strong>in</strong>g up.<br />
Jaw Length – 5/8”<br />
Total Length – 14-3/4”<br />
Weight – 11 oz<br />
Part No. CYF-590<br />
Designed to pick up 1” bush<strong>in</strong>gs.<br />
Total Length – 12-1/8”<br />
Weight – 6 oz<br />
Part No. CYF-591<br />
Designed to pick up<br />
1-3/4” bush<strong>in</strong>gs.<br />
Total Length – 13-1/8”<br />
Weight – 7 oz<br />
Part No. CYF-<br />
592<br />
Stock positi<strong>one</strong>r with<br />
screwdriver po<strong>in</strong>t. Ideal for remov<strong>in</strong>g<br />
stuck workpieces from die.<br />
Total Length – 15”<br />
Weight – 2-1/2 oz<br />
Part No. CYF-593<br />
Similar to CYF-592 with 90°<br />
bend to remove<br />
parts from die.<br />
Total Length – 14”<br />
Weight – 2-1/2 oz<br />
Part No. CYF-594<br />
Tongs designed with an offset<br />
jaw; mach<strong>in</strong>ed to fit 1” taper.<br />
Total Length – 15-1/2”<br />
Weight – 12 oz<br />
Part No. CYF-595<br />
Short–jaw tongs with longhandle<br />
protection.<br />
Jaw Length – 2”<br />
Total Length – 16”<br />
Weight – 11 oz<br />
Part No. CYF-596<br />
Tongs with 3/4” wide jaw. Ideal<br />
for gripp<strong>in</strong>g th<strong>in</strong> sheet stock.<br />
Jaw Length – 2”<br />
Total Length – 22-5/8”<br />
Weight – 20 oz<br />
Part No. CYF-597<br />
Tongs designed to hold 1/4”<br />
stock. Jaws are spaced 1/4”<br />
par<strong>all</strong>el.<br />
Jaw Length – 3”<br />
Total Length – 18”<br />
Weight – 15 oz<br />
Part No. CYF-598<br />
Stubby–nosed tongs.<br />
Jaw Length – 2”<br />
Total Length – 19-3/4”<br />
Weight – 15 oz<br />
Part No. CYF-600<br />
Lightweight tweezers.<br />
Total Length – 6-1/2”<br />
Weight – 11/10 oz<br />
Part No. CYF-601<br />
Heavier tweezers.<br />
Total Length – 9”<br />
Weight – 13/5 oz<br />
HAND FEEDING TOOLS | 3
VACUUM LIFTERS<br />
These vacuum lifters grip and hold oiled or dry sheet metal, glass, plastic, steel, plexiglass, polished st<strong>one</strong>, fiberglass, auto panels, or any other<br />
material with a smooth surface.<br />
LITTLE-GRABBER LIFTER<br />
These <strong>one</strong>-f<strong>in</strong>ger lifters are ideal for light objects or rais<strong>in</strong>g corners for<br />
better grip. Always handy and ready for use, yet leaves <strong>one</strong> hand free<br />
for other work. It has speci<strong>all</strong>y designed release tabs. Made from tough<br />
rubber compound.<br />
Part No. KMK-007 – 2-1/8" diameter (1” f<strong>in</strong>ger loop) – lifts 4 lbs<br />
Part No. KMK-056 – 2-5/8” diameter (1-1/4” f<strong>in</strong>ger loop for use with<br />
gloves) – lifts 6 lbs<br />
KNUCKLE-SAVER LIFTER<br />
This two-f<strong>in</strong>ger grip and larger cup provide extra lift<strong>in</strong>g capacity. Its<br />
larger diameter makes this lifter ideal for greater loads. Breaks oil<br />
adhesions easily. It also has speci<strong>all</strong>y designed release tabs. Lifts about<br />
10 pounds.<br />
Part No. KMK-008 – 3-1/4” diameter (1” f<strong>in</strong>ger loop)<br />
SUPER-GRABBER LIFTER<br />
This four-f<strong>in</strong>ger grip and larger cup provide extra lift<strong>in</strong>g capacity. Its<br />
larger diameter makes this lifter ideal for greater loads. Breaks oil<br />
adhesions easily. It also has speci<strong>all</strong>y designed release tabs. Lifts about<br />
12 pounds.<br />
Part No. KMK-055 – 4-3/4” diameter<br />
MEDIUM-DUTY LIFTER<br />
Sturdy construction and a fast-action metal release valve offer safe,<br />
quick handl<strong>in</strong>g of smooth surface materials. Full-hand grip for extra<br />
strength gives operator extra freedom of movement. Lifts about 10<br />
pounds.<br />
Part No. KMK-009 – 3-1/4” diameter<br />
Part No. KMK-013 – Replacement cup only – 3-1/4” diameter<br />
MEDIUM-DUTY GRABBER/LIFTER<br />
This comb<strong>in</strong>ation grabber and lifter comb<strong>in</strong>es the flexibility of a grabber<br />
with the hold<strong>in</strong>g strength of a lifter. Just lift the tipped edge to release<br />
the vacuum. Lifts about 15 pounds.<br />
Part No. KMK-040 – 3-1/4” diameter<br />
4 | HAND FEEDING TOOLS
HAND-FEEDING AND RETRIEVAL TOOLS<br />
VACUUM LIFTERS (CONTINUED)<br />
HEAVY-DUTY SHEET METAL LIFTER<br />
These lifters have powerful suction to lift heavier loads. A handy triggervalve<br />
release disengages the vacuum lifter <strong>in</strong>stantly and safely. This<br />
saves wear and tear on gloves and hands. These lifters are gener<strong>all</strong>y<br />
used for load<strong>in</strong>g, unload<strong>in</strong>g, pil<strong>in</strong>g, and shift<strong>in</strong>g sheet metal from trucks,<br />
stock, etc. The 3” cup lifts about 15 pounds; the 4” cup about 25<br />
pounds; the 5” cup about 35 pounds.<br />
Part No. KMK-047 – s<strong>in</strong>gle cup, 3” diameter<br />
Part No. KMK-043 – s<strong>in</strong>gle cup, 4” diameter<br />
Part No. KMK-010 – s<strong>in</strong>gle cup, 5” diameter<br />
DOUBLE-CUP SHEET METAL LIFTER<br />
These lifters have a convenient handle for <strong>one</strong> or two-handed lift<strong>in</strong>g.<br />
Positive grip <strong>in</strong>creases the operator’s work<strong>in</strong>g capacity. Dual trigger<br />
valves disengage the lifter from material. The 3” cups lift about 30<br />
pounds; the 4” cups about 50 pounds; and the 5” cups about 75<br />
pounds.<br />
Part No. KMK-054 – 2 cups, 3” diameter each<br />
Part No. KMK-044 – 2 cups, 4” diameter each<br />
Part No. KMK-011 – 2 cups, 5” diameter each<br />
REPLACEMENT CUPS:<br />
Part No. KMK-057 – 3” diameter s<strong>in</strong>gle cup<br />
Part No. KMK-031 – 4” diameter s<strong>in</strong>gle cup<br />
Part No. KMK-014 – 5” diameter s<strong>in</strong>gle cup<br />
TWO-MAN VACUUM LIFTER<br />
These lifters have extra capacity for extra safety. Ideal for mov<strong>in</strong>g heavy<br />
gauge metal, marble slab, heavy plate glass, and plastic sheets. The 4”<br />
cups lift about 50 pounds; the 5” cups about 75 pounds.<br />
Part No. KMK-041 – 2 cups, 4” diameter each<br />
Part No. KMK-042 – 2 cups, 5” diameter each<br />
201⁄2”<br />
DOUBLE-CUP VERTI-LIFT<br />
Powerful suction cups are used to lift and move loads from the floor<br />
without hav<strong>in</strong>g to bend over. It has a handy trigger-valve release<br />
to disengage the vacuum lifter <strong>in</strong>stantly and safely. These handoperated<br />
vacuum lifters are used for repeated lift<strong>in</strong>g and mov<strong>in</strong>g of<br />
non-porous materials on the ground level. The vertical handle is 32”<br />
and the total length is 37”. The 4” cups lift about 50 pounds; the 5”<br />
cups about 75 pounds.<br />
Part No. KMK-045 – 4” cup diameter<br />
Part No. KMK-031 – Replacement cup (4”)<br />
Part No. KMK-046 – 5” cup diameter<br />
Part No. KMK-014 – Replacement cup (5”)<br />
HAND FEEDING TOOLS | 5
VACUUM LIFTERS (CONTINUED)<br />
These lifters can be used to place and remove material <strong>in</strong> and from<br />
the mach<strong>in</strong>e. These tools are not to be used as a po<strong>in</strong>t-of-operation<br />
safeguard, but can be used to help keep the operator’s hands out of the<br />
po<strong>in</strong>t of operation when load<strong>in</strong>g parts.<br />
These lifters have strengthened steel rods and oil-resistant flexible<br />
vacuum cups. They are ideal for handl<strong>in</strong>g plastic, metal, glass, and<br />
any other material that has a smooth, non-porous surface. There are<br />
three types of lifters to choose from. The s<strong>in</strong>gle-cup lifter is available <strong>in</strong><br />
three cup sizes. The double-cup lifter is available <strong>in</strong> <strong>one</strong> cup size. The<br />
straight-handle lifter has a handle attached to the top of the vacuum<br />
cup and provides the user with extra reach. All three lifters <strong>in</strong>corporate<br />
an <strong>in</strong>stant release button. The 2-1/8” cup lifts about 3 pounds, the<br />
3-1/4” cup lifts about 5 pounds, and the 4” cup lifts about 6 pounds.<br />
The double-cup lifters lift about 6 pounds.<br />
REPLACEMENT CUPS:<br />
Part No. KMK-012 – 2-1/8” diameter<br />
Part No. KMK-013 – 3-1/4” diameter<br />
Part No. KMK-031 – 4” diameter<br />
Positive pushbutton valve<br />
assures <strong>in</strong>stant release<br />
STRAIGHT-HANDLE LIFTER<br />
PART NO. LENGTH CUP DIAMETER<br />
KMK-048 12" Handle 3-1/4"<br />
KMK-049 15" Handle 3-1/4"<br />
KMK-050 18" Handle 3-1/4"<br />
KMK-051 12" Handle 4"<br />
KMK-052 15" Handle 4"<br />
KMK-053 18" Handle 4"<br />
Seamless steel rod impregnated<br />
& strengthened for rough use<br />
Textured, contoured pistol–<br />
grip for non–slip hold<strong>in</strong>g<br />
Top quality rubber cups give<br />
long last<strong>in</strong>g wear<br />
SINGLE-CUP LIFTER<br />
PART NO. LENGTH CUP DIAMETER<br />
KMK-001 12" Handle 2-1/8"<br />
KMK-034 15" Handle 2-1/8"<br />
KMK-002 18" Handle 2-1/8"<br />
KMK-003 12" Handle 3-1/4"<br />
KMK-004 15" Handle 3-1/4"<br />
KMK-035 18" Handle 3-1/4"<br />
KMK-033 12" Handle 4"<br />
KMK-005 15" Handle 4"<br />
KMK-036 18" Handle 4"<br />
DOUBLE-CUP LIFTER<br />
PART NO. LENGTH CUP DIAMETER<br />
KMK-037 12" Handle 2-1/8"<br />
KMK-006 15" Handle 2-1/8"<br />
KMK-038 18" Handle 2-1/8"<br />
6 | HAND FEEDING TOOLS
MAGNETIC TOOLS<br />
Part No. CYF-431<br />
Pick-up capacity up to 3 pounds with<br />
release handle.<br />
S<strong>in</strong>gle magnet – 12” length<br />
Part No. CYF-432<br />
Pick-up capacity up to 7 pounds with<br />
release handle.<br />
Double magnet – 14” length<br />
Part No. CYF-602<br />
Pick-up capacity up to 3 pounds with<br />
twist release.<br />
S<strong>in</strong>gle magnet – 12” length<br />
Part No. CYF-603<br />
Pick-up capacity up to 7 pounds with<br />
twist release.<br />
Double magnet – 14” length<br />
Part No. CYF-604<br />
Pick-up capacity up to 4 ounces with<br />
low profile.<br />
S<strong>in</strong>gle magnet – 15” length<br />
Part No. CYF-605<br />
Pick-up capacity up to 8 ounces with<br />
low profile.<br />
Double magnet – 15” length<br />
HAND FEEDING TOOLS | 7
Control <strong>Systems</strong><br />
For Presses & Press Brakes<br />
www.rockfordsystems.com
Press And Press Brake Control <strong>Systems</strong> is<br />
a comprehensive catalog that features a<br />
complete l<strong>in</strong>e of control systems for mechanical<br />
power presses & press brakes, and hydraulic<br />
power presses & press brakes. The catalog is<br />
divided <strong>in</strong>to sections that offer control systems<br />
and comp<strong>one</strong>nts for:<br />
• Full-Revolution-Clutch Presses<br />
• Part-Revolution-Clutch Presses<br />
and Press Brakes<br />
• Hydraulic Presses and Press Brakes<br />
• Press Automation Control<br />
The catalog goes <strong>in</strong>to detail about the features<br />
of the systems, and describes the different<br />
options available to update or replace exist<strong>in</strong>g<br />
control systems. This catalog also <strong>in</strong>cludes<br />
spr<strong>in</strong>g-loaded turnover bars, palm button<br />
assemblies, danger signs, and a section with<br />
helpful references.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong><br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.
IN GENERAL..............................................................................3<br />
MECHANICAL POWER PRESS CONTROL SYSTEMS............... 4-6<br />
FULL-REVOLUTION-CLUTCH PRESS CONTROL SYSTEMS... 7-19<br />
Introduction............................................................................... 7-8<br />
Standard Full-Revolution Control ............................................. 9-10<br />
Custom Full-Revolution Control ...................................................10<br />
Select<strong>in</strong>g a Full-Revolution-Clutch Press Control ..........................11<br />
Individual Comp<strong>one</strong>nts........................................................... 12-14<br />
Comp<strong>one</strong>nt Packages............................................................ 15-16<br />
Air Cyl<strong>in</strong>ders................................................................................17<br />
Survey For Full-Revolution Press............................................ 18-19<br />
PART-REVOLUTION-CLUTCH PRESS CONTROL SYSTEMS......20-56<br />
SSC-1500 PRESS CONTROL ............................................................. 21-37<br />
Introduction....................................................................... 21-22<br />
SSC-1500 Standard Press Control..................................... 23-24<br />
SSC-1500 Custom Press Control.............................................25<br />
SSC-1500 Remote Operator-Style Control Boxes................ 26-27<br />
Control Module Kit.......................................................................28<br />
Keypad/Display Kit...................................................................28<br />
Remote Operator Stations........................................................28<br />
Select<strong>in</strong>g an SSC-1500 Part-Revolution Press Control...............29<br />
SSC-1500 Press Individual Comp<strong>one</strong>nts............................. 30-34<br />
Lockout Valves........................................................................35<br />
Select<strong>in</strong>g an SSC-1500 Press Comp<strong>one</strong>nt Package............ 36-37<br />
SSC-3000 PRESS AUTOMATION CONTROL .............................. 38-56<br />
SSC-3000 Standard Control....................................................39<br />
SSC-3000 Custom Control......................................................40<br />
SSC-3000 Modular Control Rack Kit........................................40<br />
SSC-3000 Touch Screen/Display Kit........................................40<br />
SSC-3000 Remote Operator Stations.......................................41<br />
SSC-3000 Basic System Features...................................... 42-43<br />
SSC-3000 Expandable Options.......................................... 44-46<br />
Select<strong>in</strong>g an SSC-3000 Press Automation Control....................47<br />
SSC-3000 Comp<strong>one</strong>nt Packages.............................................48<br />
SSC-3000 Individual Comp<strong>one</strong>nts............................................48<br />
Control Consoles.........................................................................49<br />
Special Controls .........................................................................49<br />
Remote Motor Control Operator Stations for Use With<br />
SSC-1500 Press Controls, SSC-3000 Press Controls,<br />
and SSC-1500 Press Brake Controls........................................50<br />
Control Bars................................................................................51<br />
Floor Stands for Control Bars.......................................................51<br />
Select<strong>in</strong>g a Control Bar................................................................52<br />
Survey for Part-Revolution Press............................................ 53-56<br />
HYDRAULIC POWER PRESS CONTROL SYSTEMS.............. 57-65<br />
Introduction.................................................................................57<br />
Standard Hydraulic Power Press Control ................................ 58-59<br />
Custom Hydraulic Power Press Control ........................................60<br />
Remote Operator-Style Control Boxes ......................................60<br />
HYDRAULIC POWER PRESS CONTROL SYSTEMS (CONT).... 57-65<br />
Control Module Kit...................................................................60<br />
Subpanel................................................................................60<br />
Keypad/Display Kit.......................................................................61<br />
Remote Operator Stations............................................................61<br />
Select<strong>in</strong>g an RHPC Hydraulic Press Control...................................62<br />
Hydraulic Control <strong>Systems</strong> Individual Comp<strong>one</strong>nts.........................63<br />
Survey for Hydraulic Press..................................................... 64-65<br />
PRESS BRAKE CONTROL SYSTEMS.................................. 66-84<br />
Introduction........................................................................... 66-71<br />
MECHANICAL PRESS BRAKE CONTROL SYSTEMS<br />
SSC-1500 PRESS BRAKE CONTROL.......................................... 72-84<br />
Introduction.............................................................................72<br />
SSC-1500 Standard Press Brake Control ........................... 72-73<br />
SSC-1500 Custom Press Brake Control....................................74<br />
SSC-1500 Remote Operator-Style Control Boxes................ 75-76<br />
Control Module Kit...................................................................77<br />
Keypad/Display Kit...................................................................77<br />
Remote Operator Stations........................................................77<br />
Select<strong>in</strong>g an SSC-1500 Press Brake Control.............................78<br />
SSC-1500 Individual Comp<strong>one</strong>nts...................................... 79-81<br />
Comp<strong>one</strong>nt Package for Mechanical-Friction-Clutch<br />
Press Brakes Only...............................................................82<br />
RCL-Series Air Cyl<strong>in</strong>ders..........................................................83<br />
Other Air Cyl<strong>in</strong>ders Available....................................................84<br />
SINGLE- AND TWO-SPEED AIR-CLUTCH PRESS BRAKES.......... 85-86<br />
Introduction.............................................................................85<br />
Select<strong>in</strong>g a Control System......................................................85<br />
Comp<strong>one</strong>nt Packages for S<strong>in</strong>gle- and Two-Speed Press Brakes....86<br />
HYDRAULIC PRESS BRAKE CONTROL SYSTEMS....................... 87-93<br />
Introduction.............................................................................87<br />
Standard Hydraulic Press Brake Control.............................. 88-89<br />
Custom Hydraulic Press Brake Control......................................90<br />
Remote Operator-Style Control Boxes ......................................90<br />
Control Module Kit...................................................................90<br />
Subpanel................................................................................90<br />
Keypad/Display Kit...................................................................91<br />
Remote Operator Stations........................................................91<br />
Select<strong>in</strong>g an RHPS Hydraulic Press Brake Control.....................92<br />
Hydraulic Control <strong>Systems</strong> Individual Comp<strong>one</strong>nts.....................93<br />
Survey for Press Brakes......................................................... 94-97<br />
SPRING-LOADED TURNOVER BARS.........................................98<br />
PALM BUTTON ASSEMBLIES........................................... 99-102<br />
DANGER SIGNS AND LABELS........................................ 103-105<br />
REFERENCES................................................................ 106-137<br />
INDEX............................................................................ 138-139<br />
The applications described <strong>in</strong> this catalog are for <strong>in</strong>structional and <strong>in</strong>formational purposes only; the photos <strong>in</strong> this catalog are for illustrative purposes only. They may<br />
not represent actual usage. This catalog has been carefully checked for accuracy and is thought to be fully consistent with the products described here<strong>in</strong>. However,<br />
<strong>Rockford</strong> <strong>Systems</strong>, LLC does not assume liability for the contents of this publication or for the use of any products described here<strong>in</strong>. <strong>Rockford</strong> <strong>Systems</strong>, LLC reserves<br />
the right to make changes to the products and documentation without further notice.<br />
This document conta<strong>in</strong>s proprietary <strong>in</strong>formation protected by copyright. No part of this catalog may be reproduced, transmitted, stored <strong>in</strong> a retrieval system, or<br />
translated <strong>in</strong>to any language, <strong>in</strong> any form or by any means without prior written permission from <strong>Rockford</strong> <strong>Systems</strong>, LLC, 5795 Logistics Parkway, <strong>Rockford</strong>, Ill<strong>in</strong>ois<br />
61109. <strong>Rockford</strong> <strong>Systems</strong> reserves the right to make changes or revisions to the material conta<strong>in</strong>ed <strong>in</strong> this catalog and cannot be held liable for <strong>in</strong>cidental or<br />
consequential damages result<strong>in</strong>g from the furnish<strong>in</strong>g, performance or use of this material.<br />
Copyright © 2019 by <strong>Rockford</strong> <strong>Systems</strong>, LLC. All rights reserved. Not to be reproduced <strong>in</strong> whole or <strong>in</strong> part without written permission. LITHO IN U.S.A.<br />
2 | CONTROL SYSTEMS
IN GENERAL<br />
When safeguard<strong>in</strong>g hazardous mach<strong>in</strong>ery and processes, the general<br />
requirements that apply are <strong>in</strong> OSHA (Occupational Safety and Health<br />
Adm<strong>in</strong>istration) Title 29 of the Code of Federal Regulations. The<br />
follow<strong>in</strong>g is a list:<br />
1. An Act–Public Law 91-596, 91st Congress, S. 2193, December<br />
29, 1970, Duties, Section 5(a)(1)(2)(b)<br />
2. OSHA 29 CFR sections that an employer (user) must comply<br />
with <strong>in</strong>clude:<br />
1910.211 Def<strong>in</strong>itions<br />
1910.212 General requirements for <strong>all</strong> mach<strong>in</strong>es<br />
1910.213 Woodwork<strong>in</strong>g mach<strong>in</strong>ery requirements<br />
1910.215 Abrasive wheel mach<strong>in</strong>ery<br />
1910.216 Mills and calenders <strong>in</strong> the rubber and<br />
plastics <strong>in</strong>dustry<br />
1910.217 Mechanical power presses<br />
1910.219 Mechanical power-transmission<br />
apparatus<br />
3. OSHA 29 CFR 1910.147 The control of hazardous energy<br />
(lockout/tagout).<br />
4. OSHA 29 CFR 1910.301-1910.399 Electrical<br />
These publications can be acquired by contact<strong>in</strong>g:<br />
U.S. Government Pr<strong>in</strong>t<strong>in</strong>g Office<br />
P.O. Box 979050<br />
St. Louis 63197-9000<br />
(202) 512-1800 • http://bookstore.gpo.gov<br />
The basic OSHA standard, 29 CFR 1910.212, states that any mach<strong>in</strong>e<br />
that creates a hazard must be safeguarded to protect the operator<br />
and other employees. OSHA can also cite violations referenc<strong>in</strong>g other<br />
standards such as the ANSI (American National Standards Institute) B11<br />
series. The follow<strong>in</strong>g is a list of applicable and related ANSI standards<br />
available at the pr<strong>in</strong>t<strong>in</strong>g of this publication.<br />
ANSI Publications<br />
B11–2008 General Safety Requirements Common<br />
to ANSI B11 Mach<strong>in</strong>es<br />
B11.1 Mechanical Power Presses<br />
B11.2 Hydraulic Power Presses<br />
B11.3 Power Press Brakes<br />
B11.4 Shears<br />
B11.5 Iron Workers<br />
B11.6 Lathes<br />
B11.7 Cold Headers and Cold Formers<br />
B11.8 Drill<strong>in</strong>g, Mill<strong>in</strong>g, and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.9 Gr<strong>in</strong>d<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.10 Metal Saw<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.11 Gear and Spl<strong>in</strong>e Cutt<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.12 Roll Form<strong>in</strong>g and Roll Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.13 Automatic Screw/Bar and Chuck<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.14 Withdrawn (Now see ANSI B11.18)<br />
B11.15 Pipe, Tube, and Shape Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.16 Metal Powder Compact<strong>in</strong>g Presses<br />
B11.17 Horizontal Hydraulic Extrusion Presses<br />
B11.18 Coil Process<strong>in</strong>g <strong>Systems</strong><br />
B11.19 Performance Criteria for <strong>Safeguard<strong>in</strong>g</strong><br />
B11.20 Integrated Manufactur<strong>in</strong>g <strong>Systems</strong><br />
ANSI Publications (cont<strong>in</strong>ued)<br />
B11.21 Mach<strong>in</strong>e Tools Us<strong>in</strong>g Lasers for Process<strong>in</strong>g<br />
Materials<br />
B11.22 Turn<strong>in</strong>g Centers and CNC Turn<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.23 Mach<strong>in</strong><strong>in</strong>g Centers and CNC Mill<strong>in</strong>g, Drill<strong>in</strong>g, and<br />
Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
B11.24 Transfer Mach<strong>in</strong>es<br />
B11.TR1 Ergonomic Guidel<strong>in</strong>es<br />
B11.TR2 Mist Control Considerations<br />
B11.TR3 Risk Assessment and Risk Reduction<br />
B11.TR4 Selection of Programmable Electronic <strong>Systems</strong><br />
(PES/PLC) for Mach<strong>in</strong>e Tools<br />
B11.TR5 Sound Level Measurement Guidel<strong>in</strong>es<br />
B11.TR7 Design For Safety and Lean Manufactur<strong>in</strong>g<br />
R15.06 Robotic <strong>Safeguard<strong>in</strong>g</strong><br />
B15.1 Mechanical Power Transmission Apparatus<br />
B56.5 Guided Industrial Vehicles and Automated Function<br />
of Manned Industrial Vehicles<br />
B65.1 Pr<strong>in</strong>t<strong>in</strong>g Press <strong>Systems</strong><br />
B65.2 B<strong>in</strong>d<strong>in</strong>g and F<strong>in</strong>ish<strong>in</strong>g <strong>Systems</strong><br />
B65.5 Stand-Al<strong>one</strong> Platen Presses<br />
B151.1 Horizontal (Plastic) Injection Mold<strong>in</strong>g Mach<strong>in</strong>es<br />
B152.1 Hydraulic Die Cast<strong>in</strong>g Presses<br />
B154.1 Rivet Sett<strong>in</strong>g Mach<strong>in</strong>es<br />
B155.1 Packag<strong>in</strong>g and Packag<strong>in</strong>g-Related Convert<strong>in</strong>g<br />
Mach<strong>in</strong>ery<br />
01.1 Woodwork<strong>in</strong>g Mach<strong>in</strong>ery<br />
These standards can be purchased by contact<strong>in</strong>g:<br />
ANSI (American National Standards Institute, Inc.)<br />
25 West 43rd Street, 4th Floor<br />
New York, New York 10036<br />
(212) 642-4900 • www.ansi.org<br />
Another good reference for safety on mach<strong>in</strong>e tools is the follow<strong>in</strong>g<br />
publication from the National Safety Council:<br />
<strong>Safeguard<strong>in</strong>g</strong> Concepts Illustrated—7th Edition<br />
This publication can be purchased by contact<strong>in</strong>g:<br />
National Safety Council<br />
1121 Spr<strong>in</strong>g Lake Drive<br />
Itasca, IL 60143-3201<br />
1-800-621-7615 • www.nsc.org<br />
Other sources that can be used for reference <strong>in</strong>clude:<br />
1. NFPA 79, Electrical Standard for Industrial Mach<strong>in</strong>ery<br />
2. NEC (National Electrical Code) Handbook<br />
3. NEMA (National Electrical Manufacturers Association)<br />
For additional safety <strong>in</strong>formation and assistance <strong>in</strong> devis<strong>in</strong>g,<br />
implement<strong>in</strong>g or revis<strong>in</strong>g your safety program, please contact the<br />
mach<strong>in</strong>e manufacturer, your state and local safety councils, <strong>in</strong>surance<br />
carriers, national trade associations, and your state’s occupational<br />
safety and health adm<strong>in</strong>istration.<br />
CONTROL SYSTEMS | 3
MECHANICAL POWER PRESS CONTROL SYSTEMS<br />
Each mechanical power press must be looked at as an <strong>in</strong>dividual<br />
system. This system consists of, but is not limited to, the frame, <strong>all</strong><br />
mechanical parts, clutch and brake assemblies, electrical or electronic<br />
systems, hydraulic systems, pneumatic systems, tool<strong>in</strong>g or dies<br />
(present and future), tool or die setup, safeguard<strong>in</strong>g, material handl<strong>in</strong>g,<br />
ma<strong>in</strong>tenance requirements, size or configuration of workpiece, and most<br />
importantly, production requirements.<br />
OSHA STANDARDS<br />
The controls and safeguard<strong>in</strong>g systems offered <strong>in</strong> this section of the<br />
catalog will help the user of mechanical power presses (punch presses)<br />
meet or exceed OSHA 29 CFR 1910.212, 1910.217, 1910.219,<br />
1910.147 and ANSI B11.1 safety standards as we <strong>in</strong>terpret them.<br />
OSHA’s Code of Federal Regulations can be purchased by contact<strong>in</strong>g:<br />
U.S. Government Pr<strong>in</strong>t<strong>in</strong>g Office<br />
P.O. Box 371954<br />
Pittsburgh, PA 15250-7954<br />
(202) 512-1800<br />
http://bookstore.gpo.gov<br />
ANSI STANDARDS<br />
There are several references available on press safety; however, most<br />
<strong>in</strong>dustries use the ANSI (American National Standards Institute) B11.1<br />
standard for the best safety practice on power presses. This standard<br />
can be purchased by contact<strong>in</strong>g:<br />
ANSI<br />
American National Standards Institute, Inc.<br />
25 West 43rd Street, 4th Floor<br />
New York, New York 10036<br />
(212) 642-4900<br />
www.ansi.org<br />
TYPES OF CLUTCHES ON PRESSES<br />
Most power presses have <strong>one</strong> of two types of clutches:<br />
1. Full Revolution (sometimes referred to as a mechanical clutch)<br />
2. Part Revolution, classified <strong>in</strong> two categories:<br />
— Air Clutch<br />
— Mechanical-Friction Clutch<br />
CONDITION OF THE PRESS<br />
The equipment offered <strong>in</strong> this catalog can neither cure nor overcome<br />
a malfunction<strong>in</strong>g mach<strong>in</strong>e or prevent a mechanical defect or failure of<br />
a comp<strong>one</strong>nt part thereof, nor prevent a repeat or un<strong>in</strong>tended stroke<br />
(cycle) result<strong>in</strong>g from a mechanical malfunction, defect or failure of the<br />
mach<strong>in</strong>e itself.<br />
For example, on mechanical power presses, a brake monitor<strong>in</strong>g system<br />
can only detect a gradual deterioration of the brake on the press, not a<br />
catastrophic mechanical failure <strong>in</strong> the clutch/brake mechanism.<br />
It is essential that the mach<strong>in</strong>e be thoroughly <strong>in</strong>spected and that <strong>all</strong><br />
mechanical, electrical, pneumatic, and hydraulic comp<strong>one</strong>nts and<br />
systems, <strong>in</strong>clud<strong>in</strong>g <strong>all</strong> collateral equipment, be <strong>in</strong> first-class operat<strong>in</strong>g<br />
condition before any equipment is <strong>in</strong>st<strong>all</strong>ed. A ma<strong>in</strong>tenance and<br />
<strong>in</strong>spection program must be established and implemented to keep<br />
mach<strong>in</strong>es <strong>in</strong> your plant <strong>in</strong> first-class condition. This program must<br />
<strong>in</strong>clude regular periodic <strong>in</strong>spections of each mach<strong>in</strong>e to ensure that,<br />
among other th<strong>in</strong>gs, (i) the clutch and brake mechanism, mechanical<br />
l<strong>in</strong>kages, and air counterbalances are operat<strong>in</strong>g and used properly; (ii)<br />
there is no dirt or water <strong>in</strong> the air l<strong>in</strong>es; and (iii) the mach<strong>in</strong>e is operat<strong>in</strong>g<br />
at its proper speed (RPM or SPM). Any part of the mach<strong>in</strong>e that is worn,<br />
damaged, or not operat<strong>in</strong>g correctly must immediately be replaced or<br />
repaired before the mach<strong>in</strong>e is used.<br />
4 | CONTROL SYSTEMS
MECHANICAL POWER PRESS CONTROL SYSTEMS<br />
SAFETY CONSIDERATIONS ON PRESSES<br />
Referenc<strong>in</strong>g OSHA 29 CFR 1910.217(d)(1), it states: “The employer<br />
sh<strong>all</strong> (i) use dies and operat<strong>in</strong>g methods designed to control or elim<strong>in</strong>ate<br />
hazards to operat<strong>in</strong>g personnel, and (ii) furnish and enforce the use of<br />
hand tools for free<strong>in</strong>g and remov<strong>in</strong>g stuck work or scrap pieces from<br />
the die, so that no employee need reach <strong>in</strong>to the po<strong>in</strong>t of operation for<br />
such purposes.”<br />
BASIC REQUIREMENTS<br />
When updat<strong>in</strong>g presses to comply with the <strong>in</strong>dicated safety standards,<br />
there are five basic requirements that must always be considered.<br />
They are:<br />
1. <strong>Safeguard<strong>in</strong>g</strong> (Refer to <strong>Catalog</strong>s MSD & EXAL)<br />
2. Controls (pp. 7-48)<br />
3. Disconnects (pp. 10, 11, 25, 29, 40, 47, and <strong>Catalog</strong> SFM)<br />
4. Starters (pp. 10, 11, 25, 29, 40, 47, and <strong>Catalog</strong> SFM)<br />
5. Covers (Refer to www.rockfordsystems.com for mechanical<br />
motion covers)<br />
This <strong>in</strong>troduction and subsequent pages <strong>in</strong> this catalog will provide<br />
<strong>in</strong>formation on safety requirements <strong>in</strong> the above areas.<br />
SAFEGUARDING<br />
The follow<strong>in</strong>g are OSHA-recognized methods for safeguard<strong>in</strong>g the po<strong>in</strong>t<br />
of operation on mechanical power presses:<br />
PART REVOLUTION<br />
1. Barrier Guard (Refer to <strong>Catalog</strong> EX-AL)<br />
2. Two-Hand Control (pp. 20-48)<br />
3. Presence-Sens<strong>in</strong>g Device (Refer to <strong>Catalog</strong> MSD)<br />
4. Pullback (Not offered by <strong>Rockford</strong> <strong>Systems</strong>)<br />
5. Restra<strong>in</strong>t (Refer to <strong>Catalog</strong> MSD)<br />
6. Type A or B Gate (Refer to <strong>Catalog</strong> MSD)<br />
FULL REVOLUTION<br />
1. Barrier Guard (Refer to <strong>Catalog</strong> EX-AL)<br />
2. Two-Hand Trip (pp. 7-17)<br />
3. Pullback (Not offered by <strong>Rockford</strong> <strong>Systems</strong>)<br />
4. Restra<strong>in</strong>t (Refer to <strong>Catalog</strong> MSD)<br />
5. Type A Gate (Refer to <strong>Catalog</strong> MSD)<br />
When safeguard<strong>in</strong>g, please keep <strong>in</strong> m<strong>in</strong>d that the sides and back of the<br />
po<strong>in</strong>t of operation must also be safeguarded to protect the operator and<br />
other employees.<br />
OSHA’s safety distance formula for two-hand control, two-hand trip,<br />
and presence-sens<strong>in</strong>g devices can be found on pages 119-120 of this<br />
catalog. Refer to our MSD catalog for ANSI’s safety distance formulas.<br />
CONTROLS<br />
Controls are furnished accord<strong>in</strong>g to the type of press: full revolution or<br />
part revolution. Please see later pages detail<strong>in</strong>g these requirements for<br />
further explanation.<br />
ELECTRICAL AND LOCKOUT REQUIREMENTS<br />
A press system requires a proper disconnect switch, motor starter,<br />
transformer (for reduc<strong>in</strong>g the voltage to 120 V or less), and an air<br />
lockout valve.<br />
When apply<strong>in</strong>g any of the standard control boxes offered <strong>in</strong> this catalog,<br />
a 120-V coil must exist or be changed <strong>in</strong> the present magnetic starter<br />
on the press. If a press has a manual starter, it must be replaced with<br />
a magnetic-type starter. The standard and custom control boxes are<br />
furnished with a multi-tap transformer for various primary voltages.<br />
COVERS<br />
Mechanical power-transmission apparatus <strong>in</strong>clude comp<strong>one</strong>nts on<br />
a mach<strong>in</strong>e or auxiliary equipment <strong>in</strong>clud<strong>in</strong>g shafts, crankshafts,<br />
spl<strong>in</strong>es, pulleys, sprockets, rolls, flywheels, gears, and coupl<strong>in</strong>gs. These<br />
comp<strong>one</strong>nts can create hazards to personnel who work on or around<br />
the mach<strong>in</strong>es. They must be covered <strong>in</strong> accordance with OSHA 29<br />
CFR 1910.219 and ANSI B15.1. All apparatuses that create a hazard<br />
must be guarded (covered) if at or below a seven-foot level from the<br />
floor or platform. This is usu<strong>all</strong>y d<strong>one</strong> by the user, either by modify<strong>in</strong>g<br />
exist<strong>in</strong>g guards, by contact<strong>in</strong>g a local sheet-metal fabricator to make<br />
a new cover, or refer to our Web site at www.rockfordsystems.com for<br />
mechanical motion covers.<br />
AUXILIARY SAFEGUARDING<br />
Auxiliary safeguard<strong>in</strong>g is used for additional protection from <strong>in</strong>juries for<br />
<strong>all</strong> personnel <strong>in</strong> the mach<strong>in</strong>e area. It is used <strong>in</strong> conjunction with primary<br />
safeguard<strong>in</strong>g devices. Auxiliary safeguard<strong>in</strong>g also <strong>in</strong>volves the guard<strong>in</strong>g<br />
of other comp<strong>one</strong>nts or hazardous open<strong>in</strong>gs on mach<strong>in</strong>es. One of these<br />
hazards is created by auxiliary feed<strong>in</strong>g equipment used with some<br />
power presses. Auxiliary equipment <strong>in</strong>cludes various types of feeds,<br />
shuttles, magaz<strong>in</strong>es, stackers, <strong>in</strong>dex<strong>in</strong>g tables, straighteners, reels,<br />
cradles, recoilers, scrap choppers, iron hands, robots, etc.<br />
Auxiliary safeguards <strong>in</strong>clude such items as po<strong>in</strong>t-of-operation side<br />
barriers when light curta<strong>in</strong>s are used, pressure-sensitive safety mats,<br />
workpiece tables, or horizontal light curta<strong>in</strong>s. An additional set of<br />
light curta<strong>in</strong>s can be used horizont<strong>all</strong>y to prevent an operator or other<br />
persons from stand<strong>in</strong>g between the vertical plane of light and the po<strong>in</strong>tof-operation<br />
hazard. Please remember that light curta<strong>in</strong>s can only be<br />
used on part-revolution presses.<br />
CONTROL SYSTEMS | 5
FAB ART 6<br />
MECHANICAL POWER PRESS CONTROL SYSTEMS<br />
POINT-OF-OPERATION<br />
LIGHT CURTAINS<br />
PERIMETER LIGHT CURTAIN OR<br />
TWO SINGLE-BEAM DEVICES<br />
R<br />
T T R<br />
PRESS STRAIGHTENER MATERIAL<br />
REEL<br />
T<br />
R<br />
R<br />
GUARD REQUIRED IF<br />
HAZARD EXISTS<br />
T<br />
GUARD FOR SCRAP CHOPPER<br />
AND SIDE WINDOW<br />
GUARD FOR FEED<br />
AND SIDE WINDOW<br />
SAFETY MATS<br />
STRAIGHT-SIDE PRESS ARRANGED FOR AUTOMATIC FEEDING<br />
The two most commonly used safeguards for presses equipped with<br />
automatic feeds are guards and presence-sens<strong>in</strong>g devices (light<br />
curta<strong>in</strong>s). These safeguards are detailed <strong>in</strong> our mach<strong>in</strong>e safeguard<strong>in</strong>g<br />
devices catalog—<strong>Catalog</strong> MSD. When consider<strong>in</strong>g either of these<br />
safeguards, arrange them to protect the po<strong>in</strong>t of operation as well as<br />
the feed. This may require the guard to extend to the right or left of the<br />
bolster on OBI presses. If a scrap chopper is furnished, the guard<strong>in</strong>g<br />
must also be extended to safeguard it. If a feed and scrap chopper<br />
are on the sides of straight-side presses, the feed, scrap chopper, and<br />
w<strong>in</strong>dow open<strong>in</strong>gs also need to be safeguarded.<br />
When protect<strong>in</strong>g operators and other employees <strong>in</strong> the press area from<br />
hazards created by straighteners, pay-off reels, cradles, iron hands,<br />
robots, etc., the perimeter or work envelope of this auxiliary equipment<br />
can be safeguarded as illustrated above. This is usu<strong>all</strong>y accomplished<br />
with guards, presence-sens<strong>in</strong>g devices, safety mats, or a comb<strong>in</strong>ation<br />
of these safeguards.<br />
When protect<strong>in</strong>g these areas, keep <strong>in</strong> m<strong>in</strong>d that access may be required<br />
for chang<strong>in</strong>g coils and remov<strong>in</strong>g scrap, blanks, etc.<br />
Danger signs, used for warn<strong>in</strong>g, can be mounted on the mach<strong>in</strong>e <strong>in</strong><br />
a position that is readily visible to the operator, setup person, or other<br />
personnel. Hand tools are another auxiliary safeguard often used<br />
when feed<strong>in</strong>g and retriev<strong>in</strong>g sm<strong>all</strong> workpieces or remov<strong>in</strong>g scrap from<br />
the die area. Hand tools by themselves are not a po<strong>in</strong>t-of-operation<br />
safeguard<strong>in</strong>g device.<br />
When us<strong>in</strong>g a light curta<strong>in</strong>, the mount<strong>in</strong>g brackets for the transmitter<br />
and receiver may have to be modified to <strong>in</strong>clude safeguard<strong>in</strong>g of the<br />
feed. The light curta<strong>in</strong>’s plane of light commonly protects only the front<br />
of the press. Additional guards or mirrors that reflect the light curta<strong>in</strong>’s<br />
plane of light are needed to safeguard the sides and back of the<br />
mach<strong>in</strong>e.<br />
When safeguard<strong>in</strong>g presses equipped with shuttles, magaz<strong>in</strong>es,<br />
stackers, <strong>in</strong>dex<strong>in</strong>g tables, etc., the previously discussed safeguards<br />
can be used. This assumes that the press is operat<strong>in</strong>g <strong>in</strong> either the<br />
cont<strong>in</strong>uous or automatic s<strong>in</strong>gle-stroke mode of operation. If the press<br />
is s<strong>in</strong>gle-stroked by overt operator action, other safeguards such as<br />
two-hand control, pullback devices, restra<strong>in</strong>ts, or gate devices could<br />
be used. The back and sides of the po<strong>in</strong>t of operation must always be<br />
protected as well.<br />
AIR AND HYDRAULIC PRESSES<br />
Two-hand-control packages for air presses and other air-operated mach<strong>in</strong>es and devices can be reviewed <strong>in</strong> our mach<strong>in</strong>e safeguard<strong>in</strong>g devices<br />
catalog—<strong>Catalog</strong> MSD.<br />
Controls for hydraulic presses are also available. Two-hand control is usu<strong>all</strong>y furnished along with other po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g. Please see<br />
pages 57-65 for further details.<br />
6 | CONTROL SYSTEMS
FULL-REVOLUTION-CLUTCH PRESS CONTROL SYSTEMS<br />
OSHA 29 CFR 1910.211 DEFINITION<br />
“Full-Revolution Clutch” means a type of clutch that, when tripped,<br />
cannot be disengaged until the crankshaft has completed a full<br />
revolution and the press slide a full stroke.<br />
All of the full-revolution-clutch press control systems are furnished with<br />
two-hand trip that can be used as a po<strong>in</strong>t-of-operation safeguard—refer<br />
to pages 116, 119, 120, or <strong>Catalog</strong> MSD for detailed <strong>in</strong>formation on the<br />
safety requirements for two-hand trip. Various other types of guards<br />
or devices may be more desirable, such as barrier guards, pullbacks,<br />
restra<strong>in</strong>ts, or type A gates. For these guards and devices, please refer<br />
to our barrier and perimeter guard<strong>in</strong>g systems catalog—<strong>Catalog</strong> EX-AL,<br />
and our mach<strong>in</strong>e safeguard<strong>in</strong>g devices catalog—<strong>Catalog</strong> MSD.<br />
FULL-REVOLUTION CLUTCH<br />
The full-revolution-clutch press was designed to make <strong>one</strong> full mach<strong>in</strong>e<br />
cycle (stroke) or crankshaft revolution after each engagement of the<br />
mechanical p<strong>in</strong>, collar, or roll<strong>in</strong>g key.<br />
On full-revolution presses, the ma<strong>in</strong> concern of the clutch control is that<br />
it has s<strong>in</strong>gle-stroke capability if the press is s<strong>in</strong>gle-stroked. This means<br />
that if the actuat<strong>in</strong>g means, such as the palm buttons or foot switch,<br />
is held operated through an entire stroke, the press will stop at its<br />
normal TDC (top dead center) stopp<strong>in</strong>g position, barr<strong>in</strong>g any mechanical<br />
catastrophic failures.<br />
This section <strong>in</strong>cludes trip-control systems which provide s<strong>in</strong>gle-stroke<br />
capability, a requirement of both OSHA and ANSI. These systems also<br />
provide two-hand trip which can be used as a po<strong>in</strong>t-of-operation<br />
safeguard<strong>in</strong>g device when mounted at the proper safety distance.<br />
Full-revolution s<strong>in</strong>gle-stroke trip-control systems provide other modes of<br />
operation, such as cont<strong>in</strong>uous-on-demand, foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous,<br />
automatic s<strong>in</strong>gle stroke, and two-hand motor jog for die setup and<br />
ma<strong>in</strong>tenance requirements.<br />
Two-hand motor jog is used when the die or tool<strong>in</strong>g is be<strong>in</strong>g set up<br />
<strong>in</strong> the press, with the flywheel at rest. It <strong>all</strong>ows the designated setup<br />
person to engage the clutch and jog the motor <strong>in</strong> order to br<strong>in</strong>g the<br />
slide down to BDC (bottom dead center). Usu<strong>all</strong>y when the slide is <strong>in</strong><br />
this position of crankshaft rotation (BDC), a die is removed and another<br />
is set up.<br />
Three reasons to <strong>in</strong>st<strong>all</strong> a trip-control system on full-revolution-clutch<br />
presses that may already have s<strong>in</strong>gle-stroke mechanisms are: 1) the<br />
two-hand motor jog feature, 2) the ease of operat<strong>in</strong>g a foot switch<br />
versus a mechanical foot treadle, and 3) two-hand trip elim<strong>in</strong>ates the<br />
foot pedal/treadle operation.<br />
In addition to provid<strong>in</strong>g s<strong>in</strong>gle-stroke capability with a trip-control<br />
Control Box<br />
Disconnect and<br />
Motor Starter<br />
Filter-Regulator-<br />
Lubricator<br />
Air Pressure<br />
Switch<br />
Top-of-Stroke<br />
Limit Switch<br />
Full-Revolution Press With Trip Control System and Gate<br />
Not shown are the air cyl<strong>in</strong>der and the monitored dual-solenoid<br />
air valve on the opposite side of the press.<br />
system, <strong>all</strong> full-revolution presses require a safeguard<strong>in</strong>g system. The<br />
follow<strong>in</strong>g are OSHA-recognized methods for safeguard<strong>in</strong>g the po<strong>in</strong>t of<br />
operation on full-revolution-clutch mechanical power presses:<br />
1. Barrier Guard (Refer to <strong>Catalog</strong> EX-AL)<br />
2. Two-Hand Trip (Refer to this section)<br />
3. Pullback (Not offered by <strong>Rockford</strong> <strong>Systems</strong>)<br />
4. Restra<strong>in</strong>t (Refer to <strong>Catalog</strong> MSD)<br />
5. Type A Gate (Refer to <strong>Catalog</strong> MSD)<br />
Palm Button<br />
Assembly<br />
Gate<br />
Assembly<br />
Foot<br />
Switch<br />
CONTROL SYSTEMS | 7
FULL-REVOLUTION-CLUTCH PRESS CONTROL SYSTEMS<br />
When safeguard<strong>in</strong>g, please keep <strong>in</strong> m<strong>in</strong>d that the sides and back of the<br />
po<strong>in</strong>t of operation must also be safeguarded to protect the operator and<br />
other employees.<br />
OSHA’s safety distance formula for two-hand trip can be found on<br />
page 120 of this catalog. Refer to the graph below for a guidel<strong>in</strong>e <strong>in</strong><br />
determ<strong>in</strong><strong>in</strong>g two-hand trip safety distance.<br />
Other safety considerations on a full-revolution- clutch press are the<br />
ma<strong>in</strong> power disconnect switch, magnetic motor starter, and covers for<br />
the flywheel, gears, etc.<br />
CONTROL SYSTEMS<br />
A full-revolution control system consists of:<br />
1. A control box (pp. 9-11)<br />
2a. Individual comp<strong>one</strong>nts (pp. 12-14)<br />
OR<br />
2b. Comp<strong>one</strong>nt packages (pp. 15-16)<br />
3. An air cyl<strong>in</strong>der (p. 17)<br />
4. An air lockout valve (p. 14 or 35)<br />
Comp<strong>one</strong>nts <strong>in</strong> the control system can <strong>in</strong>clude a palm button assembly,<br />
a foot switch, a monitored dual-solenoid air valve, a filter-regulatorlubricator<br />
assembly, an air pressure switch, an air lockout valve, a<br />
cam and mount<strong>in</strong>g strap assembly, and a limit switch assembly. The<br />
comp<strong>one</strong>nts for these systems will vary depend<strong>in</strong>g on the actuat<strong>in</strong>g<br />
means and the modes of operation that are chosen.<br />
SELECTING A CONTROL SYSTEM<br />
1. To order a control system, determ<strong>in</strong>e which control box is required.<br />
Choose a control from pages 9-10.<br />
2. Determ<strong>in</strong>e which comp<strong>one</strong>nts meet your mode-of-operation<br />
requirements. This depends on your production requirements. To<br />
simplify this step, comp<strong>one</strong>nt packages are available. See pages<br />
15-16.<br />
3. Select an appropriate air cyl<strong>in</strong>der. Air cyl<strong>in</strong>ders are available <strong>in</strong><br />
a variety of sizes and configurations to fit the specific mach<strong>in</strong>e<br />
application. See page 17.<br />
4. Add an air lockout valve, if required. See page 14 or 35.<br />
TWO-HAND TRIP SAFETY DISTANCE CHART<br />
To establish the proper safety distance for two-hand trip on full-revolution-clutch presses, determ<strong>in</strong>e the speed of the press <strong>in</strong> SPM (strokes per<br />
m<strong>in</strong>ute) when runn<strong>in</strong>g <strong>in</strong> the cont<strong>in</strong>uous mode and the number of engagement po<strong>in</strong>ts <strong>in</strong> the clutch mechanism. Then determ<strong>in</strong>e the safety distance<br />
from the follow<strong>in</strong>g chart.<br />
S<br />
A<br />
F<br />
E<br />
T<br />
Y<br />
D<br />
I<br />
S<br />
T<br />
A<br />
N<br />
C<br />
E<br />
M<br />
I<br />
N<br />
I<br />
M<br />
U<br />
M<br />
I<br />
N<br />
C<br />
H<br />
E<br />
S<br />
F<br />
R<br />
O<br />
M<br />
P<br />
O<br />
I<br />
N<br />
T<br />
O<br />
F<br />
O<br />
P<br />
MINIMUM INCHES FROM POINT OF OPERATION<br />
(each square is equal to 2")<br />
E<br />
R<br />
A<br />
T<br />
I<br />
O<br />
N<br />
200 190 180 170 160 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10<br />
10<br />
10<br />
20<br />
30<br />
40<br />
50<br />
60<br />
70<br />
80<br />
90<br />
100<br />
SPEED OF PRESS (IN STROKES PER MINUTE)<br />
1 Engagement Po<strong>in</strong>t<br />
14 Engagement Po<strong>in</strong>ts<br />
4 Engagement Po<strong>in</strong>ts<br />
3 Engagement Po<strong>in</strong>ts<br />
2 Engagement Po<strong>in</strong>ts<br />
20<br />
30<br />
40<br />
50<br />
60<br />
70<br />
80<br />
90<br />
100<br />
8 | CONTROL SYSTEMS
STANDARD FULL-REVOLUTION CONTROL<br />
Ground<br />
Indicator<br />
Light<br />
Off/On<br />
Selector<br />
Control<br />
Selector<br />
Actuat<strong>in</strong>g Means<br />
Selector<br />
(If furnished)<br />
The electro-pneumatic trip-control system is designed for use on fullrevolution-clutch<br />
mechanical power presses. It is designed and built<br />
to comply with OSHA 29 CFR 1910.217 and ANSI B11.1 and B11.19.<br />
This control updates full-revolution-clutch presses that do not presently<br />
have s<strong>in</strong>gle-stroke capability. It can also be a replacement for exist<strong>in</strong>g<br />
trip-control systems.<br />
This control is an economic, full-featured microprocessor-based press<br />
trip control. The system uses a microprocessor to cross-check and<br />
monitor the control relays. In the event of a control malfunction, further<br />
operation is prevented. See page 111 for details on control reliability.<br />
The multi-tap transformer has a 115-, 208-, 230-, 460-, and 575-V<br />
primary, 115-V secondary, and 100-VA rat<strong>in</strong>g. This control must be<br />
wired <strong>in</strong> to a motor starter that has a 115-V operat<strong>in</strong>g coil. This provides<br />
primary power to the clutch control and to the control box for the twohand<br />
motor jog mode of operation.<br />
The standard control box is housed <strong>in</strong> a 16” x 10” x 6” NEMA 12<br />
enclosure. The ground <strong>in</strong>dicator light and operator controls are located<br />
on the front of the enclosure door. The motor controls are usu<strong>all</strong>y<br />
located <strong>in</strong> a remote station.<br />
Standard Control Box (FPF-000-F Shown)<br />
Diagnostic<br />
Code Chart<br />
Selector<br />
Switches<br />
Control Transformer<br />
Inside View<br />
of Standard<br />
Control Box<br />
Control Module<br />
Assembly<br />
CONTROL SYSTEMS | 9
STANDARD FULL-REVOLUTION CONTROL (CONTINUED)<br />
STANDARD MODES OF OPERATION<br />
• Two-hand motor jog<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Two-hand “walk-away” cont<strong>in</strong>uous*<br />
• Foot s<strong>in</strong>gle stroke<br />
• Foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous*<br />
• Automatic s<strong>in</strong>gle stroke*<br />
• Cont<strong>in</strong>uous-on-demand*<br />
*Requires a remote prior-action station.<br />
FEATURES<br />
• S<strong>in</strong>gle-stroke capability operation<br />
• Two-hand antirepeat<br />
• Two-hand trip as a po<strong>in</strong>t-of-operation safeguard<br />
• Two-hand anti-tie down and concurrent operation<br />
• Controls <strong>all</strong> types of full-revolution clutches<br />
• Redundant-logic system microprocessor<br />
• Provisions for electric<strong>all</strong>y <strong>in</strong>terlock<strong>in</strong>g safety devices<br />
• Isolated microprocessor logic power supply<br />
• Redundantly monitored solid-state relay/captive-contact<br />
relay output for trip solenoid(s)<br />
• Saddle-clamp circuit board term<strong>in</strong>al strips<br />
• Supports redundant, self-check<strong>in</strong>g solenoid valves<br />
• Fused SSR (solid-state relay) outputs<br />
• Type A gate <strong>in</strong>terface<br />
CUSTOM FULL-REVOLUTION CONTROL<br />
Full-revolution-clutch custom control boxes and packages are available<br />
to fit your particular press room needs. A custom control box conta<strong>in</strong>s<br />
the standard control module and comp<strong>one</strong>nts as described on pages<br />
9-10 plus the follow<strong>in</strong>g:<br />
• ma<strong>in</strong> power disconnect switch<br />
• ma<strong>in</strong> drive motor starter<br />
• ram-adjust motor starter (if required)<br />
These boxes are furnished with an IEC through-the-door ma<strong>in</strong> power<br />
fused disconnect switch and an IEC magnetic motor starter (with push<br />
buttons). A revers<strong>in</strong>g ram-adjust motor starter with selector and push<br />
buttons may also be <strong>in</strong>cluded. They are prewired and built <strong>in</strong>to a larger<br />
NEMA 12 enclosure.<br />
Operator controls are located on the front of the enclosure door. The motor<br />
controls can be located <strong>in</strong> a remote station or on the enclosure door.<br />
NEMA-style disconnect switches and motor starters, and brandname<br />
comp<strong>one</strong>nts specified by our customers are also available. To<br />
ensure the starter(s) and disconnect are sized properly, please check<br />
horsepower for the ma<strong>in</strong> drive motor and slide adjust motor (if furnished)<br />
on the press, as well as full-load amps, and primary voltage to the press.<br />
After obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, please go to the chart on page 11 to<br />
determ<strong>in</strong>e the proper custom control box part number. Follow directions<br />
1-7 to determ<strong>in</strong>e the correct part number.<br />
Full-Revolution Custom Control Box With Clutch Control,<br />
Disconnect Switch, and Motor Starter<br />
10 | CONTROL SYSTEMS
SELECTING A FULL-REVOLUTION-CLUTCH PRESS CONTROL<br />
To determ<strong>in</strong>e the 8-digit configured part number for the full-revolution control required, follow directions 1-7 below and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
1. The first 2 digits for <strong>all</strong> full-revolution controls are FP.<br />
2. The 3rd digit determ<strong>in</strong>es the modes of operation required.<br />
3. The 4th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect<br />
switch provided.<br />
4. The 5th and 6th digits determ<strong>in</strong>e the size and type of nonrevers<strong>in</strong>g motor starter, if provided, <strong>in</strong> the control enclosure. Zeros<br />
(00) <strong>in</strong> both positions <strong>in</strong>dicate no motor starter provided.<br />
5. The 7th digit determ<strong>in</strong>es the location of the operator controls.<br />
7. The 8th digit will <strong>in</strong>dicate the type of modifier provided: i.e., ma<strong>in</strong> drive motor control operators remote.<br />
1 2 3 4 5 6 7<br />
SAMPLE<br />
F P F - 1 1 2 - F 5<br />
The sample shown, FPF-112-F5, <strong>in</strong>dicates that the custom full-revolution-clutch control box will provide two-hand s<strong>in</strong>gle stroke, two-hand motor<br />
jog, two-hand cont<strong>in</strong>uous, foot s<strong>in</strong>gle stroke, and foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous modes of operation. There will be an IEC 30-A disconnect switch and<br />
an IEC 18-A nonrevers<strong>in</strong>g ma<strong>in</strong> drive motor starter without ram adjust. All operator controls will be on the door of the enclosure with the exception<br />
of the ma<strong>in</strong> drive motor operators which will be located remote.<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
FP —Full-Revolution Control<br />
MODES OF OPERATION<br />
A —Two-hand s<strong>in</strong>gle stroke, two-hand motor jog, two-hand “walkaway”<br />
cont<strong>in</strong>uous, foot s<strong>in</strong>gle stroke, foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous,<br />
automatic s<strong>in</strong>gle stroke, and cont<strong>in</strong>uous-on-demand. Remote<br />
station LLD-406* is required.<br />
G —Two-hand s<strong>in</strong>gle stroke, two-hand motor jog, two-hand “walkaway”<br />
cont<strong>in</strong>uous, foot s<strong>in</strong>gle stroke, foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous,<br />
and a type A gate <strong>in</strong>terface.<br />
Remote station LLD-400* is required.<br />
H —Two-hand s<strong>in</strong>gle stroke, two-hand motor jog, and two-hand “walkaway”<br />
cont<strong>in</strong>uous.<br />
Remote station LLD-400* is required.<br />
F —Two-hand s<strong>in</strong>gle stroke, two-hand motor jog, two-hand “walkaway”<br />
cont<strong>in</strong>uous, and foot s<strong>in</strong>gle stroke and foot-ma<strong>in</strong>ta<strong>in</strong>ed<br />
cont<strong>in</strong>uous.Remote station LLD-400* is required.<br />
DISCONNECT SWITCH SIZE—IEC<br />
(PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 — No Disconnect Switch<br />
1 — 30-A Disconnect — 1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 — 60-A Disconnect — 21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 — 100-A Disconnect — 41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 — 200-A Disconnect — 67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 — 400-A Disconnect — 134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
NONREVERSING MAIN MOTORS TARTER WITH OR WITHOUT RAM ADJUST<br />
0 —No Starter<br />
1 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter without Ram Adjust<br />
3 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 12-A Ram Adjust<br />
4 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 18-A Ram Adjust<br />
5 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 25-A Ram Adjust<br />
FULL-REVOLUTION CONTROL PART NUMBERING SYSTEM CHART<br />
F P X - X X X - F X<br />
MODIFIER<br />
-- —Blank, No Modifier<br />
5 —Ma<strong>in</strong> Motor Operators Remote**<br />
6 —Ram-Adjust Operators Remote**<br />
7 —Ma<strong>in</strong> Motor and Ram-Adjust Operators Remote**<br />
CONFIGURATION & OPERATOR LOCATION<br />
F —All Operators on Door of Enclosure<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 —12 A<br />
2 —18 A<br />
3 —25 A<br />
4 —32 A<br />
5 —40 A<br />
6 —50 A<br />
7 —65 A<br />
8 —80 A<br />
9 —95 A<br />
A —115 A<br />
B —185 A<br />
C —265 A<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
*Required if two-hand cont<strong>in</strong>uous, foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous, automatic<br />
s<strong>in</strong>gle stroke, and/or cont<strong>in</strong>uous-on-demand modes of operation are used.<br />
**See page 50 for remote motor control operator stations or <strong>Catalog</strong> SFM.<br />
CONTROL SYSTEMS | 11
INDIVIDUAL COMPONENTS<br />
The comp<strong>one</strong>nts for these full-revolution control systems will vary<br />
depend<strong>in</strong>g on the actuat<strong>in</strong>g means and the modes of operation that<br />
are chosen. To simplify this, comp<strong>one</strong>nt packages are available. Please<br />
see pages 15-16 for part numbers and descriptions of the comp<strong>one</strong>nt<br />
packages. The control system can <strong>in</strong>clude the follow<strong>in</strong>g comp<strong>one</strong>nts.<br />
1⁄4” MONITORED DUAL-SOLENOID AIR VALVE<br />
Part No. RCD-140*<br />
This three-way, ¼” monitored dual-solenoid air valve is ideal for<br />
operat<strong>in</strong>g air cyl<strong>in</strong>ders on full-revolution presses. This dual valve<br />
is pneumatic<strong>all</strong>y checked. To assist <strong>in</strong> <strong>in</strong>st<strong>all</strong>ation, this valve has a<br />
common electrical connector for both solenoids with a 12-foot cord.<br />
1⁄4” FILTER-REGULATOR-LUBRICATOR ASSEMBLY (FRL)<br />
Part No. RCL-043*<br />
This assembly is needed to meet the OSHA and ANSI requirements. This<br />
FRL assembly filters, regulates, and lubricates the air go<strong>in</strong>g through<br />
it. This filtered and lubricated air then goes to the solenoid air valve<br />
assembly and air cyl<strong>in</strong>der. The regulator should be adjusted so just<br />
enough air pressure reaches the air cyl<strong>in</strong>der to operate the clutch. This<br />
assembly <strong>in</strong>cludes a gauge, coupl<strong>in</strong>g, and steel mount<strong>in</strong>g bracket.<br />
Cv (Flow Rate)<br />
Inlet 1.3<br />
Outlet 1.2<br />
Exhaust 2.4<br />
1⁄4” Monitored Dual-Solenoid<br />
Air Valve<br />
AIR PRESSURE SWITCH<br />
Part No. CTD-062*<br />
This air pressure switch is needed to meet the OSHA and ANSI<br />
requirements. The air pressure switch monitors low pressure to<br />
either the air cyl<strong>in</strong>der air supply or ram counterbalance systems.<br />
The pressure switch must be set so if the air pressure operat<strong>in</strong>g the<br />
comp<strong>one</strong>nts is not adequate, or if the air pressure suddenly drops, the<br />
press becomes <strong>in</strong>operable.<br />
Filter-Regulator-Lubricator<br />
Assembly<br />
CAM AND STRAP ASSEMBLY<br />
Part No. CML-002*<br />
A cast-alum<strong>in</strong>um cam and adjustable sta<strong>in</strong>less-steel strap are furnished<br />
so the cam can easily be mounted on the crankshaft extension. The<br />
strap is adjustable up to 6” diameter and is locked <strong>in</strong> place by tighten<strong>in</strong>g<br />
the screw.<br />
Note: Drill<strong>in</strong>g or tapp<strong>in</strong>g the end of the crankshaft is not required. All that<br />
is required to <strong>in</strong>st<strong>all</strong> it is to slip the cam and strap assembly on the<br />
crankshaft, l<strong>in</strong>e it up with the top-of-stroke limit switch assembly,<br />
and tighten. See next page.<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on pages 15-16.<br />
Air Pressure Switch<br />
Crankshaft<br />
Extension<br />
Cam and Strap Assembly<br />
12 | CONTROL SYSTEMS
INDIVIDUAL COMPONENTS (CONTINUED)<br />
TOP-OF-STROKE LIMIT SWITCH ASSEMBLY<br />
Part No. CMK-103*<br />
This top-of-stroke limit switch assembly with a 25’ cord is actuated by<br />
the cam mounted on the crankshaft and is specific<strong>all</strong>y selected for this<br />
application. The top-of-stroke limit switch provides dual force-guided<br />
contacts to provide the signals when the mach<strong>in</strong>e is <strong>in</strong> the s<strong>in</strong>gle<br />
stroke mode of operation. If the mach<strong>in</strong>e does not stop at top dead<br />
center, or if the switch assembly malfunctions, becomes improperly<br />
adjusted, or the mount<strong>in</strong>g becomes jarred loose, the control will not<br />
<strong>all</strong>ow a successive stroke.<br />
A mount<strong>in</strong>g bracket for the limit switch assembly is not furnished. To<br />
purchase the EX-AL mount<strong>in</strong>g bracket material shown <strong>in</strong> the photo,<br />
please contact <strong>Rockford</strong> <strong>Systems</strong> at 1-800-922-7533.<br />
PALM BUTTON ASSEMBLIES<br />
To meet OSHA and ANSI safety requirements, the two run/jog buttons<br />
must be protected aga<strong>in</strong>st accidental operation (with r<strong>in</strong>g guards) and<br />
separated to require the use of both hands to operate them. They also<br />
must be mounted at the proper safety distance, if they will be used as a<br />
safeguard. The electrical contact arrangement of the follow<strong>in</strong>g buttons<br />
is 1 NO and 1 NC.<br />
Part No. CTL-502*<br />
This palm button assembly consists of two black run/<strong>in</strong>ch buttons<br />
(with r<strong>in</strong>g guards), a red emergency-stop button, and a yellow top-stop<br />
button. Mount<strong>in</strong>g boxes are furnished with each button. The red and<br />
yellow palm buttons each have 1 NO and 1 NC arrangement. The red<br />
button is on a yellow-covered mount<strong>in</strong>g box and is equipped with a<br />
mechanical latch to meet NFPA 79.<br />
Part No. CTL-507*<br />
This palm button assembly consists of two black run/<strong>in</strong>ch buttons (with<br />
r<strong>in</strong>g guards), and a red emergency-stop button (for press applications<br />
without the cont<strong>in</strong>uous mode of operation). Mount<strong>in</strong>g boxes are<br />
furnished with each button. The red palm button is on a yellow-covered<br />
mount<strong>in</strong>g box and has 1 NO and 1 NC arrangement plus a mechanical<br />
latch to meet NFPA 79.<br />
See pages 99-100 for other palm button assembly options.<br />
FOOT SWITCH<br />
Part No. CTD-011*<br />
To meet OSHA and ANSI safety requirements, a foot switch must be<br />
protected from un<strong>in</strong>tentional operation. The foot switch pedal (on the<br />
<strong>in</strong>side) is protected on the top and both sides by the cast cover and the<br />
front is protected by the h<strong>in</strong>ged flap. This flap must be raised by the<br />
operator’s toe before <strong>all</strong>ow<strong>in</strong>g the foot to enter the switch. When the<br />
h<strong>in</strong>ged flap is <strong>in</strong> the down position, it is also mechanic<strong>all</strong>y <strong>in</strong>terlocked<br />
with the operat<strong>in</strong>g pedal. The contact arrangement is 1 NO and 1 NC.<br />
Top-of-Stroke Limit Switch Mounted Above Cam<br />
and Strap Assembly on the Crankshaft<br />
Foot<br />
Switch<br />
Part No. CTL-502<br />
Part No. CTL-507<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 15-16.<br />
CONTROL SYSTEMS | 13
INDIVIDUAL COMPONENTS (CONTINUED)<br />
PRIOR-ACTION STATION FOR CONTINUOUS<br />
Part No. LLD-400*<br />
This remote prior-action station is required for the cont<strong>in</strong>uous or ma<strong>in</strong>ta<strong>in</strong>ed-cont<strong>in</strong>uous mode<br />
of operation. If a comp<strong>one</strong>nt package is not supplied with the control box, this station must be<br />
ordered. The button is furnished separately <strong>in</strong> an enclosure so it can be mounted <strong>in</strong> a convenient<br />
location on the front of the press. The NEMA 12 enclosure size is 3½” x 4½” x 3½”.<br />
PRIOR-ACTION STATION FOR AUTOMATIC SINGLE STROKE OR CONTINUOUS-ON-<br />
DEMAND<br />
Part No. LLD-406*<br />
This prior-action station is required for the automatic s<strong>in</strong>gle-stroke or the cont<strong>in</strong>uous-on-demand<br />
mode of operation. These modes of operation are only available with the FPA control box. This<br />
prior-action push-button station can also be used for either the two-hand “walk-away” or the<br />
foot-ma<strong>in</strong>ta<strong>in</strong>ed-cont<strong>in</strong>uous mode of operation.<br />
This station is furnished with a three-position keyed selector switch for automatic s<strong>in</strong>gle/off/<br />
cont<strong>in</strong>uous-on-demand. It also has an illum<strong>in</strong>ated prior-action push button. If a comp<strong>one</strong>nt<br />
package is not supplied with the control box, this station must be ordered separately. It is<br />
furnished <strong>in</strong> its own enclosure so it can be mounted <strong>in</strong> a convenient location on the front of<br />
the press. The NEMA 12 enclosure size is 5 3 / 4” x 4” x 3 3 / 4”.<br />
BAR/RUN STATION<br />
Part No. LLD-404<br />
This remote bar/run station can be used <strong>in</strong> conjunction with a manual turnover bar when<br />
sett<strong>in</strong>g dies <strong>in</strong> the press. The flywheel must have holes <strong>in</strong> the periphery for <strong>in</strong>sertion of a<br />
spr<strong>in</strong>g-loaded turnover bar** (or the flywheel can be manu<strong>all</strong>y turned when the flywheel cover is<br />
removed). The remote station <strong>in</strong>cludes a three-position selector switch for bar/off/run, and <strong>one</strong><br />
push button used for energiz<strong>in</strong>g the dual-solenoid air valve to engage the clutch and release<br />
the brake. The flywheel must be at rest (static) when engag<strong>in</strong>g the clutch. After the clutch is<br />
engaged, the die setup person can manu<strong>all</strong>y turn the flywheel with a spr<strong>in</strong>g-loaded turnover<br />
bar (see page 98). The enclosure size is 5¼” x 3” x 3¼”.<br />
Prior-Action Station for Cont<strong>in</strong>uous<br />
Prior-Action Station for Automatic S<strong>in</strong>gle<br />
Stroke or Cont<strong>in</strong>uous-On-Demand<br />
Bar/Run Station<br />
1⁄4” AIR LOCKOUT VALVE<br />
Part No. RCD-071<br />
This three-way valve is operated with the manual movement of a slide that opens and closes<br />
the valve. This valve shuts off air at the press and then bleeds off downstream air. This lockout<br />
is not <strong>in</strong>cluded <strong>in</strong> the comp<strong>one</strong>nt packages listed on pages 15-16 and must be ordered<br />
separately. Different styles and valve sizes are available; please see page 35.<br />
Air Lockout Valve<br />
Pneumatic System on Full-Revolution-Clutch Power Press<br />
Air Supply<br />
Air<br />
Lockout<br />
Valve<br />
Filter-Regulator-<br />
Lubricator<br />
Solenoid Air Valve<br />
Air Cyl<strong>in</strong>der<br />
Air Pressure Switch<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on pages 15-16.<br />
**For a spr<strong>in</strong>g-loaded turnover bar, see page 98.<br />
14 | CONTROL SYSTEMS
COMPONENT PACKAGE ORDERING INFORMATION<br />
SELECTING A COMPONENT PACKAGE<br />
Determ<strong>in</strong>e which modes of operation and actuat<strong>in</strong>g means you require.<br />
Use the follow<strong>in</strong>g charts to select the comp<strong>one</strong>nt package you require.<br />
MODES OF OPERATION AVAILABLE:<br />
H—Two-Hand S<strong>in</strong>gle Stroke<br />
F—Foot S<strong>in</strong>gle Stroke<br />
M—Foot-Ma<strong>in</strong>ta<strong>in</strong>ed Cont<strong>in</strong>uous<br />
J—Two-Hand Motor Jog<br />
C—Two-Hand “Walk-Away” Cont<strong>in</strong>uous<br />
A—Automatic S<strong>in</strong>gle Stroke<br />
A—Cont<strong>in</strong>uous-On-Demand<br />
Modes of Operation<br />
COMPONENT PACKAGE SELECTION CHART<br />
Comp<strong>one</strong>nt<br />
Package<br />
H F M J C A<br />
FNH-011 X X<br />
FNH-012 X X X<br />
FNH-112 X X X X<br />
FNF-012 X X X<br />
FNF-013 X X X X<br />
FNF-014 X X X X X<br />
FNF-114 X X X X X X<br />
COMPONENT PACKAGES USED WITH FPH, FPF, OR FPG CONTROL BOXES<br />
PACKAGE NO. FNH-011<br />
TWO-HAND SINGLE STROKE AND MOTER JOG<br />
PART NO.<br />
DESCRIPTION<br />
RCD-140 1/4" Dual-Solenoid Air Valve<br />
RCL-043 1/4" Filter-Regulator-Lubricator Assembly<br />
CTD-062 Air Pressure Switch<br />
CML-002 Cam and Strap Assembly<br />
CMK-103 Top-of-Stroke Limit Switch Assembly<br />
CTL-507 Palm Button Assembly (3-button assembly)<br />
HJ<br />
PACKAGE NO. FNH-012<br />
HJ-C<br />
TWO-HAND SINGLE STROKE, MOTER JOG, AND TWO-HAND CONTINUOUS<br />
PART NO.<br />
DESCRIPTION<br />
RCD-140 1/4" Dual-Solenoid Air Valve<br />
RCL-043 1/4" Filter-Regulator-Lubricator Assembly<br />
CTD-062 Air Pressure Switch<br />
CML-002 Cam and Strap Assembly<br />
CMK-103 Top-of-Stroke Limit Switch Assembly<br />
CTL-502 Palm Button Assembly (4-button assembly)<br />
LLD-400 Cont<strong>in</strong>uous Prior-Action Station<br />
COMPONENT PACKAGES USED WITH FPA CONTROL BOXES<br />
PACKAGE NO. FNH-112<br />
HJ-CA<br />
TWO-HAND SINGLE STROKE, MOTER JOG, TWO-HAND CONTINUOUS,<br />
AUTO SINGLE STROKE, AND CONTINUOUS-ON-DEMAND<br />
PART NO.<br />
RCD-140<br />
RCL-043<br />
CTD-062<br />
CML-002<br />
CMK-103<br />
CTL-502<br />
LLD-406<br />
1/4" Dual-Solenoid Air Valve<br />
DESCRIPTION<br />
1/4" Filter-Regulator-Lubricator Assembly<br />
Air Pressure Switch<br />
Cam and Strap Assembly<br />
Top-of-Stroke Limit Switch Assembly<br />
Palm Button Assembly (4-button assembly)<br />
Automatic Prior-Action Station<br />
PACKAGE NO. FNF-114<br />
HFMJ-CA<br />
TWO-HAND & FOOT SWITCH SINGLE STROKE, FOOT MAINT.<br />
CONTINUOUS, MOTER JOG, TWO-HAND CONTINUOUS, AUTO SINGLE,<br />
AND CONTINUOUS-ON-DEMAND<br />
PART NO.<br />
RCD-140<br />
RCL-043<br />
CTD-062<br />
CML-002<br />
CMK-103<br />
CTL-502<br />
CTD-011<br />
LLD-406<br />
1/4" Dual-Solenoid Air Valve<br />
DESCRIPTION<br />
1/4" Filter-Regulator-Lubricator Assembly<br />
Air Pressure Switch<br />
Cam and Strap Assembly<br />
Top-of-Stroke Limit Switch Assembly<br />
Palm Button Assembly (4-button assembly)<br />
Foot Switch<br />
Automatic Prior-Action Station<br />
Note: For control box selection, see pages 9-11. For air cyl<strong>in</strong>der selection, see page 17, and for lockout valve, see page 14.<br />
CONTROL SYSTEMS | 15
COMPONENT PACKAGE ORDERING INFORMATION (CONTINUED)<br />
COMPONENT PACKAGES USED WITH FPF OR FPG CONTROL BOXES<br />
PACKAGE NO. FNF-012<br />
HFJ<br />
TWO-HAND & FOOT SWITCH SINGLE STROKE AND MOTER JOG<br />
PART NO.<br />
DESCRIPTION<br />
RCD-140 1/4" Dual-Solenoid Air Valve<br />
RCL-043 1/4" Filter-Regulator-Lubricator Assembly<br />
CTD-062 Air Pressure Switch<br />
CML-002 Cam and Strap Assembly<br />
CMK-103 Top-of-Stroke Limit Switch Assembly<br />
CTL-507 Palm Button Assembly (3-button assembly)<br />
CTD-011 Foot Switch<br />
PACKAGE NO. FNF-013<br />
PART NO.<br />
RCD-140<br />
RCL-043<br />
CTD-062<br />
CML-002<br />
CMK-103<br />
CTL-507<br />
CTD-011<br />
LLD-400<br />
TWO-HAND & FOOT SWITCH SINGLE STROKE,<br />
FOOT MAINTAINED CONTINUOUS, AND MOTER JOG<br />
DESCRIPTION<br />
1/4" Dual-Solenoid Air Valve<br />
1/4" Filter-Regulator-Lubricator Assembly<br />
Air Pressure Switch<br />
Cam and Strap Assembly<br />
Top-of-Stroke Limit Switch Assembly<br />
Palm Button Assembly (3-button assembly)<br />
Foot Switch<br />
Cont<strong>in</strong>uous Prior-Action Station<br />
HFMJ<br />
PACKAGE NO. FNF-014<br />
HFMJ-C<br />
TWO-HAND & FOOT SWITCH SINGLE STROKE,<br />
FOOT MAINTAINED CONTINUOUS, MOTER JOG, AND TWO-HAND<br />
CONTINUOUS<br />
PART NO.<br />
RCD-140<br />
RCL-043<br />
CTD-062<br />
CML-002<br />
CMK-103<br />
CTL-502<br />
CTD-011<br />
LLD-400<br />
1/4" Dual-Solenoid Air Valve<br />
DESCRIPTION<br />
1/4" Filter-Regulator-Lubricator Assembly<br />
Air Pressure Switch<br />
Cam and Strap Assembly<br />
Top-of-Stroke Limit Switch Assembly<br />
Palm Button Assembly (4-button assembly)<br />
Foot Switch<br />
Cont<strong>in</strong>uous Prior-Action Station<br />
Note: For control box selection, see pages 9-11. For air cyl<strong>in</strong>der selection, see page 17, and for lockout valve, see page 14.<br />
16 | CONTROL SYSTEMS
AIR CYLINDERS<br />
ALL ILLUSTRATED CYLINDERS ARE PULL-TYPE/SPRING RETURN<br />
RCL-001<br />
RCL-002<br />
RCL-003<br />
RCL-004<br />
RCL-005<br />
Yoke<br />
Spr<strong>in</strong>g<br />
Cyl<strong>in</strong>der<br />
Clevis<br />
An air cyl<strong>in</strong>der must be ordered separately us<strong>in</strong>g a specific part number. It is required to complete the control system. The air cyl<strong>in</strong>der is attached<br />
to the clutch operat<strong>in</strong>g rod <strong>in</strong> order to trip the press. Norm<strong>all</strong>y, s<strong>in</strong>gle-act<strong>in</strong>g, pull-type/spr<strong>in</strong>g-return air cyl<strong>in</strong>ders are required. The return spr<strong>in</strong>g<br />
on the cyl<strong>in</strong>der rod is compression type and is designed to prevent <strong>in</strong>terleav<strong>in</strong>g to meet OSHA and ANSI standards. A clevis mount<strong>in</strong>g arrangement<br />
is furnished to attach the cyl<strong>in</strong>der to the press frame. A rod, yoke, and p<strong>in</strong> assembly for ease <strong>in</strong> connect<strong>in</strong>g to the exist<strong>in</strong>g clutch operat<strong>in</strong>g rod is<br />
standard on <strong>all</strong> cyl<strong>in</strong>ders. Push-type/spr<strong>in</strong>g-return and longer or shorter stroke air cyl<strong>in</strong>ders are also available. To determ<strong>in</strong>e the proper size or type<br />
of air cyl<strong>in</strong>der, check the l<strong>in</strong>kage where the cyl<strong>in</strong>der will be <strong>in</strong>serted. Please consult the factory for any special requirements.<br />
Standard Pull Type<br />
Standard Push Type<br />
RCL-001 RCL-002 RCL-003 RCL-004 RCL-005<br />
RCL-022 RCL-023 RCL-024 RCL-025<br />
PRESS SIZE<br />
(TONS)<br />
SIZE (BORE<br />
X STROKE)<br />
PULL<br />
FORCE<br />
(@ 74 PSI)<br />
NPT PORT<br />
SIZE<br />
1/4 to 7 8 to 35 36 to 70 71 to 125 126 to 200<br />
1-1/2"<br />
x 1"<br />
1-1/2" x 1" 2" x 2" 2-1/2" x 2" 3" x 2"<br />
50 lb 100 lb 200 lb 300 lb 500 lb<br />
1/4" 1/4" 1/4" 1/4" 3/8"<br />
PRESS SIZE<br />
(TONS)<br />
SIZE (BORE<br />
X STROKE)<br />
PULL<br />
FORCE<br />
(@ 74 PSI)<br />
NPT PORT<br />
SIZE<br />
8 to 35 36 to 70 71 to 125 126 to 200<br />
1-1/2"<br />
x 1"<br />
2" x 2" 2-1/2" x 2" 3" x 2"<br />
100 lb 200 lb 300 lb 500 lb<br />
1/4" 1/4" 1/4" 3/8"<br />
CONTROL SYSTEMS | 17
SURVEY FOR FULL-REVOLUTION PRESS<br />
Company<br />
City<br />
State<br />
Surveyed By<br />
Date<br />
NO. ____________<br />
Proposal Sequence Reference<br />
INSTALLATION N Y<br />
When fill<strong>in</strong>g out this form, be sure that the <strong>in</strong>formation for satisfy<strong>in</strong>g the basic areas<br />
of safety are answered.<br />
They are: 1. <strong>Safeguard<strong>in</strong>g</strong> 4. Starter<br />
2. Control 5. Cover<br />
3. Disconnect 6. Other Considerations<br />
1<br />
2<br />
For identification and reference, please fill <strong>in</strong> this area first.<br />
Mach<strong>in</strong>e No.<br />
Model No.<br />
Tonnage (always required)<br />
1. <strong>Safeguard<strong>in</strong>g</strong>:<br />
Has Safeguard Provide Type, Series, or Size<br />
Pullback<br />
Not offered by RSI<br />
Restra<strong>in</strong>t<br />
Barrier Guard<br />
When provid<strong>in</strong>g, please attach completed measurement data form. Sides and back<br />
must be guarded.<br />
Type A Gate<br />
When provid<strong>in</strong>g, please attach completed measurement data form for type A gate and<br />
guards for the sides of the po<strong>in</strong>t of operation.<br />
Two-Hand Trip<br />
If press has two-hand trip, are the palm buttons at the proper safety<br />
distance? N Y If we are to provide, what is proper<br />
safety distance?________”(See pp. 55-56 <strong>in</strong> MSD catalog for details)<br />
When provid<strong>in</strong>g any of the above safeguard<strong>in</strong>g devices, the sides and rear of the po<strong>in</strong>t of operation<br />
must be safeguarded. Are side and rear guards required?<br />
N CTF (Customer to Y If Y, please complete and attach measurement form.<br />
Furnish)<br />
2. Control:<br />
A. Does clutch have s<strong>in</strong>gle-stroke capability? N Y:<br />
If Y, circle <strong>one</strong>: Mechanism or Trip Control<br />
If Trip Control, check type: Air Air/Elec.<br />
B. Information about press:<br />
1. Hand Actuat<strong>in</strong>g N Y If Y:<br />
Lever Palm Buttons No. of Stations: 1 2<br />
2. Foot Actuat<strong>in</strong>g N Y If Y:<br />
Manufacturer<br />
Serial No.<br />
Type: OBI Gap Gap DC Horn SSSC SSDC<br />
Is mach<strong>in</strong>e out of service? N Y<br />
What are methods of feed<strong>in</strong>g material?<br />
Hand, From: Front Sides: Right Left;<br />
Automatic: Coil Strip; Magaz<strong>in</strong>e;<br />
Shuttle; Slid<strong>in</strong>g Bolster; Other<br />
Pedal Foot Switch No. of Stations: 1 2<br />
3. Modes: Jog S<strong>in</strong>gle Cont<strong>in</strong>uous<br />
Ma<strong>in</strong>ta<strong>in</strong>ed Cont<strong>in</strong>uous<br />
Other__________________________________<br />
1 of 2<br />
18 | CONTROL SYSTEMS
SURVEY FOR FULL-REVOLUTION PRESS<br />
2<br />
3<br />
4<br />
C. Control System:<br />
1. Is complete trip-control system to be furnished?<br />
N Y If Y, is control box to be: Standard Custom<br />
Type A Gate Interface<br />
If Custom, see Sections 3 and 4.<br />
2. Modes Required:<br />
Jog S<strong>in</strong>gle Two-Hand Cont. Foot-Ma<strong>in</strong>t. Cont.<br />
Auto S<strong>in</strong>gle Cont<strong>in</strong>uous-on-Demand<br />
Other__________________<br />
3. Top-of-Stroke Limit Switch Assembly?<br />
N Y (Required with control)<br />
4. Actuat<strong>in</strong>g Means: How many operat<strong>in</strong>g stations? 1 2 (circle <strong>one</strong>)<br />
a. Hand (push buttons) N Y Hand (other) N Y<br />
b. E-Stop Button N Y Top-Stop Button N Y<br />
c. Foot Switch N Y<br />
5. Dual Air Valve N Y S<strong>in</strong>gle Air Valve N Y<br />
6. Is air cyl<strong>in</strong>der to be furnished?<br />
N Y Reuse exist<strong>in</strong>g<br />
If Y, provide details: Push Pull<br />
______” Bore ______” Stroke ______ Mount<br />
7. Does brake need to be modified or replaced to be<br />
<strong>in</strong>herently self-engag<strong>in</strong>g (spr<strong>in</strong>g-applied)? N Y<br />
3. Disconnect:<br />
A. Present location of disconnect:<br />
1. On Press or Off Press<br />
2. With Clutch Control<br />
Separate from Clutch Control<br />
With Starter Only<br />
Not Furnished<br />
B. Is electrical disconnect switch required?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
Y If Y, furnish HP, FLA, and voltage <strong>in</strong> Section 4C.<br />
C. How is disconnect to be furnished?<br />
Separate Box Comb<strong>in</strong>ation With Starter Custom Box<br />
D. Is 1 ⁄4” air lockout valve required? N Y<br />
4. Starter:<br />
A. Present Location of Starter:<br />
1. On Press or Off Press<br />
2. With Clutch Control<br />
Separate from Clutch Control<br />
With Disconnect Only<br />
Not Furnished<br />
B. Is transformer for reduc<strong>in</strong>g voltage to starter required?<br />
N Y (Provided <strong>in</strong> new control box if proposed.)<br />
C. Is magnetic starter required for ma<strong>in</strong> drive?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
If N, exist<strong>in</strong>g starter must have 115-V coil and <strong>one</strong><br />
norm<strong>all</strong>y open auxiliary contact.<br />
Y<br />
Estimate<br />
Actual<br />
If Y, provide: ______Horsepower ______<br />
______Full-Load Amps<br />
______<br />
______Voltage<br />
______<br />
D. How is starter to be furnished? Separate Box<br />
Comb<strong>in</strong>ation W/Disconnect<br />
Custom Box<br />
E. Is remote push-button station required?<br />
N Y<br />
5<br />
6<br />
5. Covers: (Customer to Furnish)<br />
Do mechanical power-transmission apparatuses need to be covered up to<br />
7 feet above floor or platform? N Y If Y, what needs to<br />
be covered?<br />
Flywheel N Y Connection Rod N Y<br />
Gears N Y Turnover Bar Slot N Y<br />
Shaft End N Y Other__________ N Y<br />
Are additional brackets required? N Y<br />
6. Other Considerations:<br />
A. Does press have lube system requir<strong>in</strong>g electrical<br />
tie-<strong>in</strong>? N Y<br />
B. Is safety block to be furnished? N Y:<br />
If Y, what size is needed? ________” (height)<br />
How many? _______ S M L (circle <strong>one</strong>)<br />
Interlock N Y Holder N Y<br />
C. Is spr<strong>in</strong>g-loaded turnover bar required? N Y:<br />
If Y, what diameter? ________”<br />
D. Does press have material feed<strong>in</strong>g equipment? N Y<br />
1. Is safeguard<strong>in</strong>g required for the feeder? N Y<br />
2. Is safeguard<strong>in</strong>g required for the straightener? N Y<br />
3. Is safeguard<strong>in</strong>g required for the reel? N Y<br />
4. Is safeguard<strong>in</strong>g required for the cradle? N Y<br />
E. If questionable about any <strong>in</strong>formation furnished, please enclose photos of<br />
entire front, sides (left and right), and rear of press. Include close-up photos of<br />
the <strong>in</strong>side of the exist<strong>in</strong>g control box, clutch, and crankshaft extension end.<br />
Send<strong>in</strong>g Enclosed<br />
2 of 2<br />
CONTROL SYSTEMS | 19
SAFEGUARDED PART-REVOLUTION-CLUTCH PRESS<br />
Sprockets and Cha<strong>in</strong><br />
(Under Cover)<br />
Resolver/Pulser<br />
Assembly<br />
Remote Operator<br />
Station With Keypad/<br />
Display<br />
Danger Signs<br />
Custom Pla<strong>in</strong>-Door, Solid-State<br />
Control Box With Disconnect<br />
and Motor Starter<br />
Presence-Sens<strong>in</strong>g Device<br />
(Light Curta<strong>in</strong>)<br />
Side Barrier<br />
Guards<br />
Palm Button Assembly<br />
(Two-Hand Control)<br />
Foot Switch<br />
A Part-Revolution-Clutch Press With Clutch/Brake Control and a Presence-Sens<strong>in</strong>g Device and Two-Hand Control as Safeguards<br />
20 | CONTROL SYSTEMS
SSC-1500 PRESS CONTROL<br />
PART-REVOLUTION CLUTCH<br />
The majority of part-revolution presses have an air-applied clutch and<br />
an air-released brake. They are designed to trap air <strong>in</strong> a chamber or<br />
tube. When compressed air is put <strong>in</strong>to these chambers or tubes, the<br />
clutch is engaged and the brake is released. The press then starts a<br />
cycle. To stop the press, the opposite takes place. A part-revolutionclutch<br />
press can be engaged and disengaged at any position of<br />
crankshaft rotation or revolution.<br />
Occasion<strong>all</strong>y older mechanical-friction-clutch presses are found <strong>in</strong> plants<br />
and are still be<strong>in</strong>g used. Sometimes press brakes with mechanicalfriction<br />
clutches are used as power presses. These press brakes and<br />
the older mechanical-friction-clutch presses can be updated by add<strong>in</strong>g<br />
a properly sized air cyl<strong>in</strong>der to the part-revolution control packages that<br />
are offered. See pages 83 and 84 for these air cyl<strong>in</strong>ders.<br />
Due to the many detailed OSHA requirements on part-revolutionclutch<br />
presses, most exist<strong>in</strong>g clutch/brake control systems on presses<br />
do not meet safety standards and regulations if they were <strong>in</strong>st<strong>all</strong>ed<br />
prior to 1971. Most of these presses do not have control reliability<br />
and brake monitor<strong>in</strong>g.<br />
The part-revolution-clutch/brake control-reliable systems <strong>in</strong> this catalog<br />
are designed to stop the press and render it <strong>in</strong>operable if there is<br />
a s<strong>in</strong>gle comp<strong>one</strong>nt failure <strong>in</strong> the control system. This is d<strong>one</strong> by<br />
m<strong>in</strong>imiz<strong>in</strong>g the use of static-condition comp<strong>one</strong>nts and us<strong>in</strong>g critical,<br />
redundant comp<strong>one</strong>nts that are checked. Microprocessors or relays of<br />
special construction are used <strong>in</strong> this type of reliable control system (see<br />
page 111). The clutch/brake control systems offered here are furnished<br />
with a built-<strong>in</strong>, two-hand control safeguard<strong>in</strong>g device.<br />
In addition to the clutch/brake control meet<strong>in</strong>g the requirements of the<br />
safety standards, <strong>all</strong> part-revolution presses require a safeguard<strong>in</strong>g<br />
device or guard (barrier) to protect people that operate, set up, and<br />
ma<strong>in</strong>ta<strong>in</strong> these mach<strong>in</strong>es.<br />
The follow<strong>in</strong>g are OSHA- and ANSI-recognized methods for safeguard<strong>in</strong>g<br />
the po<strong>in</strong>t of operation on part-revolution-clutch mechanical power presses:<br />
1. Barrier guard (<strong>Catalog</strong> EX-AL)<br />
2. Presence-sens<strong>in</strong>g device (<strong>Catalog</strong> MSD)<br />
3. Two-hand control (Refer to this section)<br />
4. Pullback (Not offered by <strong>Rockford</strong> <strong>Systems</strong>)<br />
5. Restra<strong>in</strong>t (<strong>Catalog</strong> MSD)<br />
6. Type A or B gate (<strong>Catalog</strong> MSD)<br />
When safeguard<strong>in</strong>g, please keep <strong>in</strong> m<strong>in</strong>d that the sides and back of the<br />
po<strong>in</strong>t of operation must also be safeguarded to protect the operator and<br />
other employees.<br />
OSHA’s safety distance formula for two-hand control, two-hand trip,<br />
and presence-sens<strong>in</strong>g devices can be found on pages 119-120 of this<br />
catalog. Refer to our MSD catalog for ANSI’s safety distance formulas.<br />
Other considerations on a part-revolution-clutch press are the ma<strong>in</strong><br />
power disconnect switch, magnetic motor starter, covers for the<br />
flywheel, gears, etc.<br />
PART-REVOLUTION CONTROL SYSTEMS<br />
A part-revolution control system consists of:<br />
1. A control box (pp. 21-29)<br />
2a. Individual comp<strong>one</strong>nts (pp. 30-35)<br />
OR<br />
2b. Comp<strong>one</strong>nt packages (pp. 36-37)<br />
We offer a variety of control boxes that can be furnished to meet your<br />
specific requirements. The SSC-1500 solid-state control box version is<br />
available as follows:<br />
1. Standard clutch/brake control<br />
2. Custom clutch/brake control which <strong>in</strong>cludes a fused<br />
disconnect switch and magnetic motor starter<br />
3. Special clutch/brake control<br />
4. Remote operator style<br />
SELECTING A CONTROL SYSTEM<br />
1. To order a complete control system which <strong>in</strong>cludes control reliability<br />
and brake monitor<strong>in</strong>g, determ<strong>in</strong>e which style control box is required.<br />
A standard control box <strong>in</strong>cludes the clutch/brake control and transformer.<br />
Standard Control<br />
CONTROL SYSTEMS | 21
SELECTING A CONTROL SYSTEM (CONTINUED)<br />
The clutch/brake control can also be furnished <strong>in</strong> a pla<strong>in</strong>-door<br />
enclosure, as a subpanel, or as a module kit. The pla<strong>in</strong>-door control<br />
requires a remote operator station. Subpanels and module kits are<br />
furnished without the enclosure; module kits <strong>in</strong>clude the primary<br />
<strong>in</strong>ternal comp<strong>one</strong>nts of the control only. Subpanels and module kits<br />
must be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong>to an exist<strong>in</strong>g enclosure by qualified personnel. The<br />
subpanel or module kit also requires a remote operator station or a<br />
keypad/display kit.<br />
A custom control box <strong>in</strong>cludes a ma<strong>in</strong> power disconnect switch and<br />
magnetic motor starter <strong>in</strong> the same enclosure as the clutch/brake<br />
control. A revers<strong>in</strong>g ram-adjust motor starter may also be <strong>in</strong>cluded.<br />
Special control boxes can <strong>in</strong>clude either a standard or custom clutch/<br />
brake control that requires modification for any special requirements.<br />
This can be an <strong>in</strong>terface of auxiliary equipment, such as a lube system,<br />
a light curta<strong>in</strong> <strong>in</strong>terface for a non-<strong>Rockford</strong> light curta<strong>in</strong>, or comp<strong>one</strong>nts<br />
specified by the end user, such as NEMA starters and disconnects.<br />
Remote operator-style control boxes <strong>in</strong>clude the clutch/brake control<br />
and are designed to be mounted close to the operator. A control<br />
transformer must be supplied separately or the exist<strong>in</strong>g transformer<br />
must be reused.<br />
2. The CMS-115 resolver/pulser assembly is always required with any<br />
of the SSC-1500 controls.<br />
3. After determ<strong>in</strong><strong>in</strong>g the style of control box, determ<strong>in</strong>e the location of<br />
the operator controls, <strong>in</strong>dicator lights, and the keypad/display. Please<br />
remember these comp<strong>one</strong>nts should be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a convenient<br />
location for the operator. These comp<strong>one</strong>nts can be supplied as follows:<br />
1. On the front of the enclosure<br />
2. In a remote operator station<br />
3. In a control bar<br />
4. In a console<br />
5. Loose for <strong>in</strong>st<strong>all</strong>ation <strong>in</strong> an exist<strong>in</strong>g box<br />
4. Determ<strong>in</strong>e which other comp<strong>one</strong>nts are required (dual-solenoid air<br />
valve, air pressure switches, etc.). If exist<strong>in</strong>g comp<strong>one</strong>nts comply with<br />
the safety requirements, they can be reused with the control box that<br />
is furnished. If the comp<strong>one</strong>nts do not comply, complete comp<strong>one</strong>nt<br />
packages are available. Please see pages 36-37.<br />
Pla<strong>in</strong>-Door Control<br />
Remote Operator Station<br />
Custom or Special Control With Remote Operator Station<br />
Remote Operator-Style Control<br />
22 | CONTROL SYSTEMS
SSC-1500 STANDARD PRESS CONTROL<br />
The SSC-1500 control is designed for use on part-revolution-clutch<br />
power presses. It is designed and built to comply with OSHA 29 CFR<br />
1910.217, and ANSI B11.1 and B11.19. These controls can update or<br />
replace exist<strong>in</strong>g relay-based control systems, found <strong>in</strong> user’s plants;<br />
they can also be furnished for new or rebuilt presses.<br />
This control <strong>in</strong>cludes control reliability (see page 111), motion detection<br />
with a time-based brake monitor, light curta<strong>in</strong> <strong>in</strong>terface, and diagnostics<br />
(eight user-programmable <strong>in</strong>puts). It also <strong>in</strong>cludes batch and stroke<br />
counters with preset, a total counter, and a hard-wired emergency-stop<br />
master control relay.<br />
The SSC-1500 is an economic, full-featured, dual-microprocessorbased<br />
control system. The system uses redundant <strong>in</strong>puts<br />
from devices such as palm buttons, foot switches, and a light<br />
curta<strong>in</strong>(s). The system output to the dual-solenoid air valve is<br />
provided by two (2) safety relays with force-guided contacts. These<br />
output relays are <strong>in</strong>dependently controlled and cross-checked by<br />
the microprocessors. This <strong>all</strong>ows control-reliable operation of the<br />
outputs <strong>in</strong> the event of a s<strong>in</strong>gle control comp<strong>one</strong>nt failure. Each<br />
microprocessor also has its own logic power supply. This decreases the<br />
possibility of simultaneous control failure because of a fault with<strong>in</strong> the<br />
power supply system. Tim<strong>in</strong>g and motion detection of the crankshaft is<br />
accomplished by the resolver/pulser assembly.<br />
The standard control box is a 20” x 20” x 8” NEMA 12 enclosure with<br />
the operator controls and keypad/display mounted <strong>in</strong> the door, as<br />
illustrated above.<br />
If a starter or disconnect is required <strong>in</strong> the same enclosure as the<br />
standard SSC-1500 control, see page 26, SSC-1500 custom controls.<br />
If a separate starter or disconnect, or comb<strong>in</strong>ation starter disconnect is<br />
required, refer to our <strong>Catalog</strong> SFM.<br />
Back of Keypad/<br />
Display<br />
Term<strong>in</strong>als<br />
Standard Control Box (PRC-000-FW Shown)<br />
Master Control<br />
Relay<br />
Multi-Tap<br />
Transformer<br />
Transformer<br />
Fuses<br />
Selectors<br />
Inside View of Standard Control Box<br />
SSC-1500<br />
Control Module Assembly<br />
CONTROL SYSTEMS | 23
SSC-1500 STANDARD PRESS CONTROL (CONTINUED)<br />
STANDARD MODES OF OPERATION<br />
• Off<br />
• Two-hand <strong>in</strong>ch (regular, timed, or top-stop)<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Foot s<strong>in</strong>gle stroke<br />
• Two-hand “walk-away” cont<strong>in</strong>uous<br />
• Cont<strong>in</strong>uous-on-demand<br />
• Automatic s<strong>in</strong>gle stroke<br />
• Two-hand-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous<br />
• Foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous<br />
• One-hand or foot trip s<strong>in</strong>gle stroke<br />
(use with light curta<strong>in</strong> or <strong>in</strong>terlocked guard only)<br />
FEATURES<br />
• Meets and exceeds OSHA 29 CFR 1910.217 and ANSI B11.1 and B11.19<br />
• Provides two-hand control safeguard<strong>in</strong>g device<br />
• Redundant/cross-check<strong>in</strong>g microprocessors<br />
• Redundant microprocessor logic power supplies<br />
•Redundant solenoid relays<br />
• 4-l<strong>in</strong>e x 20-character LCD (liquid crystal display) with 20-key operator<br />
<strong>in</strong>terface<br />
• Wide range of <strong>in</strong>put power supply — 85-to 135-V AC<br />
• Absolute resolver/pulser with sync sensor for tim<strong>in</strong>g and motion detection<br />
• Time-based brake monitor with programmable warn<strong>in</strong>g and fault set po<strong>in</strong>ts<br />
• Stop-time measurement test<br />
• 6 user-programmable 24-V DC static diagnostic <strong>in</strong>puts<br />
• Part-<strong>in</strong>-place 24-V DC <strong>in</strong>put<br />
• 2 user-programmable 24-V DC static or cyclic die protection <strong>in</strong>puts<br />
• 7-digit stroke and batch counters with preset, and a 7-digit total counter<br />
• Automatic variable-speed top-stop adjustment<br />
(for cont<strong>in</strong>uous mode only)<br />
• Light curta<strong>in</strong> <strong>in</strong>terface(s) with off/on selector<br />
• Light curta<strong>in</strong> mute dur<strong>in</strong>g the nonhazardous portion of the stroke<br />
• 4 PLS (programmable limit switch) outputs—2 on/off angles, or 1 timed<br />
off, or 1 counted output per PLS (or 3 PLS outputs and 1 auxiliary output<br />
with 1 contact)<br />
• Information displayed when the mach<strong>in</strong>e is <strong>in</strong> operation: angle, speed,<br />
batch counter, stroke counter, mode of operation, and stop time<br />
• Display of text <strong>in</strong> English or Spanish<br />
KEYPAD/DISPLAY<br />
The keypad/display is used to enter setup <strong>in</strong>formation,<br />
monitor mach<strong>in</strong>e operation, and display messages to the user.<br />
The keypad/display has a 4-l<strong>in</strong>e x 20-character LCD (liquid<br />
crystal display) with 20 keys for enter<strong>in</strong>g <strong>in</strong>formation and<br />
programm<strong>in</strong>g. As standard, this keypad/display is mounted <strong>in</strong> the<br />
control box. For operator convenience, it can be furnished <strong>in</strong> a remote<br />
enclosure up to a maximum of 150’ from the SSC-1500 control module<br />
(see page 28).<br />
Information displayed dur<strong>in</strong>g the mach<strong>in</strong>e run cycle <strong>in</strong>cludes:<br />
PROGRAMMING<br />
The SSC-1500 press control has eight (8) user-programmable <strong>in</strong>puts (6<br />
static-type and 2 static- or cyclic-type <strong>in</strong>puts) that can be programmed<br />
for equipment monitor<strong>in</strong>g or other user-def<strong>in</strong>ed functions. All <strong>in</strong>puts are<br />
24-V DC selectable current-s<strong>in</strong>k<strong>in</strong>g or sourc<strong>in</strong>g <strong>in</strong>puts.<br />
There are three parameters that can be programmed for the six statictype<br />
<strong>in</strong>puts, and five parameters that can be programmed for the two<br />
static- or cyclic-type <strong>in</strong>puts. The three parameters are <strong>in</strong>put logic, stop<br />
type, and fault message; the five parameters are <strong>in</strong>put logic, stop type,<br />
fault message, open angle, and close angle. They can be assigned to<br />
each <strong>in</strong>put from the list below. When a fault condition is detected, the<br />
mach<strong>in</strong>e will top stop or emergency stop, and the assigned message<br />
will be displayed. This feature helps when troubleshoot<strong>in</strong>g common<br />
fault conditions.<br />
FAULT MESSAGE LIST:<br />
Clutch/Brake Air Fault<br />
Counterbalance Air Fault<br />
Dual Solenoid Fault<br />
Clutch Valve Fault*<br />
Brake Valve Fault*<br />
Lube Fault<br />
High Lube Pressure<br />
Low Lube Pressure<br />
Low Lube Level<br />
Ma<strong>in</strong> Motor Overload<br />
Ram-Adjust Motor Overload<br />
Lube Motor Overload<br />
Auxiliary Motor Overload<br />
Guard Interlock Open<br />
Front Guard Open<br />
Rear Guard Open<br />
Angle of<br />
Crankshaft<br />
Batch<br />
Counter<br />
Mode of<br />
Operation<br />
Left Side Guard Open<br />
Right Side Guard Open<br />
Feeder Fault<br />
Load Monitor Fault<br />
Safety Block Interlock<br />
Shut Height Fault<br />
Variable Speed Drive Fault<br />
Die Protection Fault**<br />
Short Feed Fault**<br />
Part Ejection Fault**<br />
Stock Buckle Fault**<br />
End of Stock Fault**<br />
Pilot P<strong>in</strong> Fault**<br />
Part Input #1**<br />
Part Input #2**<br />
Part Input #3**<br />
*Only used on mach<strong>in</strong>es that have a split clutch and brake, and two dual<br />
valves have been furnished.<br />
**Messages typic<strong>all</strong>y used for die protection.<br />
Speed of<br />
Press<br />
Stroke<br />
Counter<br />
Stop<br />
Time<br />
• Angle<br />
• Speed<br />
• Batch Counter<br />
• Stroke Counter<br />
• Mode<br />
• Stop Time<br />
Example of the Ma<strong>in</strong> Run Screen on the Keypad/Display<br />
With Selector Switches<br />
24 | CONTROL SYSTEMS
SSC-1500 CUSTOM PRESS CONTROL<br />
Fused Disconnect<br />
Switch<br />
Display Screen<br />
and Keypad<br />
Operator<br />
Controls<br />
SSC-1500 Custom Control Box<br />
Part-revolution-clutch SSC-1500 custom control boxes are also<br />
available to house the clutch/brake controls, disconnect switch, motor<br />
starters, and any other electrical comp<strong>one</strong>nts to fit your press room<br />
needs. A custom control box conta<strong>in</strong>s the standard control module and<br />
comp<strong>one</strong>nts as described on pages 23-24 plus the follow<strong>in</strong>g:<br />
• ma<strong>in</strong> power disconnect switch<br />
• ma<strong>in</strong> drive motor starter<br />
• ram-adjust motor starter (if required)<br />
These boxes are furnished with an IEC through-the-door ma<strong>in</strong> power<br />
fused disconnect switch and an IEC magnetic motor starter (with push<br />
buttons). A revers<strong>in</strong>g ram-adjust motor starter with selector and push<br />
buttons may also be <strong>in</strong>cluded. They are prewired and built <strong>in</strong>to a NEMA<br />
12 enclosure.<br />
Operator controls and the keypad/display are located on the front of<br />
the door, or a pla<strong>in</strong>-door control or subpanel can be furnished. If a<br />
pla<strong>in</strong>-door custom control or a subpanel custom control is ordered, a<br />
remote operator station or keypad/display kit is required. See order<strong>in</strong>g<br />
<strong>in</strong>formation on page 28.<br />
NEMA-style disconnect switches and motor starters, and brand-name<br />
comp<strong>one</strong>nts specified by our customers are also available.<br />
To ensure the starter(s) and disconnect are sized properly, please<br />
check horsepower for the ma<strong>in</strong> drive motor and slide adjust motor (if<br />
furnished) on the press, as well as full-load amps, and primary voltage<br />
to the press. After obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, please go to the chart on<br />
page 29 to determ<strong>in</strong>e the proper custom control box part number. Make<br />
sure the proper suffix (F, P, S, K, C, X, Y, or Z) is <strong>in</strong> the part number.<br />
Follow directions 1-6 to determ<strong>in</strong>e the correct part number.<br />
Example of part number<strong>in</strong>g system: The press requires a pla<strong>in</strong>-door<br />
control and a 60-A disconnect switch (based on the full-load amp<br />
formula). It has a 10-HP motor, a revers<strong>in</strong>g 32-A ma<strong>in</strong> motor starter<br />
without ram adjust, voltage is 230 V, and has a C4000 standard light<br />
curta<strong>in</strong> <strong>in</strong>terface. The part number to order is PRC-224-PW. A remote<br />
operator station (Part No. LLD-1506G2) is required for this pla<strong>in</strong>-door<br />
control—see page 28.<br />
CONTROL SYSTEMS | 25
SSC-1500 REMOTE OPERATOR-STYLE CONTROL BOXES<br />
These remote operator-style clutch/brake control boxes <strong>in</strong>clude the<br />
same features and modes of operation as the standard SSC-1500<br />
control boxes described on pages 23-24. However, they do not have<br />
a control transformer. These control boxes are designed to be located<br />
on the front of the mach<strong>in</strong>e near the operator.<br />
These controls are for applications where the mach<strong>in</strong>e’s exist<strong>in</strong>g<br />
magnetic motor starter, fused disconnect switch, and control transformer<br />
meet the safety requirements and can be reused. If the exist<strong>in</strong>g control<br />
transformer cannot be reused or a new control transformer is required,<br />
please contact the factory.<br />
The three standard remote operator-style control boxes available have<br />
the keypad/display and <strong>all</strong> operators on the door (front) of the 20” x 20”<br />
x 8” enclosure. Please see the next page for the three styles available.<br />
Style Z Remote Operator Control Box<br />
Clutch/Brake Control and Operators In One Box<br />
Back of Keypad/<br />
Display<br />
Master Control<br />
Relay<br />
Term<strong>in</strong>als<br />
Selectors<br />
Interior of Style Z Remote Operator Control Box<br />
SSC-1500 Solid-State<br />
Clutch/Brake<br />
Control Module<br />
26 | CONTROL SYSTEMS
SSC-1500 REMOTE OPERATOR-STYLE CONTROL BOXES (CONTINUED)<br />
STYLE X INCLUDES:<br />
• Keypad/display<br />
• Program off/on selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module,<br />
master control relay, and term<strong>in</strong>als<br />
STYLE Y INCLUDES:<br />
• Keypad/display<br />
• Program off/on selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module,<br />
master control relay, and term<strong>in</strong>als<br />
• Prior-action push button<br />
• Self-latch<strong>in</strong>g emergency-stop button<br />
• Top-stop button<br />
Style Z Includes:<br />
• Keypad/display<br />
• Program off/on selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module,<br />
master control relay, and term<strong>in</strong>als<br />
• Prior-action push button<br />
• Self-latch<strong>in</strong>g emergency-stop button<br />
• Top-stop button<br />
• Two guarded run/<strong>in</strong>ch buttons located<br />
on the sides of the enclosure<br />
CONTROL SYSTEMS | 27
CONTROL MODULE KIT—PART NO. PRC-000-KW<br />
A control module kit <strong>all</strong>ows the end user to update the clutch/brake control of a press with m<strong>in</strong>imum<br />
equipment costs. The kit is supplied without the control enclosure, panel, control transformer, control<br />
fuse, term<strong>in</strong>al strips, wire duct, and wir<strong>in</strong>g.<br />
A set of electrical pr<strong>in</strong>ts is supplied to show typical wir<strong>in</strong>g and <strong>all</strong> mount<strong>in</strong>g dimensions are provided <strong>in</strong><br />
order for a qualified person to <strong>in</strong>st<strong>all</strong> the control module kit. The m<strong>in</strong>imum area required on an exist<strong>in</strong>g<br />
control panel to <strong>in</strong>st<strong>all</strong> this kit is 18” H x 18” W x 6” D.<br />
This control module kit <strong>in</strong>cludes the control module, master control relay, shock mounts, fasteners,<br />
suppressors, danger labels, and electrical pr<strong>in</strong>ts.<br />
The SSC-1500 control can be furnished as a subpanel that <strong>in</strong>cludes everyth<strong>in</strong>g <strong>in</strong> the standard control<br />
as described on pages 23-24 except for the enclosure. The area needed to mount the subpanel <strong>in</strong>side<br />
an exist<strong>in</strong>g control box is 18½” H x 18½” W x 6” D. See page 29 to determ<strong>in</strong>e the part number for<br />
the module kit or subpanel. A keypad/display kit is required unless a remote operator station is used<br />
(see below).<br />
If the cont<strong>in</strong>uous mode of operation is used, a prior-action station, Part No. LLD-1500, is required.<br />
See page 33.<br />
KEYPAD/DISPLAY KIT—PART NO. LLD-1513G2<br />
The keypad/display kit can be used with any of the control boxes or the control module kit. This kit <strong>in</strong>cludes<br />
the keypad/display, a program off/on selector switch, a light curta<strong>in</strong> off/on selector switch, a hand/foot selector<br />
switch, an off/<strong>in</strong>ch/s<strong>in</strong>gle/cont<strong>in</strong>uous selector switch, and 25’ of cable. Additional push buttons and nameplates<br />
for motor starters, etc., can be furnished depend<strong>in</strong>g on the features required. The area needed to mount the<br />
keypad/display kit is 10" H x 10½” W x 3½” D.<br />
A resolver/pulser assembly and cable, Part No. CMS-115, is required with any of the control selections. See<br />
page 30 for further details on this comp<strong>one</strong>nt.<br />
REMOTE OPERATOR STATIONS<br />
For operator convenience, a remote operator station can be furnished for use with a pla<strong>in</strong>-door control box,<br />
pla<strong>in</strong>-door custom control box, or control module kit. The remote operator station conta<strong>in</strong>s the keypad/display,<br />
program off/on selector switch, and other selector switches and push buttons as required.<br />
Remote operator stations are available <strong>in</strong> a standard format or can be customized to meet any requirements.<br />
Select from the follow<strong>in</strong>g remote operator stations or contact the factory with your special requirements.<br />
A<br />
D<br />
D<br />
28 | CONTROL SYSTEMS<br />
REMOTE OPERATOR STATIONS<br />
FEATURES<br />
PART NO.<br />
LLD-1504G2<br />
PART NO.<br />
LLD-1505G2<br />
PART NO.<br />
LLD-1506G2<br />
If any of the above remote operator stations are required without the enclosure, please consult the factory.<br />
PART NO.<br />
LLD-1507G2<br />
Remote Operator Station<br />
Part No. LLD-1504G2<br />
PART NO.<br />
LLD-1508G2<br />
KEYPAD/DISPLAY X X X X X<br />
PROGRAM OFF/ON SELECTOR SWITCH X X X X X<br />
OFF/INCH/SINGLE/CONTINUOUS SELECTOR SWITCH X X X X X<br />
HAND/FOOT SELECTOR SWITCH X X X X X<br />
LIGHT CURTAIN OFF/ON SELECTOR SWITCH X X X X X<br />
MAIN MOTOR START AND STOP PUSH BUTTONS X X X X<br />
MAIN MOTOR FORWARD/REVERSE SELECTOR SWITCH X X<br />
RAM-ADJUST OFF/ON SELECTOR SWITCH X X<br />
RAM RAISE PUSH BUTTON X X<br />
RAM LOWER PUCH BUTTON X X<br />
LIGHT CURTAIN BLANKING SELECTOR SWITCHS<br />
(Use part # at right <strong>in</strong> place of part # above)<br />
LLD-1544 G2 LLD-1520 G2 LLD-1521 G2 LLD-1522 G2 LLD-1523 G2
SELECTING AN SSC-1500 PART-REVOLUTION PRESS CONTROL<br />
TO DETERMINE THE 8- OR 9-DIGIT CONFIGURED PART NUMBER FOR THE PART-REVOLUTION CONTROL REQUIRED, FOLLOW DIRECTIONS<br />
1-6 BELOW AND USE THE INFORMATION IN THE PART NUMBERING SYSTEM CHART BELOW.<br />
1. The first 3 digits for <strong>all</strong> SSC-1500 part-revolution controls are PRC.<br />
2. The 4th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect<br />
switch provided.<br />
3. The 5th and 6th digits determ<strong>in</strong>e the size and type of motor starter(s), if provided, <strong>in</strong> the control enclosure. Zeros (00) <strong>in</strong> both positions <strong>in</strong>dicate<br />
no motor starter(s) provided.<br />
4. The 7th digit determ<strong>in</strong>es the location of the operator controls, or if it is a style X, Y, or Z control without the control transformer.<br />
5. The 8th digit is for the type of light curta<strong>in</strong> <strong>in</strong>terface provided.<br />
6. The 9th digit (if required) will <strong>in</strong>dicate the type of modifier provided: i.e., motor control operators remote.<br />
SAMPLE<br />
1 2 3 4 5 6<br />
P R C - 2 63 - F B<br />
The sample shown, PRC-263-FB, <strong>in</strong>dicates that the custom part-revolution control box with a Banner light curta<strong>in</strong> <strong>in</strong>terface will conta<strong>in</strong> an IEC 60-A<br />
disconnect switch, an IEC 25-A revers<strong>in</strong>g ma<strong>in</strong> drive motor starter, and an IEC 12-A revers<strong>in</strong>g ram-adjust motor starter. The keypad/display and <strong>all</strong><br />
operators will be located on the door of the enclosure.<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
PRC —SSC-1500 Press Control<br />
DISCONNECT SWITCH SIZE—IEC (PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 — 30-A Disconnect — 1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 — 60-A Disconnect — 21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 — 100-A Disconnect — 41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 — 200-A Disconnect — 67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 — 400-A Disconnect — 134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
REVERSING/NONREVERSING MAIN MOTOR STARTERS<br />
WITH OR WITHOUT RAM ADJUST<br />
0 —No Motor Starters<br />
1 — Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter Without Ram Adjust<br />
2 — Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter Without Ram Adjust<br />
3 — Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 12-A Ram Adjust<br />
4 — Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 18-A Ram Adjust<br />
5 — Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 25-A Ram Adjust<br />
6 — Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 12-A Ram Adjust<br />
7 — Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 18-A Ram Adjust<br />
8 — Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 25-A Ram Adjust<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 — 12 A<br />
2 — 18 A<br />
3 — 25 A<br />
4 — 32 A<br />
5 — 40 A<br />
6 — 50 A<br />
7 — 65 A<br />
8 — 80 A<br />
9 — 95 A<br />
A — 115 A<br />
B — 185 A<br />
C — 265 A<br />
SSC-1500 PRESS CONTROL PART NUMBERING SYSTEM CHART<br />
P R C - X X X - X X X<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
MODIFIER<br />
-- — Blank, No Modifier<br />
5 — Ma<strong>in</strong> Motor Operators Remote*<br />
6 — Ram-Adjust Operators Remote*<br />
7 — Ma<strong>in</strong> Motor and Ram-Adjust Operators Remote*<br />
LIGHT CURTAIN OPTIONS**<br />
B — Banner Light Curta<strong>in</strong><br />
C — C4000 Advanced With LC Operators on Door<br />
V —C4000 Advanced With LC Operators Remote<br />
W — C4000 Standard<br />
CONFIGURATION & OPERATOR LOCATION<br />
F — Keypad/Display and <strong>all</strong> Operators on Door of Enclosure<br />
P — Keypad/Display and <strong>all</strong> Operators Remote (Pla<strong>in</strong> Door)<br />
S — Subpanel Only—Without Enclosure, Keypad/Display, and Operators<br />
K — Kit With Module and Master Control Relay Only—Without Enclosure,<br />
Subpanel, Transformer, Keypad/Display, and Operators<br />
C — Console<br />
X — Same as F (above) Without Control Transformer<br />
Y — Same as F (above) Without Control Transformer but With E-Stop, Top<br />
Stop, and Prior Action on the Enclosure<br />
Z — Same as F (above) Without Control Transformer but With E-Stop, Top<br />
Stop, Prior Action, and Two (2) Guarded Run/Inch Buttons on the<br />
Enclosure<br />
*See page 50 for remote motor control operator stations or <strong>Catalog</strong> SFM.<br />
**Additional light curta<strong>in</strong> <strong>in</strong>terface options are available upon request—contact<br />
<strong>Rockford</strong> <strong>Systems</strong> at 1-800-922-7533.<br />
CONTROL SYSTEMS | 29
SSC-1500 AND SSC-3000 PRESS INDIVIDUAL COMPONENTS<br />
RESOLVER/PULSER ASSEMBLY<br />
Part No. CMS-115*—40’ Cable<br />
Part No. CMS-115-100—100’ Cable<br />
An absolute resolver/pulser tim<strong>in</strong>g device is required with the SSC-<br />
1500 control to provide the angular position and velocity/motion<br />
<strong>in</strong>formation of the mach<strong>in</strong>e crankshaft to the control. The resolver is a<br />
highly accurate and repeatable device which uses an <strong>in</strong>tern<strong>all</strong>y mounted<br />
photoelectric sensor and disk to verify the position of the crankshaft.<br />
The resolver/pulser tim<strong>in</strong>g device is conta<strong>in</strong>ed <strong>in</strong> a rugged, heavyduty<br />
hous<strong>in</strong>g with a spr<strong>in</strong>g-compression base. The spr<strong>in</strong>g base helps<br />
isolate the resolver from shock load and vibration that are common<br />
occurrences on presses. This provides longer life for the comp<strong>one</strong>nts<br />
<strong>in</strong>side the enclosure. The spr<strong>in</strong>g base also functions as a drive cha<strong>in</strong><br />
tightener. This resolver/pulser assembly can also be furnished without<br />
the spr<strong>in</strong>g base when a direct-coupl<strong>in</strong>g drive is encountered. Please<br />
consult the factory.<br />
The 3/4” diameter steel drive shaft with keyway is mounted <strong>in</strong><br />
sealed b<strong>all</strong> bear<strong>in</strong>gs. This results <strong>in</strong> a rugged resolver<br />
assembly for press applications. The resolver/pulser is<br />
furnished with a 40’ cable (or optional 100’ cable) that connects to the<br />
drive assembly and wires <strong>in</strong> to the control box. The cable can be cut to<br />
length and wired to term<strong>in</strong>als.<br />
Resolver/Pulser Assembly on Press<br />
(Sprocket and cha<strong>in</strong> cover has been removed for photo)<br />
SPROCKET ASSEMBLY<br />
Part No. CML-000*<br />
A sprocket set consists of two sprockets. One fits on the 3/4” shaft<br />
of the CMS-115 resolver/pulser assembly; the other sprocket is for<br />
mount<strong>in</strong>g to the end of the press crankshaft. These 48-tooth sprockets<br />
are designed to accept ANSI No. 35 roller cha<strong>in</strong>.<br />
ROLLER CHAIN<br />
Part No. CMS-515*<br />
ANSI No. 35 roller cha<strong>in</strong> and master l<strong>in</strong>k is 10 feet long for driv<strong>in</strong>g the<br />
above sprockets.<br />
Cable<br />
Spr<strong>in</strong>g-<br />
Loaded<br />
Base<br />
Resolver/Pulser Assembly<br />
Sprocket Set<br />
Roller Cha<strong>in</strong><br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 36 or page 37.<br />
30 | CONTROL SYSTEMS
SSC-1500 AND SSC-3000 PRESS INDIVIDUAL COMPONENTS (CONTINUED)<br />
MONITORED DUAL-SOLENOID AIR VALVE<br />
½” INLET / ½” OUTLET PORT — Part No. RCL-652<br />
(for 10- to 25-ton presses)<br />
½” INLET / ¾” OUTLET PORT — Part No. RCL-654*<br />
(for 26- to 100-ton presses)<br />
This three-way cross flow, series/par<strong>all</strong>el air valve <strong>in</strong>cludes an air<br />
pressure electrical output monitor and muffler. Air is put <strong>in</strong>to the clutch<br />
and brake when the dual-solenoid air valve is electric<strong>all</strong>y energized.<br />
When it is de-energized, the air is dumped through the muffler from the<br />
clutch and brake.<br />
This valve consists of two ma<strong>in</strong> parts: the piloted monitor assembly<br />
and the valve body assembly. The two ma<strong>in</strong> valve elements move<br />
simultaneously dur<strong>in</strong>g normal operation. If these elements should<br />
fail to move simultaneously, the <strong>in</strong>ternal spool shifts, <strong>in</strong>hibit<strong>in</strong>g<br />
further mach<strong>in</strong>e operation. The pressure switch will provide a signal<br />
to the control system to <strong>in</strong>dicate a fault condition. A reset button on<br />
the side of the valve can be used to reset the valve if an accidental<br />
valve fault is detected.<br />
MONITORED DUAL-SOLENOID AIR VALVE<br />
WITH RESET BUTTON<br />
1” INSET / 1” OUTLET PORT — Part No. RCL-656<br />
(for 101- to 300-ton presses)<br />
1½” INLET/ 2” OUTLET PORT — Part No. RCL-658<br />
(for 301- to 1000-ton presses)<br />
This cross flow, series/par<strong>all</strong>el air valve <strong>in</strong>cludes an air pressure<br />
electrical output and muffler. The separate reset button provides a<br />
remote reset at floor level if the valve latches out when an accidental air<br />
valve fault is detected. This valve is used for the clutch/brakes on large<br />
presses which require larger air volume capacity.<br />
This valve assembly consists of a pilot, monitor, valve body, and junction<br />
box. It operates on the same pr<strong>in</strong>ciples as the 1⁄2” and 3/4” valves<br />
described above.<br />
NOTE: If the clutch and brake are split, two valves may be required to<br />
provide good stopp<strong>in</strong>g times.<br />
FRL (FILTER-REGULATOR-LUBRICATOR)<br />
This assembly is required to meet the OSHA and ANSI standards. This<br />
FRL assembly filters, regulates, and lubricates the air go<strong>in</strong>g through<br />
it. This filtered and lubricated air then goes to the dual-solenoid air<br />
valve assembly and clutch/brake. The regulator should be adjusted<br />
to meet the orig<strong>in</strong>al equipment manufacturer’s requirements. The<br />
assembly <strong>in</strong>cludes a gauge, coupl<strong>in</strong>g, and a steel mount<strong>in</strong>g bracket.<br />
The FRL assembly can be used for any air-operated device on the press<br />
<strong>in</strong>clud<strong>in</strong>g the counterbalance or die cushion.<br />
AVERAGE CV (FLOW RATE)<br />
PART NO. PORTS 1 TO 2 PORTS 2 TO 3<br />
RCL-652 2.8 6.7<br />
RCL-654 2.8 6.7<br />
Monitored Dual-Solenoid Air Valve<br />
AVERAGE CV (FLOW RATE)<br />
PART NO. PORTS 1 TO 2 PORTS 2 TO 3<br />
RCL-656 4.63 12.55<br />
RCL-658 20.22 53.68<br />
Part No. RCL-046—1”<br />
Part No. RCL-047—11⁄2”<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 36 or page 37.<br />
Part No. RCL-044—1⁄2”<br />
*Part No. RCL-045—3⁄4”<br />
CONTROL SYSTEMS | 31
SSC-1500 AND SSC-3000 PRESS INDIVIDUAL COMPONENTS (CONTINUED)<br />
AIR PRESSURE SWITCH<br />
Part No. CTD-062*<br />
This air pressure switch monitors low pressure to either the clutch/<br />
brake air supply or slide counterbalance systems. Each system requires<br />
an air pressure switch. The pressure switch must be set so if the<br />
air pressure operat<strong>in</strong>g the comp<strong>one</strong>nt goes below a predeterm<strong>in</strong>ed<br />
amount, the press becomes <strong>in</strong>operable.<br />
Each air pressure switch’s low level sett<strong>in</strong>g is based on each application<br />
and the mach<strong>in</strong>e manufacturer’s recommendations. The contact<br />
arrangement is 1 NO and 1 NC.<br />
CHECK VALVE FOR COUNTERBALANCE SYSTEM<br />
(not <strong>in</strong>cluded <strong>in</strong> any comp<strong>one</strong>nt package on page 36 or page 37)<br />
A check valve is required to meet the OSHA and ANSI standards. It<br />
ma<strong>in</strong>ta<strong>in</strong>s counterbalance surge tank pressure <strong>in</strong> the event of a sudden<br />
loss of air pressure. It is <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> the air l<strong>in</strong>e go<strong>in</strong>g to the tank. Please<br />
check the size of the air l<strong>in</strong>e go<strong>in</strong>g to the tank to determ<strong>in</strong>e the proper<br />
size valve.<br />
Note: Press must have a counterbalance system with a surge tank to<br />
properly apply a check valve.<br />
PALM BUTTON ASSEMBLY<br />
To meet OSHA and ANSI safety standards, the two run/<strong>in</strong>ch buttons<br />
must be protected aga<strong>in</strong>st accidental operation (r<strong>in</strong>g guards) and<br />
separated to require the use of both hands to operate them. They must<br />
also be mounted at the proper safety distance, if they will be used as a<br />
safeguard. The contact arrangement of these buttons is 1 NO and 1 NC.<br />
Part No. CTL-502*<br />
This palm button assembly consists of two black run/<strong>in</strong>ch buttons<br />
(with r<strong>in</strong>g guards), a red emergency-stop button, and a yellow top-stop<br />
button. Mount<strong>in</strong>g boxes are furnished with each button. The red and<br />
yellow palm buttons each have 1 NO and 1 NC arrangement. The red<br />
button is on a yellow-covered mount<strong>in</strong>g box and is equipped with a<br />
mechanical latch to meet NFPA 79.<br />
Part No. CTL-507*<br />
This palm button assembly consists of two black run/<strong>in</strong>ch<br />
buttons (with r<strong>in</strong>g guards), and a red emergency-stop button (for press<br />
applications without the cont<strong>in</strong>uous mode of operation). Mount<strong>in</strong>g boxes<br />
are furnished with each button. The red palm button is on a yellowcovered<br />
mount<strong>in</strong>g box and has 1 NO and 1 NC arrangement plus a<br />
mechanical latch to meet NFPA 79.<br />
Palm buttons can also be furnished <strong>in</strong> a control bar along with push<br />
buttons and selector switches. Please see pages 51-52 for control bars,<br />
and pages 99 and 100 for other palm button assembly options.<br />
Air Pressure Switch<br />
Check Valve<br />
PART NO. RCD-061—1⁄2”<br />
PART NO. RCD-062—3⁄4”<br />
PART NO. RCD-063—1”<br />
PART NO. RCD-064—11⁄2”<br />
PART NO. RCD-065—2”<br />
Part No. CTL-502<br />
Part No. CTL-507<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 36 or page 37.<br />
32 | CONTROL SYSTEMS
SSC-1500 PRESS INDIVIDUAL COMPONENTS (CONTINUED)<br />
FOOT SWITCH<br />
Part No. CTD-011*<br />
This foot switch is protected from un<strong>in</strong>tentional operation. A die-cast<br />
cover protects the top and both sides, and the front is protected by a<br />
h<strong>in</strong>ged flap. The flap must be lifted with the toe before the foot may<br />
enter the switch. The electrical contact arrangement is 1 NO and 1 NC.<br />
Foot Switch<br />
PRIOR-ACTION STATION<br />
Part No. LLD-1500*<br />
This prior-action station has a push button that must be depressed<br />
and released by the operator before depress<strong>in</strong>g the actuat<strong>in</strong>g<br />
means <strong>in</strong> order to <strong>in</strong>itiate the cont<strong>in</strong>uous mode of operation. This<br />
type of cont<strong>in</strong>uous mode of operation is sometimes referred to<br />
as “walk-away” cont<strong>in</strong>uous. This steel enclosure is 3½” x 3¼”<br />
x 3¼”. This prior-action station is also required when us<strong>in</strong>g the<br />
cont<strong>in</strong>uous-on-demand, automatic s<strong>in</strong>gle-stroke, two-handma<strong>in</strong>ta<strong>in</strong>ed<br />
cont<strong>in</strong>uous, or foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous mode of<br />
operation. These modes of operation are furnished as standard features<br />
<strong>in</strong> the SSC-1500 control.<br />
Prior-Action Station<br />
SUPERVISORY CONTROL STATION<br />
Part No. LLD-1501<br />
Part No. LLD-283*<br />
(required when a USC-000 is used–see next page)<br />
When two or more palm button or foot switch operat<strong>in</strong>g stations are<br />
required on <strong>one</strong> mach<strong>in</strong>e, <strong>one</strong> supervisory control station is required at<br />
each operator station. This remote control station consists of an off/on<br />
keyed selector switch and a station on <strong>in</strong>dicator light. The on position<br />
<strong>all</strong>ows the operator to use that station, and the off position deactivates<br />
only that station. The enclosure size is 5¼” x 3” x 3¼”.<br />
Supervisory Control Station<br />
BAR/RUN STATION (not <strong>in</strong>cluded <strong>in</strong> any comp<strong>one</strong>nt package on<br />
page 36 or page 37)<br />
Part No. LLD-1502<br />
This remote bar/run station can be used <strong>in</strong> conjunction with a manual<br />
turnover bar when sett<strong>in</strong>g dies <strong>in</strong> the press. The flywheel must have<br />
holes <strong>in</strong> the periphery for <strong>in</strong>sertion of a spr<strong>in</strong>g-loaded turnover bar**<br />
(or the flywheel can be manu<strong>all</strong>y turned when the flywheel cover is<br />
removed). The remote station <strong>in</strong>cludes a three-position selector switch<br />
for bar/off/run, and <strong>one</strong> push button used for energiz<strong>in</strong>g the dualsolenoid<br />
air valve to engage the clutch and release the brake. The<br />
flywheel must be at rest (static) when engag<strong>in</strong>g the clutch. After the<br />
clutch is engaged, the die setup person can manu<strong>all</strong>y turn the flywheel<br />
with a spr<strong>in</strong>g-loaded turnover bar (see page 98). The enclosure size is<br />
5¼” x 3” x 3¼”.<br />
Bar/Run Station<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 36 or page 37.<br />
**For a spr<strong>in</strong>g-loaded turnover bar, see page 98.<br />
CONTROL SYSTEMS | 33
SSC-1500 PRESS INDIVIDUAL COMPONENTS (CONTINUED)<br />
MULTIPLE-OPERATOR JUNCTION BOX<br />
Part No. USC-000*<br />
When multiple operator stations are required, this junction box is furnished<br />
separately for wir<strong>in</strong>g up to four (4) operator stations. This junction box<br />
<strong>in</strong>terfaces palm button assemblies/control bars and foot switches, and<br />
will not <strong>all</strong>ow the press to run if palm buttons or a foot switch is actuated<br />
without its supervisory control station on. A lighted push button with<br />
nameplate <strong>in</strong>dicates a fault condition of an operator station. The button is<br />
pushed to reset. The enclosure size is 16” x 14” x 6”.<br />
Multiple-Operator Junction Box<br />
CRANKSHAFT ANGLE DISPLAY<br />
Part No. FTL-055<br />
The optional crankshaft angle display is a unit that shows the angular<br />
position of the crankshaft for mechanical power presses. The crankshaft<br />
position is shown both graphic<strong>all</strong>y (with red LEDs <strong>in</strong> a circle) and<br />
numeric<strong>all</strong>y (with a large, red, three-digit LED). The large display can be<br />
easily seen which helps with setup, removal of stuck workpieces, or for<br />
assistance dur<strong>in</strong>g emergency extraction procedures.<br />
FEATURES<br />
• Large LED numerical display and circular LED graphic display can<br />
be easily seen<br />
• 6” x 6” x 2” enclosure<br />
• Mounts easily<br />
• Supplied with 25’ of cable for connection to the control<br />
• Helps satisfy the requirements of Canadian Standard CSA Z142-<br />
02, Code for Power Press Operation: Health, Safety, and Guard<strong>in</strong>g<br />
Requirements, for <strong>in</strong>dication of crank angle position<br />
Crankshaft Angle Display<br />
Mounted on a Mechanical Power Press<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 36 or page 37.<br />
34 | CONTROL SYSTEMS
LOCKOUT VALVES (not <strong>in</strong>cluded <strong>in</strong> any comp<strong>one</strong>nt packages on pages 36 or 37)<br />
SLIDE-OPERATED VALVE<br />
This three-way valve is operated with the manual movement of a slide<br />
that opens and closes the valve. This valve shuts off air at the press and<br />
then bleeds off downstream air. It can be locked only <strong>in</strong> the off position.<br />
MANUAL VALVE<br />
This manu<strong>all</strong>y operated valve shuts off air flow when a mach<strong>in</strong>e needs<br />
to be locked out. To shut off and exhaust air <strong>in</strong> the l<strong>in</strong>e, the handle is<br />
pushed <strong>in</strong>. This causes the pressurized supply of air to be blocked, and<br />
the downstream air <strong>in</strong> the l<strong>in</strong>e is exhausted through the exhaust port and<br />
muffler at the bottom of the valve. The valve can be padlocked <strong>in</strong> the off<br />
position. The valve is furnished with a muffler. Port sizes available for air<br />
flow are 3/4” and 1”.<br />
Part No.<br />
Part Size<br />
In-Out<br />
Bar<br />
RCD-071 ¼" 250<br />
PART NO.<br />
PORT SIZE<br />
IN-OUT EXH.<br />
PSI BAR<br />
RCD-076 3/4" 1-1/4" 15-50 1-10<br />
RCD-077 1" 1-1/4" 15-50 1-10<br />
MANUAL PILOT VALVE<br />
This manu<strong>all</strong>y operated pilot valve is used <strong>in</strong> larger air systems. It is<br />
available for port sizes of 1½” and 2½”. It operates <strong>in</strong> a similar manner<br />
as the manual valve. By push<strong>in</strong>g the handle <strong>in</strong> or out, it controls pilot<br />
pressure to a piston which opens or closes the valve’s <strong>in</strong>let poppet. It<br />
is designed to be locked only <strong>in</strong> the off position. This valve is furnished<br />
with a muffler.<br />
EEZ-ON VALVE<br />
This valve shuts off air supply to the mach<strong>in</strong>e and bleeds downstream<br />
air when the valve is closed. When the valve is open, it gradu<strong>all</strong>y <strong>all</strong>ows<br />
air <strong>in</strong>to the air system to prevent damage to air comp<strong>one</strong>nts. It can be<br />
locked only <strong>in</strong> the off position. This valve is furnished with a muffler.<br />
PART NO.<br />
PORT SIZE<br />
IN-OUT EXH.<br />
PSI BAR<br />
RCD-078 1-1/2" 1-1/2" 15-150 1-10<br />
RCD-079 2-1/2" 2-1/2" 30-150 2-10<br />
PART NO.<br />
PORT SIZE<br />
IN-OUT EXH.<br />
PSI BAR<br />
RCD-121 1/2" 3/4" 30-150 2-10<br />
RCD-122 3/4" 3/4" 30-150 2-10<br />
CONTROL SYSTEMS | 35
SELECTING AN SSC-1500 PRESS COMPONENT PACKAGE<br />
To complete the SSC-1500 control system, comp<strong>one</strong>nt packages are available. Comp<strong>one</strong>nt packages are listed <strong>in</strong> the charts below and on the next<br />
page. These packages can be furnished with:<br />
• A STANDARD CONTROL • A CUSTOM CONTROL • A CONSOLE CONTROL • A SPECIAL CONTROL<br />
• A REMOTE OPERATOR-STYLE CONTROL • A SUBPANEL • A CONTROL MODULE KIT<br />
To select the proper comp<strong>one</strong>nt package to go with your control box, determ<strong>in</strong>e your requirements below:<br />
A<br />
MODES OF OPERATION AND ACTUATING MEANS REQUIRED.<br />
B<br />
C<br />
NUMBER OF OPERATOR STATIONS REQUIRED.<br />
NUMBER OF AIR PRESSURE SWITCHES REQUIRED.<br />
A<br />
Modes of operation: Inch, S<strong>in</strong>gle, and Cont<strong>in</strong>uous (Hand or Foot)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
SSC-1500<br />
Control Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Foot S<strong>in</strong>gle<br />
Stroke<br />
• Two-Hand<br />
Cont<strong>in</strong>uous<br />
B ONE OPERATOR STATION<br />
C ONE AIR PRESSURE SWITCH<br />
TNR-000-SSP Standard Comp<strong>one</strong>nt Package<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNR-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
B<br />
ONE AIR<br />
PRESSURE<br />
SWITCH<br />
TNR-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-502 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNR-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
CTL-502 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
A<br />
Modes of operation: Inch, S<strong>in</strong>gle, and Cont<strong>in</strong>uous (Hand Only)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
SSC-1500<br />
Control Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Two-Hand<br />
Cont<strong>in</strong>uous<br />
B<br />
C<br />
ONE OPERATOR STATION<br />
ONE AIR PRESSURE SWITCH<br />
TNC-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprockets (Set of 2)<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045<br />
3 ⁄4” Filter-Regulator-Lubricator<br />
Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
CTL-502 Palm Button Assembly<br />
LLD-1500 Prior-Action Station<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNC-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
B<br />
ONE AIR<br />
PRESSURE<br />
SWITCH<br />
TNC-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-502 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNC-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
CTL-502 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
For light curta<strong>in</strong>s, mount<strong>in</strong>g brackets, and barrier guards for the sides of the po<strong>in</strong>t of operation, see catalog MSD.<br />
36 | CONTROL SYSTEMS
SELECTING AN SSC-1500 PRESS COMPONENT PACKAGE (CONTINUED)<br />
A<br />
Modes of operation: Inch and S<strong>in</strong>gle (Hand or Foot)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
SSC-1500<br />
Control Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Foot S<strong>in</strong>gle<br />
Stroke<br />
B<br />
C<br />
ONE OPERATOR STATION<br />
ONE AIR PRESSURE SWITCH<br />
TNK-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprockets (Set of 2)<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045 3<br />
⁄4” Filter-Regulator-Lubricator<br />
Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
CTL-507 Palm Button Assembly<br />
CTD-011 Foot Switch<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNK-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
B<br />
ONE AIR<br />
PRESSURE<br />
SWITCH<br />
TNK-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple<br />
Operator Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNK-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
A<br />
Modes of operation: Inch and S<strong>in</strong>gle (Hand Only)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
SSC-1500<br />
Control Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
Console<br />
Application<br />
Only<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
SSC-1500<br />
Control Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Two-Hand<br />
Cont<strong>in</strong>uous<br />
B<br />
C<br />
ONE OPERATOR STATION<br />
ONE AIR PRESSURE SWITCH<br />
TNF-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprockets (Set of 2)<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045<br />
3 ⁄4” Filter-Regulator-Lubricator<br />
Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
CTL-507 Palm Button Assembly<br />
A<br />
B<br />
C<br />
TNX-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
with 40’ Cable and Plug<br />
CML-000 Sprockets (Set of 2)<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045<br />
3 ⁄4” Filter-Regulator-Lubricator<br />
Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNF-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
B<br />
ONE AIR<br />
PRESSURE<br />
SWITCH<br />
TNF-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple<br />
Operator Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
TNX-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
Modes of operation: Inch, S<strong>in</strong>gle, and Cont<strong>in</strong>uous (Hand Only)<br />
ONE OPERATOR STATION<br />
ONE AIR PRESSURE SWITCH<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
B<br />
ONE AIR<br />
PRESSURE<br />
SWITCH<br />
TNX-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-502 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNF-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
For light curta<strong>in</strong>s, mount<strong>in</strong>g brackets, and barrier guards for the sides of the po<strong>in</strong>t of operation, see catalog MSD.<br />
TWO AIR<br />
PRESSURE<br />
SWITCHES<br />
TNX-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CTD-062 Air Pressure<br />
Switch<br />
(For Counterbalance)<br />
CTL-502 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station<br />
USC-000 Multiple Operator<br />
Junction Box<br />
CONTROL SYSTEMS | 37
SAFEGUARDED PART-REVOLUTION PRESS WITH SSC-3000 PRESS AUTOMATION CONTROL<br />
Sprockets and Cha<strong>in</strong><br />
(Beh<strong>in</strong>d Cover)<br />
Resolver (not<br />
shown)<br />
Air Pressure<br />
Switches<br />
Filter-Regulator-<br />
Lubricator<br />
Assembly<br />
Monitored<br />
Dual-Solenoid<br />
Air Valve<br />
(not shown)<br />
Spr<strong>in</strong>g-Lift Guard<br />
Side<br />
Barrier<br />
Guard<br />
SSC-3000 Custom<br />
Control Console With<br />
Two-Hand Control<br />
Safety<br />
Precaution<br />
Pamphlet<br />
Part-Revolution Press With Clutch/Brake Control System<br />
With Po<strong>in</strong>t-of-Operation Guards<br />
38 | CONTROL SYSTEMS
SSC-3000 STANDARD CONTROL<br />
Standard SSC-3000 Control Box (PACG2-P100-VAABCXXXX Shown)<br />
The SSC-3000 solid-state press automation control is designed for use on part-revolution-clutch mechanical power presses. The SSC-3000 is a<br />
rack-mounted modular control system with expandable options. These expandable options permit changes to be made, or features to be added or<br />
deleted as press requirements change. If additional features are required, plug-<strong>in</strong> cards and/or additional equipment can be added.<br />
The basic design <strong>all</strong>ows the user or OEM (orig<strong>in</strong>al equipment manufacturer) to apply automation to mechanical power presses. The automation is<br />
usu<strong>all</strong>y applied to primary mach<strong>in</strong>es that operate <strong>in</strong> modes of cont<strong>in</strong>uous, automatic s<strong>in</strong>gle stroke, or cont<strong>in</strong>uous-on-demand. This control can also<br />
be applied to presses that operate <strong>in</strong> the s<strong>in</strong>gle-stroke mode of operation to perform manual secondary jobs that may be required to run automatic<br />
modes later.<br />
The standard control box is <strong>in</strong> a 30” x 30” x 10” NEMA 12 enclosure with the operator controls and touch screen/display located <strong>in</strong> a remote operator<br />
station. The standard automation control rack is furnished with a power supply module and a Ma<strong>in</strong> CPU (central process<strong>in</strong>g unit) Card.<br />
The rack is designed to hold eight additional cards for expandable options. These card options <strong>in</strong>clude: Clutch/Brake Control, PLS (programmable<br />
limit switch), Die Protection, Load Monitor, and Angle Display.<br />
Tim<strong>in</strong>g functions of the SSC-3000 press automation control system are generated from a rotary resolver/pulser assembly. This gives absolute<br />
position of the crankshaft (rotary) position.<br />
If a starter or disconnect is required <strong>in</strong> the same enclosure as the standard SSC-3000 control, see page 40, SSC-3000 custom control box. If a<br />
separate starter or disconnect, or comb<strong>in</strong>ation starter disconnect is required, refer to our <strong>Catalog</strong> SFM.<br />
CONTROL SYSTEMS | 39
SSC-3000 CUSTOM CONTROL<br />
SSC-3000 MODULAR CONTROL RACK KIT<br />
A part-revolution-clutch SSC-3000 custom control box is also available<br />
to fit your particular press room needs. This control <strong>in</strong>cludes the same<br />
features and modes of operation as the standard SSC-3000 control box<br />
described on the previous page.<br />
A custom SSC-3000 solid-state press automation control box <strong>in</strong>cludes<br />
a multi-tap transformer, modular control rack with power supply, and a<br />
PACG2-K000-XXXXXXXX Shown<br />
The modular control rack kit can be furnished when the exist<strong>in</strong>g control<br />
enclosure is reta<strong>in</strong>ed. The m<strong>in</strong>imum area required on an exist<strong>in</strong>g control<br />
panel <strong>in</strong>side the control box to <strong>in</strong>st<strong>all</strong> the rack kit is 15” H x 18” W x<br />
10” D. This kit <strong>in</strong>cludes a master control relay, the modular control<br />
rack, a power supply, and a Ma<strong>in</strong> CPU Card. A dual CPU press Clutch/<br />
Brake Controller Card and other expandable card options can be added<br />
(see pages 44-46). A complete sign package, <strong>in</strong>st<strong>all</strong>ation manual,<br />
<strong>in</strong>structions, and electrical diagrams are furnished.<br />
SSC-3000 TOUCH SCREEN/DISPLAY KIT<br />
Custom SSC-3000 Control Box<br />
(PACG2-P264-WAXXXXXXX Shown)<br />
Ma<strong>in</strong> CPU Card. It is furnished with an IEC through-the-door ma<strong>in</strong> power<br />
fused disconnect switch, an IEC magnetic motor starter(s) for the ma<strong>in</strong><br />
drive motor and, a motor starter for the ram-adjust motor, if applicable.<br />
The operator controls and the touch screen/display can be located on<br />
the door, or they can be located <strong>in</strong> a remote operator station for use<br />
with a pla<strong>in</strong>-door custom control box. NEMA disconnect switches and<br />
starters are also available.<br />
To ensure the starter(s) and disconnect are sized properly, please<br />
check horsepower for the ma<strong>in</strong> drive motor and ram-adjust motor (if<br />
furnished) on the press, as well as full-load amps, and primary voltage<br />
to the press. After obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, please go to page 47 to<br />
determ<strong>in</strong>e the proper custom control box part number. Follow directions<br />
1-7 to obta<strong>in</strong> the correct part number.<br />
Touch Screen/Display Kit—LLD-3023G2<br />
The touch screen/display kit <strong>in</strong>cludes the touch screen/display, an off/<br />
program/run selector, a mode selector, an actuat<strong>in</strong>g means selector,<br />
and a light curta<strong>in</strong> off/on selector switch, and 25’ of cable. The space<br />
required to mount the touch screen/display kit is 12” H x 10” W x 3”<br />
D. A remote operator station can also be furnished that has the touch<br />
screen/display kit <strong>in</strong> an enclosure. See the next page for choices of<br />
operator stations.<br />
40 | CONTROL SYSTEMS
SSC-3000 REMOTE OPERATOR STATIONS<br />
A remote operator station or operator kit—conta<strong>in</strong><strong>in</strong>g the touch screen/<br />
display, off/program/run selector switch, other selector switches,<br />
and push buttons as required—is always necessary with the press<br />
automation control system.<br />
Remote operator stations or kits are available <strong>in</strong> a standard format or can be<br />
customized to meet any requirements. Select from the follow<strong>in</strong>g or contact<br />
the factory with your special requirements. If the Clutch/Brake Controller<br />
Card is not provided as a part of the press automation control system,<br />
contact the factory for a special remote operator station.<br />
Standard Remote Operator Station<br />
Part No. LLD-3004G2<br />
SSC-3000 REMOTE OPERATOR STATIONS<br />
A<br />
D<br />
D<br />
FEATURES<br />
PART NO.<br />
LLD-3004<br />
G2<br />
PART NO.<br />
LLD-3005<br />
G2<br />
PART NO.<br />
LLD-3006<br />
G2<br />
PART NO.<br />
LLD-3007<br />
G2<br />
PART NO.<br />
LLD-3008<br />
G2<br />
ENCLOSURE X X X X X<br />
PART NO.<br />
LLD-3009<br />
G2<br />
PART NO.<br />
LLD-3010<br />
G2<br />
PART NO.<br />
LLD-3011<br />
G2<br />
PART NO.<br />
LLD-3012<br />
G2<br />
TOUCH SCREE/DISPLAY X X X X X X X X X X<br />
OFF/PROGRAM/RUN<br />
SELECTOR SWITCH<br />
MODE OF OPERATION<br />
SELECTOR SWITCH<br />
ACTUATING MEANS<br />
SELECTOR SWITCH<br />
LIGHT CURTAIN OFF/ON<br />
SELECTOR SWITCH<br />
MAIN MOTOR START &<br />
STOP PUSH BUTTONS<br />
MAIN MOTORE FORWARD/<br />
REVERSE SELECTOR<br />
RAM-ADJUST OFF/ON<br />
SELECTOR SWITCH<br />
LIGHT CURTAIN BLANKING<br />
SELECTOR SWITCHS<br />
(Use part # at right <strong>in</strong> place of<br />
part # above)<br />
PART NO.<br />
LLD-3023<br />
G2<br />
X X X X X X X X X X<br />
X X X X X X X X X X<br />
X X X X X X X X X X<br />
X X X X X X X X X X<br />
LLD-3031<br />
G2<br />
X X X X X X X X<br />
LLD-3032<br />
G2<br />
X X X X<br />
LLD-3033<br />
G2<br />
X X X X<br />
LLD-3034<br />
G2<br />
LLD-3035<br />
G2<br />
LLD-3036<br />
G2<br />
LLD-3037<br />
G2<br />
LLD-3038<br />
G2<br />
LLD-3039<br />
G2<br />
LLD-3040<br />
G2<br />
An additional light curta<strong>in</strong> off/on selector switch can be added to the above operator stations or kits. The additional selector switch is used when<br />
two <strong>in</strong>dependent light curta<strong>in</strong> systems are required. Please consult the factory.<br />
CONTROL SYSTEMS | 41
SSC-3000 BASIC SYSTEM FEATURES<br />
MODULAR RACK DESIGN<br />
The SSC-3000 press automation control consists of a modular control<br />
rack with power supply and a Ma<strong>in</strong> CPU (central process<strong>in</strong>g unit) Card.<br />
The control rack is mounted to the panel with shock/vibration mounts<br />
and measures 9½” H x 17½” W x 6” D. This modular rack is designed<br />
with additional slots for add<strong>in</strong>g expandable card options to provide the<br />
automation features you need for your press.<br />
MAIN CPU CARD<br />
Part No. FRL-318<br />
The SSC-3000 press automation control Ma<strong>in</strong> CPU Card provides <strong>all</strong><br />
the ma<strong>in</strong> process<strong>in</strong>g for the base automation system. There are red<br />
and green LEDs (light-emitt<strong>in</strong>g diodes) that <strong>all</strong>ow for visual <strong>in</strong>dication of<br />
control operation and the status of <strong>in</strong>puts and outputs. All LED names<br />
are <strong>in</strong>dicated on the cover of the Ma<strong>in</strong> CPU Card.<br />
Ma<strong>in</strong> Control Rack With Power Supply and Ma<strong>in</strong> CPU Card<br />
Ma<strong>in</strong> CPU Card Features<br />
User Inputs<br />
Twelve (12) programmable user <strong>in</strong>puts are dedicated to mach<strong>in</strong>e<br />
diagnostics. They can be programmed for equipment monitor<strong>in</strong>g or<br />
other user-def<strong>in</strong>ed functions. After programm<strong>in</strong>g the 12 <strong>in</strong>puts, the<br />
current status of these <strong>in</strong>puts can be displayed on the touch screen.<br />
When a fault condition is detected, the mach<strong>in</strong>e will top stop or<br />
emergency stop, and the assigned message will be displayed on the<br />
touch screen from the list below. An additional ten (10) user-def<strong>in</strong>ed<br />
messages can be added to this list.<br />
Example of Ma<strong>in</strong> Program Screen<br />
Standard User Input Fault Messages<br />
Clutch/Brake Air Fault<br />
Counterbalance Air Fault<br />
Dual Solenoid Fault<br />
Clutch Valve Fault*<br />
Brake Valve Fault*<br />
Lube Fault<br />
High Lube Pressure<br />
Low Lube Pressure<br />
Low Lube Level<br />
Ma<strong>in</strong> Motor Overload<br />
Ram-Adjust Motor Overload<br />
Lube Motor Overload<br />
Auxiliary Motor Overload<br />
Guard Interlock Open<br />
Front Guard Open<br />
Rear Guard Open<br />
Left Side Guard Open<br />
Right Side Guard Open<br />
Feeder Fault<br />
Load Monitor Fault<br />
Safety Block Interlock<br />
Shut Height Fault<br />
*Used when two valves are furnished for split clutch/brake<br />
**Messages typic<strong>all</strong>y used for die protection<br />
Variable Speed Drive Fault<br />
Die Protection Fault**<br />
Short Feed Fault**<br />
Part Ejection Fault**<br />
Stock Buckle Fault**<br />
End of Stock Fault**<br />
Pilot P<strong>in</strong> Fault**<br />
Part Input #1**<br />
Part Input #2**<br />
Part Input #3**<br />
42 | CONTROL SYSTEMS
SSC-3000 BASIC SYSTEM FEATURES (CONTINUED)<br />
MAIN CPU CARD FEATURES (CONTINUED)<br />
TIME-BASED BRAKE MONITOR<br />
A time-based programmable brake monitor (stopp<strong>in</strong>g performance monitor) with both warn<strong>in</strong>g and fault setpo<strong>in</strong>ts is <strong>in</strong>cluded.<br />
STM (STOP-TIME MEASUREMENT) TEST<br />
The control <strong>in</strong>cludes a stop-time measurement test. This is used for establish<strong>in</strong>g and ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g the proper safety distance when apply<strong>in</strong>g two-hand<br />
control or light curta<strong>in</strong>s as the safeguard<strong>in</strong>g method.<br />
100-JOB SETUP MEMORY<br />
Up to 100 job setups can be stored <strong>in</strong> memory <strong>all</strong>ow<strong>in</strong>g for quick changeover from die to die. The die number, description, PLS outputs, die protection<br />
<strong>in</strong>puts, load monitor sett<strong>in</strong>gs, servo feed, and counter <strong>in</strong>formation can be saved for each job.<br />
COUNTERS<br />
The batch and stroke counters can be used for die ma<strong>in</strong>tenance, quality control checks, or part b<strong>in</strong> exchanges. Each of these counters has a<br />
programmable preset and when it reaches the preset, the mach<strong>in</strong>e will top stop. The counters and presets are also saved <strong>in</strong> job memory. There is<br />
also a total counter which has security code protection. All of these counters can be displayed on the touch screen.<br />
SYSTEM SETUP<br />
The system setup screen is used to automatic<strong>all</strong>y zero the resolver, set the motion reference threshold, automatic<strong>all</strong>y set the sync switch position,<br />
and set the SPM (strokes per m<strong>in</strong>ute) range.<br />
USER MESSAGES<br />
Up to 10 user-def<strong>in</strong>ed programmable messages can be added to the general fault message list. These customized messages can be used with <strong>all</strong><br />
user <strong>in</strong>puts and die protection <strong>in</strong>puts. The messages can be alphanumeric up to 24 characters.<br />
PASSWORD CONTROL<br />
The password control screen is used to enter a supervisor security code, an operator security code, and to assign the level of security code<br />
protection—n<strong>one</strong>, operator, or supervisor. The security code is user-programmed up to 5 alphanumeric characters.<br />
CONTROL SYSTEMS | 43
SSC-3000 EXPANDABLE OPTIONS<br />
DUAL CPU PRESS CLUTCH/BRAKE CONTROL CARD<br />
Part No. FTL-319<br />
The Dual CPU Press Clutch/Brake Control Card is designed to<br />
comply with OSHA 29 CFR 1910.217, and ANSI B11.1 and B11.19.<br />
This is accomplished by a redundant cross-check<strong>in</strong>g, active dualmicroprocessor<br />
control system. The system uses redundant <strong>in</strong>puts<br />
from devices such as palm buttons, foot switches, and light curta<strong>in</strong>s.<br />
The system output to the solenoid valve(s) is provided by two<br />
monitored 24-V force-guided output relays. These primary safety<br />
output relays are <strong>in</strong>dependently controlled and cross-checked by<br />
the microprocessors. This <strong>all</strong>ows control-reliable operation of the<br />
outputs <strong>in</strong> the event of a s<strong>in</strong>gle control comp<strong>one</strong>nt failure. Each<br />
microprocessor also has its own logic power supply. This decreases<br />
the possibility of simultaneous control failure because of a fault<br />
with<strong>in</strong> the power supply system. All <strong>in</strong>puts and outputs are optic<strong>all</strong>y<br />
isolated for electrical noise immunity. The Clutch/Brake Control Card<br />
also provides angle sett<strong>in</strong>gs, timed sett<strong>in</strong>gs, optional modes, variable<br />
speed sett<strong>in</strong>gs, and a part-<strong>in</strong>-place <strong>in</strong>put.<br />
Angular position of the crankshaft is provided by a s<strong>in</strong>gle absolute<br />
resolver/pulser. A photoelectric sensor <strong>in</strong> the rotary tim<strong>in</strong>g device<br />
provides a synchronous signal which verifies the angular position.<br />
Note: Please furnish the electrical schematics if special feed<strong>in</strong>g or<br />
transfer equipment will be used on the press when the Dual CPU<br />
Press Clutch/Brake Card is used.<br />
STANDARD MODES OF OPERATION<br />
• Two-hand <strong>in</strong>ch (regular or timed)<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Foot s<strong>in</strong>gle stroke<br />
• Two-hand “walk-away” cont<strong>in</strong>uous<br />
• Cont<strong>in</strong>uous-on-demand<br />
• Automatic s<strong>in</strong>gle stroke<br />
• Two-hand-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous<br />
• Foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous<br />
• One-hand or foot trip s<strong>in</strong>gle stroke (use with light curta<strong>in</strong> or <strong>in</strong>terlocked<br />
guard only)<br />
Power<br />
Supply<br />
Clutch/Brake<br />
Card<br />
Control Rack With Cards and<br />
Card Slot Covers<br />
Ma<strong>in</strong><br />
Slots<br />
CPU 1 2 3 4 5 6 7 8<br />
PLS Card<br />
Die<br />
Protection<br />
Card<br />
Spare Slots<br />
for Additional<br />
Cards<br />
Angle<br />
Display Card<br />
Load<br />
Monitor<br />
Card<br />
PLS (PROGRAMMABLE LIMIT SWITCH) CARD<br />
Part No. FTL-320<br />
The 8-Output PLS Card is designed to provide user-programmable<br />
outputs that can be used to sequence events dur<strong>in</strong>g the press<br />
stroke. Up to two 8-Output PLS Cards can be used for a total of 16<br />
outputs. All outputs have depluggable term<strong>in</strong>al strips with LED (lightemitt<strong>in</strong>g<br />
diode) <strong>in</strong>dicators for easy <strong>in</strong>st<strong>all</strong>ation and ma<strong>in</strong>tenance. The<br />
programmed PLS sett<strong>in</strong>gs for each die are stored <strong>in</strong> job memory for<br />
QDC (quick die change).<br />
PLS outputs can be used for automatic operations such as lube mist,<br />
air blow off, or feed <strong>in</strong>itiation. Each output has a programmable on<br />
and off angle.<br />
The outputs can also be programmed to turn off after a preset period<br />
of time <strong>in</strong> hundredths of a second. This “timed output” sett<strong>in</strong>g overrides<br />
any off angle sett<strong>in</strong>g.<br />
A counter for counted output can also be programmed for auxiliary<br />
devices, such as lube or oil systems. This counter can be <strong>in</strong>terfaced to<br />
the PLS Card to provide an output signal when the counter sett<strong>in</strong>g is<br />
reached. For example, if an oil mist is required every three cycles, the<br />
counter sett<strong>in</strong>g is set to 3 strokes. When the counter reaches 3 strokes,<br />
the PLS output turns on and the oil mist is sprayed over the workpiece<br />
or die. The counter is then reset, and the cycle starts over.<br />
44 | CONTROL SYSTEMS
SSC-3000 EXPANDABLE OPTIONS (CONTINUED)<br />
DIE PROTECTION CARD<br />
Part No. FTL-321<br />
The 8-Input Die Protection Card is designed to provide user-programmable <strong>in</strong>puts that monitor static or cyclic events dur<strong>in</strong>g the press stroke. Up to<br />
three 8-Input Die Protection Cards can be used for a total of 24 <strong>in</strong>puts. The 24-V DC <strong>in</strong>puts have <strong>in</strong>dividual jumpers that set each <strong>in</strong>put to current<br />
s<strong>in</strong>k<strong>in</strong>g or sourc<strong>in</strong>g. All <strong>in</strong>puts have depluggable term<strong>in</strong>al strips with LED <strong>in</strong>dicators for easy <strong>in</strong>st<strong>all</strong>ation and ma<strong>in</strong>tenance.<br />
The die protection <strong>in</strong>puts can be used for equipment monitor<strong>in</strong>g, die protection, or other user-def<strong>in</strong>ed functions. Five (5) parameters can be<br />
programmed for each <strong>in</strong>put: logic, stop type, open angle, close angle, and fault message. Ten (10) user-def<strong>in</strong>ed messages exist at the end of the<br />
user-programmable fault list. These ten messages can be edited by the user via the programmable options <strong>in</strong> the ma<strong>in</strong> program screen.<br />
ANGLE DISPLAY CARD<br />
Part No. FTL-323<br />
The Angle Display Card is used <strong>in</strong> conjunction with the crankshaft angle display described below. The crankshaft angle display unit must be<br />
purchased <strong>in</strong> addition to the angle display card.<br />
CRANKSHAFT ANGLE DISPLAY UNIT<br />
Part No. FTL-054<br />
The optional crankshaft angle display is a unit that shows the angular position of the crankshaft for<br />
mechanical power presses. The crankshaft position is shown both graphic<strong>all</strong>y (with red LEDs <strong>in</strong> a circle)<br />
and numeric<strong>all</strong>y (with a large, red, three-digit LED). The large display can be easily seen which helps<br />
with setup, removal of stuck workpieces, or for assistance dur<strong>in</strong>g emergency extraction procedures.<br />
The Angle Display Card must be purchased <strong>in</strong> conjunction with this crankshaft angle display unit.<br />
FEATURES<br />
• Large LED numerical display and circular LED graphic display can be easily seen<br />
• 6” x 6” x 2” enclosure<br />
• Mounts easily<br />
• Supplied with 25’ of cable for connection to the control<br />
• Helps satisfy the requirements of Canadian Standard CSA Z142-02, Code for Power Press<br />
Operation: Health, Safety, and Guard<strong>in</strong>g Requirements, for <strong>in</strong>dication of crank angle position<br />
LOAD MONITOR SYSTEM<br />
Load Monitor Card<br />
Part No. FTL-322<br />
The SSC-3000 control is designed to accept <strong>one</strong> or two Load (tonnage) Monitor<br />
Cards <strong>in</strong> the ma<strong>in</strong> rack. Each card is capable of monitor<strong>in</strong>g the mach<strong>in</strong>e load at<br />
four locations on the mach<strong>in</strong>e frame or comp<strong>one</strong>nts. Four to eight load cells can<br />
be <strong>in</strong>st<strong>all</strong>ed on the mach<strong>in</strong>e to read up to a maximum of eight z<strong>one</strong>s of tonnage<br />
overload—four load cells per Load Monitor Card.<br />
The Load Monitor Card is programmable through the SSC-3000 touch screen/<br />
display. The m<strong>in</strong>imum and maximum tonnage can be set manu<strong>all</strong>y or with a<br />
learn key. The learn key will add 10% to or subtract 10% from the current<br />
high and low sett<strong>in</strong>gs. When enabled, a stop signal will be given when an over<br />
or under tonnage sett<strong>in</strong>g is detected. The system for load monitor<strong>in</strong>g also<br />
requires a load monitor control module and sensors (see next page).<br />
Crankshaft Angle Display Mounted<br />
on a Mechanical Power Press<br />
CONTROL SYSTEMS | 45
SSC-3000 EXPANDABLE OPTIONS (CONTINUED)<br />
LOAD MONITOR SYSTEM (CONTINUED)<br />
Load Monitor Control Module<br />
Part No. RYL-102<br />
The load monitor control module (9” H x 21⁄4” W x 4” D) detects the underload or overload <strong>in</strong>formation that is<br />
generated at each load sensor on the mach<strong>in</strong>e frame or comp<strong>one</strong>nt—available <strong>in</strong> a two- or four-cell sensor kit.<br />
In order to use the load monitor system, the mach<strong>in</strong>e must be calibrated with calibration cells. This is d<strong>one</strong> after<br />
<strong>in</strong>st<strong>all</strong><strong>in</strong>g the press automation control equipment and sensors. For further details on calibrat<strong>in</strong>g the load monitor<br />
system, please consult the factory.<br />
The Load Monitor Card must be purchased <strong>in</strong> conjunction with the load monitor control module and sensor kit.<br />
PART NO.<br />
RYT-030<br />
RYT-031<br />
DESCRIPTION<br />
FOUR-CELL SENSOR KIT<br />
TWO-CELL SENSOR KIT<br />
SERVO FEED INTERFACE<br />
A servo feed <strong>in</strong>terface option is available that will communicate with the exist<strong>in</strong>g servo feed controller currently attached to the press or a feed that is<br />
be<strong>in</strong>g purchased. This <strong>in</strong>terface can automate the sett<strong>in</strong>g for the feed length and feed rate. This speeds up die changeover because this <strong>in</strong>formation<br />
is stored once and then sent to the servo feed control when the tool<strong>in</strong>g is changed. The <strong>in</strong>terface consists of a connect<strong>in</strong>g cable, electrical pr<strong>in</strong>t,<br />
and software. Please furnish the manufacturer, model, and serial number of the servo feed to be <strong>in</strong>terfaced.<br />
OBI With Press Automation System and Servo Feed Interface<br />
46 | CONTROL SYSTEMS
SELECTING AN SSC-3000 PRESS AUTOMATION CONTROL<br />
To determ<strong>in</strong>e the 18-digit part number for the press automation control required, follow the directions given below and use the <strong>in</strong>formation <strong>in</strong> the<br />
PART NUMBERING SYSTEM CHART below.<br />
1. The first 5 digits for <strong>all</strong> press automation controls are PACG2.<br />
2. The 6th digit determ<strong>in</strong>es the location of the operator controls.<br />
3. The 7th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect switch provided.<br />
4. The 8th and 9th digits determ<strong>in</strong>e the size and type of motor starter(s), if provided, <strong>in</strong> the control enclosure. Zeros (00) <strong>in</strong> both positions <strong>in</strong>dicate no motor<br />
starter(s) provided.<br />
5. The 10th digit is for the type of light curta<strong>in</strong> <strong>in</strong>terface provided on the electrical schematics.<br />
6. The 11th digit <strong>in</strong>dicates if a Clutch/Brake Controller Card is required. Zero (0) <strong>in</strong>dicates n<strong>one</strong> is required.<br />
7. The 12th through the 18th digits are for the expandable rack slot options or slot covers, i.e., PLS, Die Protection, Load Monitor, Angle Display Card, and/or<br />
slot covers.<br />
SAMPLE<br />
1 2 3 4 5 6 7<br />
P A C G 2 - P 2 6 4 - W A A B C D X X X<br />
The sample shown, PACG2-P264-WAABCDXXX, <strong>in</strong>dicates that the pla<strong>in</strong>-door custom part-revolution control box will conta<strong>in</strong> a C4000 Standard light curta<strong>in</strong> <strong>in</strong>terface,<br />
an IEC 60-A disconnect switch, an IEC 30-A revers<strong>in</strong>g ma<strong>in</strong> drive motor starter, and an IEC revers<strong>in</strong>g 12-A revers<strong>in</strong>g ram adjust motor starter. The control will conta<strong>in</strong><br />
the Clutch/Brake Controller Card, an8-output PLS Card, an 8-<strong>in</strong>put Die-Protection Card, a 4-<strong>in</strong>put Load Monitor Card, an Angle Display Card, and three slot covers.<br />
SSC-3000 PRESS AUTOMATION CONTROL PART NUMBERING SYSTEM CHART<br />
P A C G 2 - X X X X - X X X X X X X X X<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
PACG2 —Press Automation Control<br />
CONFIGURATION & OPERATOR LOCATION<br />
P —All Operators Remote (Pla<strong>in</strong> Door)<br />
F —All Motor Operators on Door<br />
M —Ma<strong>in</strong> Motor Operators on Door, Ram-Adjust Operators Remote<br />
C —Console (All Operators Included)<br />
K —Kit—No Enclosure; Operators Remote<br />
N —NEMA Comp<strong>one</strong>nts; All Operators Remote (Pla<strong>in</strong> Door)<br />
DISCONNECT SWITCH SIZE—IEC (PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 —30-A Disconnect—1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 —60-A Disconnect—21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 —100-A Disconnect—41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 —200-A Disconnect—67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 —400-A Disconnect—134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
REVERSING/NONREVERSING MAIN MOTOR STARTER WITH<br />
OR WITHOUT RAM ADJUST<br />
0 —No Motor Starter<br />
1 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter without Ram Adjust<br />
2 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter without Ram Adjust<br />
3 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 12-A Ram Adjust<br />
4 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 18-A Ram Adjust<br />
5 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 25-A Ram Adjust<br />
6 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 12-A Ram Adjust<br />
7 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 18-A Ram Adjust<br />
8 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter with 25-A Ram Adjust<br />
* An RYL-102 load monitor control module and sensor kit(s) are needed <strong>in</strong> addition to the load<br />
monitor card—see pages 45-46.<br />
** An FTL-054 crankshaft angle display unit is needed <strong>in</strong> addition to the angle display card—<br />
see page 45.<br />
`<br />
RACK SLOT #2 - #8 OPTIONS<br />
Beg<strong>in</strong> with 10th digit and proceed to the right by<br />
assign<strong>in</strong>g desired option to specific slot.<br />
A —8-Output PLS Card (maximum 2 each)<br />
B —8-Input Die Protection Card (maximum 3 each)<br />
C —4-Input Load Monitor Card* (maximum 2 each)<br />
D —Angle Display Card**<br />
X —Slot Cover(s)<br />
RACK SLOT #1 CONTROLLER TYPE<br />
A —With Clutch/Brake Controller Card<br />
X —Without Clutch/Brake Controller Card—Slot Cover<br />
LIGHT CURTAIN OPTIONS**<br />
B—Banner Light Curta<strong>in</strong><br />
C—C4000 Advanced With LC Operators on Door<br />
V—C4000 Advanced With LC Operators Remote<br />
W—C4000 Standard<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 —12 A<br />
2 —18 A<br />
3 —25 A<br />
4 —32 A<br />
5 —40 A<br />
6 —50 A<br />
7 —65 A<br />
8 —80 A<br />
9 —95 A<br />
A —115 A<br />
B —185 A<br />
C —265 A<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
CONTROL SYSTEMS | 47
SSC-3000 COMPONENT PACKAGES<br />
To complete the SSC-3000 control system, comp<strong>one</strong>nt packages are available to use with the SSC-3000 control box. These comp<strong>one</strong>nt packages<br />
are similar to those listed on pages 36 and 37 for use with the SSC-1500 control box; however the prior-action comp<strong>one</strong>nt part number changes<br />
with<strong>in</strong> the comp<strong>one</strong>nt packages listed on page 36—see below.<br />
The prior-action station <strong>in</strong>cluded with the cont<strong>in</strong>uous mode of operation comp<strong>one</strong>nt packages is Part No. LLD-3000. This replaces the prior-action<br />
station Part No. LLD-1500 <strong>in</strong> the comp<strong>one</strong>nt packages listed on page 36.<br />
The comp<strong>one</strong>nt package part number also changes when order<strong>in</strong>g an SSC-3000 comp<strong>one</strong>nt package. Change the selected comp<strong>one</strong>nt<br />
package’s part number suffix -SSP listed on pages 36-37 to the suffix -SSC when order<strong>in</strong>g an SSC-3000 comp<strong>one</strong>nt package.<br />
SSC-3000 INDIVIDUAL COMPONENTS<br />
PRIOR-ACTION STATION—Part No. LLD-3000*<br />
This prior-action station has an illum<strong>in</strong>ated push button that must be depressed and released by the<br />
operator before depress<strong>in</strong>g the actuat<strong>in</strong>g means <strong>in</strong> order to <strong>in</strong>itiate the cont<strong>in</strong>uous mode of operation.<br />
This steel enclosure is 3½” x 3¼” x 3¼”. The prior-action station is required when us<strong>in</strong>g the “walkaway”<br />
cont<strong>in</strong>uous, cont<strong>in</strong>uous-on-demand, automatic s<strong>in</strong>gle stroke, two-hand-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous,<br />
or foot-ma<strong>in</strong>ta<strong>in</strong>ed cont<strong>in</strong>uous mode of operation. These modes of operation are standard features of the<br />
SSC-3000 control.<br />
Prior-Action Station<br />
SUPERVISORY CONTROL STATION<br />
Part No. LLD-3001<br />
Part No. LLD-283* (required when a USC-000 is used—see below)<br />
When multiple operator stations are required, this supervisory control station is furnished separately<br />
for each set of palm buttons and/or foot switch operator station. It has its own enclosure and<br />
<strong>in</strong>cludes an off/on key-operated selector switch and a green on <strong>in</strong>dicator light. The enclosure size<br />
is 5¼” x 3” x 3¼”.<br />
Supervisory Control Station<br />
BAR/RUN STATION (NOT INCLUDED IN ANY COMPONENT PACKAGE)<br />
Part No. LLD-3002<br />
This remote bar/run station can be used <strong>in</strong> conjunction with a manual turnover bar when sett<strong>in</strong>g dies<br />
<strong>in</strong> the press. The flywheel must have holes <strong>in</strong> the periphery for <strong>in</strong>sertion of a spr<strong>in</strong>g-loaded** turnover<br />
bar (or the flywheel can be manu<strong>all</strong>y turned when the flywheel cover is removed). The remote station<br />
<strong>in</strong>cludes a three-position selector switch for bar/off/run, and <strong>one</strong> push button used for energiz<strong>in</strong>g<br />
the dual-solenoid air valve to engage the clutch and release the brake. The flywheel must be at rest<br />
(static) when engag<strong>in</strong>g the clutch. After the clutch is engaged, the die setup person can manu<strong>all</strong>y turn<br />
the flywheel with a spr<strong>in</strong>g-loaded turnover bar (see page 98). The enclosure size is 5¼” x 3” x 3¼”.<br />
Bar/Run Station<br />
MULTIPLE-OPERATOR JUNCTION BOX<br />
PART NO. USC-000*<br />
When multiple operator stations are required, this junction box is furnished separately for wir<strong>in</strong>g up to four<br />
(4) operator stations. This junction box <strong>in</strong>terfaces palm button assemblies/control bars and foot switches,<br />
and will not <strong>all</strong>ow the press to run if palm buttons or a foot switch is actuated without its supervisory<br />
control station on. A lighted push button with nameplate <strong>in</strong>dicates a fault condition of an operator station.<br />
The button is pushed to reset. The enclosure size is 16” x 14” x 6”.<br />
Multiple-Operator Junction Box<br />
* Included <strong>in</strong> an SSC-3000 comp<strong>one</strong>nt package on page 36 or page 37 after chang<strong>in</strong>g the suffix -SSP to<br />
-SSC <strong>in</strong> the comp<strong>one</strong>nt package number.<br />
** For a spr<strong>in</strong>g-loaded turnover bar, see page 98.<br />
48 | CONTROL SYSTEMS
CONTROL CONSOLES<br />
All of the previously menti<strong>one</strong>d part-revolution-clutch controls can be<br />
furnished as special control systems eng<strong>in</strong>eered to your specifications.<br />
Please consult the factory for further details on your requirements. This<br />
page illustrate some examples of special controls that can be designed.<br />
A floor-stand<strong>in</strong>g console conta<strong>in</strong>s the clutch/brake or hydraulic controls<br />
and motor controls mounted <strong>in</strong>side on subpanels. These are typic<strong>all</strong>y<br />
used on high-speed or large presses. Consoles are used <strong>in</strong> place<br />
of controls mounted to the mach<strong>in</strong>e to avoid extreme press shock<br />
vibration. Isolat<strong>in</strong>g the press controls <strong>in</strong> the console gives electrical<br />
comp<strong>one</strong>nts a longer life. Control consoles are usu<strong>all</strong>y furnished <strong>in</strong><br />
oil-tight enclosures which have a sloped top for operator convenience.<br />
Casters are option<strong>all</strong>y available to provide mobility of the console. The<br />
enclosure door has a lockable handle so that unauthorized personnel<br />
cannot tamper with the controls.<br />
These consoles may be furnished with IEC or NEMA disconnect<br />
switches and magnetic motor starters. The disconnect handle is<br />
located on the enclosure door (lockable <strong>in</strong> the off position). The starter<br />
push buttons (and selector, when a revers<strong>in</strong>g starter is furnished)<br />
are located on the sloped front. These consoles are available <strong>in</strong> the<br />
configuration shown or any other way that meets your requirements.<br />
User-supplied or user-specified comp<strong>one</strong>nts can also be <strong>in</strong>corporated<br />
<strong>in</strong>to these control consoles.<br />
Please furnish exact motor horsepower, voltage, and full-load amps<br />
when order<strong>in</strong>g disconnect switches and motor starters.<br />
SPECIAL CONTROLS<br />
Have you ever been <strong>in</strong> a position where you required a unique control,<br />
but lacked the time or expertise to design <strong>one</strong>? If so, we can help<br />
you. We have the knowledge and experience to design, manufacture,<br />
and <strong>in</strong>st<strong>all</strong> a control panel or an entire control system to meet your<br />
specific requirements.<br />
At your request, our safety control specialists can visit your plant to<br />
determ<strong>in</strong>e exactly what is required or you can mail us your exist<strong>in</strong>g<br />
pr<strong>in</strong>ts. A proposal will be submitted to you detail<strong>in</strong>g the exact<br />
specifications and costs <strong>in</strong>volved.<br />
Our eng<strong>in</strong>eer<strong>in</strong>g personnel will design the circuit for the control system.<br />
Every control is designed to the applicable OSHA and ANSI standards.<br />
The f<strong>in</strong>al stage of design results <strong>in</strong> a complete set of control circuit<br />
schematics, connection and layout diagrams.<br />
Next, the control design is sent to our production department. Control<br />
panel assembly beg<strong>in</strong>s here with the layout and wir<strong>in</strong>g of the control.<br />
After the manufacture of the control is complete, it is subject to a<br />
rigorous test<strong>in</strong>g procedure which ensures proper operation.<br />
If you require <strong>in</strong>st<strong>all</strong>ation of the special control, we have highly skilled<br />
<strong>in</strong>st<strong>all</strong>ation crews that are available to <strong>in</strong>st<strong>all</strong> the control system or to<br />
<strong>in</strong>struct your own ma<strong>in</strong>tenance personnel.<br />
Each special mach<strong>in</strong>e control we design can be unique. You have our<br />
commitment to quality.<br />
Floor-Stand<strong>in</strong>gControl Console<br />
Special Control With Operator Interface,<br />
Push Buttons, and Selector Switches<br />
Special Control With Enclosure Door Open Show<strong>in</strong>g SSC-1500 Control,<br />
Variable Frequency Drive, and Other User-Requested Comp<strong>one</strong>nts<br />
CONTROL SYSTEMS | 49
REMOTE MOTOR CONTROL OPERATOR STATIONS FOR USE WITH SSC-1500 PRESS<br />
CONTROLS, SSC-3000 PRESS CONTROLS, AND SSC-1500 PRESS BRAKE CONTROLS<br />
Part No.VOS-1000<br />
—For use with nonrevers<strong>in</strong>g<br />
motor starters<br />
This 6¾” x 3½” x 3” station is<br />
a motor control green start push<br />
button and a red stop push button <strong>in</strong><br />
a NEMA 12 metal enclosure.<br />
Part No. LLD-3213<br />
— For use with revers<strong>in</strong>g ram<br />
adjust motor starters<br />
This 8¾” x 3½” x 3” station has<br />
black ram raise and ram lower push<br />
buttons, and a two-position ramadjust<br />
off/on selector switch <strong>in</strong> a<br />
NEMA 12 metal enclosure.<br />
Part No. VOS-1000<br />
Part No. LLD-3213<br />
Part No. VOS-1100<br />
—For use with revers<strong>in</strong>g<br />
motor starters<br />
This 8¾” x 3½” x 3” station is a motor<br />
control green start push button, a red<br />
stop push button, and a two-position<br />
forward/reverse selector switch <strong>in</strong> a<br />
NEMA 12 metal enclosure.<br />
Part No. LLD-3215<br />
— For use with revers<strong>in</strong>g ma<strong>in</strong><br />
motor starters and revers<strong>in</strong>g<br />
ram-adjust motor starters<br />
This 8¾” x 6¼” x 3¾” station<br />
has a two-position ram-adjust off/<br />
on selector switch, black ram raise<br />
and ram lower push buttons, a twoposition<br />
forward/reverse selector<br />
switch, a motor control green start<br />
push button, and a red stop push<br />
button <strong>in</strong> a NEMA 12 metal enclosure.<br />
Part No. LLD-3214<br />
Part No. VOS-1100<br />
Part No. LLD-3214<br />
— For use with nonrevers<strong>in</strong>g<br />
ma<strong>in</strong> motor starters and<br />
revers<strong>in</strong>g ram-adjust<br />
motor starters<br />
This 8¾” x 6¼” x 3¾” station has<br />
a two-position ram-adjust off/on<br />
selector switch, black ram raise and<br />
ram lower push buttons, a motor<br />
control green start push button,<br />
and a red stop push button <strong>in</strong> a<br />
NEMA 12 metal enclosure.<br />
Part No. LLD-3215<br />
50 | CONTROL SYSTEMS
CONTROL BARS<br />
Control bars of various configurations can be provided to mount either to the mach<strong>in</strong>e or on a pedestal-type floor stand. The standard control bars can<br />
have various guarded run/<strong>in</strong>ch palm buttons, emergency-stop and top-stop palm buttons, a multiple operator supervisory station selector switch with<br />
<strong>in</strong>dicator light, and either of two types of prior-action push buttons. Please refer to the CONTROL BAR PART NUMBERING SYSTEM CHART on the<br />
next page to obta<strong>in</strong> the part number of the standard control bar required.<br />
Special control bars can be provided with other required selector switches and <strong>in</strong>dicator lights, depend<strong>in</strong>g on the <strong>in</strong>dividual requirements. Consult<br />
the factory for pric<strong>in</strong>g and delivery when a special control bar is required.<br />
Part No. MCB-3111-1<br />
Part No. USC-2611-1<br />
Special Control Bar With Additional Selector Switch and<br />
Indicator Light <strong>in</strong> a Larger Enclosure<br />
FLOOR STANDS FOR CONTROL BARS<br />
Control bars and any palm button assembly can be furnished with either of these floor stands.<br />
Part No. KCL-000<br />
—Floor Stand With Base and Top Plate<br />
This 37” nonadjustable heavy-duty floor stand <strong>in</strong>cludes a top<br />
plate and a 4” x 4” column. The base has four holes for permanent<br />
attachment to the floor; bolts are not furnished.<br />
Part No. KCL-017<br />
—Adjustable Floor Stand With Base and Top Plate<br />
The adjustable column (28” to 47”) on this floor stand can easily<br />
be moved up and down for operator comfort. A hand tool is required<br />
to make adjustments. The base has four holes for permanent<br />
attachment to the floor; bolts are not furnished. Custom heights are<br />
available. Please consult the factory.<br />
CONTROL SYSTEMS | 51
SELECTING A CONTROL BAR<br />
To determ<strong>in</strong>e the 7- or 8-digit configured part number for a standard control bar, follow directions 1-6 below and use the <strong>in</strong>formation <strong>in</strong> the<br />
CONTROL BAR PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits for <strong>all</strong> control bars are MCB or USC.<br />
2. The 4th digit determ<strong>in</strong>es the size of the bar enclosure.<br />
3. The 5th digit determ<strong>in</strong>es the type of run/<strong>in</strong>ch button provided.<br />
4. The 6th digit determ<strong>in</strong>es the type of emergency-stop button provided.<br />
5. The 7th digit determ<strong>in</strong>es the type of top-stop or return button provided.<br />
6. The 8th digit will <strong>in</strong>dicate the type of modifier provided; e.g., supervisory selector switch, <strong>in</strong>dicator light, and prior-action push button.<br />
CONTROL BAR<br />
MCB —Universal Control Bar<br />
USC —Control Bar for Use With USC-000 Multiple-Operator Junction Box Only<br />
ENCLOSURE SIZE (4” x 4” x X)<br />
1 —18”—Run Buttons on Ends of Enclosure<br />
2 —24”—Run Buttons on Ends of Enclosure<br />
3 —30”—All Operators on Front of Enclosure<br />
4 —36”—All Operators on Front of Enclosure<br />
CONTROL BAR PART NUMBERING SYSTEM CHART<br />
XXX- X X X X - X<br />
RUN BUTTON OPERATOR TYPE<br />
1 —Rees Black Palm Button With <strong>Rockford</strong> <strong>Systems</strong> Guards—Front Only<br />
2 — A-B Articulated Palm Button With A-B Guards—Front Only<br />
3 –– N/A<br />
4 — IDEC Green Push Button With IDEC Guard<br />
5 — A-B Zero-Force Touch Buttons With Guards (90-264 V AC)<br />
6 — Banner Opto-Touch Buttons With Guards (20-30 V AC/DC)<br />
7 — Mushroom Push Buttons With Guards (SQ-D)<br />
8 –– Rees Chrome Light-Push Button With <strong>Rockford</strong> <strong>Systems</strong> Guards—Front Only<br />
MODIFIER<br />
0 —N<strong>one</strong><br />
1 —Includes Station Off/On Selector Switch and Indicator<br />
2 —Includes Prior-Action Push Button<br />
3 —Includes Station Off/On Selector Switch, Indicator, and<br />
Prior Action Push Button<br />
4 —Includes Lighted Prior-Action Push Button (SSC<br />
5 —Includes Station Off/On Selector Switch, Indicator, and Lighted<br />
Prior-Action Push Button<br />
TOP-STOP OR RETURN TYPE<br />
0 —N<strong>one</strong><br />
1 —Rees Yellow Top-Stop Palm Button (1 NO and 1 NC)<br />
2 —A-B Yellow Top-Stop 40 mm Mushroom Palm Button (1 NO and 1 NC)<br />
3 —Rees Yellow Return Palm Button (1 NO and 1 NC)<br />
4 —A-B Yellow Return 40 mm Mushroom Palm Button (1 NO and 1 NC)<br />
EMERGENCY-STOP TYPE<br />
1 —Rees Red Palm Button—Latch-Out Type<br />
2 —A-B Red 40 mm Two-Position—Twist-to-Return<br />
OPERATOR AND EMERGENCY-STOP TYPE BUTTONS FOR CONTROL BARS<br />
Rees Black Palm Button<br />
With RSI Guard<br />
A-B Articulated Palm<br />
Button With A-B Guard<br />
IDEC Button With Guard<br />
A-B Zero-Force Touch<br />
Button With Guard<br />
Opto-Touch Button<br />
with Guard<br />
Mushroom Push Button<br />
With Guard (SQ-D)<br />
Rees Chrome Light-Push<br />
Button With RSI Guard<br />
Rees Red E-Stop<br />
Button—Latch-Out<br />
A-B Red Two-Position<br />
E-Stop—Twist-to-Return<br />
All buttons have 1 NO and 1 NC contact arrangement.<br />
52 | CONTROL SYSTEMS
SURVEY FOR PART-REVOLUTION PRESS<br />
Company<br />
City<br />
State<br />
Surveyed By<br />
Date<br />
NO. ____________<br />
Proposal Sequence Reference<br />
INSTALLATION N Y If Y: Standard Stripped-down<br />
Is special lift for large press required for <strong>in</strong>st<strong>all</strong>ation? N Y<br />
When fill<strong>in</strong>g out this form, be sure the <strong>in</strong>formation is filled <strong>in</strong> for satisfy<strong>in</strong>g the basic<br />
areas of safety.<br />
Basic Areas–1. <strong>Safeguard<strong>in</strong>g</strong> 4. Starter<br />
2. Control 5. Cover<br />
3. Disconnect 6. Other Considerations<br />
For identification and reference, please fill <strong>in</strong> this area first.<br />
1<br />
Mach<strong>in</strong>e No.<br />
Model No.<br />
Tonnage (always required)<br />
1. <strong>Safeguard<strong>in</strong>g</strong>:<br />
Has Safeguard Provide Type, Series, or Size<br />
Pullback<br />
Not offered by RSI<br />
Restra<strong>in</strong>t<br />
Barrier Guard<br />
When provid<strong>in</strong>g, please attach completed measurement data form. Sides and rear<br />
must be guarded.<br />
Type A or B Gate<br />
When provid<strong>in</strong>g, please attach completed measurement<br />
data form on guards for the sides of the po<strong>in</strong>t of operation.<br />
Two-Hand Control<br />
Manufacturer<br />
Serial No.<br />
Clutch : Air Mechanical Friction Hydraulic Other______<br />
Type: OBI OBS Gap Gap DC Horn Toggle<br />
SSSC SSDC: R to L Bed Size Other<br />
Is mach<strong>in</strong>e out of service? N Y<br />
What are methods of feed<strong>in</strong>g material?<br />
Hand, From: Front Sides: Right Left;<br />
Automatic: Coil Strip; Magaz<strong>in</strong>e;<br />
Shuttle; Slid<strong>in</strong>g Bolster; Other<br />
If press has two-hand control, are they at the proper safety<br />
distance? N Y If we are to provide, what is the proper<br />
safety distance?________”(See page 46 <strong>in</strong> MSD catalog for details)<br />
Presence Sens<strong>in</strong>g<br />
Light Curta<strong>in</strong><br />
Cable Length______’<br />
If press has a presence-sens<strong>in</strong>g device, is it at the proper safety<br />
distance? N Y If we are to provide light curta<strong>in</strong>, what is<br />
the proper safety distance?_____________”<br />
(Customer to<br />
Are Mount<strong>in</strong>g Brackets required? N CTF Y Furnish)<br />
If Y: EX-AL Sw<strong>in</strong>g-Away N Y If Y, please complete and attach SAB<br />
Measurement Form<br />
EX-AL Stationary N Y If Y, please complete and attach<br />
SLCMB Measurement Form<br />
Are Floor Stands required? N Y<br />
Are Mirrors required? N Y If Y: 1 2<br />
If Yes, what size? ________”<br />
When provid<strong>in</strong>g any of the above safeguard<strong>in</strong>g devices, the sides and rear of the po<strong>in</strong>t of<br />
operation must be safeguarded. If light curta<strong>in</strong> sw<strong>in</strong>g-away brackets are not furnished, are<br />
side & rear guards required?<br />
(Customer to<br />
N CTF Furnish) Y<br />
If Y, please complete and attach measurement form.<br />
1 of 4<br />
CONTROL SYSTEMS | 53
SURVEY FOR PART-REVOLUTION PRESS (CONTINUED)<br />
2<br />
2. Control: (for clutch/brake)<br />
A. Does press control have control reliability? N Y<br />
B. Does press have brake monitor? N Y<br />
If Y, is it: In Control Box or Add-On Unit<br />
C. Information about press:<br />
1. Hand Actuat<strong>in</strong>g N Y Stations: 1 2 3 4 (circle <strong>one</strong>)<br />
2. Foot Actuat<strong>in</strong>g N Y Stations: 1 2 3 4 (circle <strong>one</strong>)<br />
3. Modes: Inch S<strong>in</strong>gle Cont<strong>in</strong>uous<br />
Auto S<strong>in</strong>gle Other______________<br />
4. Control Box Location: On Press N Y Remote N Y<br />
5. Operator Controls: On Control Box N Y<br />
Remote N Y: (circle <strong>one</strong>): Box Bar Stand<br />
6. If control reliability existence is questionable, please provide the follow<strong>in</strong>g<br />
<strong>in</strong>formation:<br />
Solid-State Relay Logic<br />
If relay logic, Control relays:<br />
Mfg.__________Part No._________Qty.__________<br />
7. Are any comp<strong>one</strong>nts jumpered out? N Y<br />
D. Does brake need to be changed or modified to be<br />
spr<strong>in</strong>g applied? N Y<br />
E. Is Control Box to be furnished? N Y If Y:<br />
1. Solid-State: 1500 N Y 3000 N Y<br />
If 3000 control, cards: C/B PLS: 1 2 (circle <strong>one</strong>)<br />
Die Protection: 1 2 3 (circle <strong>one</strong>)<br />
Load Monitor: 1 2 (circle <strong>one</strong>)<br />
Angle Display<br />
Is crankshaft angle display unit required? N Y<br />
Is servo <strong>in</strong>terface required? N Y<br />
If Y, Brand__________ Model________ Serial #_________<br />
2. Box: Standard N Y, Custom N Y,<br />
Remote Operator-Style (X,Y,Z) N Y, Special N Y<br />
3. If custom or special, is remote push-button station<br />
for motor controls required? N Y<br />
4. Location of Box on Press: Left Right Other____<br />
5. Location of Operators: (circle <strong>one</strong>) 1. Remote 2. Loose<br />
3. Door 4. Console 5. Kit<br />
6. 1500: Subpanel N Y<br />
Space requirements: 18 1 ⁄2” H x 18 1 ⁄2” W x 6” D<br />
Actual space available:_____” H x _____” W x _____” D<br />
Module Kit N Y<br />
Space requirements: 18” H x 18” W x 6” D<br />
Actual space available:_____” H x _____” W x _____” D<br />
Keypad/Display N Y<br />
Space requirements: 10 1 ⁄2” H x 9” W x 3” D<br />
Actual space available:_____” H x _____” W x _____” D<br />
3000: Rack Kit N Y<br />
Space requirements: 15” H x 18” W x 10” D<br />
Actual space available:_____” H x _____” W x _____” D<br />
Tou<br />
ch Screen Loose N Y Kit N Y<br />
Space requirements: 12” H x 10” W x 3” D<br />
Actual space available:_____” H x _____” W x _____” D<br />
7. Modes Required: Inch S<strong>in</strong>gle Cont<strong>in</strong>uous<br />
Auto S<strong>in</strong>gle Other________________________<br />
8. Options Required: Hour Meter Bar/Run Station<br />
Duplex Outlet N<strong>one</strong><br />
9. Brake Monitor: Time-Based<br />
F. Cycle Tim<strong>in</strong>g Device?: N Y<br />
Resolver with 40’ cable is standard with 1500 & 3000<br />
Resolver with 100’ cable<br />
G. Tim<strong>in</strong>g Device Drive?: N Y<br />
Reuse Exist<strong>in</strong>g Sprockets and Cha<strong>in</strong><br />
Sprocket Set N Y Cha<strong>in</strong> N Y<br />
Exist<strong>in</strong>g Direct Coupl<strong>in</strong>g Drive to be Reused? N Y<br />
H. If press ever operates at less than 20 SPM, what is the<br />
exact speed? ________________SPM<br />
2<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Model No.<br />
Manufacturer<br />
Serial No.<br />
2. Control: (for clutch/brake)—cont<strong>in</strong>ued<br />
I. Actuat<strong>in</strong>g Means: How many operat<strong>in</strong>g stations: 1 2 3 4<br />
(circle <strong>one</strong>)<br />
1. Hand (Push Button) N Y Hand (other) N Y________<br />
If Y: On Mach<strong>in</strong>e Control Bar Floor Stand<br />
2. E-Stop Button N Y Top-Stop Button N Y<br />
3. Foot Switch N Y<br />
Is Special Plug and Receptacle Required? N Y<br />
J. Monitored Dual Valve? N Y: (circle <strong>one</strong>):<br />
1<br />
⁄2” 3<br />
⁄4” 1” 1 1 ⁄2” How many? 1 or 2 (circle <strong>one</strong>)<br />
K. Air Pressure Switch? N Y: If Y,<br />
Clutch/Brake? N Y Counterbalance? N Y<br />
L. Counterbalance Check Valve? N Y: (circle <strong>one</strong>):<br />
1<br />
⁄2” 3<br />
⁄4” 1” 1 1 ⁄2” 2” N/A No Tank<br />
M. Filter-Regulator-Lubricator? N Y: 1 ⁄2” 3<br />
⁄4” 1” 1 1 ⁄2”<br />
(circle <strong>one</strong>)<br />
N. Air Lockout Valve? N Y: 1<br />
⁄2” 3<br />
⁄4” 1” 1 1 ⁄2”<br />
Special pip<strong>in</strong>g to floor level? N Y<br />
(circle <strong>one</strong>)<br />
O. Is Air Cyl<strong>in</strong>der to be furnished? N/A<br />
N (reus<strong>in</strong>g exist<strong>in</strong>g) Y If yes; provide details;<br />
Push Pull “ Bore “ Stroke Mount<br />
2 of 4<br />
54 | CONTROL SYSTEMS
SURVEY FOR PART-REVOLUTION PRESS (CONTINUED)<br />
3<br />
4<br />
3. Disconnect:<br />
A. Present Location of Disconnect:<br />
1. On Press or Off Press<br />
2. With Clutch/Brake Control<br />
Separate From Clutch/Brake Control<br />
With Starter Only<br />
Not Furnished<br />
B. Is electrical disconnect switch required?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
Y If Y, furnish HP, FLA, and voltage <strong>in</strong> 4C.<br />
C. How is disconnect to be furnished?<br />
Separate Box Comb<strong>in</strong>ation With Starter Box<br />
Custom Box<br />
4. Starter:<br />
A. Present Location of Starter:<br />
1. On Press or Off Press<br />
2. With Clutch/Brake Control<br />
Separate From Clutch/Brake Control<br />
With Disconnect Only<br />
Not Furnished<br />
3. Is present starter?<br />
L<strong>in</strong>e Voltage 230/460 V (most common)<br />
Reduced Voltage (used on larger presses)<br />
Two-Speed (large press)<br />
B. Is magnetic starter required for ma<strong>in</strong> drive?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
If N, exist<strong>in</strong>g starter must have 115-V coil and <strong>one</strong><br />
norm<strong>all</strong>y open auxiliary contact.<br />
Y<br />
Estimate<br />
Actual<br />
C. If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
D. Revers<strong>in</strong>g N Y Nonrevers<strong>in</strong>g N Y<br />
E. How is starter to be furnished? Separate Box<br />
Comb<strong>in</strong>ation W/Disconnect Box In Custom Box<br />
F. Is remote push-button station required? N Y<br />
G. Does press have variable-speed drive? N Y<br />
If Y: Mechanical Adjust Electromechanical<br />
Eddy Current: Make_______ Model______send schematics<br />
Electronic: AC or DC (circle <strong>one</strong>)—send schematics<br />
Provide: Horsepower___________ Voltage___________<br />
Provide: Speed Range ________ to ________ SPM<br />
Note: If exist<strong>in</strong>g variable-speed comp<strong>one</strong>nts are go<strong>in</strong>g to be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> new control, please<br />
provide dimensions of area needed for panel <strong>in</strong>side box and surface required outside<br />
the control box or console.<br />
H. Are other starters required?<br />
Ram Adjust: N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
Y<br />
Estimate<br />
Actual<br />
If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
Lube System N Y (See also 6A.)<br />
Estimate<br />
Actual<br />
If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Manufacturer<br />
Model No.<br />
Serial No.<br />
Note: If other motor starters are required, please provide appropriate <strong>in</strong>formation.<br />
3 of 4<br />
CONTROL SYSTEMS | 55
SURVEY FOR PART-REVOLUTION PRESS (CONTINUED)<br />
5<br />
6<br />
5. Covers: (Customer to Furnish)<br />
Do any mechanical power-transmission apparatuses<br />
need to be covered up to 7 feet above floor or platform?<br />
N Y If Y, what needs to be covered?<br />
Flywheel N Y Connection Rod N Y<br />
Gears N Y Turnover Bar Slot N Y<br />
Shaft End N Y Sprockets & Cha<strong>in</strong> N Y<br />
Additional brackets<br />
Other___________________<br />
required N Y ________________________<br />
6. Other Considerations:<br />
A. Does press have lube system? N Y<br />
If Y, what k<strong>in</strong>d of system?:<br />
Manual or mechanical pump N Y<br />
*Timer N Y<br />
*Motorized N Y (Please fill <strong>in</strong> Section 4H.)<br />
*Be sure to furnish lube schematics and/or <strong>in</strong>structions<br />
with this form. If only control schematics are supplied,<br />
be sure lube system is <strong>in</strong>dicated. Also provide sensor<br />
<strong>in</strong>formation such as pressure and level.<br />
B. Does air cushion require lubrication? N Y<br />
C. Is safety block to be furnished? N Y If Y:<br />
What size is needed? ________” (Height)<br />
How many? _______ S M L (circle size required)<br />
2-Contact Interlock N Y Holder N Y<br />
D. Is spr<strong>in</strong>g-loaded turnover bar required? N Y:<br />
If Y, what diameter? ________”<br />
E. Does press have material feed<strong>in</strong>g equipment? N Y<br />
1. Is safeguard<strong>in</strong>g required for the feeder? N Y<br />
2. Is safeguard<strong>in</strong>g required for the straightener? N Y<br />
3. Is safeguard<strong>in</strong>g required for the reel? N Y<br />
4. Is safeguard<strong>in</strong>g required for the cradle? N Y<br />
F. Tie <strong>in</strong> of exist<strong>in</strong>g equipment? N Y:<br />
Die clamp<strong>in</strong>g................................................................................ N Y<br />
Hydraulic overload <strong>in</strong> ram............................................................. N Y<br />
Interlocked guard......................................................................... N Y<br />
Light curta<strong>in</strong>*............................................................................... N Y<br />
Radio frequency*.......................................................................... N Y<br />
Gate*........................................................................................... N Y<br />
Air blowoff................................................................................... N Y<br />
Counter........................................................................................ N Y<br />
Index<strong>in</strong>g table*............................................................................. N Y<br />
Slid<strong>in</strong>g bolster*............................................................................. N Y<br />
Die protection*............................................................................. N Y<br />
Bar/run station............................................................................. N Y<br />
Bump<strong>in</strong>g p<strong>in</strong>................................................................................ N Y<br />
Flywheel brake............................................................................. N Y<br />
If Y: Mechanical Pneumatic with valve<br />
Tachometer*................................................................................ N Y<br />
Digital shut height <strong>in</strong>dicator........................................................... N Y<br />
Brake monitor*............................................................................. N Y<br />
Hour meter................................................................................... N Y<br />
Material feed<strong>in</strong>g equipment*......................................................... N Y<br />
Straightener................................................................................. N Y<br />
Reel............................................................................................. N Y<br />
Cradle.......................................................................................... N Y<br />
Die light....................................................................................... N Y<br />
Conveyor...................................................................................... N Y<br />
Motion detector*........................................................................... N Y<br />
Bear<strong>in</strong>g heat sensors*.................................................................. N Y<br />
Overload protection*..................................................................... N Y<br />
Robot*......................................................................................... N Y<br />
Programmable limit switch (PLS)*.................................................. N Y<br />
Safety block electrical <strong>in</strong>terlock system........................................ N Y<br />
*Individual comp<strong>one</strong>nt electrical or electronic schematic<br />
required. Send<strong>in</strong>g Enclosed<br />
6<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Model No.<br />
6. Other Considerations—cont<strong>in</strong>ued:<br />
Manufacturer<br />
Serial No.<br />
G. If questionable about any <strong>in</strong>formation furnished, please enclose photos of<br />
entire front, sides (left and right), and rear of press. Include close-up photos of<br />
the <strong>in</strong>side of the exist<strong>in</strong>g control box, clutch, and crankshaft extension end.<br />
Send<strong>in</strong>g Enclosed<br />
4 of 4<br />
56 | CONTROL SYSTEMS
HYDRAULIC POWER PRESS CONTROL SYSTEMS<br />
6.3.1 PRESS PUMP MOTORS<br />
The control system sh<strong>all</strong> not permit the <strong>in</strong>itiation of slide(s) motion<br />
unless at least <strong>one</strong> pump motor is runn<strong>in</strong>g. This requirement may not<br />
apply to die sett<strong>in</strong>g operations—see subclause 9.2.3 <strong>in</strong> ANSI B11.2.<br />
6.3.2 POWER FAILURE<br />
The control system sh<strong>all</strong> be designed so that <strong>in</strong> the event of power<br />
failure, restoration of power will not result <strong>in</strong> any hazardous slide motion.<br />
Hydraulic Press With a Light Curta<strong>in</strong> and Two-Hand<br />
Control Device as the Po<strong>in</strong>t-of-Operation Safeguard—<br />
Also Has a Hydraulic Control With Control Reliability<br />
Each hydraulic power press must be looked at as an <strong>in</strong>dividual<br />
system. This system consists of, but is not limited to, the mach<strong>in</strong>e<br />
frame, <strong>all</strong> mechanical parts, hydraulic system, electrical or electronic<br />
systems, pneumatic systems, tool<strong>in</strong>g or dies (present and future), tool<br />
or die setup, safeguard<strong>in</strong>g, material handl<strong>in</strong>g, size or configuration<br />
of workpiece, ma<strong>in</strong>tenance requirements, and most importantly,<br />
production requirements.<br />
OSHA REGULATIONS<br />
For hydraulic power presses, the ma<strong>in</strong> safety requirements that<br />
must be complied with f<strong>all</strong> under OSHA 29 CFR 1910.212, General<br />
Requirements for <strong>all</strong> Mach<strong>in</strong>es. This section of the CFR requires po<strong>in</strong>tof-operation<br />
safeguard<strong>in</strong>g.<br />
If auxiliary equipment on the hydraulic power press has mechanical<br />
power-transmission apparatuses, then OSHA 29 CFR 1910.219 must<br />
be complied with. For lockout/tagout requirements, OSHA 29 CFR<br />
1910.147 should be referenced.<br />
ANSI STANDARDS<br />
There are several references available on hydraulic press safety;<br />
however, most end-users rely on the ANSI (American National Standards<br />
Institute) B11.2 standard for best safety practices.<br />
In ANSI B11.2, subclause 6.3 Control System, it states that “All<br />
comp<strong>one</strong>nts and subsystems of the control system sh<strong>all</strong> be designed<br />
to operate together to provide total system compliance with the<br />
requirements of this clause. Control comp<strong>one</strong>nts sh<strong>all</strong> be selected,<br />
constructed and connected together <strong>in</strong> such a way as to withstand<br />
expected operational and environmental stresses. The control system<br />
sh<strong>all</strong> meet the follow<strong>in</strong>g design and construction requirements:”<br />
6.3.3 CONTROL RELIABILITY<br />
Control systems sh<strong>all</strong> be designed and constructed so a s<strong>in</strong>gle failure<br />
or fault with<strong>in</strong> the system:<br />
1. Does not prevent the normal stopp<strong>in</strong>g action from be<strong>in</strong>g applied to<br />
the press, when required;<br />
2. Does not create un<strong>in</strong>tended slide motion;<br />
3. Does prevent <strong>in</strong>itiation of a successive stroke until the failure<br />
is corrected.<br />
See Electrical Requirements <strong>in</strong> this section for other requirements found<br />
<strong>in</strong> ANSI B11.2.<br />
6.6.5 HYDRAULIC COMPONENTS AND CIRCUITS<br />
Hydraulic comp<strong>one</strong>nt circuits that control slide(s) motion sh<strong>all</strong> comply<br />
with the requirements of 6.3.3.<br />
CONTROLS<br />
The controls described <strong>in</strong> this catalog <strong>in</strong>clude two-hand control as<br />
a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g device. The palm buttons must<br />
be depressed concurrently and ma<strong>in</strong>ta<strong>in</strong>ed dur<strong>in</strong>g the hazardous<br />
downstroke of the ram. Release of <strong>one</strong> or both palm buttons reverses<br />
or stops the action of the ram. The controls offered also <strong>in</strong>clude a light<br />
curta<strong>in</strong> <strong>in</strong>terface.<br />
ELECTRICAL REQUIREMENTS<br />
The ANSI B11.2 standard requires a proper ma<strong>in</strong> power disconnect<br />
switch. A motor starter is also required that drops out when power<br />
is lost and will not restart automatic<strong>all</strong>y. All AC control circuits and<br />
solenoid valves must be powered by 120 V or less (obta<strong>in</strong>ed from the<br />
transformer), and the control system must be protected aga<strong>in</strong>st false<br />
operation due to an accidental ground.<br />
UPDATING HYDRAULIC POWER PRESSES<br />
To update the electrical system or to add po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g<br />
to hydraulic power presses, the electrical and hydraulic schematic<br />
diagrams must be reviewed by <strong>Rockford</strong> <strong>Systems</strong>’ eng<strong>in</strong>eer<strong>in</strong>g<br />
department. Please provide these schematics to our sales personnel or<br />
factory-authorized representatives when they visit your plant to conduct<br />
a mach<strong>in</strong>e survey.<br />
CONTROL SYSTEMS | 57
STANDARD HYDRAULIC POWER PRESS CONTROL<br />
This solid-state control system is designed for use on hydraulic power presses. It<br />
is designed and built to comply with OSHA 29 CFR 1910.212 and ANSI B11.2 and<br />
B11.19. This control can update or replace exist<strong>in</strong>g control systems on hydraulic<br />
power presses found <strong>in</strong> users’ plants or can be furnished for new or rebuilt hydraulic<br />
power presses.<br />
This control <strong>in</strong>cludes control reliability, two-hand control, light curta<strong>in</strong> <strong>in</strong>terface, and<br />
diagnostics (<strong>one</strong> user-programmable <strong>in</strong>put). It also <strong>in</strong>cludes batch and stroke counters<br />
with presets, and a hard-wired emergency-stop master control relay.<br />
This is an economic, full-featured dual micro-processor-based control system. The<br />
system uses redundant <strong>in</strong>puts from devices such as palm buttons, foot switches, and<br />
light curta<strong>in</strong>(s). The system output to the solenoid valves is provided by two forceguided<br />
relays. These output relays are <strong>in</strong>dependently controlled and cross-checked by<br />
the microprocessors. This <strong>all</strong>ows control-reliable operation of the outputs <strong>in</strong> the event<br />
of a s<strong>in</strong>gle control comp<strong>one</strong>nt failure <strong>in</strong> the control. The standard hydraulic power<br />
press control has m<strong>in</strong>imum requirements for the press it is to control. These m<strong>in</strong>imum<br />
requirements <strong>in</strong>clude a directional or <strong>one</strong> up and <strong>one</strong> down solenoid valve(s) for the<br />
ram, a TOS (top-of-stroke) limit switch, and a BOS (bottom-of-stroke) limit or pressure<br />
switch. In most cases, if these already exist, they can be reused. Speed-change valves<br />
and limit switches can also be supported with the standard hydraulic control. If other<br />
valves exist (additional speed change valves, prefill, regeneration, level, bypass, etc.),<br />
please consult the factory for a quote on a special-designed control.<br />
The standard control box is a 20” x 20” x 8” NEMA 12 enclosure with the operator<br />
controls and keypad/display mounted <strong>in</strong> the door, as illustrated above.<br />
A starter or disconnect can be <strong>in</strong>cluded <strong>in</strong> a larger enclosure, or a comb<strong>in</strong>ation starter<br />
disconnect can be furnished separately.<br />
Standard Control Box<br />
Back of<br />
Keypad/Display<br />
Master<br />
Control Relay<br />
Multi-Tap<br />
Transformer<br />
Output<br />
Relays<br />
Control Module<br />
Assembly<br />
Selectors<br />
Inside View of Standard<br />
Control Box<br />
58 | CONTROL SYSTEMS
STANDARD HYDRAULIC POWER PRESS CONTROL (CONTINUED)<br />
OPERATOR INTERFACE KEYPAD/DISPLAY<br />
The operator <strong>in</strong>terface keypad/display is used to enter setup <strong>in</strong>formation, monitor mach<strong>in</strong>e operation,<br />
and display messages on a 4-l<strong>in</strong>e x 20-character LCD (liquid crystal display). As standard, this keypad is<br />
mounted on the control box door. For operator convenience, it can be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a remote operator station.<br />
Programm<strong>in</strong>g is accessed by a keyed selector switch.<br />
PROGRAMMING<br />
The hydraulic power press control can be quickly and easily programmed. There is <strong>one</strong> 24-V DC selectable<br />
current-s<strong>in</strong>k<strong>in</strong>g or sourc<strong>in</strong>g programmable diagnostic <strong>in</strong>put provided for the user. A fault message, <strong>in</strong>put logic,<br />
and stop type can be assigned to the <strong>in</strong>put from the user <strong>in</strong>put fault message list. When a fault condition is<br />
detected, the mach<strong>in</strong>e will top stop or emergency stop, and the assigned message will be displayed. This<br />
feature helps when troubleshoot<strong>in</strong>g common fault conditions.<br />
Keypad/Display<br />
MODES OF OPERATION<br />
• Off<br />
• Two-hand <strong>in</strong>ch<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Foot s<strong>in</strong>gle stroke<br />
• Foot switch trip or <strong>one</strong>-hand trip s<strong>in</strong>gle stroke (used <strong>in</strong> conjunction<br />
with a po<strong>in</strong>t-of-operation safeguard)*<br />
• High, high/low, low speed change<br />
• Two-hand automatic (cont<strong>in</strong>uous)<br />
• Automatic s<strong>in</strong>gle stroke*<br />
*Additional comp<strong>one</strong>nts may be required to use this mode of operation.<br />
FEATURES<br />
• Meets and exceeds OSHA 29 CFR 1910.212 and ANSI B11.2 and B11.19<br />
• Provides two-hand control safeguard<strong>in</strong>g device<br />
• Redundant and cross-check<strong>in</strong>g microprocessors<br />
• Redundant switch<strong>in</strong>g style DC power supplies<br />
• Two monitored ram advance (up or down) 24-V force-guided output relays<br />
For control reliability<br />
• External relay monitor<strong>in</strong>g (for use when external relays are used to energize the down valves)<br />
• Block<strong>in</strong>g valve monitor<strong>in</strong>g<br />
• Press control operates on 85-135 V AC<br />
• Provisions for optional light curta<strong>in</strong> <strong>in</strong>terface with off/on supervised keyed selector switch<br />
• Easy to read back-lit liquid crystal operator <strong>in</strong>terface display hav<strong>in</strong>g 4 l<strong>in</strong>es x 20 characters<br />
• One (1) 24-V DC digital user <strong>in</strong>put, programmable, selectable canned message<br />
• One (1) ram speed change (fast-slow) output, standard 120 V AC with a selector switch for high, high/low, low speed (to support mach<strong>in</strong>es<br />
with a speed change solenoid valve)<br />
• One (1) ram return (up or down) output, standard 120 V AC with a selector switch for pressure, pressure/distance, distance return<br />
• Bottom dwell timer (0-600 seconds)<br />
• Decompression timer (50-250 ms)<br />
• 7-digit stroke counter<br />
• 7-digit batch counter with preset<br />
• Operator <strong>in</strong>terface keypad and display, text <strong>in</strong> English or Spanish<br />
CONTROL SYSTEMS | 59
CUSTOM HYDRAULIC POWER PRESS CONTROL<br />
A custom control box conta<strong>in</strong>s the standard control module and<br />
comp<strong>one</strong>nts described on pages 60-61 plus the follow<strong>in</strong>g:<br />
• ma<strong>in</strong> power disconnect switch<br />
• ma<strong>in</strong> hydraulic pump motor starter<br />
The box will vary <strong>in</strong> size based on the disconnect switch and motor<br />
starter comp<strong>one</strong>nts. The box is furnished with an IEC through-thedoor<br />
ma<strong>in</strong> power fused disconnect switch and an IEC hydraulic pump<br />
magnetic motor starter (with push buttons). They are prewired and<br />
built <strong>in</strong>to a NEMA 12 enclosure.<br />
Operator controls and the keypad/display are located on the front<br />
of the door, or a pla<strong>in</strong>-door control or subpanel can be furnished. A<br />
remote operator station or keypad/display kit is required if a pla<strong>in</strong>-door<br />
control or subpanel is ordered. See the next page for <strong>in</strong>formation on<br />
remote operator stations.<br />
To ensure the starter(s) and disconnect are sized properly, please<br />
check horsepower for the ma<strong>in</strong> hydraulic pump motor on the mach<strong>in</strong>e,<br />
as well as full-load amps and primary voltage to the mach<strong>in</strong>e. After<br />
obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, go to the chart on page 62 to determ<strong>in</strong>e<br />
the proper custom control box part number. Follow directions 1-7 to<br />
determ<strong>in</strong>e the correct part number.<br />
Remote Operator<br />
Station<br />
Custom Pla<strong>in</strong> Door<br />
Control Box<br />
REMOTE OPERATOR-STYLE CONTROL BOXES<br />
Remote operator-style X, Y, and Z hydraulic control boxes <strong>in</strong>clude the same features and modes of operation as the standard hydraulic control<br />
boxes. However, they do not have a control transformer. These control boxes are designed to be located on the front of the mach<strong>in</strong>e near the<br />
operator.<br />
These controls are for applications where the mach<strong>in</strong>e’s exist<strong>in</strong>g magnetic motor starter, fused disconnect switch, and control transformer meet the<br />
safety requirements and can be reused. If the exist<strong>in</strong>g control transformer cannot be reused or a new <strong>one</strong> is required, please contact the factory.<br />
The keypad/display and <strong>all</strong> operator controls are located on the door (front) of the remote operator-style control box.<br />
CONTROL MODULE KIT<br />
A control module kit <strong>all</strong>ows the end user to update the hydraulic control of a press with m<strong>in</strong>imum equipment costs. The kit is supplied without the<br />
control enclosure, panel, control transformer, control fuse, term<strong>in</strong>al strips, wire duct, and wir<strong>in</strong>g.<br />
A set of electrical pr<strong>in</strong>ts is supplied to show typical wir<strong>in</strong>g, and <strong>all</strong> mount<strong>in</strong>g dimensions are<br />
provided <strong>in</strong> order for a qualified person to <strong>in</strong>st<strong>all</strong> the control module kit. The m<strong>in</strong>imum area<br />
required on an exist<strong>in</strong>g control panel to <strong>in</strong>st<strong>all</strong> this kit is 18” H x 18” W x 6” D.<br />
This control module kit <strong>in</strong>cludes the control module, control relays, shock mounts, fasteners,<br />
suppressors, danger labels, and electrical pr<strong>in</strong>ts. A keypad/display kit is required unless a<br />
remote operator station is used (see next page).<br />
If the automatic (cont<strong>in</strong>uous) mode of operation is used, a prior-action station<br />
—Part No. LLD-6100—is required. See page 63.<br />
SUBPANEL<br />
A subpanel control can also be furnished. It is the same as the standard control described<br />
on pages 58-59 without the enclosure. The m<strong>in</strong>imum area required <strong>in</strong> an exist<strong>in</strong>g control<br />
enclosure is 181⁄2” H x 181⁄2” W x 6” D.<br />
60 | CONTROL SYSTEMS
KEYPAD/DISPLAY KIT<br />
Part No. LLD-6011 (for RHPC—Press Controls)<br />
The keypad/display kit can be used with any of the control boxes or the control<br />
module kit. This kit <strong>in</strong>cludes the keypad/display, an off/program/run selector<br />
switch, a light curta<strong>in</strong> off/on selector switch, a hand/foot selector switch, an<br />
<strong>in</strong>ch/s<strong>in</strong>gle/automatic selector switch, a high/low speed<br />
selector switch, a pressure/pressure distance/distance return selector switch,<br />
and 25’ of cable. Additional push buttons, nameplates, and selector switches<br />
for the motor starter, etc., can be furnished depend<strong>in</strong>g on the features<br />
required. Please consult the factory.<br />
REMOTE OPERATOR STATIONS<br />
For operator convenience, a remote operator station can be furnished for use<br />
with a pla<strong>in</strong>-door standard control box, pla<strong>in</strong>-door custom control box, module<br />
kit, or subpanel. The remote operator station conta<strong>in</strong>s the keypad/display,<br />
program selector switch, and other selector switches as required.<br />
Remote operator stations are available <strong>in</strong> a standard format or can be customized<br />
to meet any requirements. Select from the follow<strong>in</strong>g remote operator stations.<br />
Part No. LLD-6001<br />
Remote Operator Station for Hydraulic Press<br />
REMOTE OPERATOR STATIONS FOR HYDRAULIC PRESSES<br />
FEATURES<br />
PART NO.<br />
LLD-6000<br />
PART NO.<br />
LLD-6001<br />
PART NO.<br />
LLD-6002<br />
PART NO.<br />
LLD-6003<br />
PART NO.<br />
LLD-6004<br />
PART NO.<br />
LLD-6005<br />
PART NO.<br />
LLD-6006<br />
KEYPAD/DISPLAY X X X X X X X X<br />
OFF/PROGRAM/RUN SELECTOR SWITCH X X X X X X X X<br />
INCH/SINGLE/<br />
AUTOMATIC SELECTOR SWITCH<br />
PART NO.<br />
LLD-6007<br />
X X X X X X X X<br />
HAND/FOOT SELECTOR SWITCH X X X X X X X X<br />
LIGHT CURTAIN OFF/ON SELECTOR SWITCH X X X X X X X X<br />
HIGH/LOW SPEED SELECTOR SWITCH X X X X X X X X<br />
PRESSURE/PRESSURE DISTANCE/DISTANCE<br />
RETURN SELECTOR SWITCH<br />
MAIN MOTOR START AND<br />
STOP PUSH BUTTONS<br />
PRIOR-ACTION BUTTON FOR AUTOMATIC<br />
MODES OF OPERATION<br />
ADVANCED LIGHT CURTAIN BLANKING<br />
SELECTOR SWITCHES<br />
X X X X X X X X<br />
X X X X<br />
X X X X<br />
X X X X<br />
CONTROL SYSTEMS | 61
SELECTING AN RHPC HYDRAULIC PRESS CONTROL<br />
To determ<strong>in</strong>e the 10-digit configured part number for the hydraulic press control required, follow directions 1-8 below and use the <strong>in</strong>formation <strong>in</strong><br />
the PART NUMBERING SYSTEM CHART below.<br />
1. The first 4 digits for <strong>all</strong> hydraulic press controls are RHPC.<br />
2. The 5th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect<br />
switch provided.<br />
3. The 6th digit determ<strong>in</strong>es if a nonrevers<strong>in</strong>g motor starter is provided. Zero (0) <strong>in</strong>dicates no motor starter provided.<br />
4. The 7th digit determ<strong>in</strong>es the size of nonrevers<strong>in</strong>g motor starter that is provided <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no<br />
motor starter provided.<br />
5. The 8th digit determ<strong>in</strong>es the location of the operator controls, or if it is a style X, Y, or Z control without the control transformer.<br />
6. The 9th digit is for the type of light curta<strong>in</strong> <strong>in</strong>terface provided.<br />
7. The 10th digit (if required) will <strong>in</strong>dicate the type of modifier provided: i.e., motor control operators remote.<br />
SAMPLE<br />
1 2 3 4 5 6 7<br />
RHPC - 2 1 3 - F W 5<br />
The sample shown, RHPC-213-FW5, <strong>in</strong>dicates that the custom control box is for a hydraulic press with a C4000 standard light curta<strong>in</strong> <strong>in</strong>terface<br />
<strong>in</strong>clud<strong>in</strong>g an IEC 60-A disconnect switch and an IEC 25-A nonrevers<strong>in</strong>g motor starter. The keypad/display and <strong>all</strong> operators will be on the door of the<br />
enclosure, except for the motor controls which will be located remote.<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
RHPC —Hydraulic Control for Presses<br />
DISCONNECT SWITCH SIZE—IEC<br />
(PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 —30-A Disconnect—1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 —60-A Disconnect—21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 —100-A Disconnect—41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 —200-A Disconnect—67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 —400-A Disconnect—134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
NONREVERSING MAIN MOTOR STARTER<br />
0 —No Starter<br />
1 —Nonrevers<strong>in</strong>g Starter<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 —12 A<br />
2 —18 A<br />
3 —25 A<br />
4 —32 A<br />
5 —40 A<br />
6 —50 A<br />
7 —65 A<br />
8 —80 A<br />
9 —95 A<br />
A —115 A<br />
B —185 A<br />
C —265 A<br />
RHPC HYDRAULIC CONTROL PART NUMBERING SYSTEM CHART<br />
RHPC - X X X - X X X<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
MODIFIER<br />
-- —Blank, No Modifier<br />
5 —Motor Operators Remote*<br />
LIGHT CURTAIN INTERFACE OPTIONS<br />
B —Banner Standard<br />
C —C4000 Advanced With LC Operators on Door<br />
V —C4000 Advanced With LC Operators Remote<br />
W —C4000 Standard<br />
CONFIGURATION & OPERATOR LOCATION<br />
F —Keypad/Display and All Operators on Door of Enclosure<br />
P —Keypad/Display and All Operators Remote (Pla<strong>in</strong> Door)<br />
S —Subpanel Only—Without Enclosure, Keypad/Display, and Operators<br />
K —Kit with Module and Control Relays Only—Without Enclosure,<br />
Subpanel, Transformer, Keypad/Display, and Operators<br />
X —Same as F (above) Without Control Transformer<br />
Y —Same as F (above) Without Control Transformer but With<br />
E-Stop, Return/Inch-up, and Prior Action on the Enclosure<br />
Z —Same as F (above) Without Control Transformer but<br />
With E-Stop, Return/Inch-up, Prior Action, and Two (2)<br />
Guarded Run/Inch Buttons on the Enclosure<br />
*See page 50 for remote motor control operator stations or <strong>Catalog</strong> SFM.<br />
62 | CONTROL SYSTEMS
HYDRAULIC CONTROL SYSTEMS INDIVIDUAL COMPONENTS<br />
LINEAR CAM AND LIMIT SWITCH ASSEMBLY<br />
Part No. CMT-048<br />
The l<strong>in</strong>ear cam and limit switch assembly consists of two limit switches and two adjustable cams<br />
mounted on an extruded-alum<strong>in</strong>um bracket. This assembly can provide the l<strong>in</strong>ear tim<strong>in</strong>g of the top<br />
and bottom limits of the mach<strong>in</strong>e cycle on a hydraulic mach<strong>in</strong>e.<br />
HIGH/LOW LIMIT SWITCH ASSEMBLY<br />
Part No. CMT-049<br />
An additional l<strong>in</strong>ear cam and limit switch assembly can be used for a high/low signal dur<strong>in</strong>g the<br />
clos<strong>in</strong>g portion of the hydraulic stroke. This assembly consists of <strong>one</strong> limit switch and <strong>one</strong> adjustable<br />
cam mounted on an extruded-alum<strong>in</strong>um bracket.<br />
PALM BUTTON ASSEMBLY<br />
Part No. CTL-525<br />
Palm button assembly consists of two black run/<strong>in</strong>ch buttons (with r<strong>in</strong>g<br />
guards), a red emergency-stop button and a yellow return/<strong>in</strong>ch-up button.<br />
Mount<strong>in</strong>g boxes are furnished with each button. The electrical contact<br />
arrangement for <strong>all</strong> buttons is 1 NO and 1 NC.<br />
FOOT SWITCH<br />
Part No. CTD-011<br />
This foot switch is protected from un<strong>in</strong>tentional operation. A heavy-duty die-cast cover protects<br />
the top and both sides, and the front is protected by a h<strong>in</strong>ged flap. The flap must be lifted with the<br />
toe before the foot may enter the switch. The electrical contact arrangement is 1 NO and 1 NC.<br />
PRIOR-ACTION STATION<br />
Part No. LLD-6100<br />
This prior-action station has a push button that must be depressed and released by the operator<br />
before depress<strong>in</strong>g the actuat<strong>in</strong>g means <strong>in</strong> order to <strong>in</strong>itiate the automatic mode of operation. This<br />
NEMA 12 enclosure size is 3½” x 4½” x 3½”.<br />
SUPERVISORY CONTROL STATION<br />
Part No. LLD-6101<br />
Part No. LLD-283 (required when a USC-000 is used–see below)<br />
When two or more palm button or foot switch operat<strong>in</strong>g stations are required on <strong>one</strong> mach<strong>in</strong>e,<br />
<strong>one</strong> supervisory control station is required at each operator station. This remote control station<br />
consists of an off/on keyed selector switch and a station on <strong>in</strong>dicator light. The on position <strong>all</strong>ows<br />
the operator to use that station, and the off position deactivates only that station. The enclosure<br />
size is 5¼” x 3” x 3¼”<br />
MULTIPLE-OPERATOR JUNCTION BOX<br />
Part No. USC-000<br />
When multiple operator stations are required, this junction box is furnished separately for wir<strong>in</strong>g<br />
up to four (4) operator stations. This junction box <strong>in</strong>terfaces palm button assemblies/control bars<br />
and foot switches, and will not <strong>all</strong>ow the press to run if palm buttons or a foot switch is actuated<br />
without its supervisory control station on. A lighted push button with nameplate <strong>in</strong>dicates a fault<br />
condition of an operator station. The button is pushed to reset. The enclosure size is 16” x 14” x 6”.<br />
Part No. CTL-525<br />
Foot Switch<br />
Prior-Action Station<br />
Supervisory Control Station<br />
Multiple-Operator<br />
Junction Box<br />
CONTROL SYSTEMS | 63
SURVEY FOR HYDRAULIC PRESS<br />
1<br />
2<br />
Company<br />
City<br />
Surveyed By<br />
INSTALLATION N Y If Y: Standard Stripped-down<br />
Is special lift for large press required for <strong>in</strong>st<strong>all</strong>ation? N Y<br />
When fill<strong>in</strong>g out this form, be sure the <strong>in</strong>formation is filled <strong>in</strong> for satisfy<strong>in</strong>g the basic<br />
areas of safety.<br />
Basic Areas—1. <strong>Safeguard<strong>in</strong>g</strong> 4. Starter<br />
2. Control 5. Other Considerations<br />
3. Disconnect<br />
For identification and reference, please fill <strong>in</strong> this area first.<br />
Mach<strong>in</strong>e No.<br />
Model No.<br />
Tonnage (always required)<br />
What is the maximum stroke of the ram?<br />
1. <strong>Safeguard<strong>in</strong>g</strong>:<br />
Has Safeguard Provide Type, Series, or Size<br />
Pullback<br />
Restra<strong>in</strong>t<br />
Barrier Guard<br />
When provid<strong>in</strong>g, please attach completed measurement data form. Sides and rear<br />
must be guarded.<br />
Type A or B Gate<br />
When provid<strong>in</strong>g, please attach completed measurement data form on guards for the<br />
sides of the po<strong>in</strong>t of operation.<br />
Two-Hand Control<br />
If press has two-hand control, are the palm buttons at the proper safety distance?<br />
N Y If we are to provide, what is proper safety distance?________”<br />
(See page 46 <strong>in</strong> MSD catalog for details.)<br />
Presence-Sens<strong>in</strong>g<br />
Light Curta<strong>in</strong><br />
If press has presence-sens<strong>in</strong>g device, is it at the proper safety<br />
distance? N Y If we are to provide light curta<strong>in</strong>, what is the proper safety<br />
distance?________”<br />
(Customer to<br />
Are Mount<strong>in</strong>g Brackets required? N CTF<br />
Furnish)<br />
Y<br />
If Y: EX-AL Sw<strong>in</strong>g-Away N Y If Y, please complete and attach SAB<br />
Measurement Form<br />
EX-AL Stationary N Y If Y, please complete and attach<br />
SLCMB Measurement Form<br />
Are Floor Stands required? N Y<br />
Are Mirrors required? N Y If Y: 1 2<br />
If Yes, what size? ________”<br />
When provid<strong>in</strong>g any of the above safeguard<strong>in</strong>g devices, the sides<br />
and rear of the po<strong>in</strong>t of operation must be safeguarded. If light curta<strong>in</strong> sw<strong>in</strong>g-away<br />
brackets are not furnished, are side & rear guards required?<br />
(Customer to<br />
N CTF Furnish) Y<br />
If Y, please complete and attach measurement form.<br />
2. Control:<br />
Manufacturer<br />
Serial No.<br />
Type: Gap (OBS) Straight Side 4-Post H-Frame<br />
Is mach<strong>in</strong>e out of service? N Y<br />
State<br />
Date<br />
Not offered by RSI<br />
A. Does control reliability need to be furnished for exist<strong>in</strong>g hydraulic control?<br />
N Y<br />
If Y, please send electrical and hydraulic schematic for<br />
eng<strong>in</strong>eer<strong>in</strong>g to review<br />
N/A—Hydraulic press is mechanic<strong>all</strong>y operated<br />
2<br />
2. Control (cont<strong>in</strong>ued):<br />
B. Information about press:<br />
NO. ____________<br />
Proposal Sequence Reference<br />
1. Hand Actuat<strong>in</strong>g N Y Stations: 1 2 3 4<br />
(circle <strong>one</strong>)<br />
2. Foot Actuat<strong>in</strong>g N Y Stations: 1 2 3 4<br />
(circle <strong>one</strong>)<br />
3. Modes: Inch S<strong>in</strong>gle Automatic Other_________<br />
4. Control Box Location: On Press N Y<br />
Remote N Y<br />
5. Operator Controls: On Control Box N Y<br />
Remote N Y: (circle <strong>one</strong>): Box Bar Stand<br />
6. If control reliability existence is questionable, please provide the follow<strong>in</strong>g<br />
<strong>in</strong>formation: Solid-State Relay Logic<br />
If relay logic, control relays:<br />
Mfg._____________Part No.___________Qty.__________<br />
7. Are any comp<strong>one</strong>nts jumpered out? N Y<br />
8. How does mach<strong>in</strong>e operate?<br />
a. Does the ram return when the actuat<strong>in</strong>g means (hand or foot) is released?<br />
N Y<br />
b. Does the ram stop at midstroke when the actuat<strong>in</strong>g means is released?<br />
N Y<br />
c. Does the ram automatic<strong>all</strong>y return when actuat<strong>in</strong>g means is held<br />
operated? N Y<br />
d. Does the ram change speed dur<strong>in</strong>g stroke? N Y<br />
e. Does ram dwell at the bottom of stroke before return<strong>in</strong>g? N Y<br />
C. Is Control Box to be furnished? N Y If Y:<br />
1. Solid-State: RHPC N Y Other_________________<br />
2. Box: Standard N Y, Custom N Y,<br />
Remote Operator-Style (X,Y,Z) N Y, Special N Y<br />
3. Location of operators: (circle <strong>one</strong>)<br />
1. Remote 2. Loose 3. Door 4. Console 5. Kit<br />
4. Subpanel N Y (M<strong>in</strong>. space required is 18 1 ⁄2” x 18 1 ⁄2” x 6”)<br />
Actual space available______”H x ______”W x _____”D<br />
5. Module kit N Y (M<strong>in</strong>. space required is 18” x 18” x 6”)<br />
Actual space available______”H x ______”W x _____”D<br />
6. Modes required: Inch S<strong>in</strong>gle Automatic S<strong>in</strong>gle Stroke<br />
Two-Hand Automatic (Cont<strong>in</strong>uous) PSDI (Special) High/Low<br />
Dwell Other______________________<br />
D. Cycle Tim<strong>in</strong>g Device? N Y<br />
L<strong>in</strong>ear Cams & Limit Switches N Y<br />
Use Exist<strong>in</strong>g Other_______________________________<br />
E. Actuat<strong>in</strong>g Means: How many operat<strong>in</strong>g stations: 1 2 3 4<br />
1. Hand (Push Button) N Y Hand (other) N Y________<br />
If Y: On Mach<strong>in</strong>e Control Bar Floor Stand<br />
2. E-Stop Button N Y Return Button N Y<br />
3. Foot Switch N Y<br />
Is Special Plug and Receptacle Required? N Y<br />
F. Block<strong>in</strong>g Monitored Dual Valve Required? N Y: If Y, contact OEM or<br />
a hydraulic fluid specialist<br />
G. What is Voltage of Exist<strong>in</strong>g Valves?<br />
24 V DC 115 V 230 V 460 V<br />
What is Inlet flow?__________________________________ GPM<br />
What is Return flow?________________________________ GPM<br />
NOTE: Please enclose photo and schematics of the hydraulic_____ system.<br />
Enclosed Send<strong>in</strong>g<br />
1 of 2<br />
64 | CONTROL SYSTEMS
SURVEY FOR HYDRAULIC PRESS (CONTINUED)<br />
3<br />
4<br />
5<br />
3. Disconnect:<br />
A. Present Location of Disconnect:<br />
1. On Press or Off Press<br />
2. With Hydraulic Control<br />
Separate From Hydraulic Control<br />
With Starter Only<br />
Not Furnished<br />
B. Is Electrical disconnect switch required?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
Y If Y, furnish HP, FLA, and voltage <strong>in</strong> Section 4D.<br />
C. How is disconnect to be furnished?<br />
4. Starter:<br />
Separate Box<br />
Comb<strong>in</strong>ation W/Starter Box<br />
Custom Box<br />
A. Present Location of Starter:<br />
1. On Press or Off Press<br />
2. With Hydraulic Control<br />
Separate From Hydraulic Control<br />
With Disconnect Only<br />
Not Furnished<br />
B. Is transformer for reduc<strong>in</strong>g voltage to starter<br />
required? N Y<br />
C. Is magnetic starter required for hydraulic pump motor?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
If N, exist<strong>in</strong>g starter must have 115-V coil and <strong>one</strong><br />
norm<strong>all</strong>y open auxiliary contact.<br />
Y<br />
Estimate Actual<br />
D. If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
E. How is starter to be furnished? Separate Box<br />
Comb<strong>in</strong>ation W/Disconnect Box In Custom Box<br />
F. Is remote push-button station required?<br />
N Y<br />
5. Other Considerations:<br />
A. Is safety block to be furnished? N Y If Y:<br />
What size is needed? ________” (Height)<br />
How many? _______ S M L (circle size required)<br />
Interlock N Y Holder N Y<br />
B. Does press have a lube system? N Y<br />
If Y, what k<strong>in</strong>d of system?<br />
Manual or mechanical pump N Y<br />
Timer N Y<br />
Motorized N Y—Provide HP, FLA, and voltage if new starter is to<br />
be furnished<br />
HP ____________<br />
FLA ____________<br />
Voltage ____________<br />
C. If questionable about any <strong>in</strong>formation furnished, please enclose photos<br />
of entire front, sides (left and right), and rear of press. Include close-up<br />
photos of the <strong>in</strong>side of the exist<strong>in</strong>g control box.<br />
Send<strong>in</strong>g Enclosed<br />
2 of 2<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No. Manufacturer<br />
Model No. Serial No.<br />
CONTROL SYSTEMS | 65
PRESS BRAKE CONTROL SYSTEMS<br />
INTRODUCTION<br />
Press brakes are <strong>one</strong> of the most difficult mach<strong>in</strong>e tools to safeguard<br />
because of their general purpose-type use <strong>in</strong> <strong>in</strong>dustry. General purpose<br />
means a press brake can be used to bend from very sm<strong>all</strong> parts to<br />
very large parts. Production runs on these mach<strong>in</strong>es can be <strong>one</strong> part<br />
to thousands of parts. With this type of operation, press brakes must<br />
be versatile.<br />
Today, with advanced technology, it is now possible for <strong>in</strong>dustry to<br />
safeguard press brakes and ma<strong>in</strong>ta<strong>in</strong> the same levels of productivity<br />
when the employer (user) considers <strong>all</strong> comp<strong>one</strong>nts <strong>in</strong> the press brake<br />
system. A complete safeguarded system <strong>in</strong>cludes, but is not limited to,<br />
the type of press brake, the safeguard itself, tool<strong>in</strong>g to be used, size,<br />
shape or configuration of workpiece, material handl<strong>in</strong>g, production,<br />
ma<strong>in</strong>tenance, and any anticipated future needs.<br />
OSHA STANDARDS<br />
Under OSHA, press brakes are cited for noncompliance <strong>in</strong> accordance<br />
with 29 CFR 1910.212— Mach<strong>in</strong>e Guard<strong>in</strong>g, which specific<strong>all</strong>y<br />
requires po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g. All mach<strong>in</strong>es f<strong>all</strong> under<br />
this same regulation where it states: “the safeguard<strong>in</strong>g sh<strong>all</strong> be <strong>in</strong><br />
conformity with any appropriate standard.” Some states may have their<br />
own rules and regulations for press brakes.<br />
ANSI STANDARDS<br />
There are several references available on press brake safety; however,<br />
most <strong>in</strong>dustries use the ANSI (American National Standards Institute)<br />
B11.3 standard. This standard can be purchased by contact<strong>in</strong>g:<br />
ANSI<br />
American National Standards Institute, Inc.<br />
25 West 43rd Street, 4th Floor<br />
New York, New York 10036<br />
(212) 642-4900<br />
www.ansi.org<br />
TYPES OF PRESS BRAKES<br />
There are two basic categories of press brakes:<br />
1. Part-Revolution<br />
Mechanical-Friction Clutch<br />
Air Clutch (S<strong>in</strong>gle- or Two-Speed)<br />
2. Hydraulic (Down-Act<strong>in</strong>g and Up-Act<strong>in</strong>g)<br />
Each <strong>one</strong> of these press brake types is discussed on subsequent pages<br />
<strong>in</strong> this section. There are also servo-drive (electric) and hydra-mechanical<br />
press brakes that can be safeguarded. Please consult the factory.<br />
POINT-OF-OPERATION HAZARD<br />
Fortunately, most press brake operations do not require the operators<br />
to place their hands or any part of their body <strong>in</strong>to the po<strong>in</strong>t-of-operation<br />
hazard; however, exposure to po<strong>in</strong>t-of-operation <strong>in</strong>juries still exists.<br />
Because of this exposure, the operator(s) must be safeguarded from<br />
po<strong>in</strong>t-of-operation hazards. Best safety practice is when operators are<br />
never required to put their hands or any part of their body <strong>in</strong> the po<strong>in</strong>t of<br />
operation at any time. Sometimes as the workpiece bends up, a hazard<br />
may be created between the part and the front face of the slide. When<br />
this happens, be sure the operators do not place their f<strong>in</strong>gers on the<br />
top or sides of the material, but support the material from underneath.<br />
HELPERS<br />
Many times two or more operators are feed<strong>in</strong>g and retriev<strong>in</strong>g workpieces<br />
from press brake dies. The employer may describe <strong>one</strong> person as an<br />
operator and <strong>one</strong> person as a helper; however, a helper is considered<br />
an operator when exposed to any po<strong>in</strong>t-of-operation hazards. Each<br />
operator must be safeguarded and should have his/her own set of<br />
operat<strong>in</strong>g controls for cycl<strong>in</strong>g the mach<strong>in</strong>e such as palm buttons or a<br />
foot switch.<br />
66 | CONTROL SYSTEMS
METHODS FOR CYCLING AND SETUP<br />
SEQUENCE OR HIGH/LOW OPERATION<br />
When there is a concern about whip-up action of material, or position<strong>in</strong>g<br />
of a part, the sequence or high/low speed-change mode of operation<br />
is used. Sequence is accomplished by stopp<strong>in</strong>g the slide on the<br />
downstroke (on down-act<strong>in</strong>g mach<strong>in</strong>es) just above the workpiece, then<br />
complet<strong>in</strong>g the downward part of the stroke <strong>in</strong> a slow, controlled speed.<br />
In the high/low mode, the slide does not stop; when selected, it goes<br />
<strong>in</strong>to a slower speed for bend<strong>in</strong>g the workpiece.<br />
SINGLE STROKE<br />
In the s<strong>in</strong>gle-stroke mode, the mach<strong>in</strong>e slide will descend through the<br />
workpiece and return automatic<strong>all</strong>y to stop at the beg<strong>in</strong>n<strong>in</strong>g of the cycle.<br />
In a high production situation, with certa<strong>in</strong> workpieces, mach<strong>in</strong>es are<br />
usu<strong>all</strong>y s<strong>in</strong>gle-stroked (cycled) rather than operated <strong>in</strong> the sequence or<br />
high/low mode. The controls offered <strong>in</strong> this catalog <strong>all</strong>ow the operator<br />
to <strong>in</strong>ch on the downstroke <strong>in</strong> the s<strong>in</strong>gle-stroke, sequence, and high/low<br />
modes, on both mechanical and hydraulic press brakes.<br />
INCH/SETUP<br />
When the <strong>in</strong>ch mode of operation is provided on press brakes, it must<br />
be used for setup only. Never operate a press brake <strong>in</strong> the <strong>in</strong>ch mode<br />
for production operations.<br />
PRESS BRAKES USING POWER PRESS TOOLING<br />
If mechanical or hydraulic press brakes use press tool<strong>in</strong>g (i.e., conventional<br />
or unitized dies) for stamp<strong>in</strong>g parts, please refer to pages 20-56 for<br />
mechanical press control box and comp<strong>one</strong>nt selection, and pages 83<br />
and 84 for air cyl<strong>in</strong>der selection (mechanical-friction-clutch press brakes<br />
only), or pages 57-65 for hydraulic press control box selection.<br />
SAFEGUARDING<br />
Press brake safeguard<strong>in</strong>g can be accomplished by us<strong>in</strong>g <strong>one</strong> of the<br />
follow<strong>in</strong>g safeguard<strong>in</strong>g devices:<br />
1. Presence-sens<strong>in</strong>g device (Refer to <strong>Catalog</strong> MSD)<br />
2. Two-hand control device (Refer to this catalog)<br />
3. Pullback device (Not offered by <strong>Rockford</strong> <strong>Systems</strong>)<br />
4. Restra<strong>in</strong>t device (Refer to <strong>Catalog</strong> MSD)<br />
5. Hostage control device (pp. 69-70)<br />
PRESENCE-SENSING DEVICES<br />
Of <strong>all</strong> the recognized po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g devices for press<br />
brakes, the light curta<strong>in</strong> is the most versatile for short- to long-run<br />
operations and for sm<strong>all</strong> to large workpieces. Proper use of this device<br />
provides protection for <strong>all</strong> operators and passersby <strong>in</strong> production modes<br />
of operation. It also m<strong>in</strong>imizes operator resistance to us<strong>in</strong>g safety devices.<br />
A mut<strong>in</strong>g feature, most commonly used with press brakes, <strong>all</strong>ows the<br />
light curta<strong>in</strong> to be bypassed dur<strong>in</strong>g the nonhazardous portion of a press<br />
brake stroke. This is gener<strong>all</strong>y from ¼” or less above the workpiece to<br />
the bottom of the stroke and back to the top of the stroke. Blank<strong>in</strong>g of<br />
beams or the use of float blank<strong>in</strong>g are also popular options for press<br />
brake applications; however, these options must be closely supervised<br />
and discouraged whenever possible.<br />
When apply<strong>in</strong>g light curta<strong>in</strong>s, they must be mounted at a safe<br />
distance—refer to <strong>Catalog</strong> MSD.<br />
BASIC SAFETY REQUIREMENTS<br />
When updat<strong>in</strong>g press brakes to comply with the <strong>in</strong>dicated safety<br />
standards, there are five basic requirements that must always be<br />
considered. They are:<br />
1. <strong>Safeguard<strong>in</strong>g</strong> (Refer to <strong>Catalog</strong> MSD)<br />
2. Controls<br />
3. Disconnects (Refer to <strong>Catalog</strong> SFM)<br />
4. Starters (Refer to <strong>Catalog</strong> SFM)<br />
5. Covers (Refer to www.rockfordsystems.com for mechanical<br />
motion covers)<br />
This <strong>in</strong>troduction and subsequent pages <strong>in</strong> this catalog will provide<br />
<strong>in</strong>formation on safety requirements <strong>in</strong> these areas.<br />
Light Curta<strong>in</strong><br />
(Cont<strong>in</strong>ued on next page.)<br />
CONTROL SYSTEMS | 67
PRESENCE-SENSING DEVICES (CONTINUED)<br />
HOW A LIGHT CURTAIN WORKS AS A<br />
SAFEGUARDING DEVICE ON PRESS BRAKES:<br />
STEP 1 The operator <strong>in</strong>serts the workpiece <strong>in</strong>to the press brake die and<br />
supports it either with his/her hands, on rails, or on a table.<br />
STEP 2 The press brake is activated by a foot switch or palm buttons.<br />
STEP 3 If the light curta<strong>in</strong> is <strong>in</strong>terrupted dur<strong>in</strong>g the die-clos<strong>in</strong>g portion<br />
of the cycle, the press brake slide will stop.<br />
STEP 4 If the light curta<strong>in</strong> is not <strong>in</strong>terrupted, the press brake will<br />
cont<strong>in</strong>ue its downstroke and will either: 1) make contact with<br />
the workpiece and f<strong>in</strong>ish the s<strong>in</strong>gle stroke <strong>in</strong> normal speed (or<br />
<strong>in</strong> high/low speed if chosen), or 2) stop above the workpiece<br />
if <strong>in</strong> sequence mode. In the sequence mode, the workpiece<br />
may be <strong>in</strong>serted or positi<strong>one</strong>d at this time and then the slide<br />
is reactivated to f<strong>in</strong>ish the stroke.<br />
Note: The light curta<strong>in</strong> is muted once the die is a maximum of<br />
¼” above the workpiece.<br />
When the light curta<strong>in</strong> is muted, it is automatic<strong>all</strong>y turned<br />
off or bypassed dur<strong>in</strong>g the bend<strong>in</strong>g operation to permit the<br />
workpiece or operator’s hand to move through the plane of<br />
light without <strong>in</strong>terrupt<strong>in</strong>g the cycle.<br />
STEP 5 The slide returns to the beg<strong>in</strong>n<strong>in</strong>g of the cycle.<br />
LIGHT<br />
CURTAIN<br />
TOP<br />
OF<br />
STROKE<br />
BOTTOM<br />
OF<br />
STROKE<br />
SLIDE<br />
BED<br />
DIE<br />
1/4" MUTE<br />
POINT<br />
BACKGAUGE<br />
This illustration is of a down-act<strong>in</strong>g press brake bend<strong>in</strong>g a<br />
workpiece with a light curta<strong>in</strong> used as the safeguard.<br />
Two-hand control provides protection aga<strong>in</strong>st po<strong>in</strong>t-of-operation <strong>in</strong>jury<br />
dur<strong>in</strong>g the die-clos<strong>in</strong>g portion of the cycle. Two-hand control is arranged<br />
so the operator(s) must hold the palm buttons depressed until the<br />
slide reaches a po<strong>in</strong>t ¼” or less above the workpiece. If either palm<br />
button is released, the slide stops. Both palm but-tons must then be<br />
released and reactuated to f<strong>in</strong>ish the stroke. Two-hand control is usu<strong>all</strong>y<br />
arranged to provide this protection <strong>in</strong> the two-hand s<strong>in</strong>gle-stroke,<br />
sequence, or high/low mode of operation. See <strong>in</strong>formation below and<br />
on the next page for additional details on how two-hand control and<br />
sequence mode of operation work.<br />
How Two-Hand Control Works:<br />
STEP 1 By depress<strong>in</strong>g the two run buttons, the operator(s) <strong>in</strong>itiate the<br />
press brake cycle.<br />
STEP 2 The operator(s) must hold the two run buttons until the slide<br />
completes its downward travel to the workpiece or until the<br />
slide stops ¼” or less above the workpiece. If the operator(s)<br />
remove <strong>one</strong> hand from the run buttons, the slide will stop. In<br />
the s<strong>in</strong>gle-stroke or high/low mode, the slide will make <strong>one</strong><br />
complete cycle.<br />
STEP 3 In the sequence mode, the slide will automatic<strong>all</strong>y stop<br />
at a preset position ¼” or less above the workpiece. This<br />
preset position is adjustable for different feed-l<strong>in</strong>e heights or<br />
material thicknesses.<br />
STEP 4 If the workpiece is not already placed <strong>in</strong> the die, it may be<br />
<strong>in</strong>serted at this time.<br />
STEP 5 The palm buttons or the foot switch is now reactuated, caus<strong>in</strong>g<br />
the slide to cont<strong>in</strong>ue through the bottom of the cycle and<br />
automatic<strong>all</strong>y return at high speed to the beg<strong>in</strong>n<strong>in</strong>g of the cycle.<br />
Note: The controls illustrated provide the ability to <strong>in</strong>ch the slide down<br />
with the palm buttons or foot switch <strong>in</strong> the s<strong>in</strong>gle, sequence, or high/<br />
low mode of operation. By <strong>in</strong>ch<strong>in</strong>g the slide down <strong>in</strong> these modes, the<br />
operator makes sure the upper die is go<strong>in</strong>g to bend the workpiece <strong>in</strong><br />
the correct position. This also avoids hazardous whip-up action of the<br />
workpiece when <strong>in</strong>ch<strong>in</strong>g through the workpiece bend.<br />
TWO-HAND<br />
CONTROL<br />
(TWO BUTTONS)<br />
TWO-HAND CONTROL DEVICES<br />
Two-hand control, as a po<strong>in</strong>t-of-operation safe-guard<strong>in</strong>g device for<br />
press brakes, is ideal for short-run job-shop operations. Workpieces can<br />
be from very sm<strong>all</strong> to very large.<br />
Each operator station is arranged with two guarded run palm button<br />
assemblies. These buttons are usu<strong>all</strong>y mounted to the slide of the press<br />
brake; however, they can also be <strong>in</strong>st<strong>all</strong>ed on a floor stand (see page<br />
51) for more flexibility.<br />
TOP<br />
OF<br />
STROKE<br />
BOTTOM<br />
OF<br />
STROKE<br />
SLIDE<br />
BED<br />
DIE<br />
1/4" SEQUENCE<br />
STOP OR LOW-<br />
SPEED POINT<br />
BACKGAUGE<br />
This illustration is of a down-act<strong>in</strong>g press brake bend<strong>in</strong>g a workpiece<br />
with two-hand control used as the safeguard.<br />
68 | CONTROL SYSTEMS
TWO-HAND CONTROL DEVICES (CONTINUED)<br />
The control packages offered <strong>in</strong>clude control reliability to m<strong>in</strong>imize<br />
the possibility of an un<strong>in</strong>tended stroke of the slide if there is a<br />
s<strong>in</strong>gle comp<strong>one</strong>nt failure <strong>in</strong> the control system. The control features<br />
antirepeat, preset tim<strong>in</strong>g of concurrent operation of palm buttons, and<br />
nonresumption of <strong>in</strong>terrupted stroke. The palm buttons must also be<br />
mounted at the proper safety distance.<br />
When more than <strong>one</strong> operator station is required on press brakes, two<br />
palm buttons for each station must be used and must be capable of<br />
be<strong>in</strong>g supervised. The supervised operator stations are arranged so that<br />
if <strong>all</strong> operat<strong>in</strong>g stations are bypassed, the press brake will not cycle. If a<br />
foot switch is used, <strong>one</strong> is required for each operator.<br />
When us<strong>in</strong>g two-hand control, the operator cannot hold onto the<br />
workpiece dur<strong>in</strong>g the die-clos<strong>in</strong>g portion of the stroke. Material<br />
tables, rails, magnets on backgauges, etc., can be used to support<br />
the workpiece.<br />
If the dies are not the exact length of the material, auxiliary safeguard<strong>in</strong>g<br />
is required.<br />
Two-Hand<br />
Control<br />
Pullbacks<br />
RESTRAINT DEVICE<br />
Similar to the overhead pullback, restra<strong>in</strong>ts are usu<strong>all</strong>y applied on press<br />
brakes that perform long-run jobs. The parts be<strong>in</strong>g produced are usu<strong>all</strong>y<br />
medium size with the operator hold<strong>in</strong>g onto the workpiece. If sm<strong>all</strong> parts<br />
are be<strong>in</strong>g fed <strong>in</strong>to the die, a hand-feed<strong>in</strong>g tool must be used.<br />
Restra<strong>in</strong>ts are adjusted so that an operator cannot reach <strong>in</strong>to the<br />
hazardous area at any time.<br />
Both pullbacks and restra<strong>in</strong>ts must be properly worn, adjusted, and<br />
ma<strong>in</strong>ta<strong>in</strong>ed at <strong>all</strong> times.<br />
PULLBACK DEVICE (NOT OFFERED BY ROCKFORD SYSTEMS)<br />
The overhead-pullback device is usu<strong>all</strong>y applied on press brakes<br />
that perform long-run jobs and when sm<strong>all</strong>- to medium-size parts<br />
are be<strong>in</strong>g produced.<br />
The pullback is a mechanical device operated from the l<strong>in</strong>ear<br />
motion of the slide or upper die. When adjusted properly, it pulls<br />
the operator’s hands back should they <strong>in</strong>advertently be put <strong>in</strong>to the<br />
po<strong>in</strong>t-of-operation hazard.<br />
The overhead design <strong>all</strong>ows the operator freedom of movement for<br />
load<strong>in</strong>g and unload<strong>in</strong>g workpieces without <strong>in</strong>terference.<br />
Pullbacks are designed for a fixed-length-stroke mechanical press<br />
brake; therefore, when apply<strong>in</strong>g them to a hydraulic press brake that<br />
may have an adjustable stroke, the stroke length will need to rema<strong>in</strong> the<br />
same at <strong>all</strong> times.<br />
Restra<strong>in</strong>ts With<br />
Two Operators<br />
HOSTAGE DEVICE<br />
Hostage control devices are used on mach<strong>in</strong>es that perform short-run<br />
jobs with very large workpieces. The actuat<strong>in</strong>g means (hand or foot)<br />
must be protected aga<strong>in</strong>st un<strong>in</strong>tended operation and arranged so the<br />
operator(s) can never reach the po<strong>in</strong>t-of-operation hazard while the<br />
mach<strong>in</strong>e is <strong>in</strong> operation.<br />
CONTROL SYSTEMS | 69
HOSTAGE DEVICE (CONTINUED)<br />
An example of a hostage control is a foot switch which is permanently<br />
mounted to the floor far enough away from the po<strong>in</strong>t of operation<br />
that the operator(s) cannot reach the po<strong>in</strong>t-of-operation hazard when<br />
operat<strong>in</strong>g the control. Two-hand control or <strong>one</strong>-hand control can be<br />
applied as well.<br />
SAFE DISTANCE SAFEGUARDING<br />
Safe distance safeguard<strong>in</strong>g is <strong>all</strong>owable by OSHA and ANSI under<br />
certa<strong>in</strong> controlled situations. Please see ANSI B11.3 for compliance<br />
guidel<strong>in</strong>es. If safe distance is chosen as the primary safeguard, the<br />
control system for both mechanical and hydraulic press brakes must<br />
be control reliable. For assistance <strong>in</strong> determ<strong>in</strong><strong>in</strong>g your control system’s<br />
reliability, please contact <strong>Rockford</strong> <strong>Systems</strong>.<br />
AUXILIARY SAFEGUARDING<br />
Auxiliary safeguard<strong>in</strong>g is used for additional protection from <strong>in</strong>juries for<br />
<strong>all</strong> personnel <strong>in</strong> the mach<strong>in</strong>e area. It is used <strong>in</strong> conjunction with primary<br />
safeguard<strong>in</strong>g devices. Auxiliary safeguard<strong>in</strong>g also <strong>in</strong>volves the guard<strong>in</strong>g<br />
of other comp<strong>one</strong>nts or hazardous open<strong>in</strong>gs on mach<strong>in</strong>es.<br />
Auxiliary safeguards <strong>in</strong>clude such items as po<strong>in</strong>t-of-operation side<br />
barriers when light curta<strong>in</strong>s are used, pressure-sensitive floor mats,<br />
workpiece tables, or horizontal light curta<strong>in</strong>s. An additional set of<br />
light curta<strong>in</strong>s can be used horizont<strong>all</strong>y to prevent an operator or other<br />
persons from stand<strong>in</strong>g between the vertical plane of light and the po<strong>in</strong>tof-operation<br />
hazard. To prevent unauthorized entry on the back side<br />
of the press brake, an <strong>in</strong>terlocked cable and danger sign can be used<br />
(refer to <strong>Catalog</strong> SS).<br />
Danger signs, used for warn<strong>in</strong>g, can be mounted on the press brake<br />
slide <strong>in</strong> a position that is readily visible to the operator, setup person,<br />
or other personnel. Hand tools are another auxiliary safeguard often<br />
used when feed<strong>in</strong>g and retriev<strong>in</strong>g sm<strong>all</strong> workpieces. Hand tools by<br />
themselves are not a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g device.<br />
CONTROLS<br />
Press brake controls are furnished accord<strong>in</strong>g to the type of press brake:<br />
mechanical friction, air clutch, hydraulic, hydra-mechanical, or electric.<br />
The controls and system of the safety-related functions must be control<br />
reliable. Please see page 111 for further explanation.<br />
This is usu<strong>all</strong>y d<strong>one</strong> by the user, either by modify<strong>in</strong>g exist<strong>in</strong>g guards,<br />
by contact<strong>in</strong>g a local sheet-metal fabricator, or refer to our Web site at<br />
www.rockfordsystems.com for mechanical motion covers.<br />
OTHER SAFETY CONSIDERATIONS<br />
Other areas of press brake safety must be considered <strong>in</strong> order to comply<br />
with the OSHA and ANSI standards. This <strong>in</strong>cludes, but is not limited to,<br />
the po<strong>in</strong>t-of-operation hazard exposure, when the workpiece length<br />
is less than the die length. This is a questionable area when us<strong>in</strong>g a<br />
light curta<strong>in</strong> or two-hand control (to the 1⁄4” or less po<strong>in</strong>t above the<br />
workpiece) as the po<strong>in</strong>t-of operation safeguard. In some cases, there<br />
is an open<strong>in</strong>g <strong>in</strong> the die that is larger than 1⁄4” on both sides of the<br />
workpiece. Common practice is to either cut or arrange <strong>all</strong> dies to be<br />
the length of the workpiece or provide barriers on the front of the press<br />
brake <strong>all</strong>ow<strong>in</strong>g just enough open<strong>in</strong>g for the workpiece.<br />
Another safety consideration is the proper use of front and back<br />
material-position gauges. It is important that this gaug<strong>in</strong>g is designed<br />
correctly so the workpiece and hand will not <strong>in</strong>advertently slip <strong>in</strong>to<br />
the hazard area. Special care must be taken with sm<strong>all</strong> or narrow<br />
workpieces. For example, if the backgauge is not t<strong>all</strong> enough, the<br />
workpiece could slide over it <strong>all</strong>ow<strong>in</strong>g the f<strong>in</strong>gers and hands to be<br />
exposed to the po<strong>in</strong>t-of-operation hazard.<br />
When blank<strong>in</strong>g the light beam channels of a light curta<strong>in</strong>, difficulties<br />
may arise with the angle at which the workpiece is held from operator<br />
to operator. Lay<strong>in</strong>g the workpieces on a table or rails, or us<strong>in</strong>g magnets<br />
to hold workpieces made of ferrous material <strong>in</strong> position are two ways to<br />
elim<strong>in</strong>ate some of the hurdles <strong>in</strong> safeguard<strong>in</strong>g a press brake.<br />
When hold<strong>in</strong>g onto the workpiece, good safety practice is to have the<br />
operator’s thumbs and f<strong>in</strong>gers positi<strong>one</strong>d alongside or underneath the<br />
workpiece—never on top.<br />
As with <strong>all</strong> mach<strong>in</strong>ery, the best safety practice is to have a cont<strong>in</strong>u<strong>in</strong>g<br />
safety program. The operator and <strong>all</strong> personnel connected with<br />
mach<strong>in</strong>ery must be safeguarded. The operator and die setter must<br />
be fully tra<strong>in</strong>ed and <strong>in</strong>structed on <strong>all</strong> safety procedures and have<br />
full knowledge of the safeguard<strong>in</strong>g device be<strong>in</strong>g used. The setup<br />
and ma<strong>in</strong>tenance personnel must also be tra<strong>in</strong>ed on the proper safe<br />
operation of press brakes.<br />
ELECTRICAL LOCKOUT/TAGOUT REQUIREMENTS<br />
A press brake requires a ma<strong>in</strong> power disconnect switch, and a magnetictype<br />
motor starter for the ma<strong>in</strong> drive motor and the slide-adjust motor.<br />
A lockout valve is required to lock out the air power to the press brake.<br />
COVERS<br />
Mechanical power-transmission apparatuses of the press brake such<br />
as rotat<strong>in</strong>g flywheels, gears, sprockets, cha<strong>in</strong>s, and shafts must be<br />
covered <strong>in</strong> accordance with OSHA 1910.219, Mechanical Power-<br />
Transmission Apparatus and ANSI B15.1. All apparatuses that create a<br />
hazard up to 7’ above the floor or platform must be guarded (covered).<br />
70 | CONTROL SYSTEMS
PRESS BRAKE CONTROL SYSTEMS<br />
A press brake clutch/brake or hydraulic control system consists of:<br />
1. A control box or light curta<strong>in</strong> <strong>in</strong>terface<br />
2a. Individual comp<strong>one</strong>nts<br />
2b. Comp<strong>one</strong>nt packages<br />
OR<br />
We offer a variety of control boxes that can be furnished to meet your<br />
specific requirements. Solid-state control boxes are available as:<br />
1. Standard clutch/brake or hydraulic control<br />
2. Custom control which <strong>in</strong>cludes a fused disconnect switch and<br />
magnetic motor starter<br />
3. Special control<br />
SELECTING A CONTROL SYSTEM<br />
1. To order a complete control system, determ<strong>in</strong>e which style control<br />
box is required.<br />
A standard control box, with operators on the door, <strong>in</strong>cludes the<br />
clutch/brake or hydraulic control only. It can also be furnished<br />
<strong>in</strong> a pla<strong>in</strong>-door enclosure or as a subpanel. Both pla<strong>in</strong>-door or<br />
subpanel options require a remote operator station. Subpanels<br />
are furnished without the enclosure and must be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong>to an<br />
exist<strong>in</strong>g enclosure.<br />
A custom control box <strong>in</strong>cludes a ma<strong>in</strong> power disconnect switch and<br />
magnetic motor starter <strong>in</strong> the same enclosure as the clutch/brake<br />
or hydraulic control. A revers<strong>in</strong>g slide-adjust motor starter may also<br />
be <strong>in</strong>cluded.<br />
Special clutch/brake or hydraulic control boxes can <strong>in</strong>clude either a<br />
standard or custom control that requires modification for any special<br />
requirements. This can be an <strong>in</strong>terface of auxiliary equipment, a light<br />
curta<strong>in</strong> <strong>in</strong>terface for a non-<strong>Rockford</strong> light curta<strong>in</strong>, or comp<strong>one</strong>nts<br />
specified by the end user, such as NEMA starters and disconnects.<br />
2. After determ<strong>in</strong><strong>in</strong>g the style of control box, determ<strong>in</strong>e the<br />
location of the operator controls, and the keypad/display. Please<br />
remember these should be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a convenient location for<br />
the operator. These operator controls and keypad/display can be<br />
supplied as follows:<br />
1. On the front of the enclosure<br />
2. In a remote operator station<br />
3. In a control bar<br />
4. In a console<br />
5. Loose for <strong>in</strong>st<strong>all</strong>ation <strong>in</strong> an exist<strong>in</strong>g box<br />
Pla<strong>in</strong>-Door Control<br />
(Use With Remote Operator Station)<br />
Remote Operator Station<br />
(Use With Pla<strong>in</strong>-Door, Custom, or<br />
Special Control)<br />
Custom or Special Control<br />
With Remote Operator Station<br />
CONTROL SYSTEMS | 71
SSC-1500 STANDARD PRESS BRAKE CONTROL<br />
Pla<strong>in</strong><br />
Door<br />
Control<br />
Box<br />
Remote<br />
Operator<br />
Station<br />
SSC-1500 Press Brake Control System Inst<strong>all</strong>ed<br />
on a Mechanical-Friction-Clutch Press Brake<br />
The SSC-1500 solid-state control system is designed for use on press<br />
brakes. It is designed and built to comply with OSHA, ANSI B11.3 and<br />
B11.19 standards with control reliability (see page 111) and brake<br />
monitor<strong>in</strong>g. It can be used on both mechanical-friction and s<strong>in</strong>glespeed,<br />
air-clutch press brakes.<br />
The SSC-1500 solid-state control system is designed for use on press<br />
brakes. It is designed and built to comply with OSHA, ANSI B11.3 and<br />
B11.19 standards with control reliability (see page 111) and brake<br />
monitor<strong>in</strong>g. It can be used on both mechanical-friction and s<strong>in</strong>glespeed,<br />
air-clutch press brakes.<br />
When this control system is furnished for mechanical-friction-clutch<br />
press brakes, it is designed to replace the mechanical foot pedal/treadle<br />
operation. A foot switch and palm buttons replace the foot pedal/treadle<br />
to actuate the press brake. It is also designed for use on s<strong>in</strong>gle-speed<br />
and two-speed air-clutch press brakes.<br />
This control box <strong>in</strong>cludes sequence stop and a light curta<strong>in</strong> <strong>in</strong>terface.<br />
Two-hand control or light curta<strong>in</strong>s can be used as the po<strong>in</strong>t-of-operation<br />
safeguard. Please see pages 67-70 for further details on safeguard<strong>in</strong>g.<br />
The control, <strong>in</strong> sequence operation, <strong>all</strong>ows the operator to run<br />
the slide down at high speed, stopp<strong>in</strong>g just above the workpiece.<br />
When the workpiece is properly positi<strong>one</strong>d <strong>in</strong> the die, the clutch is<br />
engaged and the brake is released, <strong>all</strong>ow<strong>in</strong>g the slide to f<strong>in</strong>ish the<br />
cycle or <strong>in</strong>ch through the bottom of the stroke. This slow-speed<br />
action, by <strong>in</strong>ch<strong>in</strong>g through the bottom of the stroke, avoids the fast<br />
whip-up action of the workpiece. After go<strong>in</strong>g through the bottom<br />
of the stroke, the slide returns norm<strong>all</strong>y to the top of the stroke. If<br />
necessary, the slide can also be <strong>in</strong>ched down by the foot switch <strong>in</strong> the<br />
s<strong>in</strong>gle-stroke mode. Air cyl<strong>in</strong>ders for engag<strong>in</strong>g and<br />
disengag<strong>in</strong>g the clutch and brake on mechanical-friction clutches are<br />
detailed on pages 83-84.<br />
On s<strong>in</strong>gle-speed air-clutch/brake press brakes, the control will either<br />
<strong>all</strong>ow the slide to make a s<strong>in</strong>gle stroke or a sequence stop stroke.<br />
On two-speed air-clutch mach<strong>in</strong>es, the control <strong>all</strong>ows s<strong>in</strong>gle stroke,<br />
sequence stop stroke, and high/low automatic speed change.<br />
In many applications, a light curta<strong>in</strong> is used as the safeguard. If this<br />
is the case, it is usu<strong>all</strong>y mounted vertic<strong>all</strong>y <strong>in</strong> front of the po<strong>in</strong>t-ofoperation<br />
hazard. The control <strong>all</strong>ows the light curta<strong>in</strong> to be muted from<br />
1⁄4” or less above the workpiece, through the balance of the stroke.<br />
72 | CONTROL SYSTEMS
SSC-1500 STANDARD PRESS BRAKE CONTROL (CONTINUED)<br />
MODES OF OPERATION<br />
• Off<br />
• Two-hand <strong>in</strong>ch (regular, timed, or top-stop)<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Foot s<strong>in</strong>gle stroke<br />
• Sequence stop (hand/hand, hand/foot, foot/foot)<br />
• High/low automatic speed change (for two-speed only)<br />
FEATURES<br />
• Meets and exceeds OSHA 1910.212, ANSI<br />
B11.3 and B11.19<br />
• Provides two-hand control safeguard<strong>in</strong>g device<br />
• Redundant/cross-check<strong>in</strong>g microprocessors<br />
• Redundant microprocessor logic power supplies<br />
• Redundant solenoid relays<br />
• 4-l<strong>in</strong>e x 20-character LCD (liquid crystal display) with 20-key<br />
operator <strong>in</strong>terface<br />
• Wide range of <strong>in</strong>put power supply—85- to 135-V AC<br />
• Absolute resolver with sync sensor for tim<strong>in</strong>g and motion detection<br />
• Time-based brake monitor with programmable warn<strong>in</strong>g and fault<br />
set po<strong>in</strong>ts<br />
• Stop-time measurement test<br />
• Adjustable sequence stop angle<br />
• 6 user-programmable 24-V DC static diagnostic <strong>in</strong>puts<br />
• 2 user-programmable 24-V DC cyclic die<br />
protection <strong>in</strong>puts<br />
• 7-digit stroke and batch counters with preset, and a 7-digit<br />
total counter<br />
• Light curta<strong>in</strong> <strong>in</strong>terface(s) with off/on selector<br />
• Light curta<strong>in</strong> mute dur<strong>in</strong>g the nonhazardous portion of the stroke<br />
• 4 PLS (programmable limit switch) outputs—2 on/off angles, or<br />
1 timed off, or 1 counted output per PLS (or 3 PLS outputs and 1<br />
auxiliary output with 1 contact)<br />
• For two-speed operations: 3 PLS (programmable limit switch)<br />
outputs—2 on/off angles, or 1 timed off, or 1 counted output per<br />
PLS (or 2 PLS outputs and 1 auxiliary output with 1 contact)<br />
• Information displayed dur<strong>in</strong>g the mach<strong>in</strong>e run cycle: mode of<br />
operation, strokes per m<strong>in</strong>ute, stop time, stroke counter, batch<br />
counter, and angle of crankshaft<br />
• Display of text <strong>in</strong> English or Spanish<br />
The standard SSC-1500 press brake control is housed <strong>in</strong> a 20” x<br />
20” x 8” NEMA 12 enclosure with the operators and keypad/display<br />
mounted on the front of the enclosure.<br />
KEYPAD/DISPLAY<br />
The keypad/display is used to enter setup <strong>in</strong>formation, monitor mach<strong>in</strong>e<br />
operation, and display messages to the user. The keypad/display has a<br />
4-l<strong>in</strong>e x 20-character LCD (liquid crystal display) with 20 keys for<br />
enter<strong>in</strong>g <strong>in</strong>formation and programm<strong>in</strong>g. As standard, this keypad/<br />
display is mounted <strong>in</strong> the control box. For operator convenience, it can<br />
be furnished <strong>in</strong> a remote enclosure up to a maximum of 150’ from the<br />
SSC-1500 control module (see page 77).<br />
PROGRAMMABLE SETTINGS AT THE KEYPAD<br />
The sequence-stop angle sett<strong>in</strong>g programs the stopp<strong>in</strong>g position on the<br />
downstroke for the sequence mode of operation—no manual sett<strong>in</strong>g<br />
of cams.<br />
On two-speed press brakes, a low s<strong>in</strong>gle-stroke top-stop angle<br />
can be programmed. The high/low automatic speed change is also<br />
programmable at the keypad.<br />
DIAGNOSTICS AND FAULT MESSAGES<br />
There are eight 24-V DC selectable current-s<strong>in</strong>k<strong>in</strong>g or sourc<strong>in</strong>g<br />
programmable diagnostic <strong>in</strong>puts provided for the user. A fault message,<br />
<strong>in</strong>put logic, and stop type can be assigned to each <strong>in</strong>put from the list<br />
below. When a fault condition is detected, the mach<strong>in</strong>e will top stop<br />
or emergency stop, and the assigned message will be displayed. This<br />
feature helps when troubleshoot<strong>in</strong>g common fault conditions.<br />
FAULT MESSAGE LIST:<br />
Clutch/Brake Air Fault<br />
Counterbalance Air Fault<br />
Dual Solenoid Fault<br />
Clutch Valve Fault*<br />
Brake Valve Fault*<br />
Lube Fault<br />
High Lube Pressure<br />
Low Lube Pressure<br />
Low Lube Level<br />
Ma<strong>in</strong> Motor Overload<br />
Ram-Adjust Motor<br />
Lube Motor Overload<br />
Auxiliary Motor Overload<br />
Guard Interlock Open<br />
Front Guard Open<br />
Rear Guard Open<br />
Overload<br />
LeftSide Guard Open<br />
Right Side Guard Open<br />
Feeder Fault<br />
Load Monitor Fault<br />
Safety Block Interlock<br />
Shut Height Fault<br />
Variable Speed Drive Fault<br />
Die Protection Fault**<br />
Short Feed Fault**<br />
Part Ejection Fault**<br />
Stock Buckle Fault**<br />
End of Stock Fault**<br />
Pilot P<strong>in</strong> Fault**<br />
Part Input #1**<br />
Part Input #2**<br />
Part Input #3**<br />
*Only used on mach<strong>in</strong>es that have a split clutch and brake, and two dual<br />
valves have been furnished.<br />
**Messages typic<strong>all</strong>y used for die protection.<br />
CONTROL SYSTEMS | 73
SSC-1500 CUSTOM PRESS BRAKE CONTROL<br />
Fused<br />
Disconnect<br />
Switch<br />
Keypad/Display<br />
With Selector<br />
Switches<br />
SSC-1500 Custom Press Brake Control Box (Operators Located on Door Front)<br />
Custom SSC-1500 press brake control boxes are also available to fit your particular requirements. These boxes are furnished with an IEC throughthe-door<br />
ma<strong>in</strong> power fused disconnect switch and an IEC magnetic motor starter (with push buttons). A revers<strong>in</strong>g slide-adjust motor starter may<br />
also be <strong>in</strong>cluded. They are prewired and built <strong>in</strong>to a NEMA 12 enclosure.<br />
Operator controls can be furnished on the front (F) door of the control box or on a pla<strong>in</strong> (P) door with no operators except a disconnect switch. The<br />
SSC-1500 custom press brake control box can be furnished <strong>in</strong> many different ways. Please refer to page 78 for the part number<strong>in</strong>g system.<br />
If a pla<strong>in</strong> door custom control or a subpanel custom control is required, a remote operator station is needed. See order<strong>in</strong>g <strong>in</strong>formation on page 77.<br />
NEMA-style disconnect switches and motor starters, and brand name comp<strong>one</strong>nts specified by our customers are also available.<br />
To ensure the starter(s) and disconnect are sized properly, please check horsepower for the ma<strong>in</strong> drive motor and slide adjust motor (if furnished) on<br />
the press brake, as well as full-load amps, and primary voltage to the press brake. After obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, please go to the chart on page<br />
78 to determ<strong>in</strong>e the proper custom control box part number. Follow directions 1-6 to obta<strong>in</strong> the correct part number of the control box.<br />
Example of the part number<strong>in</strong>g system: The press brake requires a C4000 advanced light curta<strong>in</strong> <strong>in</strong>terface, a 60-A disconnect switch, a revers<strong>in</strong>g<br />
25-A revers<strong>in</strong>g ma<strong>in</strong> motor starter, and a 12-A revers<strong>in</strong>g ram adjust motor starter. All operators will be located on the door of the enclosure except<br />
the ram adjust motor control which will be located remote. The part number to order would be PRS-263-FC6.<br />
74 | CONTROL SYSTEMS
SSC-1500 REMOTE OPERATOR-STYLE CONTROL BOXES FOR PRESS BRAKES<br />
These remote operator-style clutch/brake control boxes <strong>in</strong>clude the<br />
same features and modes of operation as the standard SSC-1500<br />
control boxes described on pages 72-73. However, they do not have<br />
a control transformer. These control boxes are designed to be located<br />
on the front of the mach<strong>in</strong>e near the operator.<br />
These controls are for applications where the mach<strong>in</strong>e’s exist<strong>in</strong>g<br />
magnetic motor starter, fused disconnect switch, and control transformer<br />
meet the safety requirements and can be reused. If the exist<strong>in</strong>g control<br />
transformer cannot be reused or a new control transformer is required,<br />
please contact the factory.<br />
The three remote operator-style control boxes available have the<br />
keypad/display and <strong>all</strong> operators on the door of the 20” x 20” x 8” NEMA<br />
12 enclosure. Please see the next page for the three styles available.<br />
Style Z Remote Operator Control Box<br />
Clutch/Brake Control and Operators In One Box<br />
Back of Keypad/<br />
Display<br />
Master Control<br />
Relay<br />
Term<strong>in</strong>als<br />
SSC-1500 Press<br />
Brake Control<br />
Module<br />
Selectors<br />
Interior of Style Z Remote Operator Control Box<br />
CONTROL SYSTEMS | 75
SSC-1500 REMOTE OPERATOR-STYLE CONTROL BOXES FOR PRESS BRAKES (CONTINUED)<br />
Style X Includes:<br />
• Keypad/display<br />
• Program/run/off selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module, master control relay,<br />
and term<strong>in</strong>als<br />
Style Y Includes:<br />
• Keypad/display<br />
• Program/run/off selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module,master control relay,<br />
and term<strong>in</strong>als<br />
• Self-latch<strong>in</strong>g emergency-stop button<br />
Style Z Includes:<br />
• Keypad/display<br />
• Program off/on selector switch<br />
• Mode selector switch<br />
• Actuat<strong>in</strong>g means selector switch<br />
• Light curta<strong>in</strong> off/on selector switch<br />
• Internal clutch/brake control module, master control relay,<br />
and term<strong>in</strong>als<br />
• Self-latch<strong>in</strong>g emergency-stop button<br />
• Two guarded run/<strong>in</strong>ch buttons located on the sides<br />
of the enclosure<br />
76 | CONTROL SYSTEMS
CONTROL MODULE KIT<br />
Part No. PRS-000-KB (for SSC-1500 PRS Controls)<br />
Part No. PRT-000-KB (for SSC-1500 PRT Controls)<br />
A control module kit <strong>all</strong>ows the end user to update the clutch/brake control of a press brake with m<strong>in</strong>imum equipment costs. The kit is supplied<br />
without the control enclosure, panel, control transformer, control fuse, term<strong>in</strong>al strips, wire duct, and wir<strong>in</strong>g.<br />
This control module kit <strong>in</strong>cludes the control module, master control relay, shock mounts, fasteners, suppressors, danger labels, and electrical pr<strong>in</strong>ts.<br />
A keypad/display kit is required unless a remote operator station is used (see below).<br />
A set of electrical pr<strong>in</strong>ts is supplied to show typical wir<strong>in</strong>g and <strong>all</strong> mount<strong>in</strong>g dimensions are provided <strong>in</strong> order for a qualified person to <strong>in</strong>st<strong>all</strong> the<br />
control module kit. The m<strong>in</strong>imum area required on an exist<strong>in</strong>g control panel to <strong>in</strong>st<strong>all</strong> this kit is 18” H x 18” W x 6” D.<br />
KEYPAD/DISPLAY KIT<br />
Part No. LLD-1519G2 (for SSC-1500 PRS Controls)<br />
Part No. LLD-1545G2 (for SSC-1500 PRT Controls)<br />
The keypad/display kit can be used with any of the control boxes or the control module kit. This kit <strong>in</strong>cludes the keypad/display, a screen label,<br />
a program off/on selector switch, a light curta<strong>in</strong> off/on selector switch, a hand, hand/foot, foot selector switch, an off/<strong>in</strong>ch/s<strong>in</strong>gle/sequence stop<br />
selector switch, and 25’ of cable. Additional push buttons, nameplates, and selector switches for motor starters, etc., can be furnished depend<strong>in</strong>g<br />
on the features required.<br />
A resolver/pulser assembly and cable, Part No. CMS-115, is required with any of the control selections. See page 79 for further details<br />
on this comp<strong>one</strong>nt.<br />
REMOTE OPERATOR STATIONS<br />
For operator convenience, a remote operator station can be furnished for use with a pla<strong>in</strong>-door standard<br />
control box, pla<strong>in</strong>-door custom control box, or control module kit. The remote operator station conta<strong>in</strong>s the<br />
keypad/display, program off/on selector switch, and other selector switches and push buttons as required.<br />
Remote operator stations are available <strong>in</strong> a standard format or can be customized to meet any requirements.<br />
Select from the follow<strong>in</strong>g remote operator stations or contact the factory with your special requirements.<br />
Remote<br />
Operator<br />
Station<br />
Part No.<br />
LLD-1514G2<br />
A<br />
D<br />
D<br />
FEATURES<br />
REMOTE OPERATOR STATIONS FOR PRS CONTROLS<br />
LLD-1514<br />
G2<br />
LLD-1515<br />
G2<br />
LLD-1516<br />
G2<br />
LLD-1517<br />
G2<br />
LLD-1518<br />
G2<br />
If any of the above remote operator stations are required without the enclosure, please consult the factory.<br />
REMOTE OPERATOR STATIONS FOR PRT CONTROLS<br />
LLD-1534<br />
G2<br />
LLD-1535<br />
G2<br />
LLD-1536<br />
G2<br />
LLD-1537<br />
G2<br />
KEYPAD/DISPLAY X X X X X X X X X X<br />
PROGRAM OFF/ON SELECTOR SWITCH X X X X X X X X X X<br />
LIGHT CURTAIN OFF/ON SELECTOR SWITCH X X X X X X X X X X<br />
OFF/INCH/SINGLE/SEQUENCE STOP<br />
SELECTOR SWITCH<br />
HAND, HAND/FOOT, FOOT SELECTOR<br />
SWITCH<br />
X X X X X X X X X X<br />
X X X X X X X X X X<br />
HIGH, HIGH/LOW, LOW SELECTOR SWITCH X X X X X<br />
MAIN MOTOR START AND<br />
STOP PUSH BUTTONS<br />
MAIN MOTOR FORWARD/REVERSE<br />
SELECTOR SWITCH<br />
LLD-1538<br />
G2<br />
X X X X X X X X<br />
X X X X<br />
RAM-ADJUST OFF/ON SELECTOR SWITCH X X X X<br />
RAM RAISE PUSH BUTTON X X X X<br />
RAM LOWER PUSH BUTTON X X X X<br />
LIGHT CURTAIN BLANKING<br />
SELECTOR SWITCHES<br />
(Use part # at right <strong>in</strong> place of part # above)<br />
LLD-1524<br />
G2<br />
LLD-1525<br />
G2<br />
LLD-1526<br />
G2<br />
LLD-1527<br />
G2<br />
LLD-1528<br />
G2<br />
LLD-1539<br />
G2<br />
LLD-1540<br />
G2<br />
LLD-1541<br />
G2<br />
LLD-1542<br />
G2<br />
LLD-1543<br />
G2<br />
CONTROL SYSTEMS | 77
SELECTING AN SSC-1500 PRESS BRAKE CONTROL<br />
To determ<strong>in</strong>e the 8- or 9-digit configured part number for the press brake control required, follow directions 1-6 below and use the <strong>in</strong>formation <strong>in</strong><br />
the PART NUMBERING SYSTEM CHART below.<br />
1. The first 3 digits for <strong>all</strong> SSC-1500 press brake controls are PRS or PRT.<br />
2. The 4th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect<br />
switch provided.<br />
3. The 5th and 6th digits determ<strong>in</strong>e the size and type of motor starter(s), if provided, <strong>in</strong> the control enclosure.<br />
Zeros (00) on both positions <strong>in</strong>dicate no motor starter(s) provided.<br />
4. The 7th digit determ<strong>in</strong>es the location of the operator controls, or if it is a style X, Y, or Z control without the control transformer.<br />
5. The 8th digit is for the type of light curta<strong>in</strong> <strong>in</strong>terface provided.<br />
6. The 9th digit (if required) will <strong>in</strong>dicate the type of modifier provided: i.e., motor control operators remote.<br />
1 2 3 4 5 6<br />
SAMPLE P R S - 2 63 - F C 6<br />
The sample shown, PRS-263-FC6, <strong>in</strong>dicates that the custom part-revolution control box with sequence stop mode of operation will conta<strong>in</strong> a C4000 advanced light<br />
curta<strong>in</strong> <strong>in</strong>terface, an IEC 60-A disconnect switch, an IEC 25-A revers<strong>in</strong>g ma<strong>in</strong> drive motor starter, and an IEC 12-A revers<strong>in</strong>g ram-adjust motor starter. The keypad/<br />
display and <strong>all</strong> operators will be located on the door of the enclosure, except for the ram-adjust motor controls which will be located remote.<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
PRS —SSC-1500 Press Brake Control<br />
PRT —SSC-1500 Press Brake Control for Two-Speed Air-Clutch Press Brakes<br />
DISCONNECT SWITCH SIZE—IEC (PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 —30-A Disconnect— 1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 —60-A Disconnect— 21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 —100-A Disconnect— 41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 —200-A Disconnect— 67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 —400-A Disconnect— 134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
REVERSING/NONREVERSING MAIN MOTOR STARTERS<br />
WITH OR WITHOUT RAM ADJUST<br />
0 —No Motor Starters<br />
1 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter Without Ram Adjust<br />
2 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter Without Ram Adjust<br />
3 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 12-A Ram Adjust<br />
4 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 18-A Ram Adjust<br />
5 —Nonrevers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 25-A Ram Adjust<br />
6 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 12-A Ram Adjust<br />
7 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 18-A Ram Adjust<br />
8 —Revers<strong>in</strong>g Ma<strong>in</strong> Motor Starter With 25-A Ram Adjust<br />
SSC-1500 PRESS BRAKE CONTROL PART NUMBERING SYSTEM CHART<br />
P R X - X X X - X X X<br />
MODIFIER<br />
-- —Blank, No Modifier<br />
5 —Ma<strong>in</strong> Motor Operators Remote*<br />
6 —Ram-Adjust Operators Remote*<br />
7 —Ma<strong>in</strong> Motor and Ram-Adjust Operators Remote*<br />
LIGHT CURTAIN INTERFACE OPTIONS<br />
B —Banner Standard<br />
C —C4000 Advanced With LC Operators on Door<br />
V —C4000 Advanced With LC Operators Remote<br />
W —C4000 Standard<br />
CONFIGURATION & OPERATOR LOCATION<br />
F —Keypad/Display and <strong>all</strong> Operators on Door of Enclosure<br />
P —Keypad/Display and <strong>all</strong> Operators Remote (Pla<strong>in</strong> Door)<br />
S —Subpanel Only—Without Enclosure, Keypad/Display, and Operators<br />
K —Kit with Module and Control Relays Only—Without Enclosure, Subpanel,<br />
Transformer, Keypad/Display, and Operators<br />
C —Console<br />
X —Same as F (above) Without Control Transformer<br />
Y —Same as F (above) Without Control Transformer but with E-Stop<br />
Z —Same as F (above) Without Control Transformer but WithE-Stop and Two<br />
(2) Guarded Run/Inch Buttons on the Enclosure<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 —12 A<br />
2 —18 A<br />
3 —25 A<br />
4 —32 A<br />
5 —40 A<br />
6 —50 A<br />
7 —65 A<br />
8 —80 A<br />
9 —95 A<br />
A —115 A<br />
B —185 A<br />
C —265 A<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
*See page 50 for remote motor control operator stations or <strong>Catalog</strong> SFM.<br />
**Additional light curta<strong>in</strong> <strong>in</strong>terface options are available upon request—<br />
contact <strong>Rockford</strong> <strong>Systems</strong> at 1-800-922-7533.<br />
78 | CONTROL SYSTEMS
SSC-1500 INDIVIDUAL COMPONENTS<br />
RESOLVER/PULSER ASSEMBLY<br />
Part No. CMS-115*—40’ Cable<br />
Part No. CMS-115-100—100’ Cable<br />
An absolute resolver/pulser cycle tim<strong>in</strong>g device is required to provide<br />
the angular position and velocity/motion <strong>in</strong>formation of the mach<strong>in</strong>e<br />
crankshaft to the control. The resolver is a highly accurate and<br />
repeatable device which uses an <strong>in</strong>tern<strong>all</strong>y mounted pulser cam and<br />
disk to verify the position of the crankshaft.<br />
The resolver/pulser tim<strong>in</strong>g device is conta<strong>in</strong>ed <strong>in</strong> a rugged, heavy-duty<br />
hous<strong>in</strong>g with a spr<strong>in</strong>g-compression base. The spr<strong>in</strong>g base helps isolate<br />
the resolver from shock load and vibration that are common occurrences<br />
on press brakes. This provides longer life for the comp<strong>one</strong>nts <strong>in</strong>side the<br />
resolver. The spr<strong>in</strong>g base also functions as a drive cha<strong>in</strong> tightener.<br />
This resolver <strong>all</strong>ows the setup person to make <strong>all</strong> cycle tim<strong>in</strong>g<br />
adjustments with the keypad/display. These adjustments <strong>in</strong>clude<br />
sequence set po<strong>in</strong>t, mute set po<strong>in</strong>t, and high/low speed change.<br />
The 3⁄4” diameter steel drive shaft is mounted <strong>in</strong> sealed b<strong>all</strong> bear<strong>in</strong>gs.<br />
The resolver/pulser is furnished with a 40’ cable (or optional 100’ cable)<br />
that is connected to the drive assembly and wires <strong>in</strong>to the control box.<br />
The cable can be cut to length and wired to term<strong>in</strong>als.<br />
Cable<br />
Resolver/Pulser<br />
Assembly<br />
SPROCKET ASSEMBLY<br />
Part No. CML-000*<br />
A sprocket set consists of two 1:1 sprockets. One fits on the 3⁄4” shaft<br />
of the CMS-115 resolver/pulser assembly; the other sprocket is for<br />
mount<strong>in</strong>g to the end of the press brake crankshaft to rotate the cycle<br />
tim<strong>in</strong>g device. These 48-tooth sprockets are designed to accept ANSI<br />
No. 35 roller cha<strong>in</strong>.<br />
SPECIAL SPROCKETS<br />
Part No. CML-100<br />
If your mach<strong>in</strong>e does not have access to the crankshaft to provide 1:1<br />
ratio drive for the resolver/pulser assembly, special sprocket sets are<br />
available to match the gear drive ratio of the mach<strong>in</strong>e. The sm<strong>all</strong>er<br />
of the two sprockets is attached to the drive of the mach<strong>in</strong>e (usu<strong>all</strong>y<br />
on the backshaft) and the larger sprocket is attached to the resolver/<br />
pulser assembly. Please provide the gear ratio of the press brake when<br />
order<strong>in</strong>g these special sprockets along with the brand name and serial<br />
number of the press brake.<br />
ROLLER CHAIN<br />
Part No. CMS-515*<br />
ANSI No. 35 roller cha<strong>in</strong> and master l<strong>in</strong>k is 10 feet long for driv<strong>in</strong>g any<br />
of the above sprockets.<br />
*Included <strong>in</strong> comp<strong>one</strong>nt package on page 82.<br />
Sprocket Set<br />
Special Sprocket Set<br />
Roller Cha<strong>in</strong><br />
CONTROL SYSTEMS | 79
SSC-1500 INDIVIDUAL COMPONENTS (CONTINUED)<br />
MONITORED DUAL-SOLENOID AIR VALVE<br />
1<br />
⁄2” Port—Part No. RCL-652* for Mechanical-Friction Clutch<br />
This three-way cross flow, series/par<strong>all</strong>el air valve <strong>in</strong>cludes an air pressure electrical output<br />
monitor and muffler. Air is put <strong>in</strong>to the clutch and brake when the dual-solenoid air valve is<br />
electric<strong>all</strong>y energized. When it is de-energized, the air is dumped through the muffler from the<br />
clutch and brake.<br />
This valve consists of two ma<strong>in</strong> parts: the piloted monitor assembly and the valve body assembly.<br />
The two ma<strong>in</strong> valve elements move simultaneously dur<strong>in</strong>g normal operation. If these elements<br />
should fail to move simultaneously, the <strong>in</strong>ternal spool shifts, <strong>in</strong>hibit<strong>in</strong>g further mach<strong>in</strong>e operation.<br />
The pressure switch will provide a signal to the control system to <strong>in</strong>dicate a fault condition. A<br />
reset button on the side of the valve can be used to reset the valve if an accidental valve fault<br />
is detected.<br />
Monitored Dual-Solenoid Air Valve<br />
AVERAGE CV (FLOW RATE)<br />
PART NO. PORTS 1 TO 2 PORTS 2 TO 3<br />
RCL-652 3.0 8.0<br />
1⁄2” FILTER-REGULATOR-LUBRICATOR ASSEMBLY (FRL)<br />
Part No. RCL-044* for Mechanical-Friction Clutch<br />
This assembly is required to meet OSHA and ANSI standards. This FRL assembly filters,<br />
regulates, and lubricates the air go<strong>in</strong>g through it. This filtered and lubricated air then goes to the<br />
dual-solenoid air valve assembly and clutch/brake. The regulator should be adjusted to meet the<br />
orig<strong>in</strong>al equipment manufacturer’s requirements. The assembly <strong>in</strong>cludes a gauge, coupl<strong>in</strong>g, and<br />
a steel mount<strong>in</strong>g bracket.<br />
Filter-Regulator-Lubricator Assembly<br />
AIR PRESSURE SWITCH—Part No. CTD-062*<br />
This air pressure switch monitors low pressure to either the clutch/brake-actuat<strong>in</strong>g air cyl<strong>in</strong>der and<br />
valve or slide counterbalance systems. Each system requires an air pressure switch. The pressure<br />
switch must be set so if the air pressure operat<strong>in</strong>g the comp<strong>one</strong>nt is not adequate, or if the air pressure<br />
suddenly drops, the press brake becomes <strong>in</strong>operable.<br />
This switch is used on applications where the air pressure should not go below a predeterm<strong>in</strong>ed<br />
amount. Each air pressure switch’s low level sett<strong>in</strong>g is based on each application.<br />
Note: When press brakes have an air counterbalance system, an air pressure switch and check<br />
valve are required. See page 34 for a check valve.<br />
Air Pressure Switch<br />
PALM BUTTON ASSEMBLY<br />
To meet OSHA and ANSI safety requirements, the two run/<strong>in</strong>ch buttons must be protected<br />
aga<strong>in</strong>st accidental operation (r<strong>in</strong>g guards) and separated to require the use of both hands to<br />
operate them. They must also be mounted at the proper safety distance, if they will be used as<br />
a safeguard. The contact arrangement of these buttons is 1 NO and 1 NC.<br />
Part No. CTL-507*<br />
This palm button assembly consists of two black run/<strong>in</strong>ch buttons (with r<strong>in</strong>g guards) and a red<br />
emergency-stop button. Mount<strong>in</strong>g boxes are furnished with each button. The red palm button<br />
has 1 NO and 1 NC arrangement plus a mechanical latch.<br />
See pages 99 and 100 for other palm button assembly options. See page 51 for control bars.<br />
Part No. CTL-507<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 82.<br />
80 | CONTROL SYSTEMS
SSC-1500 INDIVIDUAL COMPONENTS (CONTINUED)<br />
FOOT SWITCH—Part No. CTD-011*<br />
This foot switch is protected from un<strong>in</strong>tentional operation. A die-cast cover protects the top and both<br />
sides, and the front is protected by a h<strong>in</strong>ged flap. The flap must be lifted with the toe before the foot<br />
may enter the switch. The electrical contact arrangement is 1 NO and 1 NC.<br />
SUPERVISORY CONTROL STATION<br />
Part No. LLD-1501<br />
Part No. LLD-283* (required when a USC-000 is used–see below)<br />
When multiple operator stations are required, this supervisory control station is furnished separately<br />
for each set of palm buttons and/or foot switch operator station. It has its own enclosure and<br />
<strong>in</strong>cludes an off/on key-operated selector switch and a green on <strong>in</strong>dicator light. The enclosure size<br />
is 3½” x 6¾” x 3”.<br />
Foot Switch<br />
MULTIPLE-OPERATOR JUNCTION BOX—Part No. USC-000*<br />
When multiple operator stations are required, this junction box is furnished separately for wir<strong>in</strong>g up to<br />
four (4) operator stations. This junction box <strong>in</strong>terfaces palm button assemblies/control bars and foot<br />
switches, and will not <strong>all</strong>ow the press brake to run if palm buttons or a foot switch is actuated without<br />
its supervisory control station on. A lighted push button with nameplate <strong>in</strong>dicates a fault condition of<br />
an operator station. The button is pushed to reset. The enclosure size is 16” x 14” x 6”.<br />
Multiple-Operator Junction Box<br />
CRANKSHAFT ANGLE DISPLAY<br />
Part No. FTL-055<br />
The optional crankshaft angle display is a unit that shows the angular position of the crankshaft<br />
for mechanical press brakes. The crankshaft position is shown both graphic<strong>all</strong>y (with red LEDs<br />
<strong>in</strong> a circle) and numeric<strong>all</strong>y (with a large, red, three-digit LED). The large display can be easily<br />
seen which helps with setup, removal of stuck workpieces, or for assistance dur<strong>in</strong>g emergency<br />
extractions procedures.<br />
Crankshaft Angle Display<br />
FEATURES<br />
• Large LED numerical display and circular LED graphic display can be easily seen<br />
• Mounts easily<br />
• Supplied with 25’ of cable for connection to the control<br />
• Helps satisfy the requirements of Canadian Standard CSA Z142-02, Code for Power<br />
Press Operation: Health, Safety, and Guard<strong>in</strong>g Requirements, for <strong>in</strong>dication of crank<br />
angle position<br />
*Included <strong>in</strong> a comp<strong>one</strong>nt package on page 82.<br />
CONTROL SYSTEMS | 81
COMPONENT PACKAGE FOR MECHANICAL-FRICTION-CLUTCH PRESS BRAKES ONLY<br />
To complete the SSC-1500 control system for mechanical-friction-clutch press brakes, comp<strong>one</strong>nt packages are available. If comp<strong>one</strong>nt<br />
packages for air clutch press brakes are required, please see page 86. Comp<strong>one</strong>nt packages are listed <strong>in</strong> the chart below. These packages can<br />
be furnished with:<br />
• A STANDARD Control (pp. 72-73) • A REMOTE OPERATOR-STYLE Control (pp. 75-76)<br />
• A CUSTOM Control (p. 74) • A SPECIAL Control (p. 74)<br />
• A SUBPANEL<br />
To select the proper comp<strong>one</strong>nt package to go with your control box, determ<strong>in</strong>e your requirements below:<br />
A<br />
B<br />
C<br />
Modes of operation and actuat<strong>in</strong>g means required.<br />
Number of operator stations required.<br />
Type of sprockets required.<br />
PRS or PRT Control<br />
Box<br />
A<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Foot S<strong>in</strong>gle<br />
Stroke<br />
• Sequence Stop<br />
A<br />
B<br />
C<br />
MNK-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115<br />
CML-000<br />
CMS-515<br />
RCL-652<br />
RCL-044<br />
CTD-062<br />
CTL-507<br />
CTD-011<br />
Modes of operation: Inch, S<strong>in</strong>gle, and Sequence Stop (Hand or Foot)<br />
ONE OPERATOR STATION<br />
STANDARD SPROCKETS<br />
Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
Sprocket Assembly<br />
10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
1<br />
⁄2” Dual-Solenoid Air Valve<br />
1<br />
⁄2” Filter-Regulator-Lubricator<br />
Assembly<br />
Air Pressure Switch<br />
Palm Button Assembly<br />
Foot Switch<br />
SPECIAL<br />
SPROCKETS<br />
MNK-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
B<br />
STANDARD<br />
SPROCKETS<br />
MNK-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
SPECIAL<br />
SPROCKETS<br />
MNK-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Op-erator<br />
Junction Box<br />
A<br />
Modes of operation: Inch and S<strong>in</strong>gle (Hand Only)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
PRS or PRT Control<br />
Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
B ONE OPERATOR STATION<br />
C STANDARD SPROCKETS<br />
MNF-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprocket Assembly<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-652 1<br />
⁄2” Dual-Solenoid Air Valve<br />
RCL-044 1<br />
⁄2” Filter-Regulator-Lubricator<br />
Assembly<br />
CTD-062 Air Pressure Switch<br />
CTL-507 Palm Button Assembly<br />
SPECIAL<br />
SPROCKETS<br />
MNF-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
B<br />
STANDARD<br />
SPROCKETS<br />
MNF-001-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
TWO OPERATOR STATIONS<br />
C C C<br />
SPECIAL<br />
SPROCKETS<br />
MNF-003-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 MultipleOp-erator<br />
Junction Box<br />
Note: If the press brake has an air counterbalance, an additional CTD-062 air pressure switch is required.<br />
Please select an air cyl<strong>in</strong>der from page 83 or 84 to complete this package. For light curta<strong>in</strong>s, mount<strong>in</strong>g brackets and barriers for sides of po<strong>in</strong>t<br />
of operation, see <strong>Catalog</strong> MSD.<br />
82 | CONTROL SYSTEMS
RCL-SERIES AIR CYLINDERS<br />
An air cyl<strong>in</strong>der must be ordered separately for mechanical-friction-clutch<br />
press brakes that are us<strong>in</strong>g the packages described on page 82. It is required<br />
to complete the control system. Standard air cyl<strong>in</strong>ders are s<strong>in</strong>gle-act<strong>in</strong>g,<br />
pull-type, and spr<strong>in</strong>g return. A clevis mount<strong>in</strong>g arrangement is furnished for<br />
attach<strong>in</strong>g the cyl<strong>in</strong>der to the mach<strong>in</strong>e frame. A rod, yoke, and p<strong>in</strong> assembly are used for ease <strong>in</strong> connect<strong>in</strong>g to the exist<strong>in</strong>g clutch/brake operat<strong>in</strong>g<br />
rod. Other types of air cyl<strong>in</strong>ders are also available. Before order<strong>in</strong>g an air cyl<strong>in</strong>der, please check the l<strong>in</strong>kage where the cyl<strong>in</strong>der will be <strong>in</strong>serted for<br />
proper stroke and diameter of air cyl<strong>in</strong>der needed. Please consult the factory for any special requirements, such as push-type cyl<strong>in</strong>ders or longer- or<br />
shorter-stroke cyl<strong>in</strong>ders.<br />
Part No. RCL-004—Air Cyl<strong>in</strong>der<br />
300-lb pull @ 75 PSI, 21⁄2” bore x 2” stroke for press brake sizes up to 8’ beds. (Cyl<strong>in</strong>ders with longer or shorter strokes, and push cyl<strong>in</strong>ders are<br />
available upon request.)<br />
Part No. RCL-005—Air Cyl<strong>in</strong>der<br />
500-lb pull @ 75 PSI, 31⁄4” bore x 2” stroke for press brake sizes 10’ to 14’ beds. (Cyl<strong>in</strong>ders with longer or shorter strokes, and push cyl<strong>in</strong>ders<br />
are available upon request.)<br />
Note: Please see the next page for special tie-rod-constructed air cyl<strong>in</strong>ders (for larger press brakes) or special mount<strong>in</strong>g features.<br />
MASTER CYLINDER-OPERATED PRESS BRAKES (OLDER WYSONG PRESS BRAKES)<br />
Press brakes that use a master cyl<strong>in</strong>der-type hydraulic system to operate a mechanical-friction clutch and brake can be retrofitted with the controls<br />
illustrated <strong>in</strong> this catalog. The follow<strong>in</strong>g illustration shows how the air cyl<strong>in</strong>der that operates the clutch and brake can be applied.<br />
FOOT SWITCH PACKAGE<br />
For control systems on pages 72-82, the RCL-004 air cyl<strong>in</strong>der can be applied as illustrated below.<br />
INE TO<br />
LUTCH<br />
TUATOR<br />
LINDER<br />
STER<br />
INDER<br />
MECHANICAL PEDAL/TREADLE<br />
IS REMOVED AND FOOT<br />
SWITCH IS FURNISHED FOR<br />
ACTUATING PRESS BRAKE<br />
BED<br />
MACHINE FRAME<br />
AIR<br />
CYLINDER<br />
LINE TO<br />
CLUTCH<br />
ACTUATOR<br />
CYLINDER<br />
DER MAY HAVE<br />
BACK TO ALLOW<br />
AIR CYLINDER<br />
FOOT SWITCH<br />
SPECIAL ADDED<br />
BRACKET FABRICATED<br />
AT TIME OF INSTALLATION<br />
FLOOR LINE<br />
MASTER<br />
CYLINDER<br />
CONTROL SYSTEMS | 83
OTHER AIR CYLINDERS AVAILABLE<br />
The follow<strong>in</strong>g custom tie-rod-constructed air cyl<strong>in</strong>ders can be furnished<br />
<strong>in</strong>stead of the standard RCL-series cyl<strong>in</strong>ders offered on the previous<br />
page. These cyl<strong>in</strong>ders are furnished when a larger and more durable<br />
cyl<strong>in</strong>der is needed to engage and disengage the mechanical-friction<br />
clutch and brake of press brakes or when the clevis mount will not fit<br />
the mach<strong>in</strong>e. Please note that they are offered <strong>in</strong> tie-rod construction,<br />
both pull-type and push-type, s<strong>in</strong>gle action with spr<strong>in</strong>g return. The push<br />
type has an <strong>in</strong>ternal spr<strong>in</strong>g. All cyl<strong>in</strong>ders are furnished with yoke and p<strong>in</strong><br />
on the operat<strong>in</strong>g rod to attach to the mach<strong>in</strong>e l<strong>in</strong>kage.<br />
When apply<strong>in</strong>g an air cyl<strong>in</strong>der to the mach<strong>in</strong>e, make sure the alignment<br />
(with the mach<strong>in</strong>e l<strong>in</strong>kage) is a straight l<strong>in</strong>e. Also make sure the cyl<strong>in</strong>der<br />
rod, yoke, or any mov<strong>in</strong>g parts will not b<strong>in</strong>d after <strong>in</strong>st<strong>all</strong>ation. Be sure the<br />
rod stroke is not too long—it could cause jackknif<strong>in</strong>g of the cyl<strong>in</strong>der and<br />
clutch operat<strong>in</strong>g rod. Please consult the factory for any other special<br />
cyl<strong>in</strong>der configuration (i.e., longer or shorter stroke) or additional force<br />
needed on the return spr<strong>in</strong>g.<br />
TYPE A—CLEVIS MOUNT<br />
This air cyl<strong>in</strong>der is usu<strong>all</strong>y mounted <strong>in</strong> the vertical position on the side<br />
of the mach<strong>in</strong>e.<br />
Clevis<br />
Push Type*<br />
TYPE B—SIDE-FOOT MOUNT<br />
This air cyl<strong>in</strong>der can be mounted vertic<strong>all</strong>y, hori-zont<strong>all</strong>y, or any angle<br />
depend<strong>in</strong>g upon application<br />
Pull Type<br />
Push Type*<br />
Side Feet<br />
TYPE B – SIDE FOOT<br />
APPROX. OVERALL<br />
LENGTH<br />
TYPE C—FRONT FLANGE MOUNT<br />
Pull Type<br />
RETURN SPRING<br />
PRESSURE<br />
AMOUNT OF PULL OR<br />
PUSH FORCE AT 75 PSI<br />
PART NO. BORE STROKE<br />
PULL TYPE<br />
RCK-544 2" 2" 21-1/2" 60 100<br />
RCK-545 2" 3" 23-1/2" 40 100<br />
RCK-546 2" 4" 25-1/2" 20 100<br />
RCK-547 3" 2" 20-1/2" 120 295<br />
RCK-548 3" 3" 22-1/2" 80 295<br />
RCK-549 3" 4" 24-1/2" 40 295<br />
RCK-550 4" 2" 28" 270 460<br />
RCK-551 4" 3" 30" 195 460<br />
RCK-552 4" 4" 32" 120 460<br />
PUSH TYPE 2" 2" 15" 60 135<br />
RCK-553 2" 3" 16" 40 135<br />
RCK-554 2" 4" 17" 20 135<br />
RCK-555 3" 2" 20" 120 330<br />
RCK-556 3" 3" 21" 82 330<br />
RCK-557 3" 4" 22" 40 330<br />
RCK-558 4" 2" 17-1/2" 270 520<br />
RCK-559 4" 3" 18-1/2" 195 520<br />
RCK-560 4" 4" 19-1/2" 120 520<br />
RCK-561 4" 5" 20-1/2" 120 520<br />
RCK-590<br />
Push Type*<br />
Pull Type<br />
TYPE A – CLEVIS<br />
APPROX. OVERALL<br />
LENGTH<br />
RETURN SPRING<br />
PRESSURE<br />
*The spr<strong>in</strong>g is <strong>in</strong>side the cyl<strong>in</strong>der on push-type air cyl<strong>in</strong>ders.<br />
AMOUNT OF PULL OR<br />
PUSH FORCE AT 75 PSI<br />
PART NO. BORE STROKE<br />
PULL TYPE<br />
RCK-526 2" 2" 23" 60 100<br />
RCK-527 2" 3" 25" 40 100<br />
RCK-528 2" 4" 27" 20 100<br />
RCK-529 3" 2" 26" 120 295<br />
RCK-530 3" 3" 28" 80 295<br />
RCK-531 3" 4" 30" 40 295<br />
RCK-532 4" 2" 30-1/2" 270 460<br />
RCK-533 4" 3" 32-1/2" 195 460<br />
RCK-534 4" 4" 34-1/2" 120 460<br />
PUSH TYPE 2" 2" 17" 60 135<br />
RCK-535 2" 3" 18" 40 135<br />
RCK-536 2" 4" 19" 20 135<br />
RCK-537 3" 2" 22" 120 330<br />
RCK-538 3" 3" 23" 82 330<br />
RCK-539 3" 4" 23" 40 330<br />
RCK-540 4" 2" 21-1/2" 270 520<br />
RCK-541 4" 3" 22-1/2" 195 520<br />
RCK-542 4" 4" 23-1/2" 120 520<br />
RCK-543<br />
Flange<br />
This air cyl<strong>in</strong>der is usu<strong>all</strong>y <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> applications where the cyl<strong>in</strong>der<br />
rod must go through the frame of the press brake. Rear-flange mount<br />
and rod extensions at both ends are also available.<br />
TYPE C – FRONT FLANGE<br />
PART NO.<br />
BORE STROKE<br />
APPROX. OVERALL<br />
LENGTH<br />
RETURN SPRING<br />
PRESSURE<br />
AMOUNT OF PULL OR<br />
PUSH FORCE AT 75 PSI<br />
PULL TYPE<br />
RCK-562 2" 2" 21" 60 100<br />
RCK-563 2" 3" 23" 40 100<br />
RCK-564 2" 4" 25" 20 100<br />
RCK-565 3" 2" 23" 120 295<br />
RCK-566 3" 3" 25" 80 295<br />
RCK-567 3" 4" 27" 40 295<br />
RCK-568 4" 2" 28" 270 460<br />
RCK-569 4" 3" 30" 195 460<br />
RCK-570 4" 4" 32" 120 460<br />
PUSH TYPE 2" 2" 16" 60 135<br />
RCK-571 2" 3" 17" 40 135<br />
RCK-572 2" 4" 18" 20 135<br />
RCK-573 3" 2" 21" 120 330<br />
RCK-574 3" 3" 22" 82 330<br />
RCK-575 3" 4" 23" 40 330<br />
RCK-576 4" 2" 22-1/4" 270 520<br />
RCK-577 4" 3" 23-1/4" 195 520<br />
RCK-578 4" 4" 24-1/4" 120 520<br />
RCK-579<br />
84 | CONTROL SYSTEMS
SINGLE- AND TWO-SPEED AIR-CLUTCH PRESS BRAKES<br />
INTRODUCTION<br />
Air-operated clutches and brakes use a friction arrangement that causes engagement and disengagement. When air pressure enters the clutch<br />
and brake, through a monitored dual-solenoid air valve, the clutch engages and the brake is released. To stop the motion of the press brake, the<br />
opposite takes place.<br />
Some press brakes have <strong>one</strong> clutch that <strong>all</strong>ows only <strong>one</strong> speed when cycl<strong>in</strong>g the mach<strong>in</strong>e while other press brakes have two clutches for two speeds.<br />
Two-speed air-clutch press brakes <strong>all</strong>ow the slide to approach the workpiece at a fast speed, disengage (air is dumped from <strong>one</strong> clutch), then <strong>all</strong>ow<br />
the second clutch to engage for a slower speed through the bend<strong>in</strong>g operation to the bottom of the stroke. This prevents fast whip-up action of the<br />
material. The clutches are aga<strong>in</strong> switched for rapid travel back to the top of the stroke.<br />
If these types of mach<strong>in</strong>es are newer, they do not always require a completely new clutch/brake control package for control reliability. To verify this,<br />
please send the electrical schematics to our eng<strong>in</strong>eer<strong>in</strong>g department for review. These schematics are also necessary to review for proper <strong>in</strong>terface<br />
when a light curta<strong>in</strong> will be furnished. If a s<strong>in</strong>gle- or two-speed air-clutch press brake doesn’t have control reliability and when brake monitor<strong>in</strong>g is<br />
needed, the SSC-1500 control can be furnished.<br />
SELECTING A CONTROL SYSTEM FOR PART-REVOLUTION-AIR-CLUTCH PRESS BRAKES<br />
1. Determ<strong>in</strong>e if the press brake is a s<strong>in</strong>gle- or two-speed press brake (<strong>one</strong> or two clutches).<br />
2. If the press brake is a s<strong>in</strong>gle-speed and sequence-stop operation is required, the SSC-1500 control on pages 72-82 can be used. Select a<br />
comp<strong>one</strong>nt package from page 82. Light curta<strong>in</strong>s, mount<strong>in</strong>g brackets, and lockout valves are not part of the comp<strong>one</strong>nt packages and must<br />
be ordered separately. Please see page 35 for an appropriate lockout valve and <strong>Catalog</strong> MSD for light curta<strong>in</strong> options and mount<strong>in</strong>g brackets.<br />
3. If the press brake has a two-speed air clutch, the standard SSC-1500 control on pages 72-82 can be used. Select the comp<strong>one</strong>nt package from<br />
page 86. Light curta<strong>in</strong>s mount<strong>in</strong>g brackets (<strong>Catalog</strong> MSD), and lockout valves (page 42) are not part of the comp<strong>one</strong>nt packages and must be<br />
ordered separately.<br />
Notes: See <strong>Catalog</strong> SS for safeguard<strong>in</strong>g the back side of the press brake.<br />
CONTROL SYSTEMS | 85
COMPONENT PACKAGES FOR SINGLE- AND TWO-SPEED AIR-CLUTCH PRESS BRAKES<br />
To complete the SSC-1500 s<strong>in</strong>gle- and two-speed air clutch press brake control system, comp<strong>one</strong>nt packages are available. Comp<strong>one</strong>nt packages<br />
are listed <strong>in</strong> the charts below. These packages can be furnished with:<br />
• A STANDARD Control (pp. 80-81) • A REMOTE OPERATOR-STYLE Control (pp. 83-84)<br />
• A CUSTOM Control (p. 82)<br />
• A CONTROL CONSOLE<br />
• A SPECIAL Control (p. 82)<br />
• A SUBPANEL<br />
To select the proper comp<strong>one</strong>nt package to go with your control box, determ<strong>in</strong>e your requirements below:<br />
A<br />
B<br />
C<br />
Modes of operation and <strong>in</strong>itiat<strong>in</strong>g means required.<br />
Number of operator stations required.<br />
Type of sprockets required.<br />
A<br />
Modes of operation: Inch, S<strong>in</strong>gle, and Sequence Stop (Hand or Foot)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
PRS or PRT Control<br />
Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
• Foot S<strong>in</strong>gle<br />
Stroke<br />
• Sequence Stop<br />
B B<br />
C<br />
ONE OPERATOR STATION<br />
STANDARD SPROCKETS<br />
TNK-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprocket Assembly<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045 3<br />
⁄4” Filter-Regulator-Lubricator Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
CTL-507 Palm Button Assembly<br />
CTD-011 Foot Switch<br />
SPECIAL<br />
SPROCKETS<br />
TNK-004-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
TNK-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple<br />
Op-erator Junction Box<br />
TWO OPERATOR STATIONS<br />
SPECIAL<br />
SPROCKETS<br />
C C C<br />
SPECIAL<br />
SPROCKETS<br />
TNK-006-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
CTL-507 Palm Button<br />
Assembly<br />
CTD-011 Foot Switch<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Operator<br />
Junction Box<br />
A<br />
Modes of operation: Inch and S<strong>in</strong>gle (Hand Only)<br />
MODES OF<br />
OPERATION TO BE<br />
USED<br />
PRS or PRT Control<br />
Box<br />
• Two-Hand Inch<br />
• Two-Hand S<strong>in</strong>gle<br />
Stroke<br />
B B<br />
C<br />
ONE OPERATOR STATION<br />
STANDARD SPROCKETS<br />
TNF-000-SSP Standard Comp<strong>one</strong>nt Package<br />
CMS-115 Resolver/Pulser Tim<strong>in</strong>g Device<br />
With 40’ Cable and Plug<br />
CML-000 Sprocket Assembly<br />
CMS-515 10’ ANSI No. 35 Roller Cha<strong>in</strong><br />
RCL-654 3<br />
⁄4” Dual-Solenoid Air Valve<br />
RCL-045 3<br />
⁄4” Filter-Regulator-Lubricator Assembly<br />
CTD-062 Air Pressure Switch<br />
(For Clutch/Brake)<br />
CTL-507 Palm Button Assembly<br />
SPECIAL<br />
SPROCKETS<br />
TNF-004-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
TNF-002-SSP<br />
Comp<strong>one</strong>nt Package<br />
COMPONENTS REQUIRED IN ADDITION<br />
TO THOSE LISTED IN STANDARD PACKAGE AT LEFT<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple<br />
Op-erator Junction Box<br />
TWO OPERATOR STATIONS<br />
SPECIAL<br />
SPROCKETS<br />
C C C<br />
SPECIAL<br />
SPROCKETS<br />
TNF-006-SSP<br />
Comp<strong>one</strong>nt Package<br />
CML-100 Special Sprockets<br />
(Replaces CML-000)<br />
CTL-507 Palm Button<br />
Assembly<br />
LLD-283 Supervisory<br />
Control Station (2)<br />
USC-000 Multiple Op- erator<br />
Junction Box<br />
Note: If the press brake has an air counterbalance, an additional CTD-062 air pressure switch is required.<br />
86 | CONTROL SYSTEMS
HYDRAULIC PRESS BRAKE CONTROL SYSTEMS<br />
INTRODUCTION<br />
Each hydraulic press brake must be looked at as an <strong>in</strong>dividual system. This<br />
system consists of, but is not limited to, the mach<strong>in</strong>e frame, <strong>all</strong> mechanical<br />
parts, hydraulic system, electrical or electronic systems, pneumatic systems,<br />
tool<strong>in</strong>g or dies (present and future), tool or die setup, safeguard<strong>in</strong>g, material<br />
handl<strong>in</strong>g, size or configuration of workpiece, ma<strong>in</strong>tenance requirements,<br />
and most importantly, production requirements.<br />
In ANSI B11.3, subclause 6.2 Performance of the Safety-Related Functions,<br />
it states that “The control system sh<strong>all</strong> meet the requirements of 8.3.”<br />
8.3 PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S)<br />
When a comp<strong>one</strong>nt, module, device or system failure occurs, such<br />
that it or a subsequent failure of another comp<strong>one</strong>nt, module, device<br />
or system would lead to the <strong>in</strong>ability of the safety-related function(s) to<br />
respond to a normal stop command or an immediate stop command,<br />
the safety-related function sh<strong>all</strong>:<br />
a) prevent <strong>in</strong>itiation of hazardous mach<strong>in</strong>e motion (or situation) until<br />
the failure is corrected or until the control system is manu<strong>all</strong>y<br />
reset; or<br />
b) <strong>in</strong>itiate an immediate stop command and prevent re<strong>in</strong>itiation<br />
of hazardous mach<strong>in</strong>e motion (or situation) until the failure is<br />
corrected or until the control system is manu<strong>all</strong>y reset; or<br />
c) prevent re-<strong>in</strong>itiation of hazardous mach<strong>in</strong>e motion (or situation) at<br />
the next normal stop command until the failure is corrected or until<br />
the control system is manu<strong>all</strong>y reset.<br />
6.14.5 HYDRAULIC COMPONENTS AND CIRCUITS<br />
Hydraulic comp<strong>one</strong>nts and circuits that control ram motion sh<strong>all</strong> comply<br />
with the requirements of 6.2 (and 8.3).<br />
Hydraulic Press Brake With Remote Operator Station<br />
CONTROLS<br />
The controls described <strong>in</strong> this catalog <strong>in</strong>clude two-hand control as<br />
a po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g device. The palm buttons must<br />
be depressed concurrently and ma<strong>in</strong>ta<strong>in</strong>ed dur<strong>in</strong>g the hazardous<br />
downstroke of the ram. Release of <strong>one</strong> or both palm buttons reverses<br />
or stops the action of the ram. The controls offered also <strong>in</strong>clude a light<br />
curta<strong>in</strong> <strong>in</strong>terface.<br />
ELECTRICAL REQUIREMENTS<br />
The ANSI B11.3 standard requires a proper ma<strong>in</strong> power disconnect<br />
switch. A motor starter is also required that drops out when power<br />
is lost and will not restart automatic<strong>all</strong>y. All AC control circuits and<br />
solenoid valves must be powered by 120 V or less (obta<strong>in</strong>ed from the<br />
transformer), and the control system must be protected aga<strong>in</strong>st false<br />
operation due to an accidental ground. Refer to subclause 6.1.<br />
UPDATING HYDRAULIC PRESS BRAKES<br />
To update the electrical system or to add po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g<br />
to a hydraulic press brake, the electrical and hydraulic schematic<br />
diagrams must be reviewed by <strong>Rockford</strong> <strong>Systems</strong>’ eng<strong>in</strong>eer<strong>in</strong>g<br />
department. Please provide these schematics to our sales personnel or<br />
factory-authorized representatives when they visit your plant to conduct<br />
a mach<strong>in</strong>e survey.<br />
CONTROL SYSTEMS | 87
STANDARD HYDRAULIC PRESS BRAKE CONTROL<br />
This solid-state control system is designed for use on hydraulic press brakes. It<br />
is designed and built to comply with OSHA 29 CFR 1910.212, ANSI B11.3 and<br />
B11.19. This control can update or replace exist<strong>in</strong>g control systems on hydraulic<br />
press brakes found <strong>in</strong> users’ plants or can be furnished for new or rebuilt<br />
hydraulic press brakes.<br />
This control <strong>in</strong>cludes control reliability, two-hand control, light curta<strong>in</strong> <strong>in</strong>terface,<br />
and diagnostics (two user-programmable <strong>in</strong>puts). It also <strong>in</strong>cludes batch and stroke<br />
counters with presets, and a hard-wired emergency-stop master control relay.<br />
This is an economic, full-featured dual micro-processor-based control system.<br />
The system uses redundant <strong>in</strong>puts from devices such as palm buttons, foot<br />
switches, and light curta<strong>in</strong>(s). The system output to the solenoid valves is provided<br />
by two force-guided relays. These output relays are <strong>in</strong>dependently controlled and<br />
cross-checked by the microprocessors. This <strong>all</strong>ows control-reliable operation of<br />
the outputs <strong>in</strong> the event of a s<strong>in</strong>gle control comp<strong>one</strong>nt failure <strong>in</strong> the control. The<br />
standard hydraulic press brake control has m<strong>in</strong>imum requirements for the press<br />
brake it is to control. These m<strong>in</strong>imum requirements <strong>in</strong>clude a directional or <strong>one</strong> up<br />
and <strong>one</strong> down solenoid valve(s) for the ram, a TOS (top-of-stroke) limit switch, and<br />
a BOS (bottom-of-stroke) limit or pressure switch. In most cases, if these already<br />
exist, they can be reused. Speed-change valves and limit switches can also be<br />
supported with the standard hydraulic control. If other valves exist (additional<br />
speed change valves, prefill, regeneration, level, bypass, etc.), please consult the<br />
factory for a quote on a special-designed control.<br />
The standard control box is a 20” x 20” x 8” NEMA 12 enclosure with the operator<br />
controls and keypad/display mounted <strong>in</strong> the door, as shown.<br />
A starter or disconnect can be <strong>in</strong>cluded <strong>in</strong> a larger enclosure, or a comb<strong>in</strong>ation<br />
starter disconnect can be furnished separately.<br />
Standard Control Box<br />
Back of<br />
Keypad/Display<br />
Master<br />
Control Relay<br />
Multi-Tap<br />
Transformer<br />
Output<br />
Relays<br />
Control Module<br />
Assembly<br />
Selectors<br />
Inside View of Standard Control Box<br />
88 | CONTROL SYSTEMS
STANDARD HYDRAULIC PRESS BRAKE CONTROL (CONTINUED)<br />
OPERATOR INTERFACE KEYPAD/DISPLAY<br />
The operator <strong>in</strong>terface keypad/display is used to enter setup <strong>in</strong>formation, monitor mach<strong>in</strong>e operation,<br />
and display messages on a 4-l<strong>in</strong>e x 20-character LCD (liquid crystal display). As standard, this keypad is<br />
mounted on the control box door. For operator convenience, it can be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a remote operator station.<br />
Programm<strong>in</strong>g is accessed by a keyed selector switch.<br />
PROGRAMMING<br />
The hydraulic press brake control can be quickly and easily programmed. There are up to two 24-V DC<br />
selectable current s<strong>in</strong>k<strong>in</strong>g or sourc<strong>in</strong>g programmable diagnostic <strong>in</strong>puts provided for the user. A fault<br />
message, <strong>in</strong>put logic, and stop type can be assigned to each <strong>in</strong>put from the list shown. When a fault<br />
condition is detected, the mach<strong>in</strong>e will top stop or emergency stop, and the assigned message will be<br />
displayed. This feature helps when troubleshoot<strong>in</strong>g common fault conditions.<br />
Keypad/Display<br />
MODES OF OPERATION<br />
• Off<br />
• Two-hand <strong>in</strong>ch<br />
• Two-hand s<strong>in</strong>gle stroke<br />
• Foot s<strong>in</strong>gle stroke<br />
• Foot switch trip or <strong>one</strong>-hand trip s<strong>in</strong>gle stroke (used <strong>in</strong> conjunction<br />
with a po<strong>in</strong>t-of-operation safeguard)*<br />
• High, high/low, low speed change<br />
• Sequence stop (hand/hand, hand/foot, foot/foot)<br />
*Additional comp<strong>one</strong>nts may be required to use this mode of operation.<br />
FEATURES<br />
• Meets and exceeds OSHA 29 CFR 1910.212, ANSI B11.3 and B11.19<br />
• Provides two-hand control safeguard<strong>in</strong>g device<br />
• Redundant and cross-check<strong>in</strong>g microprocessors<br />
• Redundant switch<strong>in</strong>g style DC power supplies<br />
• Two monitored ram advance (up or down) 24-V force-guided output relays<br />
• External relay monitor<strong>in</strong>g (for use when external relays are used to energize the down valves)<br />
• Block<strong>in</strong>g valve monitor<strong>in</strong>g<br />
• Press control operates on 85-135 V AC<br />
• Provisions for optional light curta<strong>in</strong> <strong>in</strong>terface with off/on supervised keyed selector switch<br />
• Easy to read back-lit liquid crystal operator <strong>in</strong>terface display hav<strong>in</strong>g 4 l<strong>in</strong>es x 20 characters<br />
• Two (2) 24-V DC digital user <strong>in</strong>puts, programmable, selectable canned messages<br />
• One (1) ram speed change (fast-slow) output, standard 120 V AC with a selector switch for high, high/low, low speed (to support mach<strong>in</strong>es<br />
with a speed change solenoid valve)<br />
• One (1) ram return (up or down) output, standard 120 V AC with a selector switch for pressure, pressure/distance, distance return<br />
• Bottom dwell timer (0-600 seconds)<br />
• Decompression timer (50-250 ms)<br />
• 7-digit stroke counter<br />
• 7-digit batch counter with preset<br />
• Operator <strong>in</strong>terface keypad and display, text <strong>in</strong> English or Spanish<br />
For control reliability<br />
CONTROL SYSTEMS | 89
CUSTOM HYDRAULIC PRESS BRAKE CONTROL<br />
A custom control box conta<strong>in</strong>s the standard control module and comp<strong>one</strong>nts<br />
described on pages 88-89 plus the follow<strong>in</strong>g:<br />
• ma<strong>in</strong> power disconnect switch<br />
• ma<strong>in</strong> hydraulic pump motor starter<br />
The box will vary <strong>in</strong> size based on the disconnect switch and motor starter<br />
comp<strong>one</strong>nts. The box is furnished with an IEC through-the-door ma<strong>in</strong><br />
power fused disconnect switch and an IEC hydraulic pump magnetic<br />
motor starter (with push buttons). They are prewired and built <strong>in</strong>to a<br />
NEMA 12 enclosure.<br />
Operator controls and the keypad/display are located on the front<br />
of the door, or a pla<strong>in</strong>-door control or subpanel can be furnished. A<br />
remote operator station or keypad/display kit is required if a pla<strong>in</strong>door<br />
control or subpanel is ordered. See page 91 for <strong>in</strong>formation on<br />
remote operator stations.<br />
To ensure the starter(s) and disconnect are sized properly, please check<br />
horsepower for the ma<strong>in</strong> drive motor and slide adjust motor (if furnished)<br />
on the mach<strong>in</strong>e, as well as full-load amps, and primary voltage to the<br />
mach<strong>in</strong>e. After obta<strong>in</strong><strong>in</strong>g this <strong>in</strong>formation, go to the chart on page 92 to<br />
determ<strong>in</strong>e the proper custom control box part number. Follow directions<br />
1-7 to determ<strong>in</strong>e the correct part number.<br />
Remote Operator<br />
Station<br />
Custom Pla<strong>in</strong> Door<br />
Control Box<br />
REMOTE OPERATOR-STYLE CONTROL BOXES<br />
Remote operator-style X, Y, and Z hydraulic control boxes <strong>in</strong>clude the same features and modes of operation as the standard hydraulic control<br />
boxes. However, they do not have a control transformer. These control boxes are designed to be located on the front of the mach<strong>in</strong>e near<br />
the operator.<br />
These controls are for applications where the mach<strong>in</strong>e’s exist<strong>in</strong>g magnetic motor starter, fused disconnect switch, and control transformer meet<br />
the safety requirements and can be reused. If the exist<strong>in</strong>g control transformer cannot be reused or a new <strong>one</strong> is required, please contact the factory.<br />
The keypad/display and <strong>all</strong> operator controls are located on the door (front) of the remote operator-style control box.<br />
CONTROL MODULE KIT<br />
A control module kit <strong>all</strong>ows the end user to update the hydraulic control of a press brake with m<strong>in</strong>imum equipment costs. The kit is supplied without<br />
the control enclosure, panel, control transformer, control fuse, term<strong>in</strong>al strips, wire duct, and wir<strong>in</strong>g.<br />
A set of electrical pr<strong>in</strong>ts is supplied to show typical wir<strong>in</strong>g, and <strong>all</strong> mount<strong>in</strong>g dimensions are provided <strong>in</strong> order for a qualified person to <strong>in</strong>st<strong>all</strong> the<br />
control module kit. The m<strong>in</strong>imum area required on an exist<strong>in</strong>g control panel to <strong>in</strong>st<strong>all</strong> this kit<br />
is 18” H x 18” W x 6” D.<br />
This control module kit <strong>in</strong>cludes the control module, control relays, shock mounts, fasteners,<br />
suppressors, danger labels, and electrical pr<strong>in</strong>ts. A keypad/display kit is required unless a<br />
remote operator station is used (see next page).<br />
SUBPANEL<br />
A subpanel control can also be furnished. It is the same as the standard control described<br />
on pages 89-90 without the enclosure. The m<strong>in</strong>imum area required <strong>in</strong> an exist<strong>in</strong>g control<br />
enclosure is 181⁄2” H x 181⁄2” W x 6” D.<br />
90 | CONTROL SYSTEMS
KEYPAD/DISPLAY KIT<br />
Part No. LLD-6025<br />
The keypad/display kit can be used with any of the control boxes or the<br />
control module kit. This kit <strong>in</strong>cludes the keypad/display, an off/program/run<br />
selector switch, a light curta<strong>in</strong> off/on selector switch, a hand/foot selector<br />
switch, an <strong>in</strong>ch/s<strong>in</strong>gle/sequence stop selector switch, a high/low speed<br />
selector switch, a pressure/pressure distance/distance return selector<br />
switch, and 25’ of cable. Additional push buttons, nameplates, and selector<br />
switches for the motor starter, etc., can be furnished depend<strong>in</strong>g on the<br />
features required. Please consult the factory.<br />
REMOTE OPERATOR STATIONS<br />
For operator convenience, a remote operator station can be furnished for<br />
use with a pla<strong>in</strong>-door standard control box, pla<strong>in</strong>-door custom control box,<br />
module kit, or subpanel. The remote operator station conta<strong>in</strong>s the keypad/<br />
display, program selector switch, and other selector switches as required.<br />
Remote operator stations are available <strong>in</strong> a standard format or can be<br />
customized to meet any requirements. Select from the follow<strong>in</strong>g remote<br />
operator stations.<br />
Part No. LLD-6021<br />
Remote Operator Station for Hydraulic Press Brakes<br />
REMOTE OPERATOR STATIONS FOR HYDRAULIC PRESS BRAKES<br />
FEATURES<br />
PART NO.<br />
LLD-6020<br />
PART NO.<br />
LLD-6021<br />
PART NO.<br />
LLD-6022<br />
PART NO.<br />
LLD-6023<br />
KEYPAD/DISPLAY X X X X<br />
OFF/PROGRAM/RUN SELECTOR SWITCH X X X X<br />
LIGHT CURTAIN OFF/ON SELECTOR SWITCH X X X X<br />
HIGH/LOW SPEED SELECTOR SWITCH X X X X<br />
PRESSURE/PRESSURE DISTANCE/DISTANCE<br />
RETURN SELECTOR SWITCH<br />
INCH/SINGLE/SEQUENCE STOP SELECTOR<br />
SWITCH<br />
HAND, HAND/FOOT, FOOT SELECTOR<br />
SWITCH<br />
MAIN MOTOR START AND STOP PUSH<br />
BUTTONS<br />
ADVANCED LIGHT CURTAIN BLANKING<br />
SELECTOR SWITCHES<br />
X X X X<br />
X X X X<br />
X X X X<br />
X<br />
X<br />
X<br />
X<br />
CONTROL SYSTEMS | 91
SELECTING AN RHPS HYDRAULIC PRESS BRAKE CONTROL<br />
To determ<strong>in</strong>e the 10-digit configured part number for the hydraulic press brake control required, follow directions1-7 below and use the <strong>in</strong>formation<br />
<strong>in</strong> the PART NUMBERING SYSTEM CHART below.<br />
1. The first 4 digits for <strong>all</strong> hydraulic press brake controls are RHPS.<br />
2. The 5th digit determ<strong>in</strong>es the size of the disconnect switch, if provided, <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no disconnect switch<br />
provided.<br />
3. The 6th digit determ<strong>in</strong>es if a nonrevers<strong>in</strong>g motor starter is provided. Zero (0) <strong>in</strong>dicates no motor starter provided.<br />
4. The 7th digit determ<strong>in</strong>es the size of nonrevers<strong>in</strong>g motor starter that is provided <strong>in</strong> the control enclosure. Zero (0) <strong>in</strong>dicates no motor<br />
starter provided.<br />
5. The 8th digit determ<strong>in</strong>es the location of the operator controls, or if it is a style X, Y, or Z control without the control transformer.<br />
6. The 9th digit is for the type of light curta<strong>in</strong> <strong>in</strong>terface provided.<br />
7. The 10th digit (if required) will <strong>in</strong>dicate the type of modifier provided: i.e., motor control operators remote.<br />
SAMPLE<br />
1 2 3 4 5 6 7<br />
RHPS - 3 1 5 - P W 5<br />
The sample shown, RHPS-315-PW5, <strong>in</strong>dicates that the custom control box is for a hydraulic press brake that has a pla<strong>in</strong> door box with a C4000<br />
standard light curta<strong>in</strong> <strong>in</strong>terface <strong>in</strong>clud<strong>in</strong>g an IEC 100-A disconnect switch and an IEC 40-A nonrevers<strong>in</strong>g motor starter. The keypad/display and <strong>all</strong><br />
operators <strong>in</strong>clud<strong>in</strong>g the motor controls will be located remote (see page 91).<br />
SYSTEM TYPE PRODUCT CATEGORY<br />
RHPS —Hydraulic Control for Press Brakes<br />
DISCONNECT SWITCH SIZE—IEC<br />
(PLUS MAXIMUM MAIN MOTOR FLA)<br />
0 —No Disconnect Switch<br />
1 —30-A Disconnect—1- to 20-FLA Ma<strong>in</strong> Drive Motor<br />
2 —60-A Disconnect—21- to 40-FLA Ma<strong>in</strong> Drive Motor<br />
3 —100-A Disconnect—41- to 66-FLA Ma<strong>in</strong> Drive Motor<br />
4 —200-A Disconnect—67- to 133-FLA Ma<strong>in</strong> Drive Motor<br />
5 —400-A Disconnect—134- to 266-FLA Ma<strong>in</strong> Drive Motor<br />
NONREVERSING MAIN MOTOR STARTER<br />
0 —No Starter<br />
1 —Nonrevers<strong>in</strong>g Starter<br />
MAIN MOTOR STARTER SIZE<br />
0 —No Starter<br />
IEC<br />
1 —12 A<br />
2 —18 A<br />
3 —25 A<br />
4 —32 A<br />
5 —40 A<br />
6 —50 A<br />
7 —65 A<br />
8 —80 A<br />
9 —95 A<br />
A —115 A<br />
B —185 A<br />
C —265 A<br />
RHPS HYDRAULIC CONTROL PART NUMBERING SYSTEM CHART<br />
Motor Horsepower Chart—3 Phase<br />
208 V 230 V 460 V 575 V<br />
2 3 7.5 7.5<br />
5 5 10 10<br />
5 7.5 15 15<br />
7.5 10 20 20<br />
10 10 30 30<br />
15 15 30 40<br />
20 20 50 50<br />
25 30 60 75<br />
30 30 60 75<br />
30 40 75 100<br />
50 60 125 150<br />
75 100 200 200<br />
RHPS - X X X - X X X<br />
MODIFIER<br />
-- —Blank, No Modifier<br />
5 —Motor Operators Remote*<br />
LIGHT CURTAIN INTERFACE OPTIONS<br />
B —Banner Standard<br />
C —C4000 Advanced With LC Operators on Door<br />
V —C4000 Advanced With LC Operators Remote<br />
W —C4000 Standard<br />
CONFIGURATION & OPERATOR LOCATION<br />
F —Keypad/Display and All Operators on Door of Enclosure<br />
P —Keypad/Display and All Operators Remote (Pla<strong>in</strong> Door)<br />
S —Subpanel Only—Without Enclosure, Keypad/Display, and Operators<br />
K —Kit with Module and Control Relays Only—Without Enclosure,<br />
Subpanel, Transformer, Keypad/Display, and Operators<br />
X —Same as F (above) Without Control Transformer<br />
Y —Same as F (above) Without Control Transformer but With<br />
E-Stop, Return/Inch-up, and Prior Action on theEnclosure<br />
Z —Same as F (above) Without Control Transformer but With<br />
E-Stop, Prior Action, and Two (2) Guarded Run/Inch Buttons<br />
on the Enclosure<br />
*See page 50 for remote motor control operator stations or <strong>Catalog</strong> SFM.<br />
92 | CONTROL SYSTEMS
HYDRAULIC CONTROL SYSTEMS INDIVIDUAL COMPONENTS<br />
LINEAR CAM AND LIMIT SWITCH ASSEMBLY<br />
Part No. CMT-048<br />
The l<strong>in</strong>ear cam and limit switch assembly consists of two limit switches and two<br />
adjustable cams mounted on an extruded-alum<strong>in</strong>um bracket. This assembly can<br />
provide the l<strong>in</strong>ear tim<strong>in</strong>g of the top and bottom limits of the mach<strong>in</strong>e cycle on a<br />
hydraulic mach<strong>in</strong>e.<br />
HIGH/LOW LIMIT SWITCH ASSEMBLY<br />
Part No. CMT-049<br />
An additional l<strong>in</strong>ear cam and limit switch assembly can be used for a high/low signal<br />
dur<strong>in</strong>g the clos<strong>in</strong>g portion of the hydraulic stroke. This assembly consists of <strong>one</strong> limit<br />
switch and <strong>one</strong> adjustable cam mounted on an extruded-alum<strong>in</strong>um bracket.<br />
PALM BUTTON ASSEMBLY<br />
Part No. CTL-525<br />
Palm button assembly consists of two black run/<strong>in</strong>ch buttons (with r<strong>in</strong>g guards), a<br />
red emergency-stop button and a yellow return/<strong>in</strong>ch-up button. Mount<strong>in</strong>g boxes are<br />
furnished with each button. The electrical contact arrangement for <strong>all</strong> buttons is 1 NO<br />
and 1 NC.<br />
Part No. CTL-525<br />
FOOT SWITCH<br />
Part No. CTD-011<br />
This foot switch is protected from un<strong>in</strong>tentional operation. A heavy-duty die-cast cover<br />
protects the top and both sides, and the front is protected by a h<strong>in</strong>ged flap. The flap<br />
must be lifted with the toe before the foot may enter the switch. The electrical contact<br />
arrangement is 1 NO and 1 NC.<br />
SUPERVISORY CONTROL STATION<br />
Part No. LLD-6101<br />
Part No. LLD-283 (required when a USC-000 is used–see below)<br />
When two or more palm button or foot switch operat<strong>in</strong>g stations are required on <strong>one</strong><br />
mach<strong>in</strong>e, <strong>one</strong> supervisory control station is required at each operator station. This<br />
remote control station consists of an off/on keyed selector switch and a station on<br />
<strong>in</strong>dicator light. The on position <strong>all</strong>ows the operator to use that station, and the off<br />
position deactivates only that station. The enclosure size is 5¼” x 3” x 3¼”<br />
Foot Switch<br />
Supervisory Control Station<br />
MULTIPLE-OPERATOR JUNCTION BOX<br />
Part No. USC-000<br />
When multiple operator stations are required, this junction box is furnished separately<br />
for wir<strong>in</strong>g up to four (4) operator stations. This junction box <strong>in</strong>terfaces palm button<br />
assemblies/control bars and foot switches, and will not <strong>all</strong>ow the press to run if palm<br />
buttons or a foot switch is actuated without its supervisory control station on. A lighted<br />
push button with nameplate <strong>in</strong>dicates a fault condition of an operator station. The<br />
button is pushed to reset. The enclosure size is 16” x 14” x 6”.<br />
Multiple-Operator Junction Box<br />
CONTROL SYSTEMS | 93
SURVEY FOR PRESS BRAKES NO. ____________<br />
Company<br />
City State<br />
Surveyed By Date<br />
INSTALLATION N Y If Y: Standard Stripped-down<br />
When fill<strong>in</strong>g out this form, be sure the <strong>in</strong>formation is filled <strong>in</strong> for satisfy<strong>in</strong>g the basic<br />
areas of safety.<br />
Basic Areas–1. <strong>Safeguard<strong>in</strong>g</strong> 4. Starter<br />
2. Control 5. Cover<br />
3. Disconnect 6. Other Considerations<br />
For identification and reference, please fill <strong>in</strong> this area first.<br />
Mach<strong>in</strong>e No. Manufacturer<br />
Model No. Serial No.<br />
Size (length of slide or bed <strong>in</strong> feet)<br />
Type: Mechanical-Friction Clutch N Y<br />
If Y, does it have a band brake? N Y<br />
Air Clutch N Y If Y: (circle <strong>one</strong>), 1 2 Clutches<br />
Hydraulic N Y If Y: (circle <strong>one</strong>),<br />
Down-Act<strong>in</strong>g Ram Up-Act<strong>in</strong>g Ram<br />
Hydra-Mechanical N Y<br />
Air Only N Y<br />
Servo Motor (Electrical) N Y<br />
Is press brake out of service? N Y<br />
Is press brake used as a mechanical or hydraulic power press?<br />
N Y If Y, use either mechanical power press part revolution form<br />
or hydraulic press form.<br />
(If press brake is operated from the rear, an operat<strong>in</strong>g station(s) and safeguard<strong>in</strong>g<br />
must be furnished.)<br />
1) <strong>Safeguard<strong>in</strong>g</strong>:<br />
Has Safeguard Provide Type, Series, or Size<br />
Light Curta<strong>in</strong><br />
If press brake has light curta<strong>in</strong>, is it at the proper safety distance? N Y If we<br />
are to provide the light curta<strong>in</strong>, what is proper the safety distance?________”<br />
(See MSD catalog for guidel<strong>in</strong>es.)<br />
Are Mount<strong>in</strong>g Brackets required? N CTF Y<br />
If Y: EX-AL Sw<strong>in</strong>g-Away N Y If Y, please complete and attach SAB<br />
Measurement Form<br />
EX-AL Stationary N Y If Y, please complete and attach<br />
SLCMB Measurement Form<br />
Are Floor Stands required? N Y<br />
Is No-Go Indicator required? N Y<br />
Is Material Support Table required? N Y: Size<br />
1<br />
Two-Hand Control<br />
If press brake has two-hand control, are the palm buttons at the proper safety<br />
distance? N Y If we are to provide, what is the proper safety distance?________”<br />
(See page 45 <strong>in</strong> MSD catalog)<br />
Pullback<br />
Restra<strong>in</strong>t<br />
(Customer to<br />
Furnish)<br />
When provid<strong>in</strong>g any of the above safeguard<strong>in</strong>g devices, the sides and rear of the po<strong>in</strong>t of operation<br />
must be safeguarded. If light curta<strong>in</strong> sw<strong>in</strong>g-away brackets are not furnished, are side &<br />
rear guards required?<br />
N CTF Y<br />
If Y, please complete and attach measurement form.<br />
Is switch, cable, and sign for rear of press brake required? N Y<br />
(Customer to<br />
Furnish)<br />
Not offered by RSI<br />
Proposal Sequence Reference<br />
1 of 4<br />
94 | CONTROL SYSTEMS
SURVEY FOR PRESS BRAKES (CONTINUED)<br />
2<br />
2. Control:<br />
A. Does press brake control have control reliability (if appli-cable)? N Y<br />
B. If we are furnish<strong>in</strong>g light curta<strong>in</strong> or two-hand control, can we <strong>in</strong>terface to the<br />
exist<strong>in</strong>g control? N Y If Y,<br />
please provide electrical schematics and schematics<br />
of the hydraulic system if it is a hydraulic press brake.<br />
C. If control reliability existence is questionable, please provide the follow<strong>in</strong>g <strong>in</strong>formation:<br />
Relay Logic Solid-State<br />
If relay logic, control relays:<br />
Mfg.__________ Part No._________ Qty.__________<br />
D. Information about press brake:<br />
1. Hand Actuat<strong>in</strong>g N Y Stations (circle <strong>one</strong>): 1 2 3 4<br />
2. Foot Actuat<strong>in</strong>g N Y Stations (circle <strong>one</strong>): 1 2 3 4<br />
Mechanical N Y Electric N Y<br />
3. Modes: Inch S<strong>in</strong>gle High/Low<br />
Sequence Stop Other_________________<br />
4. Control Box Location: N/A<br />
On Press Brake N Y Remote N Y<br />
5. Operator Controls: On Control Box N Y Remote N Y: (circle<br />
<strong>one</strong>): Box Bar Stand<br />
E. Is Control Box to be furnished? N Y If Y,<br />
1. Solid-State: 1500 N Y, Mechanical N Y,<br />
Hydraulic N Y<br />
2. Box: Standard N Y, Custom N Y,<br />
Remote Operator Style (X,Y,Z) N Y<br />
Special N Y<br />
3. Location of Operators: (circle <strong>one</strong>):<br />
Door Remote Loose Console Kit<br />
Space Requirements<br />
4. Subpanel N Y 18 1 ⁄2” H x 18 1 ⁄2” W x 6” D<br />
Module (Kit) N Y 18” H x 18” W x 6” D<br />
Actual space available______”H x ______”W x _____”D<br />
5. Modes Required: Inch S<strong>in</strong>gle High/Low<br />
Sequence PSDI Other________________<br />
6. Options Required: Hour Meter<br />
Duplex Outlet N<strong>one</strong><br />
7. Brake Monitor: N Y<br />
F. Cycle Tim<strong>in</strong>g Device?: N Y Resolver (1500) N Y<br />
L<strong>in</strong>ear Unit N Y<br />
Other_______________________<br />
(mechanical press brakes only)<br />
G. Tim<strong>in</strong>g Device Drive?: N Y Reuse Exist<strong>in</strong>g Standard Sprocket Set<br />
(For 1:1 drive) N Y<br />
Special Sprocket Set (If 1:1 drive is not available) N Y Cha<strong>in</strong> N<br />
Y<br />
H. Actuat<strong>in</strong>g Means: How many operat<strong>in</strong>g stations? 1 2 3 4 (circle <strong>one</strong>)<br />
1. Hand (push buttons) N Y Hand (other) N Y______<br />
2. E-Stop Button N Y Top-Stop Button N Y<br />
Return Button N Y<br />
3. Foot Switch N Y<br />
Is Special Plug and Receptacle Required? N Y<br />
H. Monitored Dual-Solenoid Valve? N Y: (circle <strong>one</strong>): 1 ⁄2” 3 ⁄4”<br />
J. Air Pressure Switch? N Y If Y:<br />
Clutch/Brake? N Y Counterbalance? N Y<br />
K. Counterbalance Check Valve? N Y: (circle <strong>one</strong>):<br />
1<br />
⁄2” 3<br />
⁄4” 1” 1 1 ⁄2” 2” N/A No Tank<br />
L. Filter-Regulator-Lubricator? N Y: (circle <strong>one</strong>): 1 ⁄2” 3<br />
⁄4”<br />
M. Air Lockout Valve? N Y: (circle <strong>one</strong>): 1 ⁄2” 3<br />
⁄4”<br />
N. Is Air Cyl<strong>in</strong>der to be furnished? N/A<br />
N (reus<strong>in</strong>g exist<strong>in</strong>g) Y: If yes; provide details;<br />
Push Pull “ Bore “ Stroke Mount<br />
Standard Tie Rod<br />
O. Does press brake have automatic backgauge? N Y<br />
If Y, please provide exist<strong>in</strong>g <strong>in</strong>terface or <strong>in</strong>clude it <strong>in</strong> control schematic supplied.<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Manufacturer<br />
Model No.<br />
Serial No.<br />
2 of 4<br />
CONTROL SYSTEMS | 95
SURVEY FOR PRESS BRAKES (CONTINUED)<br />
If press brake is hydraulic<strong>all</strong>y operated, please answer the follow<strong>in</strong>g:<br />
A. What is Maximum Stroke of slide?______________________”<br />
B. Is Cycle Tim<strong>in</strong>g device required?<br />
N Y If Y, L<strong>in</strong>ear Cams and Limit Switches<br />
Use Exist<strong>in</strong>g Other_________________<br />
C. Is Block<strong>in</strong>g Monitored Dual Valve required?<br />
N Y If Y, (circle <strong>one</strong>) 1<br />
⁄2” 3<br />
⁄4” 1” 1 1 ⁄4” 1 1 ⁄2”<br />
What is <strong>in</strong>let flow?_____GPM What is outlet flow?_____GPM<br />
What is voltage of exist<strong>in</strong>g valves? 24 V DC 115 V<br />
230 V 460 V<br />
NOTE: Please enclose or send photos and schematics of<br />
hydraulic system. Enclosed Send<strong>in</strong>g<br />
3<br />
3. Disconnect:<br />
A. Present Location of Disconnect:<br />
1. On Press Brake or Off Press Brake<br />
2. With Control<br />
Separate from Control<br />
With Starter Only<br />
Not Furnished<br />
B. Is Electrical disconnect switch required?<br />
N Reuse Exist<strong>in</strong>g Customer to Furnish<br />
Y If Y, furnish HP, FLA, and voltage <strong>in</strong> Section 4D.<br />
C. How is disconnect to be furnished?<br />
Separate Box Comb<strong>in</strong>ation W/Starter Box Custom Box<br />
4. Starter:<br />
A. Present Location of Starter:<br />
1. On Press Brake or Off Press Brake<br />
2. With Control<br />
Separate from Control<br />
With Disconnect Only<br />
Not Furnished<br />
B. Is transformer for reduc<strong>in</strong>g voltage to starter<br />
required? N Y<br />
C. Is magnetic starter required for ma<strong>in</strong> drive?<br />
N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
If N, exist<strong>in</strong>g starter must have 115-V coil and a<br />
norm<strong>all</strong>y open auxiliary contact.<br />
Y<br />
Estimate<br />
Actual<br />
D. If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
4<br />
______ Voltage ______<br />
E. Revers<strong>in</strong>g N Y Nonrevers<strong>in</strong>g N Y<br />
F. How is starter to be furnished? Separate Box<br />
Comb<strong>in</strong>ation W/Disconnect Box In Custom Box<br />
G. Is remote push-button station required? N Y<br />
If Y, Ma<strong>in</strong> Motor Ram Adjust<br />
H. Does press brake have Variable-Speed Drive?<br />
N Y If Y:<br />
Mechanical Adjust Electronic<br />
I. Are other starters required?<br />
Ram Adjust: N Reuse Exist<strong>in</strong>g<br />
Customer to Furnish<br />
Y<br />
Estimate<br />
Actual<br />
If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
Lube System N Y (Also see 6A.)<br />
Estimate<br />
Actual<br />
If Y, provide: ______ Horsepower ______<br />
______ Full-Load Amps ______<br />
______ Voltage ______<br />
N/A<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Manufacturer<br />
Model No.<br />
Serial No.<br />
3 of 4<br />
96 | CONTROL SYSTEMS
SURVEY FOR PRESS BRAKES (CONTINUED)<br />
5<br />
5. Covers:<br />
Do any mechanical power-transmission apparatuses<br />
need to be covered up to 7 feet above floor or platform?<br />
N Y If Y, what needs to be covered?<br />
Flywheel N Y Connection Rod N Y<br />
Gears N Y Shaft End N Y<br />
Additional brackets Sprockets & Cha<strong>in</strong> N Y<br />
required N Y Other____________________<br />
For identification and reference, please fill <strong>in</strong> this area.<br />
Mach<strong>in</strong>e No.<br />
Manufacturer<br />
Model No.<br />
Serial No.<br />
6<br />
6. Other Considerations:<br />
A. Does press brake have lube system? N Y<br />
If Y, what k<strong>in</strong>d of system?:<br />
Manual or mechanical pump N Y<br />
*Timer N Y<br />
*Motorized N Y (Please fill <strong>in</strong> Section 4I.)<br />
*Be sure to furnish lube schematics and/or <strong>in</strong>structions<br />
with this form. If only control schematics are<br />
supplied, be sure the lube system is <strong>in</strong>dicated.<br />
B. Is safety block to be furnished? N Y If Y:<br />
What size is needed? ________” (Height)<br />
How many? _______ S M L (circle <strong>one</strong>)<br />
Interlock N Y Holder N Y<br />
C. If questionable about any <strong>in</strong>formation furnished, please enclose photos of<br />
entire front, sides (left and right), and rear of press brake. Include close-up<br />
photos of the <strong>in</strong>side of the exist<strong>in</strong>g<br />
control box, clutch/brake, and shaft end which would drive the tim<strong>in</strong>g device. If<br />
hydraulic, enclose photos of valves, system, and exist<strong>in</strong>g cycle tim<strong>in</strong>g.<br />
Send<strong>in</strong>g Enclosed<br />
4 of 4<br />
CONTROL SYSTEMS | 97
SPRING-LOADED TURNOVER BARS<br />
In OSHA 29 CFR 1910.217, it says that “The employer sh<strong>all</strong> provide spr<strong>in</strong>g-loaded turnover bars for presses designed to accept such turnover bars.”<br />
The turnover bar is most frequently used with mechanical power presses. Turnover bars can also be used on four-slides or any other mach<strong>in</strong>e<br />
where the bar might be sent <strong>in</strong>to the air if it is <strong>in</strong>advertently left <strong>in</strong> the bar r<strong>in</strong>g hole and the mach<strong>in</strong>e is turned on. Each spr<strong>in</strong>g-loaded turnover bar<br />
is self-eject<strong>in</strong>g so it can’t be left <strong>in</strong> the bar hole.<br />
Fully Enclosed Spr<strong>in</strong>g Made of High-Tensile Steel V<strong>in</strong>yl-Coated, Yellow Handle<br />
SPRING-LOADED TURNOVER BARS<br />
PART NO.<br />
NORMAL<br />
SIZE<br />
ACTUAL<br />
SIZE<br />
BAR<br />
DIAMETER<br />
OUTISDE<br />
DIAMETER<br />
ENGAGEMENT<br />
LENGTH<br />
OVERALL<br />
LENGTH<br />
WEIGH IN<br />
POUNDS<br />
KMR-001 3/8" .365" 3/4" 1.050" 1.50" 18" 1.8<br />
KMR-002 1/2" .490" 3/4" 1.050" 1.75" 24" 3.5<br />
KMR-003 5/8" .615" 3/4" 1.050" 1.75" 24" 3.5<br />
KMR-004 3/4" .740" 15/16" 1.315" 2.00" 30" 6.7<br />
KMR-005 7/8" .865" 15/16" 1.315" 2.00" 30" 6.7<br />
KMR-006 1" .990" 1-1/4" 1.660" 2.50" 36" 13.7<br />
KMR-007 1-1/4" 1.240" 1-1/4" 1.660" 2.50" 36" 14.0<br />
*Each engag<strong>in</strong>g bar is made .010” under correspond<strong>in</strong>g hole size. End is chamfered for easy entry.<br />
Consult the factory for special sizes.<br />
Spr<strong>in</strong>g-Loaded Turnover Bar on Flywheel<br />
of Mechanical Power Press<br />
98 | CONTROL SYSTEMS
OPTIONAL PALM BUTTON ASSEMBLIES<br />
Other styles of palm buttons are available to meet the OSHA and ANSI safety standards. The follow<strong>in</strong>g pages <strong>in</strong>clude options to our standard palm<br />
buttons listed throughout this catalog.<br />
All palm buttons can be furnished:<br />
• as <strong>in</strong>dividual palm buttons<br />
• <strong>in</strong> sets of two with r<strong>in</strong>g guards for two-hand trip or two-hand control<br />
• <strong>in</strong> control bars, special boxes, or control consoles<br />
R<strong>in</strong>g guards, covers, or similar devices must protect the palm button from accidental activation. Anti tie-down protection is required for s<strong>in</strong>gle-stroke,<br />
two-hand trip, and two-hand control. It should already be built <strong>in</strong>to the control system where any of these assemblies are applied. The buttons must<br />
also be mounted at a proper safety distance accord<strong>in</strong>g to OSHA 29 CFR 1910.217 for two-hand trip or two-hand control when apply<strong>in</strong>g them to<br />
mechanical power presses. ANSI also requires that they be at the calculated safety distance on many other mach<strong>in</strong>es.<br />
The assemblies, which <strong>in</strong>clude the r<strong>in</strong>g guard and mount<strong>in</strong>g plate, provide protection aga<strong>in</strong>st un<strong>in</strong>tended operation. All emergency-stop buttons are<br />
latch-out type buttons.<br />
CONTROL SYSTEMS | 99
OPTIONAL PALM BUTTON ASSEMBLIES (CONTINUED)<br />
LIGHT-PUSH PALM BUTTONS<br />
These light-push palm button assemblies can replace the standard black palm button assemblies (shown throughout this catalog) when a lighter<br />
push is required.<br />
The run/<strong>in</strong>ch palm buttons have a s<strong>in</strong>gle plunger which provides 1 NO and 1 NC contact arrangement. The mushroom head is made of a z<strong>in</strong>c die<br />
cast and has a flat plunger. The palm button cover plate has a solid neoprene gasket which provides an oil-tight seal upon <strong>in</strong>st<strong>all</strong>ation.<br />
ORDERING INFORMATION<br />
Part No. CTL-533—Two chrome run/<strong>in</strong>ch buttons, r<strong>in</strong>g guards, and red<br />
emergency-stop palm button. The red palm button has 1 NO and 1 NC<br />
contact arrangement.<br />
Part No. CTL-534—Two chrome run/<strong>in</strong>ch buttons, r<strong>in</strong>g guards, red<br />
emergency-stop palm button, and yellow top-stop palm button. The red and<br />
yellow palm button each have 1 NO and 1 NC contact arrangement.<br />
Part No. CTL-538—Two chrome run/<strong>in</strong>ch buttons, r<strong>in</strong>g guards, red<br />
emergency-stop palm button, and yellow return/<strong>in</strong>ch-up palm button. The<br />
red and yellow palm button each have 1 NO and 1 NC contact arrangement.<br />
Part No. CTL-533<br />
Part No. CTL-534<br />
Part No. CTL-538<br />
ARTICULATED PALM BUTTONS<br />
These palm button assemblies have articulated chrome palm buttons<br />
and are offered <strong>in</strong> 24-V DC low-voltage or 115-V AC standard-voltage<br />
contacts. The low-voltage buttons are specific<strong>all</strong>y designed for use<br />
with solid-state controls only and should not be used with relay-based<br />
controls. These ergonomic, heavy-duty palm buttons can be operated at any<br />
angle and are easy to push. The buttons are chrome plated and the guards<br />
are made of steel. The buttons provide 1 NO and 1 NC contact arrangement.<br />
STANDARD-VOLTAGE CONTACT RATINGS<br />
Maximum Voltage .................................................................600 V AC/DC<br />
Typical Operat<strong>in</strong>g Force................................3.7 lb (center), 2.7 lb (perim.)<br />
LOW-VOLTAGE CONTACT RATINGS<br />
M<strong>in</strong>imum Voltage DC..................................................................5 V, 1 mA<br />
Maximum Voltage DC.............................................................. 48 V, 0.1 A<br />
Maximum Voltage AC............................................................. 240 V, 0.4 A<br />
Typical Operat<strong>in</strong>g Force................................3.7 lb (center), 2.7 lb (perim.)<br />
ORDERING INFORMATION<br />
STANDARD-VOLTAGE CONTACTS—115 V AC<br />
Part No. CTL-547—Two articulated chrome run/<strong>in</strong>ch buttons with r<strong>in</strong>g<br />
guards, mount<strong>in</strong>g boxes, and red emergency-stop palm button.<br />
Part No. CTL-548—Two articulated chrome run/<strong>in</strong>ch buttons with r<strong>in</strong>g<br />
guards, mount<strong>in</strong>g boxes, red emergency-stop palm button, and yellow topstop<br />
palm button.<br />
Part No. CTL-550—Two articulated chrome run/<strong>in</strong>ch buttons with r<strong>in</strong>g<br />
guards, mount<strong>in</strong>g boxes, red emergency-stop palm button, and yellow<br />
return/<strong>in</strong>ch-up palm button.<br />
Part No. CTL-547<br />
Part No. CTL-548<br />
Part No. CTL-550<br />
LOW-VOLTAGE CONTACTS—24 V DC<br />
Part No. CTL-541—Two articulated chrome run/<strong>in</strong>ch buttons with<br />
r<strong>in</strong>g guards, mount<strong>in</strong>g boxes, and red emergency-stop palm button.<br />
Part No. CTL-542—Two articulated chrome run/<strong>in</strong>ch buttons with<br />
r<strong>in</strong>g guards, mount<strong>in</strong>g boxes, red emergency-stop palm button, and<br />
yellow top-stop palm button.<br />
Part No. CTL-544—Two articulated chrome run/<strong>in</strong>ch buttons with<br />
r<strong>in</strong>g guards, mount<strong>in</strong>g boxes, red emergency-stop palm button, and<br />
yellow return/<strong>in</strong>ch-up palm button.<br />
100 | CONTROL SYSTEMS
REPLACEMENT PARTS FOR PALM BUTTON ASSEMBLIES<br />
Universal Run Button RING Guard<br />
Part No. CTK-006<br />
This palm button r<strong>in</strong>g guard is the way to protect new and exist<strong>in</strong>g run palm buttons from<br />
accidental operation. This high-impact PVC plastic palm button r<strong>in</strong>g guard can be used with<br />
most palm button brands. The large square r<strong>in</strong>g shape <strong>all</strong>ows the operator to change hand<br />
position as well as use other surfaces of the hand to cycle the mach<strong>in</strong>e. This r<strong>in</strong>g guard resists<br />
deterioration that can occur from cutt<strong>in</strong>g oils and other types of lubricants that come <strong>in</strong> contact<br />
with it. This r<strong>in</strong>g guard has a relief for the wrist, and the word run is molded <strong>in</strong>to the top of the<br />
r<strong>in</strong>g guard. Four 1¼” screws are furnished with each r<strong>in</strong>g guard.<br />
.18”<br />
12 holes for vertical or horizontal<br />
mount<strong>in</strong>g<br />
2.8”<br />
4.9”<br />
5.4”<br />
4.9”<br />
CHROME PALM BUTTON<br />
Part No. CTC-737<br />
This heavy-duty, light-push, s<strong>in</strong>gle plunger run/<strong>in</strong>ch palm button provides 1 NO and 1 NC<br />
contact arrangement. This 2¼” button is constructed of z<strong>in</strong>c cast and has a flat plunger. The<br />
palm button cover plate has a solid neoprene gasket which provides an oil-tight seal upon<br />
<strong>in</strong>st<strong>all</strong>ation. This palm button can replace the black palm button described below when a<br />
lighter push is required. The force required to operate this button is 2.5 lb.<br />
ARTICULATED CHROME PALM BUTTON WITH GUARD<br />
Part No. CTC-746—Standard Voltage<br />
Part No. CTC-751—Low Voltage<br />
This ergonomic, heavy-duty palm button provides 1 NO and 1 NC contact arrangement. The<br />
palm button is chrome plated and the guard is made of steel. The straight-push force required<br />
to operate this button is 3.7 lb.<br />
BLACK PALM BUTTON<br />
Part No. CTC-726<br />
This standard heavy-duty, s<strong>in</strong>gle plunger run/<strong>in</strong>ch palm button provides 1 NO and 1 NC<br />
contact arrangement. This 2¼” button is mushroom shaped. The palm button cover plate has<br />
a solid neoprene gasket which provides an oil-tight seal upon <strong>in</strong>st<strong>all</strong>ation. The force required<br />
to operate this button is 5 lb.<br />
YELLOW TOP-STOP PALM BUTTON<br />
Part No. CTC-727<br />
This heavy-duty, s<strong>in</strong>gle plunger yellow top-stop palm button provides 1 NO and 1 NC contact<br />
arrangement. This 2¼” button has a mushroom-shaped plunger. The palm button cover plate<br />
has a solid neoprene gasket which provides an oil-tight seal upon <strong>in</strong>st<strong>all</strong>ation. The force<br />
required to operate this button is 5 lb.<br />
CONTROL SYSTEMS | 101
REPLACEMENT PARTS FOR PALM BUTTON ASSEMBLIES (CONTINUED)<br />
YELLOW RETURN/INCH-UP PALM BUTTON<br />
Part No. CTC-740<br />
This heavy-duty, s<strong>in</strong>gle plunger yellow return/<strong>in</strong>ch-up palm button provides 1 NO and 1 NC contact arrangement.<br />
This 2¼” button has a mushroom-shaped plunger. The palm button cover plate has a solid neoprene gasket<br />
which provides an oil-tight seal upon <strong>in</strong>st<strong>all</strong>ation. This button is used to return/<strong>in</strong>ch-up the ram on hydraulic<strong>all</strong>y<br />
or pneumatic<strong>all</strong>y operated mach<strong>in</strong>es. The force required to operate this button is 5 lb.<br />
RED EMERGENCY-STOP PALM BUTTON WITH LOCKOUT<br />
Part No. CTC-736<br />
This heavy-duty, s<strong>in</strong>gle plunger red emergency-stop palm button provides 1 NO and 1 NC contact arrangement.<br />
This 2¼” button has a mushroom-shaped plunger with a spr<strong>in</strong>g latch that keeps the button latched down when<br />
pushed. A release is <strong>in</strong>corporated. It also has provisions for attach<strong>in</strong>g a padlock to the latch. The palm button<br />
cover plate has a solid neoprene gasket which provides an oil-tight seal upon <strong>in</strong>st<strong>all</strong>ation. The force required to<br />
operate this button is 12.5 lb.<br />
ELECTRICAL RATINGS FOR ALL BUTTONS (EXCEPT ARTICULATED)<br />
– HEAVY-DUTY ANSI 600/NEMA 300<br />
NORMAL POTENTIAL NORMAL CURRENT INRUSH CURRENT<br />
110 TO 120 V AC* 6.0 A 60.0 A<br />
220 TO 240 V AC* 3.0 A 30.0 A<br />
440 TO 480 V AC* 1.5 A 15.0 A<br />
550 TO 600 V AC* 1.2 A 12.0<br />
115 TO 125 V DC** 2.2 A –<br />
230 TO 250 V DC** 1.1 A –<br />
*Power factor of 0.35 or less<br />
**Inductive loads as specified <strong>in</strong> Section 125 of Industrial Control Devices, Controllers and<br />
Assemblies, ANSI/NEMA ICS 2-1988<br />
MOUNTING BOXES (WITH 3 ⁄4” NPT THREADED HUBS)<br />
Part No. CTK-004<br />
A s<strong>in</strong>gle-hub mount<strong>in</strong>g box is supplied with <strong>all</strong> palm button assemblies. It is used when wire term<strong>in</strong>ates<br />
at this box. It can also be used when remote mount<strong>in</strong>g electrical cut-off systems or duplex power outlets.<br />
Part No. CTK-003<br />
A double-hub mount<strong>in</strong>g box is supplied with <strong>all</strong> palm button assemblies. It is used when wires are<br />
required to go through the box and on to another mount<strong>in</strong>g box.<br />
S<strong>in</strong>gle<br />
Hub<br />
Double<br />
Hub<br />
102 | CONTROL SYSTEMS
The signs offered <strong>in</strong> this catalog are .055” thick l<strong>in</strong>ear polyethylene. They are semi-rigid plastic and are capable of withstand<strong>in</strong>g a temperature range<br />
of -60° to 130° F. They are resistant to tears and may be mounted with nails, rivets, screws, bolts, nylon lock-straps, double-face adhesive tape,<br />
etc. Each sign is protected from fad<strong>in</strong>g, chipp<strong>in</strong>g, scratch<strong>in</strong>g, weather extremes, physical abuse, grease, oil, moisture, chemicals and acids. These<br />
signs do not rust, dent, or corrode. They do not curl up or rip and are lightweight and easy to handle.<br />
OPERATOR SAFETY PRECAUTIONS FOR METALFORMING MACHINERY—81⁄2” X 11” X .055” THICK<br />
Part No. KSC-000—English<br />
Part No. KSC-000S—Spanish<br />
OPERATOR<br />
Handout for Any<strong>one</strong> Operat<strong>in</strong>g This Mach<strong>in</strong>e<br />
!<br />
Part No. KSC-000<br />
KSC-000 Front—English<br />
KSC-000 Back—English<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
8<br />
9<br />
10<br />
Antes de Manejar esta Máqu<strong>in</strong>a<br />
Lea y Familiarícese con las<br />
Siguientes Medidas de Seguridad.<br />
Nunca maneje la máqu<strong>in</strong>a hasta haber comprendido<br />
los peligros que ésta representa. Nunca coloque las<br />
manos ni n<strong>in</strong>guna otra parte del cuerpo en la<br />
máqu<strong>in</strong>a, puesto que podría ocasionar la pérdida de<br />
dedos, extremidades e <strong>in</strong>cluso la muerte.<br />
Nunca maneje la máqu<strong>in</strong>a s<strong>in</strong> un protector en el<br />
punto de funcionamiento* o dispositivo de seguridad<br />
que lo proteja contra lesi<strong>one</strong>s corporales.<br />
Nunca maneje la máqu<strong>in</strong>a con un conmutador a<br />
pedal, salvo que tenga un protector en el punto de<br />
funcionamiento o dispositivo debidamente mantenido.<br />
Nunca se “monte” en el control a pedal o el<br />
conmutador a pedal. Nunca descanse el pie sobre el<br />
control a pedal o dentro del conmutador a pedal.<br />
Retire siempre el pie completamente del control a<br />
pedal o conmutador a pedal después de cada ciclo y<br />
manténgalo fuera del <strong>in</strong>terruptor en todo momento si<br />
no va a arrancar la máqu<strong>in</strong>a.<br />
Use siempre herramientas manuales para alimentar<br />
o retirar material del punto de funcionamiento o<br />
cualquier otra pieza peligrosa de la máqu<strong>in</strong>a. No<br />
alcance a través o dentro del punto de<br />
funcionamiento bajo n<strong>in</strong>guna circunstancia.<br />
Nunca maneje la máqu<strong>in</strong>a a menos que haya recibido<br />
la capacitación debida y comprenda cabalmente todas<br />
las <strong>in</strong>strucci<strong>one</strong>s de manejo. Esté seguro de saber<br />
cómo funcionar y controlar la máqu<strong>in</strong>a.<br />
Nunca maneje la máqu<strong>in</strong>a hasta haberla puesto en<br />
prueba con el protector o dispositivo de seguridad<br />
antes de <strong>in</strong>iciar o re<strong>in</strong>iciar la producción. No ponga a<br />
funcionar la máqu<strong>in</strong>a, salvo que esté seguro de que<br />
el dispositivo de seguridad esté ajustado debidamente<br />
y funcionando correctamente. Si no está seguro,<br />
llame a su supervisor.<br />
Nunca maneje la máqu<strong>in</strong>a si no está funcionando<br />
debidamente o si usted notara un ruido raro o<br />
cambio en el rendimiento de la misma. Apague la<br />
máqu<strong>in</strong>a <strong>in</strong>mediatamente y notifique a su supervisor.<br />
Nunca maneje la máqu<strong>in</strong>a con dispositivos de retorno<br />
(si los hubiera) salvo que hayan sido ajustados<br />
adecuadamente para usted. Pídale a su supervisor<br />
que le demuestre cómo al bajar el vástago, los<br />
dispositivos de retorno mantienen los dedos alejados<br />
de las puntas de espolón. Use siempre las<br />
muñequeras adecuadamente y bien aseguradas.<br />
Nunca maneje la máqu<strong>in</strong>a con dispositivos de<br />
retorno (si los hubiera) s<strong>in</strong> antes leer y comprender<br />
cabalmente las <strong>in</strong>strucci<strong>one</strong>s. Las <strong>in</strong>strucci<strong>one</strong>s<br />
deben estar a su disposición y mantenerse en todo<br />
momento junto al dispositivo de retorno. Obtenga,<br />
lea y siga dichas <strong>in</strong>strucci<strong>one</strong>s.<br />
11<br />
12<br />
13<br />
14<br />
15<br />
16<br />
17<br />
18<br />
19<br />
20<br />
Nunca maneje la máqu<strong>in</strong>a a menos que el<br />
desc<strong>one</strong>ctador a dos manos, el control a dos manos<br />
o el detector de presencia (si lo hubiera) se<br />
encuentre <strong>in</strong>stalado correctamente y a una distancia<br />
adecuada de seguridad. Consulte con su supervisor<br />
si tuviera dudas sobre la distancia adecuada de<br />
seguridad.<br />
Nunca maneje la máqu<strong>in</strong>a a menos que la cort<strong>in</strong>a<br />
de luz (si la hubiera) se encuentre c<strong>one</strong>ctada<br />
correctamente en el sistema de control de la<br />
máqu<strong>in</strong>a. Debe apagarse únicamente durante el<br />
ciclo de piezas no peligrosas de la máqu<strong>in</strong>a: no se<br />
recomienda su supresión.<br />
Nunca altere, rehaga la <strong>in</strong>stalación eléctrica ni<br />
desvíe n<strong>in</strong>gún comp<strong>one</strong>nte, control o dispositivo de<br />
seguridad de la máqu<strong>in</strong>a.<br />
Use siempre gafas de seguridad, protectores para<br />
oídos o cualquier otro equipo de protección personal<br />
que necesite para manejar la máqu<strong>in</strong>a.<br />
Nunca maneje la máqu<strong>in</strong>a si trae los cabellos<br />
largos, lleva ropa suelta o joyas. Pueden atascarse<br />
en las piezas de la máqu<strong>in</strong>a o el equipo auxiliar.<br />
Asegúrese de que todas las personas estén<br />
alejadas de la máqu<strong>in</strong>a antes de p<strong>one</strong>rla en marcha,<br />
especialmente si hay varios operadores o<br />
ayudantes. No maneje la máqu<strong>in</strong>a a menos que<br />
usted y todos los operadores y/o ayudantes estén<br />
protegidos contra lesi<strong>one</strong>s con un protector o<br />
dispositivo de seguridad.<br />
Manténgase siempre alerta (no sueñe despierto) al<br />
manejar la máqu<strong>in</strong>a y nunca lo haga bajo la<br />
<strong>in</strong>fluencia de alcohol ni drogas, <strong>in</strong>cluidos<br />
medicamentos con receta.<br />
Al personal de mantenimiento y preparación de<br />
troquelado: Nunca trabaje en la máqu<strong>in</strong>a a menos<br />
que esté apagada y bloqueada, el volante esté<br />
desactivado, los bloques de seguridad colocados<br />
entre los troqueles o matrices y toda las fuentes de<br />
energía (eléctrica, neumática, hidráulica, etc.) se<br />
encuentren en cero.<br />
Esté siempre preparado para una situación de<br />
emergencia. Debe saber cómo parar y apagar la<br />
máqu<strong>in</strong>a si fuera necesario.<br />
Nunca maneje la máqu<strong>in</strong>a a menos que todas los<br />
comp<strong>one</strong>ntes de transmisión mecánica (volantes,<br />
engranajes, etc.) y el equipo auxiliar estén libres de<br />
peligros.<br />
* Punto de funcionamiento: “Lugar de la máqu<strong>in</strong>a-herramienta donde se coloca el material y se realiza un proceso.” (ANSI B11.19)<br />
AVISO AL EMPLEADOR: Deberá entregarse copia de estas “Medidas de seguridad para el operador” a<br />
todos los operadores (<strong>in</strong>cluidos el personal de preparación, mantenimiento y supervisores) de la<br />
máqu<strong>in</strong>a. El presente folleto deberá colgarse en la máqu<strong>in</strong>a a disponibilidad y visibilidad del operador.<br />
Están disponibles folletos de seguridad adicionales a pedido del <strong>in</strong>teresado.<br />
IMPORTANTE: Si debido a limitaci<strong>one</strong>s del idioma o escolaridad, el usuario no pudiera leer ni<br />
comprender el contenido de las Medidas de seguridad para el operador, dicha <strong>in</strong>formación deberá ser<br />
traducida, leída o <strong>in</strong>terpretada a la persona, verificándose su comprensión. Comuníquese con la fábrica<br />
si necesitara folletos de las Medidas de seguridad en <strong>in</strong>glés o francés.<br />
REVISE DIARIAMENTE ESTA MEDIDA DE SEGURIDAD.<br />
KSC-000S Front—Spanish<br />
KSC-000S Back—Spanish<br />
CONTROL SYSTEMS | 103
GENERAL METALFORMING SIGN<br />
—5” X 6 “ X .055” THICK<br />
FOOT SWITCH SIGN<br />
—5” X 6 “ X .055” THICK<br />
Part No. KSC-054—English<br />
Part No. KSC-055—English<br />
Reverse Side of Signs (English)<br />
Part No. KSC-054S—Spanish<br />
Part No. KSC-055S—Spanish<br />
Also available <strong>in</strong> French—<br />
Part No. KSC-055F (not shown)<br />
This sign does not cover <strong>all</strong> dangers<br />
that could happen while operat<strong>in</strong>g<br />
this mach<strong>in</strong>e.<br />
General Danger Sign<br />
—10” x 12” x .055” thick<br />
PRESS BRAKE DANGER SIGN<br />
—10” X 12” X .055” THICK<br />
Reverse Side of Above Signs—English<br />
104 | CONTROL SYSTEMS
Notice Sign for Metalform<strong>in</strong>g Mach<strong>in</strong>ery<br />
Part No. KSC-033 5” x 6” x .055” thick<br />
Flywheel Rotation Sign<br />
Part No. KSC-045 1¼” x 5” x .055” thick<br />
Part No. KSC-010 2½” x 10” x .055” thick<br />
The labels offered on this page are <strong>all</strong> furhished with an adhesive back so they will stick to most clean surfaces. All mylar labels are .002” thick. Some<br />
labels are offered <strong>in</strong> various sizes to fit onto a product or <strong>in</strong>to a specific area.<br />
ROTATING GEARS AND PULLEY LABEL<br />
DANGER–CLOSING RAM AND DIE LABELS<br />
Part No. KST-181 3³/4” x 2½” x .002” thick<br />
Part No. KST-146 3” x 5” x .002” thick<br />
Part No. KST-134 8” x 4³/8” x .002” thick<br />
Part No. KST-134S 8” x 4³/8” x .002” thick—Spanish<br />
Part No. KST-145 6¼” x 3½” x .002” thick<br />
Part No. KST-145S 6¼” x 3½” x .002” thick—Spanish<br />
Hazardous Voltage Label<br />
Part No. KST-152 2½” x 1½” x .002” thick<br />
Part No. KST-153 3” x 5” x .002” thick<br />
Part No. KST-135 5” x 5½” x .002” thick<br />
Part No. KST-136 2½” x 3” x .002” thick<br />
Part No. KST-136S 2½” x 3” x .002” thick—Spanish<br />
Part No. KST-137 7¼” x 8” x .002” thick<br />
Part No. KST-137S 7¼” x 8” x .002” thick—Spanish<br />
Part No. KST-143 5” x 3” x .002” thick<br />
Danger—High Voltage Label<br />
Part No. KST-194 2 7 / 8” x 5 7 / 8” x .003” thick<br />
CONTROL SYSTEMS | 105
SAMPLE PRESS INSPECTION REPORT<br />
Company ______________________________________________________________________________________________<br />
Build<strong>in</strong>g___________________________________________Department____________________ Press No. _________________<br />
Parts Inspected 4 OK Defective Condition Corrective Action Date Repaired<br />
1. Frame<br />
2. Motor<br />
3. Flywheel<br />
4. Gears (if applicable)<br />
5. Crankshaft<br />
6. Clutch<br />
7. Brake<br />
8. Ram and Gibs<br />
9. Connection (Pitman) and<br />
Ram Adjust<strong>in</strong>g Screw<br />
10. Slide Counterbalance<br />
(if furnished)<br />
11. Air System<br />
12. Electrical System<br />
13. Foot Switch<br />
14. Po<strong>in</strong>t-of-Operation<br />
<strong>Safeguard<strong>in</strong>g</strong><br />
A) Guard<br />
B) Presence-Sens<strong>in</strong>g (Light<br />
Curta<strong>in</strong> or Radio Frequency)<br />
C) Pullback (Pullout)<br />
D) Type A or B Gate<br />
(Movable Barrier)<br />
E) Restra<strong>in</strong>t (Holdout)<br />
F) Two-Hand Trip or Control<br />
15. Miscellaneous<br />
Inspected by: Date Approved for Use Not Approved<br />
See guide on next page<br />
106 | CONTROL SYSTEMS
GUIDE FOR THE INSPECTION OF MECHANICAL POWER PRESSES<br />
*Inspect for Code Violations, defects, miss<strong>in</strong>g parts, malfunctions, ma<strong>in</strong>tenance<br />
INSPECTION OF<br />
1. Frame<br />
2. Motor<br />
3. Flywheel<br />
4. Gears<br />
5. Crankshaft<br />
6. Clutch<br />
7. Brake<br />
8. Ram and gibs<br />
9. Connection (pitman) &<br />
ram adjust<strong>in</strong>g screw<br />
10. Ram counterbalance<br />
11. Air system<br />
Cracks? Broken or loose parts? Loose<br />
hold down bolts?<br />
Clean? Lubrication? Overheat<strong>in</strong>g?<br />
Rotates <strong>in</strong> correct direction? Free<br />
runn<strong>in</strong>g? Covered?<br />
Loose? Broken or cracked teeth? Excess<br />
noise? Proper lubrication? Covered?<br />
Cracks? Bent?<br />
Proper clearance <strong>in</strong> bear<strong>in</strong>gs?<br />
Full-revolution: s<strong>in</strong>gle-stroke capability,<br />
loose or worn parts, <strong>in</strong>clud<strong>in</strong>g l<strong>in</strong>kage?<br />
Weak or broken spr<strong>in</strong>gs? Compression<br />
spr<strong>in</strong>gs operat<strong>in</strong>g on rod, or guided<br />
with<strong>in</strong> hole or tube? Properly adjusted?<br />
Part-revolution: air or oil leaks? Proper<br />
alignment? Disengagement? Stopp<strong>in</strong>g<br />
position? Worn clutch l<strong>in</strong><strong>in</strong>g? Weak or<br />
broken spr<strong>in</strong>gs? Power or air pressure<br />
failure or deactivation? Momentary<br />
operation of stop control applies<br />
brake and releases clutch? Retripp<strong>in</strong>g<br />
required? Red stop button?<br />
Brake l<strong>in</strong><strong>in</strong>g worn? Brake properly<br />
adjusted? Does it stop slide quickly?<br />
Are friction brakes set with compression<br />
spr<strong>in</strong>gs operat<strong>in</strong>g on rod, or guided<br />
with<strong>in</strong> a hole or tube?<br />
Face of ram par<strong>all</strong>el to bolser? Proper<br />
gib clearance? Any scor<strong>in</strong>g?<br />
Proper bear<strong>in</strong>g and b<strong>all</strong> sear clearances?<br />
Screw turns freely?<br />
Spr<strong>in</strong>g type: proper adjustment? Broken<br />
spr<strong>in</strong>gs or loose nuts? Pneumatic type:<br />
air leakage? Proper air pressure? Loose<br />
connection to slide?<br />
Proper air pressure? Valve operation?<br />
Pressure gauges? Leaks?<br />
Can ma<strong>in</strong> power switch be locked only<br />
<strong>in</strong> aoof position? Ground<strong>in</strong>g?Condition of<br />
wir<strong>in</strong>g? Relays? Rotary limit switches?<br />
12. Electrical system<br />
13. Foot switch<br />
14. Po<strong>in</strong>t-of-operation<br />
safeguard<strong>in</strong>g<br />
15. Miscellaneous<br />
Solenoids? Motor starter disconnects from<br />
voltage fluctuation or power failure? Retripp<strong>in</strong>g<br />
required? Is any comp<strong>one</strong>nt bypassed?<br />
Nonslip pad on contact are? Shielded from<br />
accidental operation?<br />
A) Guard – Barrier that prevents entry of<br />
operator's hands or f<strong>in</strong>gers <strong>in</strong>to the po<strong>in</strong>t-ofoperation<br />
area? Adjustment and ma<strong>in</strong>tenance?<br />
P<strong>in</strong>ch po<strong>in</strong>ts rema<strong>in</strong>g<strong>in</strong>g <strong>in</strong> adjacent areas?<br />
B) Presence-Sens<strong>in</strong>g (light curat<strong>in</strong> or radio<br />
frequency – part-revolut<strong>in</strong> clutch only) – reliable<br />
design and proper electrical tie-<strong>in</strong> to control?<br />
Fized at proper safety distance from p<strong>in</strong>ch<br />
po<strong>in</strong>t? Barrier guards for other hazardous po<strong>in</strong>tof-operation<br />
areas?<br />
C) Pullback (Pullout) – enough or too much pull<br />
on cables? Is proper adjustment be<strong>in</strong>g made<br />
for change <strong>in</strong> operator, die, shift? Records of<br />
<strong>in</strong>spection/ma<strong>in</strong>tenance be<strong>in</strong>g kept?<br />
D) Type A or B Gate (B gate for part-revolution<br />
clutch only) – po<strong>in</strong>t of operation enclosed before<br />
press cycle can be <strong>in</strong>itiated? Barrier guards for<br />
other hazardous po<strong>in</strong>t-of-operation areas?<br />
E) Restra<strong>in</strong>t (Holdout) – adjusted so that<br />
operator's f<strong>in</strong>gers cannot reach <strong>in</strong>to dies?<br />
Securely anchored? Adjusted for each operator,<br />
die, shift?<br />
F) Two-hand Trip or Control (two-hand control<br />
for part-revolution clitch only) – shielded<br />
aga<strong>in</strong>st un<strong>in</strong>tended operation? Concurrent,<br />
antirepeat? Fized <strong>in</strong> place at proper safety<br />
distance from p<strong>in</strong>ch po<strong>in</strong>t? Interrupted stroke<br />
protection and adequite hold<strong>in</strong>g time (for twohand<br />
control only)?<br />
Comment on any other <strong>in</strong>tems such as:<br />
Protection from f<strong>all</strong><strong>in</strong>g overhead parts. Light<strong>in</strong>g.<br />
Cleanl<strong>in</strong>ess. Lubriacation. Pressure vessels.<br />
Hdraulic-equipment. Auxiliary equipment.<br />
General ma<strong>in</strong>tenance. Special types of clutches<br />
or brakes. Cover<strong>in</strong>g of gears, belts, pulleys.<br />
Overload<strong>in</strong>g. All auzilary equipment.<br />
*Refer to OSHA 29 CFR 1910.212, 1910.217, 1910.219, on pages 116 through 127, ANSI B11.1 & B15.1, and other applicable regulations and standards.<br />
CONTROL SYSTEMS | 107
FULL-REVOLUTION OBI PRESS<br />
Tim<strong>in</strong>g Device<br />
Motor<br />
Motor Starter<br />
Disconnect Switch<br />
Control Box<br />
Incl<strong>in</strong><strong>in</strong>g Mechanism<br />
Cam and Mount<strong>in</strong>g Strip Assembly<br />
Crankshaft<br />
Drag Brake<br />
Knockout Rod<br />
Knockout Bracket<br />
Operator s Station<br />
Ram (Slide)<br />
Frame (Body)<br />
Knockout Bar<br />
Side Barriers<br />
Left-Side View<br />
Leg<br />
Belts<br />
Sheave<br />
Tim<strong>in</strong>g Device<br />
Crankshaft<br />
Lift<strong>in</strong>g Bolt<br />
Flywheel<br />
Connection<br />
(Pitman)<br />
Lubricator<br />
Die Clamp<br />
Rear Barrier<br />
Bolster<br />
Clutch Area<br />
Cover<br />
Ram-Adjust<strong>in</strong>g Screw<br />
Run Buttons<br />
Gib<br />
Air Cyl<strong>in</strong>der<br />
Bed<br />
Front View<br />
Leg Bolts<br />
Leg Tie Rod<br />
Foot Switch<br />
108 | CONTROL SYSTEMS
PART-REVOLUTION OBI PRESS<br />
Motor<br />
Resolver/Pulser<br />
Assembly (Beh<strong>in</strong>d Cover)<br />
Dual-Solenoid Valve<br />
Comb<strong>in</strong>ation Disconnect<br />
Switch and Motor Starter<br />
Clutch/Brake Control Panel<br />
Incl<strong>in</strong><strong>in</strong>g Mechanism<br />
Air Pressure Switch<br />
for Clutch/Brake<br />
Filter-Regulator-Lubricator<br />
Assembly for Clutch/Brake<br />
Air-Releas<strong>in</strong>g Brake<br />
Knockout Rod<br />
Knockout Bracket<br />
Lubricator<br />
Operator's Station<br />
Ram (Slide)<br />
Knockout Bar<br />
Side Guard<br />
Left-Side View<br />
Frame<br />
(Body)<br />
Air Pressure Switch<br />
for Counterbalance<br />
Leg<br />
Resolver/Pulser<br />
Assembly<br />
Belts<br />
Sheave<br />
Lift<strong>in</strong>g Bolt<br />
Flywheel<br />
Crankshaft<br />
Air Friction Clutch<br />
Connection<br />
(Pitman)<br />
Lubricator<br />
Top-Stop Button<br />
Prior-Action Push Button<br />
Die Clamp<br />
Rear Guard<br />
Cover<br />
Ram Adjust<strong>in</strong>g Screw<br />
Run Buttons<br />
Gib<br />
Emergency-Stop Button<br />
Bolster<br />
Bed<br />
Leg Bolts<br />
Front View<br />
Leg Tie Rod<br />
Foot Switch<br />
CONTROL SYSTEMS | 109
PART-REVOLUTION STRAIGHT-SIDE PRESS<br />
Resolver/Pulser Assembly<br />
(Beh<strong>in</strong>d Cover)<br />
Ma<strong>in</strong> Drive<br />
Air Surge Tank<br />
Lift<strong>in</strong>g Lug<br />
Crown<br />
Air Releas<strong>in</strong>g Brake<br />
Dual-Solenoid Valve<br />
Air Pressure Switch<br />
for Clutch/Brake<br />
Air Pressure Switch<br />
for Counterbalance<br />
Filter-Regulator-Lubricator<br />
Assembly for Clutch/Brake<br />
Lubricator<br />
Operator s Station<br />
Left-Side View<br />
Upright or Column<br />
Side Guard<br />
Filter-Regulator-Guage<br />
for Die Cushion<br />
Bed<br />
Resolver/Pulser<br />
Assembly<br />
Air Counterbalance Cyl<strong>in</strong>ders<br />
Tie Rod Nut<br />
Belts<br />
Sheave<br />
Ma<strong>in</strong> Gear<br />
Tie Rod<br />
Flywheel<br />
Crankshaft<br />
Air Friction Clutch<br />
Connection (Pitman)<br />
Ram-Adjust<strong>in</strong>g<br />
Mechanism<br />
Ram (Slide)<br />
Cover<br />
Knockout Bracket<br />
Knockout Rod<br />
Knockout Bar<br />
Gib<br />
Run Buttons<br />
Top-Stop Button<br />
Prior-Action Push Button<br />
Clutch/Brake Control<br />
Panel With Starter and<br />
Disconnect Switch<br />
Emergency-Stop Button<br />
Front View<br />
Bolster<br />
110 | CONTROL SYSTEMS
CONTROL RELIABILITY<br />
Control reliability is a term used <strong>in</strong> OSHA standard 29 CFR 1910.217 for<br />
mechanical power presses and <strong>in</strong> the ANSI B11 series of standards for<br />
safety of mach<strong>in</strong>e tools. A new term com<strong>in</strong>g out <strong>in</strong> the ANSI standards<br />
that equates to control reliability is performance of safety-related<br />
functions. These terms deal with the part of the system that controls<br />
hazardous motion of a mach<strong>in</strong>e.<br />
A much older term previously used for control reliability was fail-safe.<br />
Fail-safe was often considered the safe state or condition a mach<strong>in</strong>e<br />
went to when any and <strong>all</strong> possible comp<strong>one</strong>nt failure comb<strong>in</strong>ations<br />
occurred, <strong>in</strong>clud<strong>in</strong>g multiple and simultaneous failures. This is not<br />
possible; therefore, the term fail-safe should not be used to describe<br />
control reliability of performance of safety-related functions.<br />
Control reliability should be present to ensure that a failure of the control<br />
system or device would not result <strong>in</strong> the loss of the safety-related<br />
functions. Control reliability is not just redundancy of comp<strong>one</strong>nts or<br />
a system; it must also <strong>in</strong>clude monitor<strong>in</strong>g (check<strong>in</strong>g). The comp<strong>one</strong>nts<br />
or systems used to provide safety-related functions require proper<br />
design and application. These comp<strong>one</strong>nts or systems <strong>in</strong>clude<br />
electrical, electronic, pneumatic, or hydraulic systems or devices.<br />
They frequently consist of monitored multiple, <strong>in</strong>dependent, par<strong>all</strong>el, or<br />
series comp<strong>one</strong>nts, subassemblies, or modules. The reliability of the<br />
mechanical portions of the mach<strong>in</strong>e relied upon for safety must depend<br />
on design, ma<strong>in</strong>tenance, proper lubrication, and proper use.<br />
The ma<strong>in</strong> purpose of control reliability is to make sure the mach<strong>in</strong>e will<br />
stop when required <strong>in</strong> the event of a s<strong>in</strong>gle comp<strong>one</strong>nt failure with<strong>in</strong> the<br />
system. In the event of a comp<strong>one</strong>nt failure, mach<strong>in</strong>e actuation must<br />
be prevented, a stop command must be given, and reactuation of the<br />
mach<strong>in</strong>e must be prevented until the failure is corrected or the system<br />
or device is manu<strong>all</strong>y reset.<br />
Two possible ways, among others, for achiev<strong>in</strong>g control reliability of the<br />
mach<strong>in</strong>e control systems or devices are by the use of:<br />
1. Diverse redundancy with monitor<strong>in</strong>g—two or more dissimilar<br />
comp<strong>one</strong>nts, subassemblies, or modules are used and the<br />
proper operation of each is verified (monitored) by the other(s)<br />
to ensure the performance of the safety functions.<br />
2. Homogeneous redundancy with monitor<strong>in</strong>g—two or more<br />
identical comp<strong>one</strong>nts, subassemblies, or modules are used<br />
and the proper operation of each is verified (monitored) by the<br />
other(s) to ensure the performance of the safety functions.<br />
The selection and <strong>in</strong>tegration of the comp<strong>one</strong>nts (relays, valves, etc.),<br />
subassemblies, and modules that are designed for safety-related<br />
functions must be used when build<strong>in</strong>g a mach<strong>in</strong>e or <strong>in</strong>tegrat<strong>in</strong>g<br />
equipment to an exist<strong>in</strong>g mach<strong>in</strong>e.<br />
Numerous details about the safety-related functions must be kept <strong>in</strong><br />
m<strong>in</strong>d to accomplish control reliability of the mach<strong>in</strong>e’s control system.<br />
The ma<strong>in</strong> concern is that the mach<strong>in</strong>e’s hazardous motion stops when<br />
a stop command is given.<br />
<strong>Rockford</strong> <strong>Systems</strong> offers control reliable systems <strong>in</strong> this catalog for<br />
mechanic<strong>all</strong>y, hydraulic<strong>all</strong>y, and pneumatic<strong>all</strong>y operated mach<strong>in</strong>es.<br />
RISK ASSESSMENT<br />
Every day <strong>in</strong> <strong>in</strong>dustrial plants, mach<strong>in</strong>e operators, and setup and<br />
ma<strong>in</strong>tenance personnel are exposed to potential hazardous situations<br />
when runn<strong>in</strong>g production, chang<strong>in</strong>g tools, and repair<strong>in</strong>g mach<strong>in</strong>es.<br />
They sometimes assume a certa<strong>in</strong> amount of risk around mach<strong>in</strong>es,<br />
know<strong>in</strong>gly or unknow<strong>in</strong>gly.<br />
We <strong>all</strong> take risks <strong>in</strong> our everyday lives dur<strong>in</strong>g our normal, daily<br />
rout<strong>in</strong>es. Obviously, most of us are will<strong>in</strong>g to take these risks to<br />
live a normal life. In our litigious society, some people believe the<br />
manufacturer of mach<strong>in</strong>ery, equipment, and products should be liable<br />
for any accidents and personal <strong>in</strong>juries that occur on mach<strong>in</strong>es with<br />
the mach<strong>in</strong>e’s operator(s) assum<strong>in</strong>g no risk. In a perfectly planned<br />
and executed environment, this should hold true. However, we<br />
know mach<strong>in</strong>e safeguards and controls are sometimes bypassed,<br />
circumvented, misadjusted, or removed, thus creat<strong>in</strong>g additional risks.<br />
Mach<strong>in</strong>e operators can also make mistakes which can <strong>in</strong>crease risks<br />
and cause <strong>in</strong>jury.<br />
For years, several European countries have been conduct<strong>in</strong>g risk<br />
assessments on <strong>in</strong>dustrial mach<strong>in</strong>es us<strong>in</strong>g the EN-1050 European<br />
Normative Standard. Most of these European countries place the<br />
safeguard<strong>in</strong>g responsibility on the OEM (orig<strong>in</strong>al equipment<br />
manufacturer). In the United States however, the responsibility for safety<br />
is placed upon the user or employer by OSHA. ANSI is try<strong>in</strong>g to distribute<br />
this responsibility. They have f<strong>in</strong>alized the B11.TR3:2000 Technical<br />
Report entitled Risk Assessment and Risk Reduction—a guidel<strong>in</strong>e to<br />
estimate, evaluate and reduce risks associated with mach<strong>in</strong>e tools. All<br />
other ANSI B11 series mach<strong>in</strong>e tool safety standards, as revised, will<br />
likely refer to this technical report.<br />
To comply with the <strong>in</strong>tent of the ANSI B11.TR3 Technical Report, the<br />
OEM, modifier (mach<strong>in</strong>e rebuilder, safeguard manufacturer), and the<br />
user will be required to work together more closely to determ<strong>in</strong>e how<br />
to properly protect or safeguard mach<strong>in</strong>e operators, and setup and<br />
ma<strong>in</strong>tenance personnel. They will need to conduct a risk/task hazard<br />
analysis and risk assessment of each mach<strong>in</strong>e to determ<strong>in</strong>e the type<br />
of safeguard to apply. A risk assessment will take <strong>in</strong>to consideration<br />
several factors <strong>in</strong>clud<strong>in</strong>g the severity of harm (catastrophic, serious,<br />
moderate, or m<strong>in</strong>or), and the probability of occurrence (very likely, likely,<br />
unlikely, or remote). A risk cannot be tot<strong>all</strong>y elim<strong>in</strong>ated, so the ultimate<br />
goal is to lessen the risk until it reaches a tolerable risk level.<br />
CONTROL SYSTEMS | 111
RISK ASSESSMENT (CONTINUED)<br />
As an example, a risk assessment may determ<strong>in</strong>e the need for a safeguard across the full length of a press brake’s die area to safeguard the po<strong>in</strong>t<br />
of operation. A light curta<strong>in</strong> may be chosen as the safeguard<strong>in</strong>g device. If the risk level is significant, the light curta<strong>in</strong> would need to be mounted<br />
properly so an operator could not reach over, under, around, or through it to get <strong>in</strong>to the po<strong>in</strong>t of operation. Additional guards or barriers may be<br />
required on the sides of the press brake. A simple electric<strong>all</strong>y <strong>in</strong>terlocked cable with a warn<strong>in</strong>g sign could be applied to the rear of the press brake.<br />
In this example, three po<strong>in</strong>t-of-operation risk decisions—front, sides and rear of the press brake—have been made. Different risk decisions would<br />
have to be made for additional operators.<br />
In <strong>in</strong>dustry, tolerable risk level decisions must be made <strong>in</strong> order to produce a product. Risk assessments and decisions for the methods of<br />
safeguard<strong>in</strong>g used on mach<strong>in</strong>es are made every day, and cont<strong>in</strong>ue to be part of every mach<strong>in</strong>e requirement for <strong>all</strong> production, and setup and<br />
ma<strong>in</strong>tenance tasks. The ANSI B11.TR 3 serves to provide a voluntary methodology for the risk assessment activity and has been described as “the<br />
greatest stride forward <strong>in</strong> the field of safety <strong>in</strong> the past 20 years.”<br />
MACHINE SAFEGUARDING CHOICES<br />
I. Po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g/metal fabricat<strong>in</strong>g mach<strong>in</strong>es<br />
A. Guards<br />
1. Die enclosure<br />
2. Fixed<br />
3. Interlocked<br />
4. Adjustable<br />
B. Devices<br />
1. Presence-sens<strong>in</strong>g (light curta<strong>in</strong>s or radio frequency)<br />
2. Two-hand control<br />
3. Two-hand trip<br />
4. Pullback<br />
5. Restra<strong>in</strong>t<br />
6. Gates<br />
7. Drop probes<br />
C. Other methods<br />
1. Distance—safe hold<strong>in</strong>g (last resort)<br />
2. Location<br />
3. Hostage (see ANSI B11.19)<br />
4. Safe open<strong>in</strong>g (adjustable stroke, sequential operation, adjustable<br />
restrictor)<br />
5. Part-<strong>in</strong>-place<br />
D. Auxiliary safety equipment<br />
1. Guards or barriers<br />
2. Mats<br />
3. Presence-sens<strong>in</strong>g<br />
a. Multiple beam with larger MOS<br />
b. S<strong>in</strong>gle beam<br />
c. Radio frequency<br />
4. Emergency stop (red)<br />
a. Push button (multiple)<br />
b. Cable<br />
c. Trip bar<br />
d. Kick plate<br />
5. Awareness devices<br />
a. Barrier<br />
b. Visual<br />
c. Audible<br />
6. Hand-feed<strong>in</strong>g tools<br />
II. Po<strong>in</strong>t-of-operation safeguard<strong>in</strong>g of metal turn<strong>in</strong>g mach<strong>in</strong>es<br />
A. Shields (barrier)—protects employees from rotat<strong>in</strong>g mach<strong>in</strong>e comp<strong>one</strong>nts,<br />
chips & coolant<br />
1. Metal<br />
2. Plastic<br />
B. Guards<br />
C. Devices<br />
1. Presence-sens<strong>in</strong>g<br />
2. Two-hand control<br />
3. Gates<br />
III. Perimeter safeguard<strong>in</strong>g (for work stations, see po<strong>in</strong>t<br />
of operation)<br />
A. Guards and barriers (latch-out/reset)<br />
B. Presence-sens<strong>in</strong>g (latch-out/reset)<br />
1. Light curta<strong>in</strong>s<br />
2. S<strong>in</strong>gle beams<br />
C. Mats (latch-out/reset)<br />
D. Distance—safe hold<strong>in</strong>g (last resort)<br />
E. Location<br />
IV. Supplemental<br />
A. Personal protective equipment<br />
B. Color-cod<strong>in</strong>g<br />
C. Warn<strong>in</strong>g signs<br />
D. Deadman—hold-to-run<br />
E. Tra<strong>in</strong><strong>in</strong>g (documented)<br />
F. Supervision<br />
G. Proper light<strong>in</strong>g<br />
H. Inspect<strong>in</strong>g<br />
I. Lockout/tagout (disconnects and valves)<br />
J. Safety blocks<br />
K. Spr<strong>in</strong>g-loaded turnover bars<br />
L. Covers for mechanical power-transmission apparatuses<br />
V. Control of hazardous motion/control reliability<br />
A. Electrical or electronic<br />
B. Pneumatic<br />
C. Hydraulic<br />
VI. Motor stop<br />
VII. Motor brake (electronic)<br />
VIII. Mechanical condition—<strong>in</strong>spection procedures<br />
A. Weekly with tests<br />
B. Periodic/regular<br />
IX. <strong>Safeguard<strong>in</strong>g</strong> dur<strong>in</strong>g mach<strong>in</strong>e setup<br />
A. Procedure<br />
B. Two-hand<br />
C. Lockout/tagout<br />
X. <strong>Safeguard<strong>in</strong>g</strong> dur<strong>in</strong>g m<strong>in</strong>or repair of die or tool<strong>in</strong>g<br />
A. Procedure<br />
B. Die-safety block <strong>in</strong>terlocked<br />
XI. <strong>Safeguard<strong>in</strong>g</strong> dur<strong>in</strong>g ma<strong>in</strong>tenance of mach<strong>in</strong>e<br />
A. Procedure<br />
B. Lockout/tagout<br />
112 | CONTROL SYSTEMS
SAFETY REQUIREMENTS FOR POWER PRESSES TAKEN FROM OSHA<br />
Any comp<strong>one</strong>nt of the safety system mounted on this<br />
press is available from <strong>one</strong> source:<br />
ROCKFORD SYSTEMS, LLC.<br />
OSHA’s Code of Federal Regulations can be<br />
purchased by contact<strong>in</strong>g:<br />
U.S. Government Pr<strong>in</strong>t<strong>in</strong>g Office<br />
P.O. Box 371954<br />
Pittsburgh, PA 15250-7954<br />
(202) 512-1800<br />
http://bookstore.gpo.gov<br />
OSHA 29 CFR 1910.211, 1910.212, 1910.217, 1910.219, and<br />
1910.147 are <strong>in</strong>cluded <strong>in</strong> this catalog for use as a reference when<br />
determ<strong>in</strong><strong>in</strong>g safety requirements for br<strong>in</strong>g<strong>in</strong>g mach<strong>in</strong>es <strong>in</strong>to compliance<br />
with the federal standards.<br />
This <strong>in</strong>formation is a comprehensive guide to understand<strong>in</strong>g Federal<br />
OSHA (Occupational Safety and Health Adm<strong>in</strong>istration) and apply<strong>in</strong>g its<br />
requirements to mechanical power presses and other mach<strong>in</strong>es. It is<br />
copied verbatim from the Federal Register and conta<strong>in</strong>s <strong>all</strong> pert<strong>in</strong>ent<br />
sections of the OSHA standards concern<strong>in</strong>g power presses with which<br />
an employer (user) must comply. 29 CFR 1910.212 and 1910.219 can<br />
be applied to presses, press brakes and other mach<strong>in</strong>es discussed <strong>in</strong><br />
this catalog as well as lathes, mill<strong>in</strong>g mach<strong>in</strong>es, etc. Safety standards<br />
for these types of mach<strong>in</strong>es are available from ANSI (American National<br />
Standards Institute). For a copy of the appropriate B11-series standard,<br />
see page 3 for the contact <strong>in</strong>formation. Be sure to review these<br />
standards before updat<strong>in</strong>g or <strong>in</strong>st<strong>all</strong><strong>in</strong>g any equipment on a mach<strong>in</strong>e.<br />
If you are unfamiliar with how to properly safeguard the po<strong>in</strong>t of<br />
operation or how to calculate the safety distance for two-hand control,<br />
etc., we offer a series of monthly mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ars to<br />
educate the employer/user on the safety requirements. Please see<br />
pages 4 through 8 for further details.<br />
Follow<strong>in</strong>g this section is OSHA standard 29 CFR 1910.147 which<br />
conta<strong>in</strong>s requirements for the control of hazardous energy (lockout/<br />
tagout). This standard covers the servic<strong>in</strong>g and ma<strong>in</strong>tenance of<br />
mach<strong>in</strong>es and equipment where the unexpected energiz<strong>in</strong>g or start-up<br />
of the mach<strong>in</strong>es or equipment, or release of stored energy could cause<br />
<strong>in</strong>jury to employees. See page 35 for <strong>in</strong>formation on air lockout valves<br />
and refer to our <strong>Catalog</strong> DSB for <strong>in</strong>formation on die safety blocks.<br />
CONTROL SYSTEMS | 113
OSHA 29 CFR 1910.211—DEFINITIONS<br />
AS USED IN 29 CFR 1910.217 AND 1910.219 UNLESS THE<br />
CONTENT CLEARLY REQUIRES OTHERWISE, THE FOLLOWING<br />
POWER PRESS AND MECHANICAL POWER-TRANSMISSION<br />
GUARDING TERMS SHALL HAVE THE FOLLOWING MEANING:<br />
Adjustable barrier guard means a barrier requir<strong>in</strong>g adjustment for each<br />
job or die setup.<br />
Antirepeat means the part of the clutch/brake control system designed<br />
to limit the press to a s<strong>in</strong>gle stroke if the tripp<strong>in</strong>g means is held<br />
operated. Antirepeat requires release of <strong>all</strong> tripp<strong>in</strong>g mechanisms<br />
before another stroke can be <strong>in</strong>itiated. Antirepeat is also c<strong>all</strong>ed<br />
s<strong>in</strong>gle stroke reset or reset circuit.<br />
Authorized person means <strong>one</strong> to whom the authority and responsibility<br />
to perform a specific assignment has been given by the employer.<br />
Automatic feed<strong>in</strong>g means feed<strong>in</strong>g where<strong>in</strong> the material or part be<strong>in</strong>g<br />
processed is placed with<strong>in</strong> or removed from the po<strong>in</strong>t of operation<br />
by a method or means not requir<strong>in</strong>g action by an operator on each<br />
stroke of the press.<br />
Belts <strong>in</strong>clude <strong>all</strong> power transmission belts, such as flat belts, round<br />
belts, V-belts, etc., unless otherwise specified.<br />
Belt shifter means a device for mechanic<strong>all</strong>y shift<strong>in</strong>g belts from tight<br />
to loose pulleys or vice versa, or for shift<strong>in</strong>g belts on c<strong>one</strong>s of<br />
speed pulleys.<br />
Belt pole (sometimes c<strong>all</strong>ed a belt shipper or shipper pole) means<br />
a device used <strong>in</strong> shift<strong>in</strong>g belts on and off fixed pulleys on l<strong>in</strong>e or<br />
countershaft where there are no loose pulleys.<br />
Bolster plate means the plate attached to the top of the bed of the press<br />
hav<strong>in</strong>g drilled holes or T-slots for attach<strong>in</strong>g the lower die or die shoe.<br />
Brake means the mechanism used on a mechanical power press to stop<br />
and/or hold the crankshaft, either directly or through a gear tra<strong>in</strong>,<br />
when the clutch is disengaged.<br />
Brake Monitor means a sensor designed, constructed, and arranged to<br />
monitor the effectiveness of the press brak<strong>in</strong>g system.<br />
Clutch means the coupl<strong>in</strong>g mechanism used on a mechanical power<br />
press to couple the flywheel to the crankshaft, either directly or<br />
through a gear tra<strong>in</strong>.<br />
Concurrent means act<strong>in</strong>g <strong>in</strong> conjunction, and is used to describe a<br />
situation where<strong>in</strong> two or more controls exist <strong>in</strong> an operated condition<br />
at the same time.<br />
Cont<strong>in</strong>uous means un<strong>in</strong>terrupted multiple strokes of the slide without<br />
<strong>in</strong>terven<strong>in</strong>g stops (or other clutch control action) at the end of<br />
<strong>in</strong>dividual strokes.<br />
Control System means sensors, manual <strong>in</strong>put and mode selection<br />
elements, <strong>in</strong>terlock<strong>in</strong>g and decision-mak<strong>in</strong>g circuitry, and output<br />
elements to press operat<strong>in</strong>g mechanism.<br />
Counterbalance means the mechanism that is used to balance or support<br />
the weight of the connect<strong>in</strong>g rods, slide, and slide attachments.<br />
Device means a press control or attachment that:<br />
(i) Restra<strong>in</strong>s the operator from <strong>in</strong>advertently reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t<br />
of operation; or<br />
(ii) Prevents normal press operation if the operator’s hands are<br />
<strong>in</strong>advertently with<strong>in</strong> the po<strong>in</strong>t of operation; or<br />
(iii) Automatic<strong>all</strong>y withdraws the operator’s hands, if the operator’s<br />
hands are <strong>in</strong>advertently with<strong>in</strong> the po<strong>in</strong>t of operation as the dies close.<br />
Die means the tool<strong>in</strong>g used <strong>in</strong> a press for cutt<strong>in</strong>g or form<strong>in</strong>g material.<br />
An upper and a lower die make a complete set.<br />
Die builder means any person who builds dies for power presses.<br />
Die enclosure guard means an enclosure attached to the die shoe or<br />
stripper, or both, <strong>in</strong> a fixed position.<br />
Die set means a tool holder held <strong>in</strong> alignment by guide posts and<br />
bush<strong>in</strong>gs and consist<strong>in</strong>g of a lower shoe, an upper shoe or punch<br />
holder, and guide posts and bush<strong>in</strong>gs.<br />
Die setter means an <strong>in</strong>dividual who places or removes dies <strong>in</strong> or from<br />
mechanical power presses, and who, as a part of his duties, makes<br />
the necessary adjustments to cause the tool<strong>in</strong>g to function properly<br />
and safely.<br />
Die sett<strong>in</strong>g means the process of plac<strong>in</strong>g or remov<strong>in</strong>g dies <strong>in</strong> or from<br />
a mechanical power press, and the process of adjust<strong>in</strong>g the dies,<br />
other tool<strong>in</strong>g and safeguard<strong>in</strong>g means to cause them to function<br />
properly and safely.<br />
Die shoe means a plate or block upon which a die holder is mounted.<br />
A die shoe functions primarily as a base for the complete die<br />
assembly, and, when used, is bolted or clamped to the bolster plate<br />
or the face of slide.<br />
Direct drive means the type driv<strong>in</strong>g arrangement where<strong>in</strong> no<br />
clutch is used; coupl<strong>in</strong>g and decoupl<strong>in</strong>g of the driv<strong>in</strong>g torque is<br />
accomplished by energiz<strong>in</strong>g and deenergization of a motor. Even<br />
though not employ<strong>in</strong>g a clutch, direct drives match the operational<br />
characteristics of “part revolution clutches” because the driv<strong>in</strong>g<br />
power may be disengaged dur<strong>in</strong>g the stroke of the press.<br />
Exposed to contact means that the location of an object is such that a<br />
person is likely to come <strong>in</strong>to contact with it and be <strong>in</strong>jured.<br />
Ejector means a mechanism for remov<strong>in</strong>g work or material from<br />
between the dies.<br />
Face of slide means the bottom surface of the slide to which the punch<br />
or upper die is gener<strong>all</strong>y attached.<br />
Feed<strong>in</strong>g means the process of plac<strong>in</strong>g or remov<strong>in</strong>g material with<strong>in</strong> or<br />
from the po<strong>in</strong>t of operation.<br />
Fixed barrier guard means a die space barrier attached to the press frame.<br />
Flywheels <strong>in</strong>clude flywheels, balance wheels, and flywheel pulleys<br />
mounted and revolv<strong>in</strong>g on crankshaft of eng<strong>in</strong>e or other shaft<strong>in</strong>g.<br />
Foot control means the foot operated control mechanism designed to be<br />
used with a clutch or clutch/brake control system.<br />
Foot pedal means the foot operated lever designed to operate the<br />
mechanical l<strong>in</strong>kage that trips a full revolution clutch.<br />
Full-revolution clutch means a type of clutch that, when tripped, cannot<br />
be disengaged until the crankshaft has completed a full revolution<br />
and the press slide a full stroke.<br />
Gate or movable barrier device means a movable barrier arranged<br />
to enclose the po<strong>in</strong>t of operation before the press stroke can<br />
be started.<br />
Guard means a barrier that prevents entry of the operator’s hands or<br />
f<strong>in</strong>gers <strong>in</strong>to the po<strong>in</strong>t of operation.<br />
Guide post means the p<strong>in</strong> attached to the upper or lower die shoe,<br />
operat<strong>in</strong>g with<strong>in</strong> the bush<strong>in</strong>g on the oppos<strong>in</strong>g die shoe, to ma<strong>in</strong>ta<strong>in</strong><br />
the alignment of the upper and lower dies.<br />
Hand feed<strong>in</strong>g tool means any hand-held tool designed for plac<strong>in</strong>g or<br />
remov<strong>in</strong>g material or parts to be processed with<strong>in</strong> or from the po<strong>in</strong>t<br />
of operation.<br />
Holdout or restra<strong>in</strong>t device means a mechanism, <strong>in</strong>clud<strong>in</strong>g attachments<br />
for operator’s hands, that when anchored and adjusted prevent the<br />
operator’s hands from enter<strong>in</strong>g the po<strong>in</strong>t of operation.<br />
114 | CONTROL SYSTEMS
Inch means an <strong>in</strong>termittent motion imparted to the slide (on mach<strong>in</strong>es<br />
us<strong>in</strong>g part revolution clutches) by momentary operation of the “Inch”<br />
operat<strong>in</strong>g means. Operation of the “Inch” operat<strong>in</strong>g means engages<br />
the driv<strong>in</strong>g clutch so that a sm<strong>all</strong> portion of <strong>one</strong> stroke or <strong>in</strong>def<strong>in</strong>ite<br />
strok<strong>in</strong>g can occur, depend<strong>in</strong>g upon the length of time the “Inch”<br />
operat<strong>in</strong>g means is held operated. “Inch” is a function used by the<br />
die setter for setup of dies and tool<strong>in</strong>g, but is not <strong>in</strong>tended for use<br />
dur<strong>in</strong>g production operations by the operator.<br />
Interlocked press barrier guard means a barrier attached to the press<br />
frame and <strong>in</strong>terlocked so that the press stroke cannot be started<br />
norm<strong>all</strong>y unless the guard itself, or its h<strong>in</strong>ged or movable sections,<br />
enclose the po<strong>in</strong>t of operation.<br />
Jog means an <strong>in</strong>termittent motion imparted to the slide by momentary<br />
operation of the drive motor, after the clutch is engaged with the<br />
flywheel at rest.<br />
Knockout means a mechanism for releas<strong>in</strong>g material from either die.<br />
Liftout means the mechanism also known as knockout.<br />
Ma<strong>in</strong>tenance runway means any permanent runway or platform used<br />
for oil<strong>in</strong>g, ma<strong>in</strong>tenance, runn<strong>in</strong>g adjustment, or repair work, but not<br />
for passageway.<br />
Manual feed<strong>in</strong>g means feed<strong>in</strong>g where<strong>in</strong> the material or part be<strong>in</strong>g<br />
processed is handled by the operator on each stroke of the press.<br />
Nip-po<strong>in</strong>t belt and pulley guard means a device which encloses the<br />
pulley and is provided with rounded or rolled edge slots through<br />
which the belt passes.<br />
Operator’s station means the complete complement of controls used<br />
by or available to an operator on a given operation for strok<strong>in</strong>g<br />
the press.<br />
Part-revolution clutch means a type of clutch that can be disengaged at<br />
any po<strong>in</strong>t before the crankshaft has completed a full revolution and<br />
the press slide a full stroke.<br />
P<strong>in</strong>ch po<strong>in</strong>t means any po<strong>in</strong>t other than the po<strong>in</strong>t of operation at<br />
which it is possible for a part of the body to be caught between<br />
the mov<strong>in</strong>g parts of a press or auxiliary equipment, or between<br />
mov<strong>in</strong>g and stationary parts of a press or auxiliary equipment or<br />
between the material and mov<strong>in</strong>g part or parts of the press or<br />
auxiliary equipment.<br />
Po<strong>in</strong>t of operation means the area of the press where material is actu<strong>all</strong>y<br />
positi<strong>one</strong>d and work is be<strong>in</strong>g performed dur<strong>in</strong>g any process such as<br />
shear<strong>in</strong>g, punch<strong>in</strong>g, form<strong>in</strong>g, or assembl<strong>in</strong>g.<br />
Presence-sens<strong>in</strong>g device means a device designed, constructed and<br />
arranged to create a sens<strong>in</strong>g field or area and to deactivate the<br />
clutch control of the press when an operator’s hand or any other<br />
part of his body is with<strong>in</strong> such field or area.<br />
Press means a mechanic<strong>all</strong>y powered mach<strong>in</strong>e that shears, punches,<br />
forms or assembles metal or other material by means of cutt<strong>in</strong>g,<br />
shap<strong>in</strong>g, or comb<strong>in</strong>ation dies attached to slides. A press consists of<br />
a stationary bed or anvil, and a slide (or slides) hav<strong>in</strong>g a controlled<br />
reciprocat<strong>in</strong>g motion toward and away from the bed surface, the<br />
slide be<strong>in</strong>g guided <strong>in</strong> a def<strong>in</strong>ite path by the frame of the press.<br />
Prime movers <strong>in</strong>clude steam, gas, oil, and air eng<strong>in</strong>es, motors, steam and<br />
hydraulic turb<strong>in</strong>es, and other equipment used as a source of power.<br />
Pullout device means a mechanism attached to the operator’s hands<br />
and connected to the upper die or slide of the press, that is<br />
designed, when properly adjusted, to withdraw the operator’s hands<br />
as the dies close, if the operator’s hands are <strong>in</strong>advertently with<strong>in</strong> the<br />
po<strong>in</strong>t of operation.<br />
Repeat means an un<strong>in</strong>tended or unexpected successive stroke of the<br />
press result<strong>in</strong>g from a malfunction.<br />
Safety block means a prop that, when <strong>in</strong>serted between the upper and<br />
lower dies or between the bolster plate and the face of the slide,<br />
prevents the slide from f<strong>all</strong><strong>in</strong>g of its own deadweight.<br />
Safety system means the <strong>in</strong>tegrated total system, <strong>in</strong>clud<strong>in</strong>g the pert<strong>in</strong>ent<br />
elements of the press, the controls, the safeguard<strong>in</strong>g and any<br />
required supplemental safeguard<strong>in</strong>g, and their <strong>in</strong>terfaces with the<br />
operator, and the environment, designed, constructed and arranged<br />
to operate together as a unit, such that a s<strong>in</strong>gle failure or s<strong>in</strong>gle<br />
operat<strong>in</strong>g error will not cause <strong>in</strong>jury to personnel due to po<strong>in</strong>t of<br />
operation hazards.<br />
Semiautomatic feed<strong>in</strong>g means feed<strong>in</strong>g where<strong>in</strong> the material or part<br />
be<strong>in</strong>g processed is placed with<strong>in</strong> or removed from the po<strong>in</strong>t of<br />
operation by an auxiliary means controlled by the operator on each<br />
stroke of the press.<br />
Sheaves mean grooved pulleys, and sh<strong>all</strong> be so classified unless used<br />
as flywheels.<br />
S<strong>in</strong>gle stroke means <strong>one</strong> complete stroke of the slide, usu<strong>all</strong>y <strong>in</strong>itiated<br />
from a full open (or up) position, followed by clos<strong>in</strong>g (or down), and<br />
then a return to the full open position.<br />
S<strong>in</strong>gle-stroke mechanism means an arrangement used on a fullrevolution<br />
clutch to limit the travel of the slide to <strong>one</strong> complete<br />
stroke at each engagement of the clutch.<br />
Slide means the ma<strong>in</strong> reciprocat<strong>in</strong>g press member. A slide is also c<strong>all</strong>ed<br />
a ram, plunger, or platen.<br />
Stop control means an operator control designed to immediately deactivate<br />
the clutch control and activate the brake to stop slide motion.<br />
Stripper means a mechanism or die part for remov<strong>in</strong>g the parts or<br />
material from the punch.<br />
Strok<strong>in</strong>g selector means the part of the clutch/brake control that<br />
determ<strong>in</strong>es the type of strok<strong>in</strong>g when the operat<strong>in</strong>g means is<br />
actuated. The strok<strong>in</strong>g selector gener<strong>all</strong>y <strong>in</strong>cludes positions for<br />
Off (Clutch Control), Inch, S<strong>in</strong>gle Stroke, and Cont<strong>in</strong>uous (when<br />
Cont<strong>in</strong>uous is furnished).<br />
Sweep device means a s<strong>in</strong>gle or double arm (rod) attached to the upper<br />
die or slide of the press and designed to move the operator’s hands<br />
to a safe position as the dies close, if the operator’s hands are<br />
<strong>in</strong>advertently with<strong>in</strong> the po<strong>in</strong>t of operation.<br />
Trip or (tripp<strong>in</strong>g) means activation of the clutch to “run” the press.<br />
Turnover bar means a bar used <strong>in</strong> die sett<strong>in</strong>g to manu<strong>all</strong>y turn the<br />
crankshaft of the press.<br />
Two-hand trip means a clutch actuat<strong>in</strong>g means requir<strong>in</strong>g the concurrent<br />
use of both hands of the operator to trip the press.<br />
Two-hand control device means a two-hand trip that further requires<br />
concurrent pressure from both hands of the operator dur<strong>in</strong>g a<br />
substantial part of the die-clos<strong>in</strong>g portion of the stroke of the press.<br />
Unitized tool<strong>in</strong>g means a type of die <strong>in</strong> which the upper and lower<br />
members are <strong>in</strong>corporated <strong>in</strong>to self-conta<strong>in</strong>ed units arranged as to<br />
hold the die members <strong>in</strong> alignment.<br />
CONTROL SYSTEMS | 115
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES<br />
EDITED FOR POWER PRESSES<br />
As taken from Title 29 of the Code of Federal Regulations (CFR),<br />
Sections 1910.147, 1910.212, 1910.217, and 1910.219.<br />
Many people f<strong>in</strong>d the OSHA standards confus<strong>in</strong>g and difficult to read<br />
as published <strong>in</strong> the Code of Federal Regulations. As an aid to the metal<br />
stampers and fabricators, we have rearranged and labeled certa<strong>in</strong><br />
paragraphs and sections to help categorize the subject material. Each<br />
paragraph has been identified so that the reader can refer to the<br />
regulations and read the paragraph <strong>in</strong> context as the government wrote<br />
it. No words of the text have been changed; however, this <strong>in</strong>formation<br />
should never be used <strong>in</strong> place of the actual standards. We can assume<br />
no liability for acts taken as a result of reference to it. We offer this guide<br />
for use <strong>in</strong> analyz<strong>in</strong>g problems and f<strong>in</strong>d<strong>in</strong>g solutions for br<strong>in</strong>g<strong>in</strong>g full- and<br />
part-revolution mechanical power presses <strong>in</strong>to compliance with the<br />
federal regulations.<br />
WHEN MUST THINGS BE DONE?<br />
(A)(4) RECONSTRUCTION AND MODIFICATION<br />
It sh<strong>all</strong> be the responsibility of any person reconstruct<strong>in</strong>g, or modify<strong>in</strong>g<br />
a mechanical power press to do so <strong>in</strong> accordance with paragraph (b)<br />
of this section.<br />
(A)(5) EXCLUDED MACHINES<br />
Press brakes, hydraulic and pneumatic power presses, bulldozers, hot<br />
bend<strong>in</strong>g and hot metal presses, forg<strong>in</strong>g presses and hammers, rivet<strong>in</strong>g<br />
mach<strong>in</strong>es and similar types of fastener applicators are excluded from<br />
the requirements of this section.<br />
CONSTRUCTION OF PRESS AND ITS CONTROLS —FULL<br />
REVOLUTION CLUTCHES<br />
(B)(3) MACHINES USING FULL REVOLUTION POSITIVE CLUTCHES<br />
(i) Mach<strong>in</strong>es us<strong>in</strong>g full revolution clutches sh<strong>all</strong> <strong>in</strong>corporate a<br />
s<strong>in</strong>gle stroke mechanism.<br />
(ii) If the s<strong>in</strong>gle stroke mechanism is dependent upon spr<strong>in</strong>g<br />
action, the spr<strong>in</strong>g(s) sh<strong>all</strong> be of the compression type, operat<strong>in</strong>g<br />
on a rod or guided with<strong>in</strong> a hole or tube, and designed to prevent<br />
<strong>in</strong>terleav<strong>in</strong>g of the spr<strong>in</strong>g coils <strong>in</strong> event of breakage.<br />
METHODS OF INITIATING PRESS CYCLE<br />
(B)(4) FOOT PEDALS (TREADLE)<br />
(i) The pedal mechanism sh<strong>all</strong> be protected to prevent un<strong>in</strong>tended<br />
operation from f<strong>all</strong><strong>in</strong>g or mov<strong>in</strong>g objects or by accidental stepp<strong>in</strong>g<br />
onto the pedal.<br />
(ii) A pad with a nonslip contact area sh<strong>all</strong> be firmly attached to<br />
the pedal.<br />
(iii) The pedal return spr<strong>in</strong>g(s) sh<strong>all</strong> be of the compression type,<br />
operat<strong>in</strong>g on a rod or guided with<strong>in</strong> a hole or tube, and designed<br />
to prevent <strong>in</strong>terleav<strong>in</strong>g of spr<strong>in</strong>g coils <strong>in</strong> event of breakage.<br />
(iv) If pedal counterweights are provided, the path of the travel of<br />
the weight sh<strong>all</strong> be enclosed.<br />
(B)(5) HAND OPERATED LEVERS<br />
(i) Hand-lever-operated power presses sh<strong>all</strong> be equipped with<br />
a spr<strong>in</strong>g latch on the operat<strong>in</strong>g lever to prevent premature or<br />
accidental tripp<strong>in</strong>g.<br />
(ii) The operat<strong>in</strong>g levers on hand-tripped presses hav<strong>in</strong>g more<br />
than <strong>one</strong> operat<strong>in</strong>g station sh<strong>all</strong> be <strong>in</strong>terlocked to prevent the<br />
tripp<strong>in</strong>g of the press except by the “concurrent” use of <strong>all</strong> levers.<br />
(B)(6) TWO-HAND TRIP<br />
See page 120, paragraph (c)(3)(viii).<br />
(i) A two-hand trip sh<strong>all</strong> have the <strong>in</strong>dividual operator’s hand<br />
controls protected aga<strong>in</strong>st un<strong>in</strong>tentional operation and have<br />
the <strong>in</strong>dividual operator’s hand controls arranged by design and<br />
construction and/or separation to require the use of both hands to<br />
trip the press and use a control arrangement requir<strong>in</strong>g concurrent<br />
operation of the <strong>in</strong>dividual operator’s hand controls.<br />
(ii) Two-hand trip systems on full revolution clutch mach<strong>in</strong>es sh<strong>all</strong><br />
<strong>in</strong>corporate an antirepeat feature.<br />
(iii) If two-hand trip systems are used on multiple operator<br />
presses, each operator sh<strong>all</strong> have a separate set of controls.<br />
116 | CONTROL SYSTEMS
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
PART REVOLUTION CLUTCHES<br />
(AIR AND MECHANICAL-FRICTION CLUTCHES)<br />
(B)(7) MACHINES USING PART REVOLUTION CLUTCHES<br />
(i) The clutch sh<strong>all</strong> release and the brake sh<strong>all</strong> be applied when the<br />
external clutch engag<strong>in</strong>g means is removed, deactivated or deenergized.<br />
Stop control<br />
(ii) A red color stop control sh<strong>all</strong> be provided with the clutch/<br />
brake control system. Momentary operation of the stop control sh<strong>all</strong><br />
immediately deactivate the clutch and apply the brake. The stop control<br />
sh<strong>all</strong> override any other control, and reactuation of the clutch sh<strong>all</strong><br />
require use of the operat<strong>in</strong>g (tripp<strong>in</strong>g) means which has been selected.<br />
Press strok<strong>in</strong>g selector<br />
(iii) A means of select<strong>in</strong>g Off, Inch, S<strong>in</strong>gle Stroke, and Cont<strong>in</strong>uous<br />
(when the cont<strong>in</strong>uous function is furnished) sh<strong>all</strong> be supplied with the<br />
clutch/brake control to select type of operation of the press. Fix<strong>in</strong>g of<br />
selection sh<strong>all</strong> be by means capable of supervision by the employer.<br />
Inch operation<br />
(iv) The “Inch” operat<strong>in</strong>g means sh<strong>all</strong> be designed to prevent exposure<br />
of the worker’s hands with<strong>in</strong> the po<strong>in</strong>t of operation by:<br />
(a) Requir<strong>in</strong>g the concurrent use of both hands to actuate the clutch;<br />
OR<br />
(b) Be<strong>in</strong>g a s<strong>in</strong>gle control protected aga<strong>in</strong>st accidental actuation and<br />
so located that the worker cannot reach <strong>in</strong>to the po<strong>in</strong>t of operation while<br />
operat<strong>in</strong>g the s<strong>in</strong>gle control.<br />
S<strong>in</strong>gle stroke - Two-hand control<br />
See page 119, paragraph (c)(3)(vii)<br />
(v) Two-hand controls for s<strong>in</strong>gle stroke sh<strong>all</strong> conform to the follow<strong>in</strong>g<br />
requirements:<br />
(a) Each hand control sh<strong>all</strong> be protected aga<strong>in</strong>st un<strong>in</strong>tended operation<br />
and arranged by design, construction, and/or separation so that the<br />
concurrent use of both hands is required to trip the press.<br />
(b) The control system sh<strong>all</strong> be designed to permit an adjustment<br />
which will require concurrent pressure from both hands dur<strong>in</strong>g the die<br />
clos<strong>in</strong>g portion of the stroke.<br />
(c) The control system sh<strong>all</strong> <strong>in</strong>corporate an antirepeat feature.<br />
(d) The control systems sh<strong>all</strong> be designed to require release of <strong>all</strong><br />
operators’ hand controls before an <strong>in</strong>terrupted stroke can be resumed.<br />
This requirement perta<strong>in</strong>s only to those s<strong>in</strong>gle stroke, two-hand controls<br />
manufactured and <strong>in</strong>st<strong>all</strong>ed on or after August 31, 1971. (Refer to (c)(5)<br />
(ii) on page 120.)<br />
(vi) Reserved<br />
Multiple operat<strong>in</strong>g stations<br />
(vii) Controls for more than <strong>one</strong> operat<strong>in</strong>g station sh<strong>all</strong> be designed to<br />
be activated and deactivated <strong>in</strong> complete sets of two operators’ hand<br />
controls per operat<strong>in</strong>g station by means capable of be<strong>in</strong>g supervised by<br />
the employer. The clutch/brake control system sh<strong>all</strong> be designed and<br />
constructed to prevent actuation of the clutch if <strong>all</strong> operat<strong>in</strong>g stations<br />
are bypassed.<br />
Cont<strong>in</strong>uous<br />
(viii) Those clutch/brake control systems which conta<strong>in</strong> both s<strong>in</strong>gle and<br />
cont<strong>in</strong>uous functions sh<strong>all</strong> be designed so that completion of cont<strong>in</strong>uous<br />
circuits may be supervised by the employer. The <strong>in</strong>itiation of cont<strong>in</strong>uous<br />
run sh<strong>all</strong> require a prior action or decision by the operator <strong>in</strong> addition to<br />
the selection of Cont<strong>in</strong>uous on the strok<strong>in</strong>g selector, before actuation of<br />
the operat<strong>in</strong>g means will result <strong>in</strong> cont<strong>in</strong>uous strok<strong>in</strong>g.<br />
Hand/foot selection<br />
(ix) If foot control is provided, the selection method between hand and<br />
foot control sh<strong>all</strong> be separate from the strok<strong>in</strong>g selector and sh<strong>all</strong> be<br />
designed so that the selection may be supervised by the employer.<br />
Foot control<br />
(x) Foot operated tripp<strong>in</strong>g controls, if used, sh<strong>all</strong> be protected so as<br />
to prevent operation from f<strong>all</strong><strong>in</strong>g or mov<strong>in</strong>g objects, or from un<strong>in</strong>tended<br />
operation by accidental stepp<strong>in</strong>g onto the foot control.<br />
Clutch/brake air valve failure<br />
(xi) The control of air-clutch mach<strong>in</strong>es sh<strong>all</strong> be designed to prevent a<br />
significant <strong>in</strong>crease <strong>in</strong> the normal stopp<strong>in</strong>g time due to a failure with<strong>in</strong><br />
the operat<strong>in</strong>g valve mechanism, and to <strong>in</strong>hibit further operation if such<br />
failure does occur. This requirement sh<strong>all</strong> apply only to those clutch/<br />
brake air valve controls manufactured and <strong>in</strong>st<strong>all</strong>ed on or after August<br />
31, 1971, but sh<strong>all</strong> not apply to mach<strong>in</strong>es <strong>in</strong>tended only for cont<strong>in</strong>uous,<br />
automatic feed<strong>in</strong>g applications.<br />
(Refer to (c)(5)(iii) on page 120.)<br />
Press drive motor <strong>in</strong>terlock<br />
(xii) The clutch/brake control sh<strong>all</strong> <strong>in</strong>corporate an automatic means<br />
to prevent <strong>in</strong>itiation or cont<strong>in</strong>ued activation of the S<strong>in</strong>gle Stroke or<br />
cont<strong>in</strong>uous functions unless the press drive motor is energized and <strong>in</strong><br />
the forward direction.<br />
Engag<strong>in</strong>g method failure<br />
(xiii) The clutch/brake control sh<strong>all</strong> automatic<strong>all</strong>y deactivate <strong>in</strong> event of<br />
failure of the power or pressure supply for the clutch engag<strong>in</strong>g means.<br />
Reactivation of the clutch sh<strong>all</strong> require restoration of normal supply and<br />
the use of the tripp<strong>in</strong>g mechanism(s).<br />
Air counterbalance supply<br />
(xiv) The clutch/brake control sh<strong>all</strong> automatic<strong>all</strong>y deactivate <strong>in</strong> event<br />
of failure of the counterbalance(s) air supply. Reactivation of the clutch<br />
sh<strong>all</strong> require restoration of normal air supply and use of the tripp<strong>in</strong>g<br />
mechanism(s).<br />
Turnover bar operation<br />
(xv) Selection of bar operation sh<strong>all</strong> be by means capable of be<strong>in</strong>g<br />
supervised by the employer. A separate pushbutton sh<strong>all</strong> be employed<br />
to activate the clutch, and the clutch sh<strong>all</strong> be activated only if the drive<br />
motor is deenergized.<br />
CONTROL SYSTEMS | 117
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
METHODS OF SAFEGUARDING THE POINT OF OPERATION<br />
(C)(1) GENERAL REQUIREMENTS<br />
(i) It sh<strong>all</strong> be the responsibility of the employer to provide and <strong>in</strong>sure<br />
the usage of “po<strong>in</strong>t-of-operation guards” or properly applied and<br />
adjusted po<strong>in</strong>t-of-operation devices on every operation performed on a<br />
mechanical power press. See Table O-10.<br />
(ii) The requirement of paragraph (c)(1)(i) of this section sh<strong>all</strong> not apply<br />
when the po<strong>in</strong>t-of-operation open<strong>in</strong>g is <strong>one</strong>-fourth <strong>in</strong>ch or less. See<br />
Table O-10.<br />
(C)(2) POINT OF OPERATION GUARDS<br />
(i) Every po<strong>in</strong>t of operation guard sh<strong>all</strong> meet the follow<strong>in</strong>g design,<br />
construction, application, and adjustment requirements:<br />
(a) It sh<strong>all</strong> prevent entry of hands or f<strong>in</strong>gers <strong>in</strong>to the po<strong>in</strong>t of operation<br />
by reach<strong>in</strong>g through, over, under or around the guard;<br />
(b) It sh<strong>all</strong> conform to the maximum permissible open<strong>in</strong>gs of Table O-10;<br />
(c) It sh<strong>all</strong>, <strong>in</strong> itself, create no p<strong>in</strong>ch po<strong>in</strong>t between the guard and<br />
mov<strong>in</strong>g mach<strong>in</strong>e parts;<br />
(d) It sh<strong>all</strong> utilize fasteners not readily removable by operator, so as to<br />
m<strong>in</strong>imize the possibility of misuse or removal of essential parts;<br />
(e) It sh<strong>all</strong> facilitate its <strong>in</strong>spection, and<br />
(f) It sh<strong>all</strong> offer maximum visibility of the po<strong>in</strong>t of operation consistent<br />
with the other requirements.<br />
(ii) A die enclosure guard sh<strong>all</strong> be attached to the die shoe or stripper<br />
<strong>in</strong> a fixed position.<br />
(iii) A fixed barrier guard sh<strong>all</strong> be attached securely to the frame of the<br />
press or to the bolster plate.<br />
(iv) An <strong>in</strong>terlocked press barrier guard sh<strong>all</strong> be attached to the press<br />
frame or bolster and sh<strong>all</strong> be <strong>in</strong>terlocked with the press clutch control<br />
so that the clutch cannot be activated unless the guard itself, or the<br />
h<strong>in</strong>ged or movable sections of the guard are <strong>in</strong> position to conform to<br />
the requirements of Table O-10.<br />
(v) The h<strong>in</strong>ged or movable sections of an <strong>in</strong>terlocked press barrier<br />
guard sh<strong>all</strong> not be used for manual feed<strong>in</strong>g. The guard sh<strong>all</strong> prevent<br />
open<strong>in</strong>g of the <strong>in</strong>terlocked section and reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation prior to die closure or prior to the cessation of slide motion.<br />
See paragraph (c)(3)(ii) of this section regard<strong>in</strong>g manual feed<strong>in</strong>g through<br />
<strong>in</strong>terlocked press barrier devices.<br />
(vi) The adjustable barrier guard sh<strong>all</strong> be securely attached to the<br />
press bed, bolster plate, or die shoe, and sh<strong>all</strong> be adjusted and<br />
operated <strong>in</strong> conformity with Table O-10 and the requirements of this<br />
subparagraph. Adjustments sh<strong>all</strong> be made only by authorized personnel<br />
whose qualifications <strong>in</strong>clude a knowledge of the provisions of Table<br />
O-10 and this subparagraph.<br />
(vii) A po<strong>in</strong>t of operation enclosure which does not meet the<br />
requirements of this subparagraph and Table O-10 sh<strong>all</strong> be used only <strong>in</strong><br />
conjunction with po<strong>in</strong>t-of-operation devices.<br />
TABLE 0-10<br />
DANGER LINE<br />
CLEARANCE LINE<br />
GUARD MUST EXTEND FROM SOME POINT ON<br />
CLEARANCE LINE TO SOME POINT ON OPENING<br />
LINE<br />
MINIMUM GUARDING LINE<br />
1"<br />
2<br />
TYPICAL<br />
GUARD<br />
LOCATIONS<br />
1"<br />
4<br />
3"<br />
8<br />
1"<br />
2<br />
5"<br />
8<br />
3"<br />
4<br />
7"<br />
8<br />
1"<br />
14<br />
1"<br />
12<br />
7"<br />
18<br />
1"<br />
2 8<br />
6"<br />
MAXIMUM<br />
1"<br />
1 1" 1" 2" 1" 1" 5" 3" 2" 14"<br />
2<br />
17 1"<br />
2<br />
STOCK TRAVEL LINE<br />
AT<br />
DISTANCES<br />
OVER 31- 1 /2"<br />
USE 6" AS<br />
MAXIMUM<br />
OPENING<br />
Explanation of above diagram:<br />
This diagram shows the accepted safe open<strong>in</strong>gs between the bottom edge<br />
of a guard and feed table at various distances from the danger l<strong>in</strong>e (po<strong>in</strong>t<br />
of operation).<br />
The clearance l<strong>in</strong>e marks the distance required to prevent contact between<br />
guard and mov<strong>in</strong>g parts.<br />
The m<strong>in</strong>imum guard<strong>in</strong>g l<strong>in</strong>e is the distance between the <strong>in</strong>feed side of the<br />
guard and the danger l<strong>in</strong>e which is <strong>one</strong>-half <strong>in</strong>ch from the clearance l<strong>in</strong>e.<br />
The various open<strong>in</strong>gs are such that for average size hands an operator’s<br />
f<strong>in</strong>gers won’t reach the po<strong>in</strong>t of operation.<br />
After <strong>in</strong>st<strong>all</strong>ation of po<strong>in</strong>t-of-operation guards and before a mach<strong>in</strong>e is<br />
released for operation, a check should be made to verify that the guard will<br />
prevent the operator’s hands from reach<strong>in</strong>g the po<strong>in</strong>t of operation.<br />
TABLE O-10<br />
Distance of open<strong>in</strong>g<br />
Maximum width<br />
from po<strong>in</strong>t-of-operation<br />
of open<strong>in</strong>g<br />
hazard (<strong>in</strong>ches)<br />
(<strong>in</strong>ches)<br />
1<br />
⁄2 to 1 1 ⁄2................................................................................ 1 ⁄4<br />
1 1 ⁄2 to 2 1 ⁄2.............................................................................. 3 ⁄8<br />
2 1 ⁄2 to 3 1 ⁄2.............................................................................. 1 ⁄2<br />
3 1 ⁄2 to 5 1 ⁄2.............................................................................. 5 ⁄8<br />
5 1 ⁄2 to 6 1 ⁄2.............................................................................. 3 ⁄4<br />
6 1 ⁄2 to 7 1 ⁄2.............................................................................. 7 ⁄8<br />
7 1 ⁄2 to 12 1 ⁄2.......................................................................... 1 1 ⁄4<br />
12 1 ⁄2 to 15 1 ⁄2........................................................................ 1 1 ⁄2<br />
15 1 ⁄2 to 17 1 ⁄2........................................................................ 1 7 ⁄8<br />
17 1 ⁄2 to 31 1 ⁄2........................................................................ 2 1 ⁄8<br />
This table shows the distances that guards sh<strong>all</strong> be positi<strong>one</strong>d from the danger l<strong>in</strong>e<br />
<strong>in</strong> accordance with the required open<strong>in</strong>gs.<br />
118 | CONTROL SYSTEMS
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
(C)(3) POINT OF OPERATION DEVICES<br />
(i) Po<strong>in</strong>t of operation devices sh<strong>all</strong> protect the operator by:<br />
(a) Prevent<strong>in</strong>g and/or stopp<strong>in</strong>g normal strok<strong>in</strong>g of the press if the<br />
operator’s hands are <strong>in</strong>advertently placed <strong>in</strong> the po<strong>in</strong>t of operation; or<br />
(b) Prevent<strong>in</strong>g the operator from <strong>in</strong>advertently reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t<br />
of operation; or withdraw<strong>in</strong>g his hands if they are <strong>in</strong>advertently located<br />
<strong>in</strong> the po<strong>in</strong>t of operation as the dies close; or<br />
(c) Prevent<strong>in</strong>g the operator from <strong>in</strong>advertently reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t<br />
of operation at <strong>all</strong> times; or<br />
(d) [Reserved] (formerly sweep device)<br />
(e) Requir<strong>in</strong>g application of both of the operator’s hands to mach<strong>in</strong>e<br />
operat<strong>in</strong>g controls and locat<strong>in</strong>g such controls at such a safety distance<br />
from the po<strong>in</strong>t of operation that the slide completes the downward travel<br />
or stops before the operator can reach <strong>in</strong>to the po<strong>in</strong>t of operation with<br />
his hands; or<br />
(f) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be<br />
<strong>in</strong>itiated, and ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g this closed condition until the motion of the<br />
slide has ceased; or<br />
(g) Enclos<strong>in</strong>g the po<strong>in</strong>t of operation before a press stroke can be<br />
<strong>in</strong>itiated, so as to prevent an operator from reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of<br />
operation prior to die closure or prior to cessation of slide motion dur<strong>in</strong>g<br />
the downward stroke.<br />
Gate or movable barrier device<br />
(ii) A gate or movable barrier device sh<strong>all</strong> protect the operator as follows:<br />
(a) A Type A gate or movable barrier device sh<strong>all</strong> protect the operator<br />
<strong>in</strong> the manner specified <strong>in</strong> paragraph (c)(3)(i)(f) of this section, and<br />
(b) A Type B gate or movable barrier device sh<strong>all</strong> protect the operator<br />
<strong>in</strong> the manner specified <strong>in</strong> paragraph (c)(3)(i)(g) of this section.<br />
Presence sens<strong>in</strong>g<br />
(iii) A presence sens<strong>in</strong>g po<strong>in</strong>t of operation device sh<strong>all</strong> protect the<br />
operator as provided <strong>in</strong> paragraph (c)(3)(i)(a) of this section, and sh<strong>all</strong><br />
be <strong>in</strong>terlocked <strong>in</strong>to the control circuit to prevent or stop slide motion if<br />
the operator’s hand or other part of his body is with<strong>in</strong> the sens<strong>in</strong>g field<br />
of the device dur<strong>in</strong>g the downstroke of the press slide.<br />
(a) The devices may not be used on mach<strong>in</strong>es us<strong>in</strong>g full revolution clutches.<br />
(b) The devices may not be used as a tripp<strong>in</strong>g means to <strong>in</strong>itiate slide<br />
motion, except when used <strong>in</strong> total conformance with paragraph (h) of<br />
this section. (Paragraph (h) omitted.)<br />
(c) The device sh<strong>all</strong> be constructed so that a failure with<strong>in</strong> the<br />
system does not prevent the normal stopp<strong>in</strong>g action from be<strong>in</strong>g<br />
applied to the press when required, but does prevent the <strong>in</strong>itiation of<br />
a successive stroke until the failure is corrected. The failure sh<strong>all</strong> be<br />
<strong>in</strong>dicated by the system.<br />
(d) Mut<strong>in</strong>g (bypass<strong>in</strong>g of the protective function) of such device dur<strong>in</strong>g<br />
the upstroke of the press slide is permitted for the purpose of parts<br />
ejection, circuit check<strong>in</strong>g, and feed<strong>in</strong>g.<br />
(e) The safety distance (Ds) from the sens<strong>in</strong>g field to the po<strong>in</strong>t<br />
of operation sh<strong>all</strong> be greater than the distance determ<strong>in</strong>ed by the<br />
follow<strong>in</strong>g formula:<br />
Ds = 63 <strong>in</strong>ches/second x Ts; where:<br />
Ds = m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
Ts = stopp<strong>in</strong>g time of the press measured at approximately 90° position<br />
of the crankshaft rotation (seconds).<br />
(f) Guards sh<strong>all</strong> be used to protect <strong>all</strong> areas of entry to the po<strong>in</strong>t of<br />
operation not protected by the presence sens<strong>in</strong>g device.<br />
Pull-out (pullback)<br />
(iv) The pull-out device sh<strong>all</strong> protect the operator as specified <strong>in</strong><br />
paragraph (c)(3)(i)(b) of this section and sh<strong>all</strong> <strong>in</strong>clude attachments for<br />
each of the operator’s hands.<br />
(a) Attachments sh<strong>all</strong> be connected to and operated only by the press<br />
slide or upper die.<br />
(b) Attachments sh<strong>all</strong> be adjusted to prevent the operator from<br />
reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of operation or to withdraw the operator’s hands<br />
from the po<strong>in</strong>t of operation before the dies close.<br />
(c) A separate pull-out device sh<strong>all</strong> be provided for each operator if<br />
more than <strong>one</strong> operator is used on the press.<br />
(d) Each pull-out device <strong>in</strong> use sh<strong>all</strong> be visu<strong>all</strong>y <strong>in</strong>spected and checked<br />
for proper adjustment at the start of each operator shift, follow<strong>in</strong>g a new<br />
die setup, and when operators are changed. Necessary ma<strong>in</strong>tenance<br />
or repair or both sh<strong>all</strong> be performed and completed before the press<br />
is operated. Records of <strong>in</strong>spections and ma<strong>in</strong>tenance sh<strong>all</strong> be kept <strong>in</strong><br />
accordance with paragraph (e) of this section.<br />
Sweep<br />
(v) The sweep device may not be used for po<strong>in</strong>t-of-operation<br />
safeguard<strong>in</strong>g after December 31, 1976.<br />
Holdout or restra<strong>in</strong>t<br />
(vi) A holdout or a restra<strong>in</strong>t device sh<strong>all</strong> protect the operator as<br />
specified <strong>in</strong> paragraph (c)(3)(i)(c) of this section and sh<strong>all</strong> <strong>in</strong>clude<br />
attachments for each of the operator’s hands. Such attachments sh<strong>all</strong><br />
be securely anchored and adjusted <strong>in</strong> such a way that the operator is<br />
restra<strong>in</strong>ed from reach<strong>in</strong>g <strong>in</strong>to the po<strong>in</strong>t of operation. A separate set of<br />
restra<strong>in</strong>ts sh<strong>all</strong> be provided for each operator if more than <strong>one</strong> operator<br />
is required on a press.<br />
Two-hand control (part revolution only)<br />
(vii) The two-hand control device sh<strong>all</strong> protect the operator as specified<br />
<strong>in</strong> paragraph (c)(3)(i)(e) of this section.<br />
(a) When used <strong>in</strong> press operations requir<strong>in</strong>g more than <strong>one</strong> operator,<br />
separate two-hand controls sh<strong>all</strong> be provided for each operator, and<br />
sh<strong>all</strong> be designed to require concurrent application of <strong>all</strong> operators’<br />
controls to activate the slide. The removal of a hand from any control<br />
button sh<strong>all</strong> cause the slide to stop.<br />
(b) Each two-hand control sh<strong>all</strong> meet the construction requirements of<br />
paragraph (b)(7)(v) of this section.<br />
(c) The safety distance (Ds) between each two-hand control device<br />
and the po<strong>in</strong>t of operation sh<strong>all</strong> be greater than the distance determ<strong>in</strong>ed<br />
by the follow<strong>in</strong>g formula:<br />
Ds = 63 <strong>in</strong>ches/second x Ts; where:<br />
Ds = m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
Ts = stopp<strong>in</strong>g time of the press measured at approximately 90° position<br />
of the crankshaft rotation (seconds).<br />
(d) Two-hand controls sh<strong>all</strong> be fixed <strong>in</strong> position so that only a<br />
supervisor or safety eng<strong>in</strong>eer is capable of relocat<strong>in</strong>g the controls.<br />
CONTROL SYSTEMS | 119
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
Two-hand trip<br />
(viii) The two-hand trip device sh<strong>all</strong> protect the operator as specified <strong>in</strong><br />
paragraph (c)(3)(i)(e) of this section.<br />
(a) When used <strong>in</strong> press operations requir<strong>in</strong>g more than <strong>one</strong> operator,<br />
separate two-hand trips sh<strong>all</strong> be provided for each operator, and sh<strong>all</strong><br />
be designed to require concurrent application of <strong>all</strong> operator controls to<br />
activate the slide.<br />
(b) Each two-hand trip sh<strong>all</strong> meet the construction requirements of<br />
paragraph (b)(6) of this section.<br />
(c) The safety distance (Dm) between the two-hand trip and the po<strong>in</strong>t<br />
of operation sh<strong>all</strong> be greater than the distance determ<strong>in</strong>ed by the<br />
follow<strong>in</strong>g formula:<br />
Dm = 63 <strong>in</strong>ches/second x Tm; where:<br />
Dm = m<strong>in</strong>imum safety distance (<strong>in</strong>ches);<br />
63 <strong>in</strong>ches/second = hand speed constant; and<br />
Tm = the maximum time the press takes for the die closure after it has<br />
been tripped (seconds). For full revolution clutch presses with only <strong>one</strong><br />
engag<strong>in</strong>g po<strong>in</strong>t, Tm is equal to the time necessary for <strong>one</strong> and <strong>one</strong>-half<br />
revolutions of the crankshaft. For full revolution clutch presses with<br />
more than <strong>one</strong> engag<strong>in</strong>g po<strong>in</strong>t, Tm sh<strong>all</strong> be calculated as follows:<br />
(d) Two-hand trips sh<strong>all</strong> be fixed <strong>in</strong> position so that only a supervisor<br />
or safety eng<strong>in</strong>eer is capable of relocat<strong>in</strong>g the controls.<br />
(C)(4) HAND FEEDING TOOLS<br />
Hand feed<strong>in</strong>g tools are <strong>in</strong>tended for plac<strong>in</strong>g and remov<strong>in</strong>g materials<br />
<strong>in</strong> and from the press. Hand feed<strong>in</strong>g tools are not a po<strong>in</strong>t of operation<br />
guard or protection device and sh<strong>all</strong> not be used <strong>in</strong> lieu of the “guards”<br />
or devices required <strong>in</strong> this section.<br />
*(C)(5) ADDED REQUIREMENTS<br />
Additional requirements for safeguard<strong>in</strong>g. Where the operator feeds or<br />
removes parts by plac<strong>in</strong>g <strong>one</strong> or both hands <strong>in</strong> the po<strong>in</strong>t of operation,<br />
and a two-hand control, presence sens<strong>in</strong>g device or Type B gate or<br />
movable barrier (on a part revolution clutch) is used for safeguard<strong>in</strong>g:<br />
(i) The employer sh<strong>all</strong> use a control system and a brake monitor<br />
which comply with paragraphs (b)(13) and (14) of this section. This<br />
requirement sh<strong>all</strong> be complied with by November 1, 1975;<br />
(ii) The exception <strong>in</strong> paragraph (b)(7)(v)(d) of this section for two-hand<br />
controls manufactured and <strong>in</strong>st<strong>all</strong>ed before August 31, 1971 is not<br />
applicable under this paragraph (c)(5);<br />
(iii) The control of air clutch mach<strong>in</strong>es sh<strong>all</strong> be designed to prevent<br />
a significant <strong>in</strong>crease <strong>in</strong> the normal stopp<strong>in</strong>g time due to a failure<br />
with<strong>in</strong> the operat<strong>in</strong>g valve mechanism, and to <strong>in</strong>hibit further operation<br />
if such failure does occur, where a part revolution clutch is employed.<br />
The exception <strong>in</strong> paragraph (b)(7)(xi) of this section for controls<br />
manufactured and <strong>in</strong>st<strong>all</strong>ed before August 31, 1971, is not applicable<br />
under this paragraph (c)(5).<br />
(B)(13) CONTROL RELIABILITY*<br />
When required by paragraph (c)(5) of this section, the control system<br />
sh<strong>all</strong> be constructed so that a failure with<strong>in</strong> the system does not<br />
prevent the normal stopp<strong>in</strong>g action from be<strong>in</strong>g applied to the press<br />
when required, but does prevent <strong>in</strong>itiation of a successive stroke until<br />
the failure is corrected. The failure sh<strong>all</strong> be detectable by a simple test,<br />
or <strong>in</strong>dicated by the control system. This requirement does not apply<br />
to those elements of the control system which have no effect on the<br />
protection aga<strong>in</strong>st po<strong>in</strong>t of operation <strong>in</strong>juries.<br />
(B)(14) BRAKE MONITORING*<br />
When required by paragraph (c)(5) of this section, the brake monitor<br />
sh<strong>all</strong> meet the follow<strong>in</strong>g requirements:<br />
(i) Be so constructed as to automatic<strong>all</strong>y prevent the activation of a<br />
successive stroke if the stopp<strong>in</strong>g time or brak<strong>in</strong>g distance deteriorates<br />
to a po<strong>in</strong>t where the safety distance be<strong>in</strong>g utilized does not meet the<br />
requirements set forth <strong>in</strong> paragraph (c)(3)(iii)(e) or (c)(3)(vii)(c) of this<br />
section. The brake monitor used with the Type B gate or movable barrier<br />
device sh<strong>all</strong> be <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a manner to detect slide top-stop overrun<br />
beyond the normal limit reasonably established by the employer;<br />
(ii) Be <strong>in</strong>st<strong>all</strong>ed on a press so that it <strong>in</strong>dicates when the performance<br />
of the brak<strong>in</strong>g system has deteriorated to the extent described <strong>in</strong><br />
paragraph (b)(14)(i) of this section; and<br />
(iii) Be constructed and <strong>in</strong>st<strong>all</strong>ed <strong>in</strong> a manner to monitor brake system<br />
performance on each stroke.<br />
*Applies to part revolution only.<br />
T m<br />
= 1/2 +<br />
1<br />
Number of engag<strong>in</strong>g<br />
X<br />
po<strong>in</strong>ts per revolution<br />
time necessary to complete<br />
<strong>one</strong> revolution of the crankshaft<br />
(seconds)<br />
120 | CONTROL SYSTEMS
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
CONSTRUCTION OF PRESS AND ITS CONTROLS<br />
—FOR ALL PRESSES<br />
(B)(1) HAZARDS TO PERSONNEL ASSOCIATED WITH BROKEN OR<br />
FALLING MACHINE COMPONENTS<br />
Mach<strong>in</strong>e comp<strong>one</strong>nts sh<strong>all</strong> be designed, secured or covered to m<strong>in</strong>imize<br />
hazards caused by breakage or loosen<strong>in</strong>g and f<strong>all</strong><strong>in</strong>g or release of<br />
mechanical energy (i.e., broken spr<strong>in</strong>gs).<br />
(B)(2) BRAKES<br />
Friction brakes provided for stopp<strong>in</strong>g or hold<strong>in</strong>g a slide movement sh<strong>all</strong><br />
be <strong>in</strong>herently self-engag<strong>in</strong>g by requir<strong>in</strong>g power or force from an external<br />
source to cause disengagement. Brake capacity sh<strong>all</strong> be sufficient to<br />
stop the motion of the slide quickly and capable of hold<strong>in</strong>g the slide and<br />
its attachments at any po<strong>in</strong>t <strong>in</strong> its travel.<br />
(B)(8) ELECTRICAL DISCONNECT<br />
(i) A ma<strong>in</strong> power disconnect switch capable of be<strong>in</strong>g locked only <strong>in</strong> the<br />
Off position sh<strong>all</strong> be provided with every power press control system.<br />
Starter<br />
(ii) The motor start button sh<strong>all</strong> be protected aga<strong>in</strong>st accidental operation.<br />
(iii) All mechanical power press controls sh<strong>all</strong> <strong>in</strong>corporate a type of<br />
drive motor starter that will disconnect the drive motor from the power<br />
source <strong>in</strong> event of control voltage or power source failure, and require<br />
operation of the motor start button to restart the motor when voltage<br />
conditions are restored to normal.<br />
Transformer<br />
(iv) All a.c. control circuits and solenoid valve coils sh<strong>all</strong> be powered<br />
by not more than a nom<strong>in</strong>al 120-volt a.c. supply obta<strong>in</strong>ed from a<br />
transformer with an isolated secondary. Higher voltages that may be<br />
necessary for operation of mach<strong>in</strong>e or control mechanisms sh<strong>all</strong> be<br />
isolated from any control mechanism handled by the operator, but motor<br />
starters with <strong>in</strong>tegral Start-Stop buttons may utilize l<strong>in</strong>e voltage control.<br />
All d.c. control circuits sh<strong>all</strong> be powered by not more than a nom<strong>in</strong>al<br />
240-volt d.c. supply isolated from any higher voltage.<br />
Ground<br />
(v) All clutch/brake control electrical circuits sh<strong>all</strong> be protected aga<strong>in</strong>st<br />
the possibility of an accidental ground <strong>in</strong> the control circuit caus<strong>in</strong>g false<br />
operation of the press.<br />
Control circuit<br />
(vi) All clutch/brake control circuits sh<strong>all</strong> <strong>in</strong>corporate features to<br />
m<strong>in</strong>imize the possibility of an un<strong>in</strong>tended stroke <strong>in</strong> the event of the<br />
failure of a control comp<strong>one</strong>nt to function properly, <strong>in</strong>clud<strong>in</strong>g relays, limit<br />
switches, and static output circuits.<br />
(B)(9) SLIDE COUNTERBALANCE SYSTEMS<br />
(i) Spr<strong>in</strong>g counterbalance systems, when used, sh<strong>all</strong> <strong>in</strong>corporate<br />
means to reta<strong>in</strong> system parts <strong>in</strong> event of breakage.<br />
(ii) Spr<strong>in</strong>g counterbalances, when used, sh<strong>all</strong> have the capability to<br />
hold the slide and its attachments at midstroke, without brake applied.<br />
(iii) Air counterbalance cyl<strong>in</strong>ders sh<strong>all</strong> <strong>in</strong>corporate means to reta<strong>in</strong> the<br />
piston and rod <strong>in</strong> case of breakage or loosen<strong>in</strong>g.<br />
(iv) Air counterbalance cyl<strong>in</strong>ders sh<strong>all</strong> have adequate capability to<br />
hold the slide and its attachments at any po<strong>in</strong>t <strong>in</strong> stroke, without<br />
brake applied.<br />
(v) Air counterbalance cyl<strong>in</strong>ders sh<strong>all</strong> <strong>in</strong>corporate means to prevent<br />
failure of capability (sudden loss of pressure) <strong>in</strong> event of air supply failure.<br />
(B)(10) AIR CONTROLLING EQUIPMENT<br />
Air controll<strong>in</strong>g equipment sh<strong>all</strong> be protected aga<strong>in</strong>st foreign material<br />
and water enter<strong>in</strong>g the pneumatic system of the press. A means of air<br />
lubrication sh<strong>all</strong> be provided when needed.<br />
(B)(11) HYDRAULIC EQUIPMENT<br />
The maximum anticipated work<strong>in</strong>g pressures <strong>in</strong> any hydraulic system on<br />
a mechanical power press sh<strong>all</strong> not exceed the safe work<strong>in</strong>g pressure<br />
rat<strong>in</strong>g of any comp<strong>one</strong>nt used <strong>in</strong> the system.<br />
(B)(12) PRESSURE VESSELS<br />
All pressure vessels used <strong>in</strong> conjunction with power presses sh<strong>all</strong><br />
conform to the American Society of Mechanical Eng<strong>in</strong>eers Code for<br />
Pressure Vessels, 1968 Edition. (Also see 1910.169 Air Receivers.)<br />
DESIGN, CONSTRUCTION, SETTING AND FEEDING OF DIES<br />
(D)(1) GENERAL REQUIREMENTS<br />
The employer sh<strong>all</strong>: (i) use dies and operat<strong>in</strong>g methods designed to<br />
control or elim<strong>in</strong>ate hazards to operat<strong>in</strong>g personnel, and (ii) furnish and<br />
enforce the use of hand tools for free<strong>in</strong>g and remov<strong>in</strong>g stuck work or<br />
scrap pieces from the die, so that no employee need reach <strong>in</strong>to the po<strong>in</strong>t<br />
of operation for such purposes.<br />
(D)(2) RESERVED<br />
(D)(3) SCRAP HANDLING<br />
The employer sh<strong>all</strong> provide means for handl<strong>in</strong>g scrap from roll feed<br />
or random length stock operations. Scrap cutters used <strong>in</strong> conjunction<br />
with scrap handl<strong>in</strong>g systems sh<strong>all</strong> be safeguarded <strong>in</strong> accordance with<br />
paragraph (c) of this section and with 1910.219.<br />
CONTROL SYSTEMS | 121
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
(D)(4) GUIDE POST HAZARD<br />
The hazard created by a guide post (when it is located <strong>in</strong> the immediate<br />
vic<strong>in</strong>ity of the operator) when separated from its bush<strong>in</strong>g by more than<br />
<strong>one</strong>-fourth <strong>in</strong>ch sh<strong>all</strong> be considered as a po<strong>in</strong>t of operation hazard and<br />
be protected <strong>in</strong> accordance with paragraph (c) of this section.<br />
(D)(5) UNITIZED TOOLING<br />
If unitized tool<strong>in</strong>g is used, the open<strong>in</strong>g between the top of the punch<br />
holder and the face of the slide, or strik<strong>in</strong>g pad, sh<strong>all</strong> be safeguarded<br />
<strong>in</strong> accordance with the requirements of paragraph (c) of this section.<br />
(D)(6) TONNAGE, STROKE, AND WEIGHT DESIGNATION<br />
All dies sh<strong>all</strong> be:<br />
(i) Stamped with the tonnage and stroke requirements; or have these<br />
characteristics recorded if these records are readily available to the<br />
die setter;<br />
(ii) Stamped to <strong>in</strong>dicate upper die weight when necessary for air<br />
counterbalance pressure adjustment; and<br />
(iii) Stamped to <strong>in</strong>dicate complete die weight when handl<strong>in</strong>g equipment<br />
may become overloaded.<br />
(D)(8) DIE HANDLING<br />
Handl<strong>in</strong>g equipment attach po<strong>in</strong>ts sh<strong>all</strong> be provided on <strong>all</strong> dies requir<strong>in</strong>g<br />
mechanical handl<strong>in</strong>g.<br />
(D)(9) DIE SETTING<br />
(i) The employer sh<strong>all</strong> establish a die sett<strong>in</strong>g procedure that will <strong>in</strong>sure<br />
compliance with paragraph (c) of this section.<br />
(ii) The employer sh<strong>all</strong> provide spr<strong>in</strong>g loaded turnover bars, for presses<br />
designed to accept such turnover bars.<br />
(iii) The employer sh<strong>all</strong> provide die stops or other means to prevent<br />
los<strong>in</strong>g control of the die while sett<strong>in</strong>g or remov<strong>in</strong>g dies <strong>in</strong> presses which<br />
are <strong>in</strong>cl<strong>in</strong>ed.<br />
(iv) The employer sh<strong>all</strong> provide and enforce the use of safety blocks for<br />
use whenever dies are be<strong>in</strong>g adjusted or repaired <strong>in</strong> the press.<br />
(v) The employer sh<strong>all</strong> provide brushes, swabs, lubricat<strong>in</strong>g rolls, and<br />
automatic or manual pressure guns so that operators and die setters<br />
sh<strong>all</strong> not be required to reach <strong>in</strong>to the po<strong>in</strong>t of operation or other hazard<br />
areas to lubricate material, punches or dies.<br />
(D)(7) DIE FASTENING<br />
Provision sh<strong>all</strong> be made <strong>in</strong> both the upper and lower shoes for securely<br />
mount<strong>in</strong>g the die to the bolster and slide. Where clamp caps or<br />
setscrews are used <strong>in</strong> conjunction with punch stems, additional means<br />
of secur<strong>in</strong>g the upper shoe to the slide sh<strong>all</strong> be used.<br />
INSPECTION, MAINTENANCE, AND MODIFICATION OF PRESSES<br />
(E)(1) INSPECTION AND MAINTENANCE RECORDS<br />
(i) It sh<strong>all</strong> be the responsibility of the employer to establish and follow<br />
a program of periodic and regular <strong>in</strong>spections of his power presses to<br />
<strong>in</strong>sure that <strong>all</strong> their parts, auxiliary equipment, and safeguards are <strong>in</strong> a<br />
safe operat<strong>in</strong>g condition and adjustment. The employer sh<strong>all</strong> ma<strong>in</strong>ta<strong>in</strong> a<br />
certification record of <strong>in</strong>spections which <strong>in</strong>cludes the date of <strong>in</strong>spection,<br />
the signature of the person who performed the <strong>in</strong>spection, and the serial<br />
number, or other identifier, of the power press that was <strong>in</strong>spected.<br />
(ii) Each press sh<strong>all</strong> be <strong>in</strong>spected and tested no less than weekly<br />
to determ<strong>in</strong>e the condition of the clutch/brake mechanism-antirepeat<br />
feature and s<strong>in</strong>gle stroke mechanism. Necessary ma<strong>in</strong>tenance or repair<br />
or both sh<strong>all</strong> be performed and completed before the press is operated.<br />
These requirements do not apply to those presses which comply with<br />
paragraphs (b)(13) and (14) of this section. The employer sh<strong>all</strong> ma<strong>in</strong>ta<strong>in</strong><br />
a certification record of <strong>in</strong>spections, tests and ma<strong>in</strong>tenance work which<br />
<strong>in</strong>cludes the date of the <strong>in</strong>spection, test or ma<strong>in</strong>tenance; the signature<br />
of the person who performed the <strong>in</strong>spection, test, or ma<strong>in</strong>tenance; and<br />
the serial number or other identifier of the press that was <strong>in</strong>spected,<br />
tested or ma<strong>in</strong>ta<strong>in</strong>ed.<br />
(E)(2) MODIFICATION<br />
It sh<strong>all</strong> be the responsibility of any person modify<strong>in</strong>g a power press to<br />
furnish <strong>in</strong>structions with the modification to establish new or changed<br />
guidel<strong>in</strong>es for use and care of the power press so modified.<br />
(E)(3) TRAINING OF MAINTENANCE PERSONNEL<br />
It sh<strong>all</strong> be the responsibility of the employer to <strong>in</strong>sure the orig<strong>in</strong>al<br />
and cont<strong>in</strong>u<strong>in</strong>g competence of personnel car<strong>in</strong>g for, <strong>in</strong>spect<strong>in</strong>g, and<br />
ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g power presses.<br />
OPERATION OF POWER PRESSES<br />
(F)(1) RESERVED<br />
(F)(2) INSTRUCTION TO OPERATORS<br />
The employer sh<strong>all</strong> tra<strong>in</strong> and <strong>in</strong>struct the operator <strong>in</strong> the safe method of<br />
work before start<strong>in</strong>g work on any operation covered by this section. The<br />
employer sh<strong>all</strong> <strong>in</strong>sure by adequate supervision that correct operat<strong>in</strong>g<br />
procedures are be<strong>in</strong>g followed.<br />
(F)(3) WORK AREA<br />
The employer sh<strong>all</strong> provide clearance between mach<strong>in</strong>es so that<br />
movement of <strong>one</strong> operator will not <strong>in</strong>terfere with the work of another.<br />
Ample room for clean<strong>in</strong>g mach<strong>in</strong>es, handl<strong>in</strong>g material, work pieces, and<br />
scrap sh<strong>all</strong> also be provided. All surround<strong>in</strong>g floors sh<strong>all</strong> be kept <strong>in</strong> good<br />
condition and free from obstructions, grease, oil, and water.<br />
(F)(4) OVERLOADING<br />
The employer sh<strong>all</strong> operate his presses with<strong>in</strong> the tonnage and<br />
attachment weight rat<strong>in</strong>gs specified by the manufacturer.<br />
122 | CONTROL SYSTEMS
OSHA 29 CFR 1910.217—MECHANICAL POWER PRESSES (CONTINUED)<br />
REPORTS OF INJURIES TO EMPLOYEES<br />
OPERATING MECHANICAL POWER PRESSES<br />
(g)(1) The employer sh<strong>all</strong>, with<strong>in</strong> 30 days of the occurrence, report<br />
to either the Director of the Directorate of Safety Standards Programs,<br />
OSHA, U.S. Department of Labor, Wash<strong>in</strong>gton, D.C. 20210, or the State<br />
agency adm<strong>in</strong>ister<strong>in</strong>g plan approved by the Assistant Secretary of<br />
Labor for Occupational Safety and Health, <strong>all</strong> po<strong>in</strong>t of operation <strong>in</strong>juries<br />
to operators or other employees. The follow<strong>in</strong>g <strong>in</strong>formation sh<strong>all</strong> be<br />
<strong>in</strong>cluded <strong>in</strong> the report:<br />
(i) Employer’s name, address and location of the workplace (establishment).<br />
(ii) Employee’s name, <strong>in</strong>jury susta<strong>in</strong>ed, and the task be<strong>in</strong>g performed<br />
(operation, setup, ma<strong>in</strong>tenance, or other).<br />
(iii) Type of clutch used on the press (full revolution, part revolution or<br />
direct drive).<br />
(iv) Type of safeguard(s) be<strong>in</strong>g used (two-hand control, two-hand trip,<br />
pullouts, sweeps or other). If the safeguard is not described <strong>in</strong> this<br />
section, give a complete description.<br />
(v) Cause of the accident (repeat of press, safeguard failure, remov<strong>in</strong>g<br />
stuck part or scrap, no safeguard provided, no safeguard <strong>in</strong> use or other).<br />
(vi) Type of feed<strong>in</strong>g (manual with hands <strong>in</strong> dies or with hands out of<br />
dies, semi-automatic, automatic or other).<br />
(vii) Means used to actuate press stroke (foot trip, foot control, hand<br />
trip, hand control or other).<br />
(viii) Number of operators required for the operation and the number<br />
of operators provided with controls and safeguards.<br />
OSHA 29 CFR 1910.212—GENERAL REQUIREMENTS FOR ALL MACHINES<br />
(a) Mach<strong>in</strong>e guard<strong>in</strong>g—(1) Types of guard<strong>in</strong>g. One or more methods<br />
of mach<strong>in</strong>e guard<strong>in</strong>g sh<strong>all</strong> be provided to protect the operator and other<br />
employees <strong>in</strong> the mach<strong>in</strong>e area from hazards such as those created by<br />
po<strong>in</strong>t of operation, <strong>in</strong>go<strong>in</strong>g nip po<strong>in</strong>ts, rotat<strong>in</strong>g parts, fly<strong>in</strong>g chips and<br />
sparks. Examples of guard<strong>in</strong>g methods are—barrier guards, two-hand<br />
tripp<strong>in</strong>g devices, electronic safety devices, etc.<br />
(2) General requirements for mach<strong>in</strong>e guards. Guards sh<strong>all</strong> be affixed<br />
to the mach<strong>in</strong>e where possible and secured elsewhere if for any reason<br />
attachment to the mach<strong>in</strong>e is not possible. The guard sh<strong>all</strong> be such that<br />
it does not offer an accident hazard <strong>in</strong> itself.<br />
(3) Po<strong>in</strong>t of operation guard<strong>in</strong>g. (i) Po<strong>in</strong>t of operation is the area<br />
on a mach<strong>in</strong>e where work is actu<strong>all</strong>y performed upon the material<br />
be<strong>in</strong>g processed.<br />
(ii) The po<strong>in</strong>t of operation of mach<strong>in</strong>es whose operation exposes an<br />
employee to <strong>in</strong>jury sh<strong>all</strong> be guarded. The guard<strong>in</strong>g device sh<strong>all</strong> be <strong>in</strong><br />
conformity with any appropriate standards therefor; or, <strong>in</strong> the absence of<br />
applicable specific standards, sh<strong>all</strong> be so designed and constructed as<br />
to prevent the operator from hav<strong>in</strong>g any part of his body <strong>in</strong> the danger<br />
z<strong>one</strong> dur<strong>in</strong>g the operat<strong>in</strong>g cycle.<br />
(iii) Special hand tools for plac<strong>in</strong>g and remov<strong>in</strong>g material sh<strong>all</strong> be such<br />
as to permit easy handl<strong>in</strong>g of material without the operator plac<strong>in</strong>g<br />
a hand <strong>in</strong> the danger z<strong>one</strong>. Such tools sh<strong>all</strong> not be <strong>in</strong> lieu of other<br />
guard<strong>in</strong>g required by this section, but can only be used to supplement<br />
protection provided.<br />
(iv) The follow<strong>in</strong>g are some of the mach<strong>in</strong>es which usu<strong>all</strong>y require<br />
po<strong>in</strong>t of operation guard<strong>in</strong>g:<br />
(a) Guillot<strong>in</strong>e cutters<br />
(b) Shears<br />
(c) Alligator shears<br />
(d) Power presses<br />
(e) Mill<strong>in</strong>g mach<strong>in</strong>es<br />
(f) Power saws<br />
(g) Jo<strong>in</strong>ters<br />
(h) Portable power tools<br />
(i) Form<strong>in</strong>g rolls and calenders<br />
(4) Barrels, conta<strong>in</strong>ers and drums. Revolv<strong>in</strong>g drums, barrels and<br />
conta<strong>in</strong>ers sh<strong>all</strong> be guarded by an enclosure which is <strong>in</strong>terlocked with<br />
the drive mechanism, so that the barrel, drum or conta<strong>in</strong>er cannot<br />
revolve unless the guard enclosure is <strong>in</strong> place.<br />
(5) Exposure of blades. When the periphery of the blades of a fan is less<br />
than seven (7) feet above the floor or work<strong>in</strong>g level, the blades sh<strong>all</strong> be<br />
guarded. The guard sh<strong>all</strong> have open<strong>in</strong>gs no larger than <strong>one</strong>-half (1⁄2) <strong>in</strong>ch.<br />
(b) Anchor<strong>in</strong>g fixed mach<strong>in</strong>ery. Mach<strong>in</strong>es designed for a fixed location<br />
sh<strong>all</strong> be securely anchored to prevent walk<strong>in</strong>g or mov<strong>in</strong>g.<br />
CONTROL SYSTEMS | 123
OSHA 29 CFR 1910.219—MECHANICAL POWER-TRANSMISSION APPARATUS<br />
(a) General requirements. (1) This section covers <strong>all</strong> types and shapes<br />
of power-transmission belts, except the follow<strong>in</strong>g when operat<strong>in</strong>g at two<br />
hundred and fifty (250) feet per m<strong>in</strong>ute or less: (i) Flat belts <strong>one</strong> (1) <strong>in</strong>ch<br />
or less <strong>in</strong> width, (ii) flat belts two (2) <strong>in</strong>ches or less <strong>in</strong> width which are<br />
free from metal lac<strong>in</strong>gs or fasteners, (iii) round belts <strong>one</strong>-half ( 1 ⁄2) <strong>in</strong>ch<br />
or less <strong>in</strong> diameter; and (iv) s<strong>in</strong>gle strand V-belts, the width of which is<br />
thirteen thirty-seconds ( 13 ⁄32) <strong>in</strong>ch or less.<br />
(2) Vertical and <strong>in</strong>cl<strong>in</strong>ed belts (paragraphs (e) (3) and (4) of this<br />
section) if not more than two and <strong>one</strong>-half (2 1 ⁄2) <strong>in</strong>ches wide and<br />
runn<strong>in</strong>g at a speed of less than <strong>one</strong> thousand (1,000) feet per m<strong>in</strong>ute,<br />
and if free from metal lac<strong>in</strong>gs or fasten<strong>in</strong>gs may be guarded with a nippo<strong>in</strong>t<br />
belt and pulley guard.<br />
(3) For the textile <strong>in</strong>dustry, because of the presence of excessive<br />
deposits of l<strong>in</strong>t which constitutes a serious fire hazard, the sides and<br />
face sections only of nip-po<strong>in</strong>t belt and pulley guards are required,<br />
provided the guard sh<strong>all</strong> extend at least six (6) <strong>in</strong>ches beyond the rim<br />
of the pulley on the <strong>in</strong>-runn<strong>in</strong>g and off-runn<strong>in</strong>g sides of the belt and<br />
at least two (2) <strong>in</strong>ches away from the rim and face of the pulley <strong>in</strong> <strong>all</strong><br />
other directions.<br />
(4) This section covers the pr<strong>in</strong>cipal features with which powertransmission<br />
safeguards sh<strong>all</strong> comply.<br />
(b) Prime-mover guards—(1) Flywheels. Flywheels located so that<br />
any part is seven (7) feet or less above floor or platform sh<strong>all</strong> be<br />
guarded <strong>in</strong> accordance with the requirements of this subparagraph:<br />
(i) With an enclosure of sheet, perforated, or expanded metal,<br />
or woven wire;<br />
(ii) With guard rails placed not less than fifteen (15) <strong>in</strong>ches nor<br />
more than twenty (20) <strong>in</strong>ches from rim. When flywheel extends <strong>in</strong>to<br />
pit or is with<strong>in</strong> twelve (12) <strong>in</strong>ches of floor, a standard toeboard sh<strong>all</strong><br />
also be provided;<br />
(iii) When the upper rim of flywheel protrudes through a work<strong>in</strong>g floor,<br />
it sh<strong>all</strong> be entirely enclosed or surrounded by a guardrail and toeboard.<br />
(iv) For flywheels with smooth rims five (5) feet or less <strong>in</strong> diameter,<br />
where the preced<strong>in</strong>g methods cannot be applied, the follow<strong>in</strong>g may be<br />
used: A disk attached to the flywheel <strong>in</strong> such manner as to cover the<br />
spokes of the wheel on the exposed side and present a smooth surface<br />
and edge, at the same time provid<strong>in</strong>g means for periodic <strong>in</strong>spection. An<br />
open space, not exceed<strong>in</strong>g four (4) <strong>in</strong>ches <strong>in</strong> width, may be left between<br />
the outside edge of the disk and the rim of the wheel if desired, to<br />
facilitate turn<strong>in</strong>g the wheel over. Where a disk is used, the keys or other<br />
dangerous projections not covered by disk sh<strong>all</strong> be cut off or covered.<br />
This subdivision does not apply to flywheels with solid web centers.<br />
(v) Adjustable guard to be used for start<strong>in</strong>g eng<strong>in</strong>e or for runn<strong>in</strong>g<br />
adjustment may be provided at the flywheel of gas or oil eng<strong>in</strong>es. A slot<br />
open<strong>in</strong>g for jack bar will be permitted.<br />
(vi) Wherever flywheels are above work<strong>in</strong>g areas, guards sh<strong>all</strong><br />
be <strong>in</strong>st<strong>all</strong>ed hav<strong>in</strong>g sufficient strength to hold the weight of the<br />
flywheel <strong>in</strong> the event of a shaft or wheel mount<strong>in</strong>g failure.<br />
(2) Cranks and connect<strong>in</strong>g rods. Cranks and connect<strong>in</strong>g rods,<br />
when exposed to contact, sh<strong>all</strong> be guarded <strong>in</strong> accordance with<br />
paragraphs (m) and (n) of this section, or by a guardrail as<br />
described <strong>in</strong> paragraph (o)(5) of this section.<br />
(3) Tail rods or extension piston rods. Tail rods or extension piston<br />
rods sh<strong>all</strong> be guarded <strong>in</strong> accordance with paragraphs (m) and (o) of<br />
this section, or by a guardrail on sides and end, with a clearance of<br />
not less than fifteen (15) nor more than twenty (20) <strong>in</strong>ches when rod<br />
is fully extended.<br />
(c) Shaft<strong>in</strong>g—(1) Inst<strong>all</strong>ation. (i) Each cont<strong>in</strong>uous l<strong>in</strong>e of shaft<strong>in</strong>g<br />
sh<strong>all</strong> be secured <strong>in</strong> position aga<strong>in</strong>st excessive endwise movement.<br />
(ii) Incl<strong>in</strong>ed and vertical shafts, particularly <strong>in</strong>cl<strong>in</strong>ed idler shafts, sh<strong>all</strong><br />
be securely held <strong>in</strong> position aga<strong>in</strong>st endwise thrust.<br />
(2) Guard<strong>in</strong>g horizontal shaft<strong>in</strong>g. (i) All exposed parts of horizontal<br />
shaft<strong>in</strong>g seven (7) feet or less from floor or work<strong>in</strong>g platform, except<strong>in</strong>g<br />
runways used exclusively for oil<strong>in</strong>g, or runn<strong>in</strong>g adjustments, sh<strong>all</strong> be<br />
protected by a stationary cas<strong>in</strong>g enclos<strong>in</strong>g shaft<strong>in</strong>g completely or by<br />
a trough enclos<strong>in</strong>g sides and top or sides and bottom of shaft<strong>in</strong>g as<br />
location requires.<br />
(ii) Shaft<strong>in</strong>g under bench mach<strong>in</strong>es sh<strong>all</strong> be enclosed by a stationary<br />
cas<strong>in</strong>g, or by a trough at sides and top or sides and bottom, as location<br />
requires. The sides of the trough sh<strong>all</strong> come with<strong>in</strong> at least six (6) <strong>in</strong>ches<br />
of the underside of table, or if shaft<strong>in</strong>g is located near floor with<strong>in</strong> six (6)<br />
<strong>in</strong>ches of floor. In every case the sides of trough sh<strong>all</strong> extend at least two<br />
(2) <strong>in</strong>ches beyond the shaft<strong>in</strong>g or protuberance.<br />
(3) Guard<strong>in</strong>g vertical and <strong>in</strong>cl<strong>in</strong>ed shaft<strong>in</strong>g. Vertical and <strong>in</strong>cl<strong>in</strong>ed<br />
shaft<strong>in</strong>g seven (7) feet or less from floor or work<strong>in</strong>g platform, except<strong>in</strong>g<br />
ma<strong>in</strong>tenance runways, sh<strong>all</strong> be enclosed with a stationary cas<strong>in</strong>g <strong>in</strong><br />
accordance with requirements of paragraphs (m) and (o) of this section.<br />
(4) Project<strong>in</strong>g shaft ends. (i) Project<strong>in</strong>g shaft ends sh<strong>all</strong> present<br />
a smooth edge and end and sh<strong>all</strong> not project more than <strong>one</strong>-half<br />
the diameter of the shaft unless guarded by nonrotat<strong>in</strong>g caps or<br />
safety sleeves.<br />
(ii) Unused keyways sh<strong>all</strong> be filled up or covered.<br />
(5) Power-transmission apparatus located <strong>in</strong> basements. All<br />
mechanical power-transmission apparatus located <strong>in</strong> basements,<br />
towers, and rooms used exclusively for power-transmission equipment<br />
sh<strong>all</strong> be guarded <strong>in</strong> accordance with this section, except that the<br />
requirements for safeguard<strong>in</strong>g belts, pulleys, and shaft<strong>in</strong>g need not be<br />
complied with when the follow<strong>in</strong>g requirements are met:<br />
(i) The basement, tower, or room occupied by transmission equipment<br />
is locked aga<strong>in</strong>st unauthorized entrance.<br />
(ii) The vertical clearance <strong>in</strong> passageways between the floor and<br />
power-transmission beams, ceil<strong>in</strong>g, or any other objects, is not less than<br />
five feet six <strong>in</strong>ches (5 ft. 6 <strong>in</strong>.).<br />
(iii) The <strong>in</strong>tensity of illum<strong>in</strong>ation conforms to the requirements of ANSI<br />
A11.1-1965 (R-1970).<br />
(iv) [Reserved]<br />
(v) The route followed by the oiler is protected <strong>in</strong> such manner as to<br />
prevent accident.<br />
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OSHA 29 CFR 1910.219—MECHANICAL POWER-TRANSMISSION APPARATUS (CONTINUED)<br />
(d) Pulleys—(1) Guard<strong>in</strong>g. Pulleys, any parts of which are seven<br />
(7) feet or less from the floor or work<strong>in</strong>g platform, sh<strong>all</strong> be guarded <strong>in</strong><br />
accordance with the standards specified <strong>in</strong> paragraphs (m) and (o) of<br />
this section. Pulleys serv<strong>in</strong>g as balance wheels (e.g., punch presses) on<br />
which the po<strong>in</strong>t of contact between belt and pulley is more than six feet<br />
six <strong>in</strong>ches (6 ft. 6 <strong>in</strong>.) from the floor or platform may be guarded with a<br />
disk cover<strong>in</strong>g the spokes.<br />
(2) Location of pulleys. (i) Unless the distance to the nearest fixed<br />
pulley, clutch or hanger exceeds the width of the belt used, a guide sh<strong>all</strong><br />
be provided to prevent the belt from leav<strong>in</strong>g the pulley on the side where<br />
<strong>in</strong>sufficient clearance exists.<br />
(ii) [Reserved]<br />
(3) Broken pulleys. Pulleys with cracks or pieces broken out of rims<br />
sh<strong>all</strong> not be used.<br />
(4) Pulley speeds. Pulleys <strong>in</strong>tended to operate at rim speed <strong>in</strong> excess<br />
of manufacturers normal recommendations sh<strong>all</strong> be speci<strong>all</strong>y designed<br />
and carefully balanced for the speed at which they are to operate.<br />
(e) Belt, rope, and cha<strong>in</strong> drives—(1) Horizontal belts and ropes. (i)<br />
Where both runs of horizontal belts are seven (7) feet or less from the<br />
floor level, the guard sh<strong>all</strong> extend to at least fifteen (15) <strong>in</strong>ches above<br />
the belt or to a standard height (see Table O-12), except that where<br />
both runs of a horizontal belt are 42 <strong>in</strong>ches or less from the floor, the<br />
belt sh<strong>all</strong> be fully enclosed <strong>in</strong> accordance with paragraphs (m) and (o)<br />
of this section.<br />
(ii) In power plants or power-development rooms, a guardrail may be<br />
used <strong>in</strong> lieu of the guard required by subdivision (i) of this subparagraph.<br />
(2) Overhead horizontal belts. (i) Overhead horizontal belts, with<br />
lower parts seven (7) feet or less from the floor or platform, sh<strong>all</strong> be<br />
guarded on sides and bottom <strong>in</strong> accordance with paragraph (o)(3) of<br />
this section.<br />
(ii) Horizontal overhead belts more than seven (7) feet above<br />
floor or platform sh<strong>all</strong> be guarded for their entire length under the<br />
follow<strong>in</strong>g conditions:<br />
(a) If located over passageways or work places and travel<strong>in</strong>g 1,800<br />
feet or more per m<strong>in</strong>ute.<br />
(b) If center to center distance between pulleys is ten (10) feet or more.<br />
(c) If belt is eight (8) <strong>in</strong>ches or more <strong>in</strong> width.<br />
(iii) Where the upper and lower runs of horizontal belts are so located<br />
that passage of persons between them would be possible, the passage<br />
sh<strong>all</strong> be either:<br />
(a) Completely barred by a guardrail or other barrier <strong>in</strong> accordance<br />
with paragraphs (m) and (o) of this section; or<br />
(b) Where passage is regarded as necessary, there sh<strong>all</strong> be a platform<br />
over the lower run guarded on either side by a rail<strong>in</strong>g completely filled <strong>in</strong><br />
with wire mesh or other filler, or by a solid barrier. The upper run sh<strong>all</strong><br />
be so guarded as to prevent contact therewith either by the worker or<br />
by objects carried by him. In power plants only the lower run of the belt<br />
need be guarded.<br />
(iv) Overhead cha<strong>in</strong> and l<strong>in</strong>k belt drives are governed by the same<br />
rules as overhead horizontal belts and sh<strong>all</strong> be guarded <strong>in</strong> the same<br />
manner as belts.<br />
(3) Vertical and <strong>in</strong>cl<strong>in</strong>ed belts. (i) Vertical and <strong>in</strong>cl<strong>in</strong>ed belts sh<strong>all</strong> be<br />
enclosed by a guard conform<strong>in</strong>g to standards <strong>in</strong> paragraphs (m) and (o)<br />
of this section.<br />
(ii) All guards for <strong>in</strong>cl<strong>in</strong>ed belts sh<strong>all</strong> be arranged <strong>in</strong> such a manner<br />
that a m<strong>in</strong>imum clearance of seven (7) feet is ma<strong>in</strong>ta<strong>in</strong>ed between belt<br />
and floor at any po<strong>in</strong>t outside of guard.<br />
4) Vertical belts. Vertical belts runn<strong>in</strong>g over a lower pulley more than<br />
seven (7) feet above floor or platform sh<strong>all</strong> be guarded at the bottom <strong>in</strong> the<br />
same manner as horizontal overhead belts, if conditions are as stated <strong>in</strong><br />
paragraphs (e)(2)(ii) (a) and (c) of this section.<br />
(5) C<strong>one</strong>-pulley belts. (i) The c<strong>one</strong> belt and pulley sh<strong>all</strong> be equipped<br />
with a belt shifter so constructed as to adequately guard the nip po<strong>in</strong>t<br />
of the belt and pulley. If the frame of the belt shifter does not adequately<br />
guard the nip po<strong>in</strong>t of the belt and pulley, the nip po<strong>in</strong>t sh<strong>all</strong> be further<br />
protected by means of a vertical guard placed <strong>in</strong> front of the pulley and<br />
extend<strong>in</strong>g at least to the top of the largest step of the c<strong>one</strong>.<br />
(ii) If the belt is of the endless type or laced with rawhide laces, and<br />
a belt shifter is not desired, the belt will be considered guarded if the nip<br />
po<strong>in</strong>t of the belt and pulley is protected by a nip po<strong>in</strong>t guard located <strong>in</strong><br />
front of the c<strong>one</strong> extend<strong>in</strong>g at least to the top of the largest step of the<br />
c<strong>one</strong>, and formed to show the contour of the c<strong>one</strong> <strong>in</strong> order to give the<br />
nip po<strong>in</strong>t of the belt and pulley the maximum protection.<br />
(iii) If the c<strong>one</strong> is located less than 3 feet from the floor or work<strong>in</strong>g<br />
platform, the c<strong>one</strong> pulley and belt sh<strong>all</strong> be guarded to a height of 3 feet<br />
regardless of whether the belt is endless or laced with rawhide.<br />
(6) Belt tighteners. (i) Suspended counterbalanced tighteners and <strong>all</strong><br />
parts thereof sh<strong>all</strong> be of substantial construction and securely fastened;<br />
the bear<strong>in</strong>gs sh<strong>all</strong> be securely capped. Means must be provided to<br />
prevent tightener from f<strong>all</strong><strong>in</strong>g, <strong>in</strong> case the belt breaks.<br />
(ii) Where suspended counterweights are used and not guarded by<br />
location, they sh<strong>all</strong> be so encased as to prevent accident.<br />
(f) Gears, sprockets, and cha<strong>in</strong>s—(1) Gears. Gears sh<strong>all</strong> be<br />
guarded <strong>in</strong> accordance with <strong>one</strong> of the follow<strong>in</strong>g methods:<br />
(i) By a complete enclosure; or<br />
(ii) By a standard guard as described <strong>in</strong> paragraph (o) of this<br />
section, at least seven (7) feet high extend<strong>in</strong>g six (6) <strong>in</strong>ches above<br />
the mesh po<strong>in</strong>t of the gears; or<br />
CONTROL SYSTEMS | 125
OSHA 29 CFR 1910.219—MECHANICAL POWER-TRANSMISSION APPARATUS (CONTINUED)<br />
(iii) By a band guard cover<strong>in</strong>g the face of gear and hav<strong>in</strong>g<br />
flanges extended <strong>in</strong>ward beyond the root of the teeth on the<br />
exposed side or sides. Where any portion of the tra<strong>in</strong> of gears<br />
guarded by a band guard is less than six (6) feet from the floor<br />
a disk guard or a complete enclosure to the height of six (6) feet<br />
sh<strong>all</strong> be required.<br />
(2) Hand-operated gears. Paragraph (f)(1) of this section does not<br />
apply to hand-operated gears used only to adjust mach<strong>in</strong>e parts and<br />
which do not cont<strong>in</strong>ue to move after hand power is removed. However,<br />
the guard<strong>in</strong>g of these gears is highly recommended.<br />
(3) Sprockets and cha<strong>in</strong>s. All sprocket wheels and cha<strong>in</strong>s sh<strong>all</strong><br />
be enclosed unless they are more than seven (7) feet above the<br />
floor or platform. Where the drive extends over other mach<strong>in</strong>e or<br />
work<strong>in</strong>g areas, protection aga<strong>in</strong>st f<strong>all</strong><strong>in</strong>g sh<strong>all</strong> be provided. This<br />
subparagraph does not apply to manu<strong>all</strong>y operated sprockets.<br />
(4) Open<strong>in</strong>gs for oil<strong>in</strong>g. When frequent oil<strong>in</strong>g must be d<strong>one</strong>, open<strong>in</strong>gs<br />
with h<strong>in</strong>ged or slid<strong>in</strong>g self-clos<strong>in</strong>g covers sh<strong>all</strong> be provided. All po<strong>in</strong>ts not<br />
readily accessible sh<strong>all</strong> have oil feed tubes if lubricant is to be added<br />
while mach<strong>in</strong>ery is <strong>in</strong> motion.<br />
(g) Guard<strong>in</strong>g friction drives. The driv<strong>in</strong>g po<strong>in</strong>t of <strong>all</strong> friction drives<br />
when exposed to contact sh<strong>all</strong> be guarded, <strong>all</strong> arm or spoke friction<br />
drives and <strong>all</strong> web friction drives with holes <strong>in</strong> the web sh<strong>all</strong> be entirely<br />
enclosed, and <strong>all</strong> project<strong>in</strong>g belts on friction drives where exposed to<br />
contact sh<strong>all</strong> be guarded.<br />
(h) Keys, setscrews, and other projections. (1) All project<strong>in</strong>g keys,<br />
setscrews, and other projections <strong>in</strong> revolv<strong>in</strong>g parts sh<strong>all</strong> be removed<br />
or made flush or guarded by metal cover. This subparagraph does not<br />
apply to keys or setscrews with<strong>in</strong> gear or sprocket cas<strong>in</strong>gs or other<br />
enclosures, nor to keys, setscrews, or oilcups <strong>in</strong> hubs of pulleys less<br />
than twenty (20) <strong>in</strong>ches <strong>in</strong> diameter where they are with<strong>in</strong> the plane of<br />
the rim of the pulley.<br />
(2) It is recommended, however, that no project<strong>in</strong>g setscrews or<br />
oilcups be used <strong>in</strong> any revolv<strong>in</strong>g pulley or part of mach<strong>in</strong>ery.<br />
(i) Collars and coupl<strong>in</strong>gs—(1) Collars. All revolv<strong>in</strong>g collars, <strong>in</strong>clud<strong>in</strong>g<br />
split collars, sh<strong>all</strong> be cyl<strong>in</strong>drical, and screws or bolts used <strong>in</strong> collars sh<strong>all</strong><br />
not project beyond the largest periphery of the collar.<br />
(2) Coupl<strong>in</strong>gs. Shaft coupl<strong>in</strong>gs sh<strong>all</strong> be so constructed as to present<br />
no hazard from bolts, nuts, setscrews, or revolv<strong>in</strong>g surfaces. Bolts, nuts,<br />
and setscrews will, however, be permitted where they are covered with<br />
safety sleeves or where they are used par<strong>all</strong>el with the shaft<strong>in</strong>g and are<br />
countersunk or else do not extend beyond the flange of the coupl<strong>in</strong>g.<br />
(j) Bear<strong>in</strong>gs and facilities for oil<strong>in</strong>g. All drip cups and pans sh<strong>all</strong> be<br />
securely fastened.<br />
(k) Guard<strong>in</strong>g of clutches, cutoff coupl<strong>in</strong>gs, and clutch pulleys—<br />
(1) Guards. Clutches, cutoff coupl<strong>in</strong>gs, or clutch pulleys hav<strong>in</strong>g<br />
project<strong>in</strong>g parts, where such clutches are located seven (7) feet<br />
or less above the floor or work<strong>in</strong>g platform, sh<strong>all</strong> be enclosed by a<br />
stationary guard constructed <strong>in</strong> accordance with this section. A “U”<br />
type guard is permissible.<br />
(2) Eng<strong>in</strong>e rooms. In eng<strong>in</strong>e rooms a guardrail, preferably with<br />
toeboard, may be used <strong>in</strong>stead of the guard required by paragraph (k)<br />
(1) of this section, provided such a room is occupied only by eng<strong>in</strong>e<br />
room attendants.<br />
(l) Belt shifters, clutches, shippers, poles, perches, and fasteners—<br />
(1) Belt shifters. (i) Tight and loose pulleys on <strong>all</strong> new <strong>in</strong>st<strong>all</strong>ations made<br />
on or after August 31, 1971, sh<strong>all</strong> be equipped with a permanent belt<br />
shifter provided with mechanical means to prevent belt from creep<strong>in</strong>g<br />
from loose to tight pulley. It is recommended that old <strong>in</strong>st<strong>all</strong>ations be<br />
changed to conform to this rule.<br />
(ii) Belt shifter and clutch handles sh<strong>all</strong> be rounded and be located<br />
as far as possible from danger of accidental contact, but with<strong>in</strong> easy<br />
reach of the operator. Where belt shifters are not directly located over a<br />
mach<strong>in</strong>e or bench, the handles sh<strong>all</strong> be cut off six feet six <strong>in</strong>ches (6 ft.<br />
6 <strong>in</strong>.) above floor level.<br />
(2) Belt shippers and shipper poles. The use of belt poles as<br />
substitutes for mechanical shifters is not recommended.<br />
(3) Belt perches. Where loose pulleys or idlers are not practicable,<br />
belt perches <strong>in</strong> form of brackets, rollers, etc., sh<strong>all</strong> be used to keep idle<br />
belts away from the shafts.<br />
(4) Belt fasteners. Belts which of necessity must be shifted by hand<br />
and belts with<strong>in</strong> seven (7) feet of the floor or work<strong>in</strong>g platform which are<br />
not guarded <strong>in</strong> accordance with this section sh<strong>all</strong> not be fastened with<br />
metal <strong>in</strong> any case, nor with any other fasten<strong>in</strong>g which by construction<br />
or wear will constitute an accident hazard.<br />
(m) Standard guards—general requirements—(1) Materials. (i)<br />
Standard conditions sh<strong>all</strong> be secured by the use of the follow<strong>in</strong>g<br />
materials: expanded metal, perforated or solid sheet metal, wire mesh<br />
on a frame of angle iron or iron pipe securely fastened to floor or to<br />
frame of mach<strong>in</strong>e.<br />
(ii) All metal should be free from burrs and sharp edges.<br />
(2) Methods of manufacture. (i) Expanded metal, sheet or perforated<br />
metal, and wire mesh sh<strong>all</strong> be securely fastened to frame.<br />
(n) [Reserved]<br />
(o) Approved materials—(1) M<strong>in</strong>imum requirements. The materials<br />
and dimensions specified <strong>in</strong> this paragraph sh<strong>all</strong> apply to <strong>all</strong> guards,<br />
except horizontal overhead belts, rope, cable or cha<strong>in</strong> guards more than<br />
seven (7) feet above floor or platform.<br />
(i) [Reserved]<br />
(a) All guards sh<strong>all</strong> be rigidly braced every three (3) feet or fractional<br />
part of their height to some fixed part of mach<strong>in</strong>ery or build<strong>in</strong>g structure.<br />
Where guard is exposed to contact with mov<strong>in</strong>g equipment additional<br />
strength may be necessary.<br />
(2) Wood guards. (i) Wood guards may be used <strong>in</strong> the woodwork<strong>in</strong>g<br />
and chemical <strong>in</strong>dustries, <strong>in</strong> <strong>in</strong>dustries where the presence of fumes or<br />
where manufactur<strong>in</strong>g conditions would cause the rapid deterioration<br />
of metal guards; also <strong>in</strong> construction work and <strong>in</strong> locations outdoors<br />
where extreme cold or extreme heat make metal guards and rail<strong>in</strong>gs<br />
undesirable. In <strong>all</strong> other <strong>in</strong>dustries, wood guards sh<strong>all</strong> not be used.<br />
126 | CONTROL SYSTEMS
OSHA 29 CFR 1910.219—MECHANICAL POWER-TRANSMISSION APPARATUS (CONTINUED)<br />
(3) Guards for horizontal overhead belts. (i) Guards for horizontal<br />
overhead belts sh<strong>all</strong> run the entire length of the belt and follow the<br />
l<strong>in</strong>e of the pulley to the ceil<strong>in</strong>g or be carried to the nearest w<strong>all</strong>, thus<br />
enclos<strong>in</strong>g the belt effectively. Where belts are so located as to make it<br />
impracticable to carry the guard to w<strong>all</strong> or ceil<strong>in</strong>g, construction of guard<br />
sh<strong>all</strong> be such as to enclose completely the top and bottom runs of belt<br />
and the face of pulleys.<br />
(ii) [Reserved]<br />
(iii) Suitable re<strong>in</strong>forcement sh<strong>all</strong> be provided for the ceil<strong>in</strong>g rafters<br />
or overhead floor beams, where such is necessary, to susta<strong>in</strong> safely<br />
the weight and stress likely to be imposed by the guard. The <strong>in</strong>terior<br />
surface of <strong>all</strong> guards, by which is meant the surface of the guard with<br />
which a belt will come <strong>in</strong> contact, sh<strong>all</strong> be smooth and free from <strong>all</strong><br />
projections of any character, except where construction demands it;<br />
protrud<strong>in</strong>g sh<strong>all</strong>ow roundhead rivets may be used. Overhead belt guards<br />
sh<strong>all</strong> be at least <strong>one</strong>-quarter wider than belt which they protect, except<br />
that this clearance need not <strong>in</strong> any case exceed six (6) <strong>in</strong>ches on each<br />
side. Overhead rope drive and block and roller-cha<strong>in</strong>-drive guards sh<strong>all</strong><br />
be not less than six (6) <strong>in</strong>ches wider than the drive on each side. In<br />
overhead silent cha<strong>in</strong>-drive guards where the cha<strong>in</strong> is held from lateral<br />
displacement on the sprockets, the side clearances required on drives<br />
of twenty (20) <strong>in</strong>ch centers or under sh<strong>all</strong> be not less than <strong>one</strong>-fourth<br />
<strong>in</strong>ch from the nearest mov<strong>in</strong>g cha<strong>in</strong> part, and on drives of over twenty<br />
(20) <strong>in</strong>ch centers a m<strong>in</strong>imum of <strong>one</strong>-half <strong>in</strong>ch from the nearest mov<strong>in</strong>g<br />
cha<strong>in</strong> part.<br />
(4) Guards for horizontal overhead rope and cha<strong>in</strong> drives. Overheadrope<br />
and cha<strong>in</strong>-drive guard construction sh<strong>all</strong> conform to the rules for<br />
overhead-belt guard.<br />
(5) Guardrails and toeboards. (i) Guardrail sh<strong>all</strong> be forty-two (42)<br />
<strong>in</strong>ches <strong>in</strong> height, with midrail between top rail and floor.<br />
(ii) Posts sh<strong>all</strong> be not more than eight (8) feet apart; they are to be<br />
permanent and substantial, smooth, and free from protrud<strong>in</strong>g nails,<br />
bolts, and spl<strong>in</strong>ters. If made of pipe, the post sh<strong>all</strong> be <strong>one</strong> and <strong>one</strong>fourth<br />
(1¼) <strong>in</strong>ches <strong>in</strong>side diameter or larger. If made of metal shapes or<br />
bars, their section sh<strong>all</strong> be equal <strong>in</strong> strength to that of <strong>one</strong> and <strong>one</strong>-half<br />
(1½) by <strong>one</strong> and <strong>one</strong>-half (1½) by three-sixteenths (3/16) <strong>in</strong>ch angle<br />
iron. If made of wood, the posts sh<strong>all</strong> be two by four (2 x 4) <strong>in</strong>ches or<br />
larger. The upper rail sh<strong>all</strong> be two by four (2 x 4) <strong>in</strong>ches or two <strong>one</strong> by<br />
four (1 x 4) strips, <strong>one</strong> at the top and <strong>one</strong> at the side of posts. The<br />
midrail may be <strong>one</strong> by four (1 x 4) <strong>in</strong>ches or more. Where panels are<br />
fitted with expanded metal or wire mesh as noted <strong>in</strong> Table O-12 the<br />
middle rails may be omitted. Where guard is exposed to contact with<br />
mov<strong>in</strong>g equipment, additional strength may be necessary.<br />
(iii) Toeboards sh<strong>all</strong> be four (4) <strong>in</strong>ches or more <strong>in</strong> height, of wood,<br />
metal or of metal grill not exceed<strong>in</strong>g <strong>one</strong> (1) <strong>in</strong>ch mesh.<br />
(p) Care of equipment—(1) General. All power-transmission<br />
equipment sh<strong>all</strong> be <strong>in</strong>spected at <strong>in</strong>tervals not exceed<strong>in</strong>g 60 days and<br />
be kept <strong>in</strong> good work<strong>in</strong>g condition at <strong>all</strong> times.<br />
(2) Shaft<strong>in</strong>g. (i) Shaft<strong>in</strong>g sh<strong>all</strong> be kept <strong>in</strong> alignment, free from rust and<br />
excess oil or grease.<br />
(ii) Where explosives, explosive dusts, flammable vapors or flammable<br />
liquids exist, the hazard of static sparks from shaft<strong>in</strong>g sh<strong>all</strong> be carefully<br />
considered.<br />
(3) Bear<strong>in</strong>gs. Bear<strong>in</strong>gs sh<strong>all</strong> be kept <strong>in</strong> alignment and properly<br />
adjusted.<br />
(4) Hangers. Hangers sh<strong>all</strong> be <strong>in</strong>spected to make certa<strong>in</strong> that <strong>all</strong><br />
support<strong>in</strong>g bolts and screws are tight and that supports of hanger boxes<br />
are adjusted properly.<br />
(5) Pulleys. (i) Pulleys sh<strong>all</strong> be kept <strong>in</strong> proper alignment to prevent<br />
belts from runn<strong>in</strong>g off.<br />
(6) Care of belts.<br />
(i) [Reserved]<br />
(ii) Inspection sh<strong>all</strong> be made of belts, lac<strong>in</strong>gs, and fasteners and such<br />
equipment kept <strong>in</strong> good repair.<br />
(7) Lubrication. The regular oilers sh<strong>all</strong> wear tight-fitt<strong>in</strong>g cloth<strong>in</strong>g.<br />
Mach<strong>in</strong>ery sh<strong>all</strong> be oiled when not <strong>in</strong> motion, wherever possible.<br />
CONTROL SYSTEMS | 127
OSHA 29 CFR 1910.147—THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT)<br />
(a) Scope, application and purpose—(1) Scope.<br />
(i) This standard covers the servic<strong>in</strong>g and ma<strong>in</strong>tenance of mach<strong>in</strong>es<br />
and equipment <strong>in</strong> which the unexpected energiz<strong>in</strong>g or start-up of<br />
the mach<strong>in</strong>es or equipment; or release of stored energy could cause<br />
<strong>in</strong>jury to employees. This standard establishes m<strong>in</strong>imum performance<br />
requirements for the control of such hazardous energy.<br />
(ii) This standard does not cover the follow<strong>in</strong>g:<br />
(A) Construction, agriculture and maritime employment;<br />
(B) Inst<strong>all</strong>ations under the exclusive control of electric utilities for the<br />
purpose of power generation, transmission and distribution, <strong>in</strong>clud<strong>in</strong>g<br />
related equipment for communication or meter<strong>in</strong>g; and<br />
(C) Exposure to electrical hazards from work on, near, or with<br />
conductors or equipment <strong>in</strong> electric utilization <strong>in</strong>st<strong>all</strong>ations, which is<br />
covered by Subpart S of this part; and<br />
(D) Oil and gas well drill<strong>in</strong>g and servic<strong>in</strong>g.<br />
(2) Application. (i) This standard applies to the control of energy dur<strong>in</strong>g<br />
servic<strong>in</strong>g and/or ma<strong>in</strong>tenance of mach<strong>in</strong>es and equipment.<br />
(ii) Normal production operations are not covered by this standard (see<br />
Subpart O of this part). Servic<strong>in</strong>g and/or ma<strong>in</strong>tenance which takes place<br />
dur<strong>in</strong>g normal production operations is covered by this standard only if:<br />
(A) An employee is required to remove or bypass a guard or other<br />
safety device; or<br />
(B) An employee is required to place any part of his or her body<br />
<strong>in</strong>to an area on a mach<strong>in</strong>e or piece of equipment where work is<br />
actu<strong>all</strong>y performed upon the material be<strong>in</strong>g processed (po<strong>in</strong>t of<br />
operation) or where an associated danger z<strong>one</strong> exists dur<strong>in</strong>g a<br />
mach<strong>in</strong>e operat<strong>in</strong>g cycle.<br />
Note: Exception to paragraph (a)(2)(ii):<br />
M<strong>in</strong>or tool changes and adjustments, and other m<strong>in</strong>or servic<strong>in</strong>g<br />
activities, which take place dur<strong>in</strong>g normal production operations, are<br />
not covered by this standard if they are rout<strong>in</strong>e, repetitive, and <strong>in</strong>tegral<br />
to the use of the equipment for production, provided that the work is<br />
performed us<strong>in</strong>g alternative measures which provide effective protection<br />
(see subpart O of this Part).<br />
(iii) This standard does not apply to the follow<strong>in</strong>g:<br />
(A) Work on cord and plug connected electric equipment for which<br />
exposure to the hazards of unexpected energiz<strong>in</strong>g or start-up of the<br />
equipment is controlled by the unplugg<strong>in</strong>g of the equipment from the<br />
energy source and by the plug be<strong>in</strong>g under the exclusive control of the<br />
employee perform<strong>in</strong>g the servic<strong>in</strong>g or ma<strong>in</strong>tenance.<br />
(B) Hot tap operations <strong>in</strong>volv<strong>in</strong>g transmission and distribution systems<br />
for substances such as gas, steam, water or petroleum products when<br />
they are performed on pressurized pipel<strong>in</strong>es, provided that the employer<br />
demonstrates that (1) cont<strong>in</strong>uity of service is essential; (2) shutdown of<br />
the system is impractical; and (3) documented procedures are followed,<br />
and special equipment is used which will provide proven effective<br />
protection for employees.<br />
(3) Purpose. (i) This section requires employers to establish a<br />
program and utilize procedures for affix<strong>in</strong>g appropriate lockout devices<br />
or tagout devices to energy isolat<strong>in</strong>g devices, and to otherwise disable<br />
mach<strong>in</strong>es or equipment to prevent unexpected energiz<strong>in</strong>g, start-up or<br />
release of stored energy <strong>in</strong> order to prevent <strong>in</strong>jury to employees.<br />
(ii) When other standards <strong>in</strong> this part require the use of lockout or<br />
tagout, they sh<strong>all</strong> be used and supplemented by the procedural and<br />
tra<strong>in</strong><strong>in</strong>g requirements of this section.<br />
(b) Def<strong>in</strong>itions applicable to this section.<br />
Affected employee. An employee whose job requires him/her<br />
to operate or use a mach<strong>in</strong>e or equipment on which servic<strong>in</strong>g or<br />
ma<strong>in</strong>tenance is be<strong>in</strong>g performed under lockout or tagout; or whose<br />
job requires him/her to work <strong>in</strong> an area <strong>in</strong> which such servic<strong>in</strong>g or<br />
ma<strong>in</strong>tenance is be<strong>in</strong>g performed.<br />
Authorized employee. A person who locks or implements a tagout<br />
system procedure on mach<strong>in</strong>es or equipment to perform the servic<strong>in</strong>g<br />
or ma<strong>in</strong>tenance on that mach<strong>in</strong>e or equipment. An authorized<br />
employee and an affected employee may be the same person when<br />
the affected employee’s duties also <strong>in</strong>clude perform<strong>in</strong>g ma<strong>in</strong>tenance<br />
or service on a mach<strong>in</strong>e or equipment which must be locked or a<br />
tagout system implemented.<br />
“Capable of be<strong>in</strong>g locked out.” An energy isolat<strong>in</strong>g device will be<br />
considered to be capable of be<strong>in</strong>g locked out either if it is designed with<br />
a hasp or other attachment or <strong>in</strong>tegral part to which, or through which,<br />
a lock can be affixed, or if it has a lock<strong>in</strong>g mechanism built <strong>in</strong>to it. Other<br />
energy isolat<strong>in</strong>g devices will also be considered to be capable of be<strong>in</strong>g<br />
locked out, if lockout can be achieved without the need to dismantle,<br />
rebuild, or replace the energy isolat<strong>in</strong>g device or permanently alter its<br />
energy control capability.<br />
Energized. Connected to an energy source or conta<strong>in</strong><strong>in</strong>g residual or<br />
stored energy.<br />
Energy isolat<strong>in</strong>g device. A mechanical device that physic<strong>all</strong>y prevents<br />
the transmission or release of energy, <strong>in</strong>clud<strong>in</strong>g but not limited to the<br />
follow<strong>in</strong>g: a manu<strong>all</strong>y operated electrical circuit breaker; a disconnect<br />
switch; a manu<strong>all</strong>y operated switch by which the conductors of a circuit<br />
can be disconnected from <strong>all</strong> ungrounded supply conductors and, <strong>in</strong><br />
addition, no pole can be operated <strong>in</strong>dependently; a slide gate; a slip<br />
bl<strong>in</strong>d; a l<strong>in</strong>e valve; a block; and any similar device used to block or<br />
isolate energy. The term does not <strong>in</strong>clude a push button, selector switch,<br />
and other control circuit type devices.<br />
Energy source. Any source of electrical, mechanical, hydraulic,<br />
pneumatic, chemical, thermal or other energy.<br />
Hot tap. A procedure used <strong>in</strong> the repair, ma<strong>in</strong>tenance and services<br />
activities which <strong>in</strong>volves weld<strong>in</strong>g on a piece of equipment (pipel<strong>in</strong>es,<br />
vessels or tanks) under pressure, <strong>in</strong> order to <strong>in</strong>st<strong>all</strong> connections or<br />
appurtenances. It is commonly used to replace or add sections of<br />
pipel<strong>in</strong>e without the <strong>in</strong>terruption of service for air, gas, water, steam, and<br />
petrochemical distribution systems.<br />
128 | CONTROL SYSTEMS
OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT (CONTINUED)<br />
Lockout. The placement of a lockout device on an energy isolat<strong>in</strong>g<br />
device, <strong>in</strong> accordance with an established procedure, ensur<strong>in</strong>g that the<br />
energy isolat<strong>in</strong>g device and the equipment be<strong>in</strong>g controlled cannot be<br />
operated until the lockout device is removed.<br />
Lockout device. A device that utilizes a positive means such as a lock,<br />
either key or comb<strong>in</strong>ation type, to hold an energy isolat<strong>in</strong>g device <strong>in</strong> the<br />
safe position and prevent the energiz<strong>in</strong>g of a mach<strong>in</strong>e or equipment.<br />
Normal production operations. The utilization of a mach<strong>in</strong>e or<br />
equipment to perform its <strong>in</strong>tended production function.<br />
Servic<strong>in</strong>g and/or ma<strong>in</strong>tenance. Workplace activities such as<br />
construct<strong>in</strong>g, <strong>in</strong>st<strong>all</strong><strong>in</strong>g, sett<strong>in</strong>g up, adjust<strong>in</strong>g, <strong>in</strong>spect<strong>in</strong>g, modify<strong>in</strong>g, and<br />
ma<strong>in</strong>ta<strong>in</strong><strong>in</strong>g and/or servic<strong>in</strong>g mach<strong>in</strong>es or equipment. These activities<br />
<strong>in</strong>clude lubrication, clean<strong>in</strong>g or unjamm<strong>in</strong>g of mach<strong>in</strong>es or equipment<br />
and mak<strong>in</strong>g adjustments or tool changes, where the employee may be<br />
exposed to the unexpected energiz<strong>in</strong>g or start-up of the equipment or<br />
release of hazardous energy.<br />
Sett<strong>in</strong>g up. Any work performed to prepare a mach<strong>in</strong>e or equipment to<br />
perform its normal production operation.<br />
Tagout. The placement of a tagout device on an energy isolat<strong>in</strong>g<br />
device, <strong>in</strong> accordance with an established procedure, to <strong>in</strong>dicate that<br />
the energy isolat<strong>in</strong>g device and the equipment be<strong>in</strong>g controlled may not<br />
be operated until the tagout device is removed.<br />
Tagout device. A prom<strong>in</strong>ent warn<strong>in</strong>g device, such as a tag and a means<br />
of attachment, which can be securely fastened to an energy isolat<strong>in</strong>g<br />
device <strong>in</strong> accordance with an established procedure, to <strong>in</strong>dicate that the<br />
energy isolat<strong>in</strong>g device and the equipment be<strong>in</strong>g controlled may not be<br />
operated until the tagout device is removed.<br />
(c) General—(1) Energy control program. The employer sh<strong>all</strong> establish<br />
a program consist<strong>in</strong>g of an energy control procedure and employee<br />
tra<strong>in</strong><strong>in</strong>g to ensure that before any employee performs any servic<strong>in</strong>g<br />
or ma<strong>in</strong>tenance on a mach<strong>in</strong>e or equipment where the unexpected<br />
energiz<strong>in</strong>g, start-up or release of stored energy could occur and cause<br />
<strong>in</strong>jury, the mach<strong>in</strong>e or equipment sh<strong>all</strong> be isolated, and rendered<br />
<strong>in</strong>operative, <strong>in</strong> accordance with paragraph (c)(4) of this section.<br />
(2) Lockout/tagout (i) If an energy isolat<strong>in</strong>g device is not capable<br />
of be<strong>in</strong>g locked out, the employer’s energy control program under<br />
paragraph (c)(1) of this section sh<strong>all</strong> utilize a tagout system.<br />
(ii) If an energy isolat<strong>in</strong>g device is capable of be<strong>in</strong>g locked out, the<br />
employer’s energy control program under paragraph (c)(1) of this<br />
section sh<strong>all</strong> utilize lockout, unless the employer can demonstrate that<br />
the utilization of a tagout system will provide full employee protection as<br />
set forth <strong>in</strong> paragraph (c)(3) of this section.<br />
(iii) After January 2, 1990, whenever major replacement, repair,<br />
renovation or modification of mach<strong>in</strong>es or equipment is performed, and<br />
whenever new mach<strong>in</strong>es or equipment are <strong>in</strong>st<strong>all</strong>ed, energy isolat<strong>in</strong>g<br />
devices for such mach<strong>in</strong>es or equipment sh<strong>all</strong> be designed to accept a<br />
lockout device.<br />
(3) Full employee protection. (i) When a tagout device is used on an<br />
energy isolat<strong>in</strong>g device which is capable of be<strong>in</strong>g locked out, the tagout<br />
device sh<strong>all</strong> be attached at the same location that the lockout device<br />
would have been attached, and the employer sh<strong>all</strong> demonstrate that the<br />
tagout program will provide a level of safety equivalent to that obta<strong>in</strong>ed<br />
by us<strong>in</strong>g a lockout program.<br />
(ii) In demonstrat<strong>in</strong>g that a level of safety is achieved <strong>in</strong> the tagout<br />
program which is equivalent to the level of safety obta<strong>in</strong>ed by us<strong>in</strong>g<br />
a lockout program, the employer sh<strong>all</strong> demonstrate full compliance<br />
with <strong>all</strong> tagout-related provisions of this standard together with such<br />
additional elements as are necessary to provide the equivalent safety<br />
available from the use of a lockout device. Additional means to be<br />
considered as part of the demonstration of full employee protection sh<strong>all</strong><br />
<strong>in</strong>clude the implementation of additional safety measures such as the<br />
removal of an isolat<strong>in</strong>g circuit element, block<strong>in</strong>g of a controll<strong>in</strong>g switch,<br />
open<strong>in</strong>g of an extra disconnect<strong>in</strong>g device, or the removal of a valve<br />
handle to reduce the likelihood of <strong>in</strong>advertent energiz<strong>in</strong>g.<br />
(4) Energy control procedure. (i) Procedures sh<strong>all</strong> be developed,<br />
documented and utilized for the control of potenti<strong>all</strong>y hazardous energy<br />
when employees are engaged <strong>in</strong> the activities covered by this section.<br />
Note: Exception: The employer need not document the required<br />
procedure for a particular mach<strong>in</strong>e or equipment, when <strong>all</strong> of the<br />
follow<strong>in</strong>g elements exist: (1) The mach<strong>in</strong>e or equipment has no potential<br />
for stored or residual energy or reaccumulation of stored energy after<br />
shut down which could endanger employees; (2) the mach<strong>in</strong>e or<br />
equipment has a s<strong>in</strong>gle energy source which can be readily identified<br />
and isolated; (3) the isolation and lock<strong>in</strong>g out of that energy source<br />
will completely de-energize and deactivate the mach<strong>in</strong>e or equipment;<br />
(4) the mach<strong>in</strong>e or equipment is isolated from that energy source and<br />
locked out dur<strong>in</strong>g servic<strong>in</strong>g or ma<strong>in</strong>tenance; (5) a s<strong>in</strong>gle lockout device<br />
will achieve a locked-out condition; (6) the lockout device is under the<br />
exclusive control of the authorized employee perform<strong>in</strong>g the servic<strong>in</strong>g or<br />
ma<strong>in</strong>tenance; (7) the servic<strong>in</strong>g or ma<strong>in</strong>tenance does not create hazards<br />
for other employees; and (8) the employer, <strong>in</strong> utiliz<strong>in</strong>g this exception, has<br />
had no accidents <strong>in</strong>volv<strong>in</strong>g the unexpected activation or reenergization<br />
of the mach<strong>in</strong>e or equipment dur<strong>in</strong>g servic<strong>in</strong>g or ma<strong>in</strong>tenance.<br />
(ii) The procedures sh<strong>all</strong> clearly and specific<strong>all</strong>y outl<strong>in</strong>e the scope,<br />
purpose, authorization rules, and techniques to be utilized for the control<br />
of hazardous energy, and the means to enforce compliance <strong>in</strong>clud<strong>in</strong>g,<br />
but not limited to, the follow<strong>in</strong>g:<br />
(A) A specific statement of the <strong>in</strong>tended use of the procedure;<br />
(B) Specific procedural steps for shutt<strong>in</strong>g down, isolat<strong>in</strong>g, block<strong>in</strong>g and<br />
secur<strong>in</strong>g mach<strong>in</strong>es or equipment to control hazardous energy;<br />
(C) Specific procedural steps for the placement, removal and transfer<br />
of lockout devices or tagout devices and the responsibility for them; and<br />
(D) Specific requirements for test<strong>in</strong>g a mach<strong>in</strong>e or equipment to<br />
determ<strong>in</strong>e and verify the effectiveness of lockout devices, tagout<br />
devices, and other energy control measures.<br />
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OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT (CONTINUED)<br />
(5) Protective materials and hardware. (i) Locks, tags, cha<strong>in</strong>s, wedges,<br />
key blocks, adapter p<strong>in</strong>s, self-lock<strong>in</strong>g fasteners, or other hardware<br />
sh<strong>all</strong> be provided by the employer for isolat<strong>in</strong>g, secur<strong>in</strong>g or block<strong>in</strong>g of<br />
mach<strong>in</strong>es or equipment from energy sources.<br />
(ii) Lockout devices and tagout devices sh<strong>all</strong> be s<strong>in</strong>gularly identified;<br />
sh<strong>all</strong> be the only device(s) used for controll<strong>in</strong>g energy; sh<strong>all</strong> not be used<br />
for other purposes; and sh<strong>all</strong> meet the follow<strong>in</strong>g requirements:<br />
(A) Durable. (1) Lockout and tagout devices sh<strong>all</strong> be capable of<br />
withstand<strong>in</strong>g the environment to which they are exposed for the<br />
maximum period of time that exposure is expected.<br />
(2) Tagout devices sh<strong>all</strong> be constructed and pr<strong>in</strong>ted so that exposure<br />
to weather conditions or wet and damp locations will not cause the tag<br />
to deteriorate or the message on the tag to become illegible.<br />
(3) Tags sh<strong>all</strong> not deteriorate when used <strong>in</strong> corrosive environments<br />
such as areas where acid and alkali chemicals are handled and stored.<br />
(B) Standardized. Lockout and tagout devices sh<strong>all</strong> be standardized<br />
with<strong>in</strong> the facility <strong>in</strong> at least <strong>one</strong> of the follow<strong>in</strong>g criteria: Color; shape;<br />
or size; and addition<strong>all</strong>y, <strong>in</strong> the case of tagout devices, pr<strong>in</strong>t and format<br />
sh<strong>all</strong> be standardized.<br />
(C) Substantial—(1) Lockout devices. Lockout devices sh<strong>all</strong> be<br />
substantial enough to prevent removal without the use of excessive<br />
force or unusual techniques, such as with the use of bolt cutters or other<br />
metal cutt<strong>in</strong>g tools.<br />
(2) Tagout devices. Tagout devices, <strong>in</strong>clud<strong>in</strong>g and their means of<br />
attachment, sh<strong>all</strong> be substantial enough to prevent <strong>in</strong>advertent or<br />
accidental removal. Tagout device attachment means sh<strong>all</strong> be of a nonreusable<br />
type, attachable by hand, self-lock<strong>in</strong>g, and non-releasable with<br />
a m<strong>in</strong>imum unlock<strong>in</strong>g strength of no less than 50 pounds and hav<strong>in</strong>g<br />
the general design and basic characteristics of be<strong>in</strong>g at least equivalent<br />
to a <strong>one</strong>-piece, <strong>all</strong>-environment-tolerant nylon cable tie.<br />
(D) Identifiable. Lockout devices and tagout devices sh<strong>all</strong> <strong>in</strong>dicate the<br />
identity of the employee apply<strong>in</strong>g the device(s).<br />
(iii) Tagout devices sh<strong>all</strong> warn aga<strong>in</strong>st hazardous conditions if the<br />
mach<strong>in</strong>e or equipment is energized and sh<strong>all</strong> <strong>in</strong>clude a legend such as<br />
the follow<strong>in</strong>g: Do Not Start, Do Not Open, Do Not Close, Do Not Energize,<br />
Do Not Operate.<br />
(6) Periodic <strong>in</strong>spection. (i) The employer sh<strong>all</strong> conduct a periodic<br />
<strong>in</strong>spection of the energy control procedure at least annu<strong>all</strong>y to<br />
ensure that the procedure and the requirements of this standard are<br />
be<strong>in</strong>g followed.<br />
(A) The periodic <strong>in</strong>spection sh<strong>all</strong> be performed by an authorized<br />
employee other than the <strong>one</strong>(s) utiliz<strong>in</strong>g the energy control procedure<br />
be<strong>in</strong>g <strong>in</strong>spected.<br />
(B) The periodic <strong>in</strong>spection sh<strong>all</strong> be designed to correct any deviations<br />
or <strong>in</strong>adequacies observed.<br />
(C) Where lockout is used for energy control, the periodic <strong>in</strong>spection<br />
sh<strong>all</strong> <strong>in</strong>clude a review, between the <strong>in</strong>spector and each authorized<br />
employee, of that employee’s responsibilities under the energy control<br />
procedure be<strong>in</strong>g <strong>in</strong>spected.<br />
(D) Where tagout is used for energy control, the periodic <strong>in</strong>spection<br />
sh<strong>all</strong> <strong>in</strong>clude a review, between the <strong>in</strong>spector and each authorized<br />
and affected employee, of that employee’s responsibilities under the<br />
energy control procedure be<strong>in</strong>g <strong>in</strong>spected, and the elements set forth <strong>in</strong><br />
paragraph (c)(7)(ii) of this section.<br />
(ii) The employer sh<strong>all</strong> certify that the periodic <strong>in</strong>spections have been<br />
performed. The certification sh<strong>all</strong> identify the mach<strong>in</strong>e or equipment on<br />
which the energy control procedure was be<strong>in</strong>g utilized, the date of the<br />
<strong>in</strong>spection, the employees <strong>in</strong>cluded <strong>in</strong> the <strong>in</strong>spection, and the person<br />
perform<strong>in</strong>g the <strong>in</strong>spection.<br />
(7) Tra<strong>in</strong><strong>in</strong>g and communication. (i) The employer sh<strong>all</strong> provide tra<strong>in</strong><strong>in</strong>g<br />
to ensure that the purpose and function of the energy control program<br />
are understood by employees and that the knowledge and skills<br />
required for the safe application, usage, and removal of energy controls<br />
are required by employees. The tra<strong>in</strong><strong>in</strong>g sh<strong>all</strong> <strong>in</strong>clude the follow<strong>in</strong>g:<br />
(A) Each authorized employee sh<strong>all</strong> receive tra<strong>in</strong><strong>in</strong>g <strong>in</strong> the recognition<br />
of applicable hazardous energy sources, the type and magnitude of<br />
the energy available <strong>in</strong> the workplace, and the methods and means<br />
necessary for energy isolation and control.<br />
(B) Each affected employee sh<strong>all</strong> be <strong>in</strong>structed <strong>in</strong> the purpose and use<br />
of the energy control procedure.<br />
(C) All other employees whose work operations are or may be <strong>in</strong><br />
an area where energy control procedures may be utilized, sh<strong>all</strong> be<br />
<strong>in</strong>structed about the procedure, and about the prohibition relat<strong>in</strong>g to<br />
attempts to restart or reenergize mach<strong>in</strong>es or equipment which are<br />
locked out or tagged out.<br />
(ii) When tagout systems are used, employees sh<strong>all</strong> also be tra<strong>in</strong>ed <strong>in</strong><br />
the follow<strong>in</strong>g limitations of tags:<br />
(A) Tags are essenti<strong>all</strong>y warn<strong>in</strong>g devices affixed to energy isolat<strong>in</strong>g<br />
devices, and do not provide the physical restra<strong>in</strong>t on those devices that<br />
is provided by a lock.<br />
(B) When a tag is attached to an energy isolat<strong>in</strong>g means, it is not to be<br />
removed without authorization of the authorized person responsible for<br />
it, and it is never to be bypassed, ignored or otherwise defeated.<br />
(C) Tags must be legible and understandable by <strong>all</strong> authorized<br />
employees, affected employees, and <strong>all</strong> other employees whose work<br />
operations are or may be <strong>in</strong> the area, <strong>in</strong> order to be effective.<br />
(D) Tags and their means of attachment must be made of materials<br />
which will withstand the environmental conditions encountered <strong>in</strong><br />
the workplace.<br />
(E) Tags may evoke a false sense of security, and their mean<strong>in</strong>g needs<br />
to be understood as part of the over<strong>all</strong> energy control program.<br />
(F) Tags must be securely attached to energy isolat<strong>in</strong>g devices so that<br />
they cannot be <strong>in</strong>advertently or accident<strong>all</strong>y detached dur<strong>in</strong>g use.<br />
(iii) Employee retra<strong>in</strong><strong>in</strong>g.<br />
(A) Retra<strong>in</strong><strong>in</strong>g sh<strong>all</strong> be provided for <strong>all</strong> authorized and affected<br />
employees whenever there is a change <strong>in</strong> their job assignments, a<br />
change <strong>in</strong> mach<strong>in</strong>es, equipment or processes that present a new<br />
hazard, or when there is a change <strong>in</strong> the energy control procedures.<br />
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OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT (CONTINUED)<br />
(B) Additional retra<strong>in</strong><strong>in</strong>g sh<strong>all</strong> also be conducted whenever a periodic<br />
<strong>in</strong>spection under paragraph (c)(6) of this section reveals, or whenever<br />
the employer has reason to believe, that there are deviations from<br />
or <strong>in</strong>adequacies <strong>in</strong> the employee’s knowledge or use of the energy<br />
control procedures.<br />
(C) The retra<strong>in</strong><strong>in</strong>g sh<strong>all</strong> reestablish employee proficiency and <strong>in</strong>troduce<br />
new or revised control methods and procedures, as necessary.<br />
(iv) The employer sh<strong>all</strong> certify that employee tra<strong>in</strong><strong>in</strong>g has been<br />
accomplished and is be<strong>in</strong>g kept up to date. The certification sh<strong>all</strong><br />
conta<strong>in</strong> each employee’s name and dates of tra<strong>in</strong><strong>in</strong>g.<br />
(8) Energy isolation. Implementation of lockout or the tagout system<br />
sh<strong>all</strong> be performed only by authorized employees.<br />
(9) Notification of employees. Affected employees sh<strong>all</strong> be notified by<br />
the employer or authorized employee of the application and removal<br />
of lockout devices or tagout devices. Notification sh<strong>all</strong> be given before<br />
the controls are applied, and after they are removed from the mach<strong>in</strong>e<br />
or equipment.<br />
(d) Application of control. The established procedure for the application<br />
of energy control (implementation of lockout or tagout system<br />
procedures) sh<strong>all</strong> cover the follow<strong>in</strong>g elements and actions and sh<strong>all</strong> be<br />
d<strong>one</strong> <strong>in</strong> the follow<strong>in</strong>g sequence:<br />
(1) Preparation for shutdown. Before an authorized or affected<br />
employee turns off a mach<strong>in</strong>e or equipment, the authorized employee<br />
sh<strong>all</strong> have knowledge of the type and magnitude of the energy, the<br />
hazards of the energy to be controlled, and the method or means to<br />
control the energy.<br />
(2) Mach<strong>in</strong>e or equipment shutdown. The mach<strong>in</strong>e or equipment<br />
sh<strong>all</strong> be turned off or shut down us<strong>in</strong>g the procedures required<br />
by this standard. An orderly shutdown must be utilized to avoid<br />
any additional or <strong>in</strong>creased hazard(s) to employees as a result of<br />
equipment deenergization.<br />
(3) Mach<strong>in</strong>e or equipment isolation. All energy isolat<strong>in</strong>g devices that<br />
are needed to control the energy to the mach<strong>in</strong>e or equipment sh<strong>all</strong><br />
be physic<strong>all</strong>y located and operated <strong>in</strong> such a manner as to isolate the<br />
mach<strong>in</strong>e or equipment from the energy source(s).<br />
(4) Lockout or tagout device application. (i) Lockout or tagout devices<br />
sh<strong>all</strong> be affixed to each energy isolat<strong>in</strong>g device by authorized employees.<br />
(ii) Lockout devices, where used, sh<strong>all</strong> be affixed <strong>in</strong> a manner that will<br />
hold the energy isolat<strong>in</strong>g devices <strong>in</strong> a “safe” or “off” position.<br />
(iii) Tagout devices, where used, sh<strong>all</strong> be affixed <strong>in</strong> such a manner as<br />
will clearly <strong>in</strong>dicate that the operation or movement of energy isolat<strong>in</strong>g<br />
devices from the “safe” or “off” position is prohibited.<br />
(A) Where tagout devices are used with energy isolat<strong>in</strong>g devices<br />
designed with the capability of be<strong>in</strong>g locked, the tag attachment sh<strong>all</strong> be<br />
fastened at the same po<strong>in</strong>t at which the lock would have been attached.<br />
(B) Where a tag cannot be affixed directly to the energy isolat<strong>in</strong>g<br />
device, the tag sh<strong>all</strong> be located as close as safely possible to the device,<br />
<strong>in</strong> a position that will be immediately obvious to any<strong>one</strong> attempt<strong>in</strong>g to<br />
operate the device.<br />
(5) Stored energy. (i) Follow<strong>in</strong>g the application of lockout or tagout<br />
devices to energy isolat<strong>in</strong>g devices, <strong>all</strong> potenti<strong>all</strong>y hazardous stored<br />
or residual energy sh<strong>all</strong> be relieved, disconnected, restra<strong>in</strong>ed, and<br />
otherwise rendered safe.<br />
(ii) If there is a possibility of reaccumulation of stored energy to a<br />
hazardous level, verification of isolation sh<strong>all</strong> be cont<strong>in</strong>ued until the<br />
servic<strong>in</strong>g or ma<strong>in</strong>tenance is completed, or until the possibility of such<br />
accumulation no longer exists.<br />
(6) Verification of isolation. Prior to start<strong>in</strong>g work on mach<strong>in</strong>es or<br />
equipment that have been locked out or tagged out, the authorized<br />
employee sh<strong>all</strong> verify that isolation and deenergization of the mach<strong>in</strong>es<br />
or equipment have been accomplished.<br />
(e) Release from lockout or tagout. Before lockout or tagout devices<br />
are removed and energy is restored to the mach<strong>in</strong>e or equipment,<br />
procedures sh<strong>all</strong> be followed and actions taken by the authorized<br />
employee(s) to ensure the follow<strong>in</strong>g:<br />
(1) The mach<strong>in</strong>e or equipment. The work area sh<strong>all</strong> be <strong>in</strong>spected to<br />
ensure that n<strong>one</strong>ssential items have been removed and to ensure that<br />
mach<strong>in</strong>e or equipment comp<strong>one</strong>nts are operation<strong>all</strong>y <strong>in</strong>tact.<br />
(2) Employees. (i) The work area sh<strong>all</strong> be checked to ensure that <strong>all</strong><br />
employees have been safely positi<strong>one</strong>d or removed.<br />
(ii) Before lockout or tagout devices are removed and before mach<strong>in</strong>es<br />
or equipment are energized, affected employees sh<strong>all</strong> be notified that<br />
the lockout or tagout devices have been removed.<br />
(3) Lockout or tagout devices removal. Each lockout or tagout device<br />
sh<strong>all</strong> be removed from each energy isolat<strong>in</strong>g device by the employee<br />
who applied the device. Exception to paragraph (e)(3): when the<br />
authorized employee who applied the lockout or tagout device is not<br />
available to remove it, that device may be removed under the direction<br />
of the employer, provided that specific procedures and tra<strong>in</strong><strong>in</strong>g for such<br />
removal have been developed, documented and <strong>in</strong>corporated <strong>in</strong>to the<br />
employer’s energy control program. The employer sh<strong>all</strong> demonstrate<br />
that the specific procedure provides equivalent safety to the removal<br />
of the device by the authorized employee who applied it. The specific<br />
procedure sh<strong>all</strong> <strong>in</strong>clude at least the follow<strong>in</strong>g elements:<br />
(i) Verification by the employer that the authorized employee who<br />
applied the device is not at the facility;<br />
(ii) Mak<strong>in</strong>g <strong>all</strong> reasonable efforts to contact the authorized employee to<br />
<strong>in</strong>form him/her that his/her lockout or tagout device has been removed; and<br />
(iii) Ensur<strong>in</strong>g that the authorized employee has this knowledge before<br />
he/she resumes work at that facility.<br />
(f) Additional requirements (1) Test<strong>in</strong>g or position<strong>in</strong>g of mach<strong>in</strong>es,<br />
equipment or comp<strong>one</strong>nts thereof. In situations <strong>in</strong> which lockout or<br />
tagout devices must be temporarily removed from the energy isolat<strong>in</strong>g<br />
device and the mach<strong>in</strong>e or equipment energized to test or position the<br />
mach<strong>in</strong>e, equipment or comp<strong>one</strong>nt thereof, the follow<strong>in</strong>g sequence of<br />
actions sh<strong>all</strong> be followed.<br />
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OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT (CONTINUED)<br />
(i) Clear the mach<strong>in</strong>e or equipment of tools and materials <strong>in</strong><br />
accordance with paragraph (e)(1) of this section;<br />
(ii) Remove employees from the mach<strong>in</strong>e or equipment area <strong>in</strong><br />
accordance with paragraph (e)(2) of this section;<br />
(iii) Remove the lockout or tagout devices as specified <strong>in</strong> paragraph (e)<br />
(3) of this section;<br />
(iv) Energize and proceed with test<strong>in</strong>g or position<strong>in</strong>g;<br />
(v) De-energize <strong>all</strong> systems and reapply energy control measures <strong>in</strong><br />
accordance with paragraph (d) of this section to cont<strong>in</strong>ue the servic<strong>in</strong>g<br />
and/or ma<strong>in</strong>tenance.<br />
(2) Outside personnel (contractors, etc.). (i) Whenever outside<br />
servic<strong>in</strong>g personnel are to be engaged <strong>in</strong> activities covered by the<br />
scope and application of this standard, the on-site employer and the<br />
outside employer sh<strong>all</strong> <strong>in</strong>form each other of their respective lockout or<br />
tagout procedures.<br />
(ii) The on-site employer sh<strong>all</strong> ensure that his/her personnel understand<br />
and comply with restrictions and prohibitions of the outside employer’s<br />
energy control procedures.<br />
(3) Group lockout or tagout. (i) When servic<strong>in</strong>g and/or ma<strong>in</strong>tenance<br />
is performed by a crew, craft, department or other group, they sh<strong>all</strong><br />
utilize a procedure which affords the employees a level of protection<br />
equivalent to that provided by the implementation of a personal lockout<br />
or tagout device.<br />
(ii) Group lockout or tagout devices sh<strong>all</strong> be used <strong>in</strong> accordance with<br />
the procedures required by paragraph (c)(4) of this section <strong>in</strong>clud<strong>in</strong>g, but<br />
not necessarily limited to, the follow<strong>in</strong>g specific requirements:<br />
APPENDIX A—TYPICAL MINIMAL LOCKOUT OR TAGOUT SYSTEM<br />
PROCEDURES<br />
GENERAL<br />
Lockout is the preferred method of isolat<strong>in</strong>g mach<strong>in</strong>es or equipment<br />
from energy sources. To assist employers <strong>in</strong> develop<strong>in</strong>g a procedure<br />
which meets the requirements of the standard, however, the follow<strong>in</strong>g<br />
simple procedure is provided for use <strong>in</strong> both lockout or tagout programs.<br />
This procedure may be used when there are limited number or types<br />
of mach<strong>in</strong>es or equipment or there is a s<strong>in</strong>gle power source. For more<br />
complex systems, a more comprehensive procedure will need to be<br />
developed, documented, and utilized.<br />
LOCKOUT (OR TAGOUT) PROCEDURE FOR (NAME OF COMPANY).<br />
PURPOSE<br />
This procedure establishes the m<strong>in</strong>imum requirements for the lockout<br />
or tagout of energy isolat<strong>in</strong>g devices. It sh<strong>all</strong> be used to ensure that the<br />
mach<strong>in</strong>e or equipment is isolated from <strong>all</strong> potenti<strong>all</strong>y hazardous energy,<br />
and locked out or tagged out before employees perform any servic<strong>in</strong>g<br />
or ma<strong>in</strong>tenance activities where the unexpected energiz<strong>in</strong>g, start-up or<br />
release of stored energy could cause <strong>in</strong>jury (Type(s) and Magnitude(s)<br />
of Energy and Hazards).<br />
(A) Primary responsibility is vested <strong>in</strong> an authorized employee for a set<br />
number of employees work<strong>in</strong>g under the protection of a group lockout<br />
or tagout device (such as an operations lock);<br />
(B) Provision for the authorized employee to ascerta<strong>in</strong> the exposure<br />
status of <strong>in</strong>dividual group members with regard to the lockout or tagout<br />
of the mach<strong>in</strong>e or equipment; and<br />
(C) When more than <strong>one</strong> crew, craft, department, etc., is <strong>in</strong>volved,<br />
assignment of over<strong>all</strong> job-associated lockout or tagout control<br />
responsibility to an authorized employee designated to coord<strong>in</strong>ate<br />
affected work forces and ensure cont<strong>in</strong>uity of protection; and<br />
(D) Each authorized employee sh<strong>all</strong> affix a personal lockout or tagout<br />
device to the group lockout device, group lockbox, or comparable<br />
mechanism when he or she beg<strong>in</strong>s work, and sh<strong>all</strong> remove those<br />
devices when he or she stops work<strong>in</strong>g on the mach<strong>in</strong>e or equipment<br />
be<strong>in</strong>g serviced or ma<strong>in</strong>ta<strong>in</strong>ed.<br />
(4) Shift or personnel changes. Specific procedures sh<strong>all</strong> be utilized<br />
dur<strong>in</strong>g shift or personnel changes to ensure the cont<strong>in</strong>uity of lockout or<br />
tagout protection, <strong>in</strong>clud<strong>in</strong>g provision for the orderly transfer of lockout<br />
or tagout devices between offgo<strong>in</strong>g and oncom<strong>in</strong>g employees, to<br />
m<strong>in</strong>imize exposure to hazards from the unexpected energiz<strong>in</strong>g, start-up<br />
of the mach<strong>in</strong>e or equipment, or release of stored energy.<br />
Note: The follow<strong>in</strong>g Appendix to §1910.147 serves as a<br />
nonmandatory guidel<strong>in</strong>e to assist employers and employees <strong>in</strong> comply<strong>in</strong>g<br />
with the requirements of this section, as well as to provide other helpful<br />
<strong>in</strong>formation. Noth<strong>in</strong>g <strong>in</strong> the Appendix adds to or detracts from any of the<br />
requirements of this section.<br />
RESPONSIBILITY<br />
Appropriate employees sh<strong>all</strong> be <strong>in</strong>structed <strong>in</strong> the safety significance<br />
of the lockout (or tagout) procedure (Name(s)/Job Title(s) of employees<br />
authorized to lockout or tagout). Each new or transferred affected<br />
employee and other employees whose work operations are or may be<br />
<strong>in</strong> the area sh<strong>all</strong> be <strong>in</strong>structed <strong>in</strong> the purpose and use of the lockout<br />
or tagout procedure (Name(s)/Job Title(s) of affected employees and<br />
how to notify).<br />
PREPARATION FOR LOCKOUT OR TAGOUT<br />
Make a survey to locate and identify <strong>all</strong> isolat<strong>in</strong>g devices to be<br />
certa<strong>in</strong> which switch(es), valve(s) or other energy isolat<strong>in</strong>g devices<br />
apply to the equipment to be locked or tagged out. More than <strong>one</strong><br />
energy source (electrical, mechanical or others) may be <strong>in</strong>volved.<br />
(Type(s) and Location(s) of energy isolat<strong>in</strong>g means.)<br />
SEQUENCE OF LOCKOUT OR TAGOUT<br />
SYSTEM PROCEDURE<br />
(1) Notify <strong>all</strong> affected employees that a lockout or tagout system is<br />
go<strong>in</strong>g to be utilized and the reason therefor. The authorized employee<br />
sh<strong>all</strong> know the type and magnitude of energy that the mach<strong>in</strong>e or<br />
equipment utilizes and sh<strong>all</strong> understand the hazards thereof.<br />
(2) If the mach<strong>in</strong>e or equipment is operat<strong>in</strong>g, shut it down by the normal<br />
stopp<strong>in</strong>g procedure (depress stop button, open toggle switch, etc.).<br />
132 | CONTROL SYSTEMS
OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT (CONTINUED)<br />
(3) Operate the switch, valve, or other energy isolat<strong>in</strong>g device(s)<br />
so that the equipment is isolated from its energy source(s). Stored<br />
energy (such as that <strong>in</strong> spr<strong>in</strong>gs, elevated mach<strong>in</strong>e members,<br />
rotat<strong>in</strong>g flywheels, hydraulic systems, and air, gas, steam, or water<br />
pressure, etc.) must be dissipated or restra<strong>in</strong>ed by methods such as<br />
reposition<strong>in</strong>g, block<strong>in</strong>g, bleed<strong>in</strong>g down, etc. (Type(s) of Stored Energymethods<br />
to dissipate or restra<strong>in</strong>.)<br />
(4) Lockout and/or tagout the energy isolat<strong>in</strong>g devices with assigned<br />
<strong>in</strong>dividual lock(s) and tag(s) (Method(s) Selected; i.e., locks tags,<br />
additional safety measures).<br />
(5) After ensur<strong>in</strong>g that no personnel are exposed, and as a check on<br />
hav<strong>in</strong>g disconnected the energy sources, operate the push button or<br />
other normal operat<strong>in</strong>g controls to make certa<strong>in</strong> the equipment will not<br />
operate (Type(s) of Equipment checked to ensure disconnections).<br />
CAUTION: Return operat<strong>in</strong>g control(s) to “neutral” or “off” position<br />
after the test.<br />
(6) The equipment is now locked out or tagged out.<br />
RESTORING MACHINES OR EQUIPMENT TO NORMAL PRODUCTION<br />
OPERATIONS<br />
(1) After the servic<strong>in</strong>g and/or ma<strong>in</strong>tenance is complete and equipment<br />
is ready for normal production operations, check the area around the<br />
mach<strong>in</strong>es or equipment to ensure that no <strong>one</strong> is exposed.<br />
(2) After <strong>all</strong> tools have been removed from the mach<strong>in</strong>e or equipment,<br />
guards have been re<strong>in</strong>st<strong>all</strong>ed and employees are <strong>in</strong> the clear, remove<br />
<strong>all</strong> lockout or tagout devices. Operate the energy isolat<strong>in</strong>g devices to<br />
restore energy to the mach<strong>in</strong>e or equipment.<br />
PROCEDURE INVOLVING MORE THAN ONE PERSON<br />
In the preced<strong>in</strong>g steps, if more than <strong>one</strong> <strong>in</strong>dividual is required to lockout<br />
or tagout equipment, each sh<strong>all</strong> place his/her own personal lockout<br />
device or tagout device on the energy isolat<strong>in</strong>g device(s). When an<br />
energy isolat<strong>in</strong>g device cannot accept multiple locks or tags, a multiple<br />
lockout or tagout device (hasp) may be used. If lockout is used, a s<strong>in</strong>gle<br />
lock may be<br />
used to lockout the mach<strong>in</strong>e or equipment with the key be<strong>in</strong>g placed<br />
<strong>in</strong> a lockout box or cab<strong>in</strong>et which <strong>all</strong>ows the use of mul-tiple locks to<br />
secure it. Each employee will then use his/her own lock to secure the<br />
box or cab<strong>in</strong>et. As each person no longer needs to ma<strong>in</strong>ta<strong>in</strong> his or her<br />
lockout protection, that person will remove his/her lock from the box or<br />
cab<strong>in</strong>et. (Name(s)/Job Title(s) of employees authorized for group lockout<br />
or tagout.)<br />
BASIC RULES FOR USING LOCKOUT OR TAGOUT SYSTEM<br />
PROCEDURE<br />
All equipment sh<strong>all</strong> be locked out or tagged out to protect aga<strong>in</strong>st<br />
accidental or <strong>in</strong>advertent operation when such operation could cause<br />
<strong>in</strong>jury to personnel. Do not attempt to operate any switch, valve, or other<br />
energy isolat<strong>in</strong>g device where it is locked or tagged out.<br />
LOCKOUT (OR TAGOUT) PROCEDURE<br />
Entry No. (Description)<br />
1 Name of Company<br />
2 Type(s) and Magnitude(s) of energy and<br />
hazards<br />
3 Name(s)/Job Title(s) of employees authorized<br />
to lockout or tagout<br />
4 Name(s)/Job Title(s) of affected employees and<br />
how to notify<br />
5 Type(s) and Location of energy isolat<strong>in</strong>g means<br />
6 Type(s) of Stored Energy-methods to dissipate<br />
or restra<strong>in</strong><br />
7 Method(s) Selected i.e., locks, tags, additional<br />
safety measures, etc.<br />
8 Type(s) of Equipment checked to ensure<br />
disconnections<br />
9 Name(s)/Job Title(s) of employees authorized<br />
for group lockout or tagout<br />
STD 1-7.3 LOCKOUT/TAGOUT<br />
OSHA Instruction STD 1-7.3 (issued September 11, 1990)— Inspection<br />
Procedures and Interpretive Guidance is for 29 CFR 1910.147, The<br />
Control of Hazardous Energy (commonly referred to as OSHA’s Lockout/<br />
Tagout Standard).<br />
The purpose of STD 1-7.3 is to establish policies and provide<br />
clarification to ensure uniform enforcement of the Lockout/Tagout<br />
Standard. STD 1-7.3 also provides for the acceptance of “alternative<br />
procedures” <strong>in</strong> the servic<strong>in</strong>g and ma<strong>in</strong>tenance of sophisticated<br />
and complex equipment such as that found <strong>in</strong> the petroleum and<br />
chemical <strong>in</strong>dustries.<br />
The follow<strong>in</strong>g is an outl<strong>in</strong>e of highlights from STD 1-7.3. This outl<strong>in</strong>e<br />
is <strong>in</strong>tended to s<strong>in</strong>gle out some of the new <strong>in</strong>formation which was not<br />
<strong>in</strong>cluded <strong>in</strong> 29 CFR 1910.147. Reference must be made to the entire<br />
STD 1-7.3 to ensure complete compliance.<br />
UNDER LETTER I. INTERPRETIVE GUIDANCE<br />
1. Scope (f)(1) provides an explanation of cord and plug connected<br />
equipment by def<strong>in</strong><strong>in</strong>g when the (unplugged) plug is under the exclusive<br />
control of the employee perform<strong>in</strong>g the servic<strong>in</strong>g and/or ma<strong>in</strong>tenance.<br />
Listed are the follow<strong>in</strong>g three options:<br />
1) plug is physic<strong>all</strong>y <strong>in</strong> the possession of the employee<br />
2) <strong>in</strong> arm’s reach and <strong>in</strong> l<strong>in</strong>e of sight of the employee<br />
3) if the employee has affixed a lockout/tagout device on the plug<br />
Scope (f)(2) requires that the company lockout/tagout procedures<br />
specify the acceptable procedure for handl<strong>in</strong>g cord and plug<br />
connected equipment.<br />
CONTROL SYSTEMS | 133
STD 1-7.3 LOCKOUT/TAGOUT (CONTINUED)<br />
2. Procedures (c) states that “similar mach<strong>in</strong>es and/or equipment<br />
(such as those us<strong>in</strong>g the same type and magnitude of energy and<br />
the same or similar types of controls) can be covered with a s<strong>in</strong>gle<br />
written procedure.”<br />
3. Lockout versus Tagout (a) states that “OSHA has determ<strong>in</strong>ed that<br />
lockout is a surer means of ensur<strong>in</strong>g deenergization of equipment than<br />
tagout, and that it is the preferred method.” (over tagout)<br />
4. Employees and Tra<strong>in</strong><strong>in</strong>g (b) states that “employees who exclusively<br />
perform functions related to normal production operations, and who<br />
perform servic<strong>in</strong>g and/or ma<strong>in</strong>tenance under the protection of normal<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g, need only be tra<strong>in</strong>ed as “affected” (rather than<br />
“authorized”) employees even if tagout procedures are used.” (See I.1.d.<br />
and I.1.e. of this <strong>in</strong>struction.)<br />
5. Periodic Inspection by the Employer (a)(3) states that “energy control<br />
procedures used less frequently than once a year need be <strong>in</strong>spected<br />
only when used.”<br />
6. Equipment Test<strong>in</strong>g or Position<strong>in</strong>g (no changes from 1910.147)<br />
7. Group Lockout/Tagout states that “group lockout/tagout procedures<br />
sh<strong>all</strong> be tailored to the specific <strong>in</strong>dustrial operation and may be unique<br />
<strong>in</strong> the manner that employee protection from the release of hazardous<br />
energy is achieved. Irrespective of the situation, the requirements of this<br />
generic standard specify that each employee perform<strong>in</strong>g ma<strong>in</strong>tenance<br />
or servic<strong>in</strong>g activities sh<strong>all</strong> be <strong>in</strong> control of hazardous energy dur<strong>in</strong>g his/<br />
her period of exposure.”<br />
(a) Group operations norm<strong>all</strong>y require that a lockout/tagout program<br />
be implemented which ensures that each authorized employee is<br />
protected from the unexpected release of hazardous energy by<br />
his/her personal lockout/tagout device(s). No employee may affix<br />
the personal lockout/tagout device of another employee. Various<br />
group lockout/tagout procedures discussed <strong>in</strong> Appendix C provide<br />
for each authorized employee’s use of his/her personal lockout/<br />
tagout device(s).<br />
(b) One of the most difficult problems addressed by the standard<br />
<strong>in</strong>volves the servic<strong>in</strong>g and ma<strong>in</strong>tenance of complex equipment. Such<br />
equipment is frequently used <strong>in</strong> the petrochemical and chemical<br />
<strong>in</strong>dustries. Acceptable group lockout/tagout procedures for complex<br />
equipment are discussed further <strong>in</strong> Appendix C.<br />
The follow<strong>in</strong>g is the explanation for potenti<strong>all</strong>y hazardous stored energy<br />
or residual energy which might reaccumulate:<br />
8. Compliance with Group Lockout/Tagout (e)(2) “Monitor<strong>in</strong>g may<br />
be accomplished, for example, by observation or with the aid of a<br />
monitor<strong>in</strong>g device which will sound an alarm if a hazardous energy level<br />
is be<strong>in</strong>g approached.”<br />
(h) In regards to group lockout/tagout operations, “... a master tag<br />
is a personal tagout device if each employee person<strong>all</strong>y signs on<br />
and signs off on it and if the tag clearly identifies each authorized<br />
employee who is be<strong>in</strong>g protected by it.”<br />
SUBPART J. CLASSIFICATION OF VIOLATIONS<br />
1. A deficiency <strong>in</strong> the employer’s energy control program and/or<br />
procedure that could contribute to a potential exposure capable<br />
of produc<strong>in</strong>g serious physical harm or death sh<strong>all</strong> be cited as a<br />
serious violation.<br />
2. The failure to tra<strong>in</strong> “authorized,” “affected,” and “other” employees as<br />
required for their respective classifications should norm<strong>all</strong>y be cited as<br />
a serious violation.<br />
3. Paperwork deficiencies <strong>in</strong> lockout/tagout programs where effective<br />
lockout/tagout work procedures are <strong>in</strong> place sh<strong>all</strong> be cited as otherthan-serious.<br />
134 | CONTROL SYSTEMS
STD 1-7.3 LOCKOUT/TAGOUT (CONTINUED)<br />
APPENDIX B<br />
This flow diagram does not constitute the exclusive or def<strong>in</strong>itive means of comply<strong>in</strong>g with the standard <strong>in</strong> any particular situation and is presented<br />
solely as an aid.<br />
CONTROL SYSTEMS | 135
STD 1-7.3 LOCKOUT/TAGOUT (CONTINUED)<br />
APPENDIX C<br />
A. NORMAL PRODUCTION OPERATIONS<br />
1. <strong>Safeguard<strong>in</strong>g</strong> of servic<strong>in</strong>g/ma<strong>in</strong>tenance workers can be ensured by:<br />
a. Effective mach<strong>in</strong>e safeguard<strong>in</strong>g <strong>in</strong> compliance with Subpart O<br />
[mach<strong>in</strong>e guard<strong>in</strong>g requirements—see (A) (2)].<br />
b. Compliance with 29 CFR 1910.147 (Lockout/Tagout) <strong>in</strong><br />
situations where the normal production operation safeguards<br />
are rendered <strong>in</strong>effective or do not protect the servic<strong>in</strong>g/<br />
ma<strong>in</strong>tenance worker.<br />
2. Rout<strong>in</strong>e and repetitive activities are not covered by this standard if<br />
alternative measures provide effective protection from the hazards<br />
associated with unexpected energiz<strong>in</strong>g. Compliance with the<br />
mach<strong>in</strong>e guard<strong>in</strong>g requirements of Subpart O is an example of such<br />
alternative measures.<br />
3. Examples of rout<strong>in</strong>e ma<strong>in</strong>tenance/servic<strong>in</strong>g which can often be<br />
d<strong>one</strong> under the protection of “production-mode safeguard<strong>in</strong>g” are:<br />
lubricat<strong>in</strong>g, dra<strong>in</strong><strong>in</strong>g sumps, servic<strong>in</strong>g of filters, and <strong>in</strong>spection for<br />
leaks and/or mechanical malfunction.<br />
Examples that are not considered to be normal rout<strong>in</strong>e ma<strong>in</strong>tenance<br />
functions and would therefore trigger the need for lockout/tagout<br />
are: replacement of mach<strong>in</strong>e or process equipment comp<strong>one</strong>nts<br />
such as valves, gauges, l<strong>in</strong>kages, support structure, etc.<br />
4. It is expla<strong>in</strong>ed that some of the safeguard<strong>in</strong>g alternatives presented<br />
<strong>in</strong> ANSI B11.19 can be used to provide protection while clear<strong>in</strong>g<br />
m<strong>in</strong>or jams and perform<strong>in</strong>g other m<strong>in</strong>or servic<strong>in</strong>g functions. The two<br />
safeguard<strong>in</strong>g alternatives menti<strong>one</strong>d are <strong>in</strong>terlocked barrier guards<br />
and presence sens<strong>in</strong>g devices.<br />
B. GROUP LOCKOUT/TAGOUT<br />
Example procedures are given to illustrate the implementation of<br />
a group lockout/tagout procedure <strong>in</strong>volv<strong>in</strong>g many energy isolat<strong>in</strong>g<br />
devices and/or many servic<strong>in</strong>g/ma<strong>in</strong>tenance personnel. Several<br />
examples are given <strong>in</strong>volv<strong>in</strong>g authorized employees who affix<br />
personal lockout/tagout devices <strong>in</strong> a group lockout/tagout sett<strong>in</strong>g.<br />
1. Def<strong>in</strong>itions.<br />
The follow<strong>in</strong>g new def<strong>in</strong>itions for group lockout/tagout are given:<br />
a. Primary Authorized Employee is the authorized employee<br />
who exercises over<strong>all</strong> responsibility for adherence to the<br />
company lockout/tagout procedure.<br />
b. Pr<strong>in</strong>ciple Authorized Employee is an authorized employee<br />
who oversees or leads a group of servic<strong>in</strong>g/ma<strong>in</strong>tenance<br />
workers (e.g. plumbers, carpenters, electricians, metal<br />
workers, mechanics).<br />
c. Job-Lock is a device used to ensure the cont<strong>in</strong>uity of energy<br />
isolation dur<strong>in</strong>g a multi-shift operation. It is placed upon a<br />
lock-box. A key to the job-lock is controlled by each assigned<br />
primary authorized employee from each shift.<br />
d. Job-Tag with Tab is a special tag for tagout of energy isolat<strong>in</strong>g<br />
devices dur<strong>in</strong>g group lockout/tagout procedures. The tab of the<br />
tag is removed for <strong>in</strong>sertion <strong>in</strong>to the lock-box. The company<br />
procedure would require that the tagout job-tag cannot be<br />
removed until the tab is rejo<strong>in</strong>ed to it.<br />
e. Master Lockbox is the lockbox <strong>in</strong>to which <strong>all</strong> keys and tabs<br />
from the lockout or tagout devices secur<strong>in</strong>g the mach<strong>in</strong>e or<br />
equipment are <strong>in</strong>serted and which would be secured by a “joblock”<br />
dur<strong>in</strong>g multi-shift operations.<br />
f. Satellite Lockbox is a secondary lockbox or lockboxes to<br />
which each authorized employee affixes his/her personal<br />
lock or tag.<br />
g. Master Tag is a document used as an adm<strong>in</strong>istrative control<br />
and accountability device. This device is norm<strong>all</strong>y controlled by<br />
the operations department personnel and is a personal tagout<br />
device if each employee person<strong>all</strong>y signs on and signs off on it,<br />
and if the tag clearly identifies each authorized employee who<br />
is be<strong>in</strong>g protected by it.<br />
h. Work Permit is a control document which authorizes specific<br />
tasks and procedures to be accomplished.<br />
2. Organization.<br />
A sample “basic organizational structure” is outl<strong>in</strong>ed to expla<strong>in</strong> the<br />
relationship between and responsibilities of the primary authorized<br />
employee, pr<strong>in</strong>cipal authorized employee, authorized employees,<br />
and equipment operators.<br />
3. Examples of Procedures for Group Lockout/Tagout.<br />
Examples are presented for the various methods of lockout/tagout<br />
us<strong>in</strong>g lockbox procedures.<br />
a. Four procedures (Type A, Type B, Type C, Type D) address<br />
circumstances rang<strong>in</strong>g from a sm<strong>all</strong> group of servic<strong>in</strong>g/<br />
ma<strong>in</strong>tenance employees dur<strong>in</strong>g a <strong>one</strong>-shift operation to a<br />
comprehensive operation <strong>in</strong>volv<strong>in</strong>g many workers over a longer<br />
period. They are:<br />
(1) Type A. Each authorized employee places his/ her personal<br />
lock or tag upon each energy isolat<strong>in</strong>g device and removes<br />
it upon departure from that assignment. Each authorized<br />
employee verifies or observes the deenergization of the<br />
equipment.<br />
(2) Type B. Under a lockbox procedure, a lock or job-tag<br />
with tab is placed upon each energy isolation device<br />
after deenergization. The key(s) and removed tab(s) are<br />
then placed <strong>in</strong>to a lockbox. Each authorized employee<br />
assigned to the job then affixes his/her personal lock or<br />
tag to the lockbox. As a member of a group, each assigned<br />
authorized employee verifies that <strong>all</strong> hazardous energy has<br />
been rendered safe. The lockout/tagout devices cannot be<br />
removed or the energy isolat<strong>in</strong>g device turned on until the<br />
appropriate key or tab is matched to its lock or tag.<br />
136 | CONTROL SYSTEMS
STD 1-7.3 LOCKOUT/TAGOUT (CONTINUED)<br />
(3) Type C. After each energy isolat<strong>in</strong>g device is locked/<br />
tagged out and the keys/tabs placed <strong>in</strong>to a master lockbox,<br />
each servic<strong>in</strong>g/ma<strong>in</strong>tenance group “pr<strong>in</strong>cipal” authorized<br />
employee places his/her personal lock or tag upon the<br />
master lockbox. Then each pr<strong>in</strong>cipal authorized employee<br />
<strong>in</strong>serts his/her key <strong>in</strong>to a satellite lockbox to which each<br />
authorized employee <strong>in</strong> that specific group affixes his/<br />
her personal lock or tag. As a member of a group, each<br />
assigned authorized employee verifies that <strong>all</strong> hazardous<br />
energy has been rendered safe. Only after the servic<strong>in</strong>g/<br />
ma<strong>in</strong>tenance functions of the specific sub-group have been<br />
concluded and the personal locks or tags of the respective<br />
employees have been removed from the satellite lockbox<br />
can the pr<strong>in</strong>cipal authorized employee remove his/her lock<br />
from the master lockbox.<br />
(4) Type D. Dur<strong>in</strong>g operations to be conducted over more than<br />
<strong>one</strong> shift (or even many days or weeks), a system such<br />
as described here might be used. S<strong>in</strong>gle locks/tags are<br />
affixed upon a lockbox by each authorized employee as<br />
described at Type B or Type C above. The master lockbox<br />
is first secured with a job-lock before subsequent locks<br />
by the pr<strong>in</strong>cipal authorized employees are put <strong>in</strong> place<br />
on the master lockbox. The job-lock may have multiple<br />
keys if they are <strong>in</strong> the sole possession of the various<br />
primary authorized employees (<strong>one</strong> on each shift). As a<br />
member of a group, each assigned authorized employee<br />
verifies that <strong>all</strong> hazardous energy has been rendered<br />
safe. In this manner, the security provisions of the energy<br />
control system are ma<strong>in</strong>ta<strong>in</strong>ed across shift changes<br />
while permitt<strong>in</strong>g reenergization of the equipment at any<br />
appropriate time or shift.<br />
b. Normal group lockout/tagout procedures require the affix<strong>in</strong>g of<br />
<strong>in</strong>dividual lockout/tagout devices by each authorized employee<br />
to a group lockout device, as discussed <strong>in</strong> paragraph B.3.a.<br />
of this appendix. However, <strong>in</strong> the servic<strong>in</strong>g and ma<strong>in</strong>tenance<br />
of sophisticated and complex equipment, such as process<br />
equipment <strong>in</strong> petroleum ref<strong>in</strong><strong>in</strong>g, petroleum production, and<br />
chemical production, there may be a need for adaptation<br />
and modification of normal group lockout/tagout procedures<br />
<strong>in</strong> order to ensure the safety of the employees perform<strong>in</strong>g<br />
the servic<strong>in</strong>g and ma<strong>in</strong>tenance. To provide greater worker<br />
safety through implementation of a more feasible system,<br />
and to accommodate the special constra<strong>in</strong>ts of the standard’s<br />
requirement for ensur<strong>in</strong>g employees a level of protection<br />
equivalent to that provided by the use of a personal lockout or<br />
tagout device, an alternative procedure may be implemented<br />
if the company documentation justifies it. Lockout/tagout,<br />
blank<strong>in</strong>g, block<strong>in</strong>g, etc., is often supplemented <strong>in</strong> these<br />
situations by the use of work permits and a system of<br />
cont<strong>in</strong>uous worker accountability. In evaluat<strong>in</strong>g whether the<br />
equipment be<strong>in</strong>g serviced or ma<strong>in</strong>ta<strong>in</strong>ed is so complex as<br />
to necessitate a departure from the normal group lockout/<br />
tagout procedures (discussed <strong>in</strong> paragraph B.3.a.), to the<br />
use of an alternative procedure, the follow<strong>in</strong>g factors (often<br />
occurr<strong>in</strong>g simultaneously) are some of those which must<br />
be evaluated: physical size and extent of the equipment<br />
be<strong>in</strong>g serviced/ma<strong>in</strong>ta<strong>in</strong>ed; the relative <strong>in</strong>accessibility of the<br />
energy isolat<strong>in</strong>g devices; the number of employees perform<strong>in</strong>g<br />
the servic<strong>in</strong>g/ma<strong>in</strong>tenance; the number of energy isolat<strong>in</strong>g<br />
devices to be locked/tagged out; and the <strong>in</strong>terdependence and<br />
<strong>in</strong>terrelationship of the comp<strong>one</strong>nts <strong>in</strong> the system or between<br />
different systems.<br />
(1) “Once the equipment is shut down and the hazardous<br />
energy has been controlled, ma<strong>in</strong>tenance/servic<strong>in</strong>g<br />
personnel, together with operations personnel, must verify<br />
that the isolation of the equipment is effective . . .”<br />
(2) (Fifteen) specific issues related to the control of hazardous<br />
energy <strong>in</strong> complex process equipment are described . . . <strong>in</strong><br />
a typical situation which could be found at any facility.”<br />
c. “It should be noted that the purpose of the lockout/tagout<br />
standard is to reduce the likelihood of worker <strong>in</strong>juries and<br />
fatalities dur<strong>in</strong>g servic<strong>in</strong>g/ma<strong>in</strong>tenance operations . . .”<br />
OTHER SERVICES OFFERED BY ROCKFORD<br />
SYSTEMS<br />
OSHA 29 CFR 1910.147—LOCKOUT/TAGOUT REQUIREMENTS<br />
Accord<strong>in</strong>g to OSHA 29 CFR 1910.147, The control of hazardous<br />
energy (lockout/tagout), <strong>all</strong> employers must develop a complete<br />
hazardous control program by January 2, 1990. To assist employers<br />
<strong>in</strong> accomplish<strong>in</strong>g this, <strong>Rockford</strong> <strong>Systems</strong> covers this subject <strong>in</strong> our<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ar. Students are <strong>in</strong>structed on lockout/<br />
tagout procedures and taught the OSHA regulations for lockout/tagout.<br />
This subject is taught through the use of classroom discussions,<br />
visual aids and handouts, <strong>in</strong>clud<strong>in</strong>g OSHA 29 CFR 1910.147, STD<br />
1-7.3—Inspection Procedures and Interpretive Guidance for 29 CFR<br />
1910.147—The Control of Hazardous Energy.<br />
CONTROL SYSTEMS | 137
A<br />
B<br />
C<br />
D<br />
E<br />
Air-Clutch Press Brake Control...............................85-86<br />
Air-Cyl<strong>in</strong>ders...................................................... 16, 90-91<br />
Air Lockout Valve.....................................................13, 35<br />
Air Pressure Switch ..........................................11, 32, 80<br />
Angle Display Card, SSC-3000.......................................45<br />
ANSI Publications List......................................................4<br />
Articulated Palm Buttons......................................100, 101<br />
Automation, SSC-300 Press Control..........................38-48<br />
Bar/Run Station ..............................................13, 33, 48<br />
Bush<strong>in</strong>gs, Drill Press Shields .........................................13<br />
Cam and Strap Assembly ...........................................11<br />
Check Valve..................................................................32<br />
Comp<strong>one</strong>nt Packages<br />
Full-Revolution-Clutch Press.............................14-15<br />
Mechanical-Friction-Clutch Press Brake..................82<br />
SSC-1500 Power Press....................................36-37<br />
SSC-1500 Press Brake..........................................82<br />
SSC-3000 Press Automation..................... 36-37, 48<br />
S<strong>in</strong>gle- and Two-Speed Air-Clutch Press Brake...............86<br />
Control Bars.............................................................51-52<br />
Control Consoles............................................................49<br />
Control Module Kit<br />
Hydraulic Power Press Control Module Kit...............60<br />
Hydraulic Press Brake Control Module Kit...............90<br />
SSC-1500 Press Brake Control Module Kit.............77<br />
SSC-1500 Press Control Module Kit.......................28<br />
Control Rack Kit, SSC-3000...........................................40<br />
Control Reliability.........................................................112<br />
Controls<br />
Full-Revolution-Clutch Press...............................6-18<br />
Hydraulic Power Press......................................57-65<br />
Hydraulic Press Brake.......................................87-97<br />
Part-Revolution-Press.......................................19-56<br />
Press Brake.....................................................66-86<br />
SSC-1500 Power Press ...................................22-37<br />
SSC-1500 Press Brake.....................................72-84<br />
SSC-3000 Press Automation ...........................39-48<br />
Crankshaft Angle Display ..................................34, 45, 81<br />
Danger Signs and Labels ..................................103-106<br />
Die Protection Card, SSC-3000......................................45<br />
Dual CPU Press Clutch/Brake Card, SSC-3000...............44<br />
Dual-Solenoid Air Valves..............................11, 31, 81, 85<br />
EEZ-On Air Lockout Valve ...........................................35<br />
Electrical Labels .........................................................106<br />
Emergency-Stop Buttons .......................................52, 102<br />
F<br />
H<br />
K<br />
L<br />
M<br />
O<br />
P<br />
Filter-Regulator-Lubricator Assembly ......11, 31, 81, 85<br />
Floor Stands .................................................................51<br />
Foot Switch ..........................................12, 33, 63, 81, 93<br />
Full-Revolution-Clutch Press Control ...........................6-18<br />
High/Low Limit Switch Assembly .........................63, 93<br />
Hydraulic Power Press Control...................................57-65<br />
Hydraulic Press Brake Control...................................87-97<br />
Keypad/Display Kit<br />
Hydraulic Power Press Keypad/Display Kit .............61<br />
Hydraulic Press Brake Keypad/Display Kit ..............91<br />
SSC-1500 Press Brake Keypad/Display Kit ............28<br />
SSC-1500 Press Keypad/Display Kit ......................28<br />
Labels, Danger and Warn<strong>in</strong>g .............................103-106<br />
Light-Push Palm Buttons......................................100, 101<br />
Limit Switch, High/Low.............................................63, 93<br />
L<strong>in</strong>ear Cam and Limit Switch Assembly.....................63, 93<br />
Load Monitor System, SSC-3000..............................45-46<br />
Lockout Valves........................................................13, 35<br />
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong> Choices ................................113<br />
Ma<strong>in</strong> CPU Card, SSC-3000............................................42<br />
Manual Pilot Valve.........................................................35<br />
Manual Valve.................................................................35<br />
Mechanical Press Brake Control <strong>Systems</strong>...................72-86<br />
Modular Control Rack Kit, SSC-3000......................................40<br />
Monitored Dual-Solenoid Air Valves.....................11, 31, 79, 85<br />
Mount<strong>in</strong>g Boxes, Palm Buttons.....................................102<br />
Multiple-Operator Junction Box.....................34, 48, 81, 93<br />
Operator Buttons......................................... 52, 101-102<br />
OSHA Standards<br />
OSHA 29 CFR 1910.147..............................129-134<br />
OSHA 29 CFR 1910.211..............................115-116<br />
OSHA 29 CFR 1910.212.....................................124<br />
OSHA 29 CFR 1910.217..............................117-124<br />
OSHA 29 CFR 1910.219..............................125-128<br />
STD 1-7.3....................................................134-138<br />
Palm Button Assemblies........12, 32, 63, 81, 93, 99-100<br />
Palm Buttons..........................................................99-102<br />
Part Number<strong>in</strong>g System Chart<br />
Control Bar............................................................52<br />
Full-Revolution-Clutch Press Control.......................10<br />
Hydraulic Power Press Control...............................62<br />
Hydraulic Press Brake Control................................92<br />
SSC-1500 Part-Revolution Press Control................29<br />
SSC-1500 Press Brake Control..............................29<br />
SSC-3000 Press Automation Control......................47<br />
Part-Revolution-Clutch Press Control.........................19-56<br />
138 | CONTROL SYSTEMS
P<br />
R<br />
PLS (Programmable Limit Switch) Card, SSC-3000.........44<br />
Power Press Control <strong>Systems</strong>......................................3-56<br />
Press Automation Control, SSC-3000........................38-48<br />
Press Brake Control <strong>Systems</strong>.....................................66-97<br />
Press Inspection Report.........................................107-108<br />
Prior-Action Station......................................13, 23, 48, 63<br />
References.........................................................107-109<br />
Remote Operator Stations<br />
Hydraulic Power Press Remote Operator Stations....61<br />
Hydraulic Press Brake Remote Operator Stations.....61<br />
SSC-1500 Press Brake Remote Operator Stations......77<br />
SSC-1500 Press Remote Operator Stations............28<br />
SSC-3000 Press Automation Remote Operator Stations<br />
........................................................................41<br />
Remote Operator-Style Control Boxes<br />
SSC-1500 Part-Revolution Press.......................26-27<br />
SSC-1500 Press Brake.....................................75-76<br />
Hydraulic Power Press...........................................60<br />
Hydraulic Press Brake............................................90<br />
Resolver/Pulser Assembly........................................30, 79<br />
Return/Inch-Up Palm Button.........................................102<br />
R<strong>in</strong>g Guard..................................................................101<br />
Risk Assessment..................................................112-113<br />
S<br />
T<br />
W<br />
Hydraulic Press................................................64-65<br />
Part-Revolution Press.......................................53-56<br />
Press Brake.....................................................94-97<br />
Switches<br />
Air Pressure..............................................11, 32, 80<br />
Foot..............................................12, 33, 63, 81, 93<br />
Table O-10.................................................................119<br />
Top-of-Stroke Limit Switch.............................................12<br />
Top-Stop Palm Button..................................................101<br />
Touch screen/Display Kit, SSC-3000..............................40<br />
Turnover Bars, Spr<strong>in</strong>g-Loaded......................................198<br />
Two-Hand Control Devices........................................68-69<br />
Two-Speed Air-Clutch Press Brakes..........................85-86<br />
Warn<strong>in</strong>g Labels..........................................................106<br />
S<br />
Roller Cha<strong>in</strong>.............................................................30, 79<br />
Servo Feed Interface, SSC-3000.................................46<br />
S<strong>in</strong>gle-Speed Air-Clutch Press Brakes........................85-86<br />
Slide-Operated Air Lockout Valve....................................35<br />
Solenoid Air Valves........................................11, 31, 8, 85<br />
Special Controls.............................................................49<br />
Special Sprockets..........................................................79<br />
Spr<strong>in</strong>g-Loaded Turnover Bar...........................................98<br />
Sprocket Assembly..................................................30, 79<br />
SSC-1500 Press Brake Control.................................72-83<br />
SSC-1500 Part-Revolution Press Control...................22-37<br />
SSC-1500 Press Remote Operator Stations....................28<br />
SSC-3000 Press Automation Control<br />
SSC-3000 Control Rack Kit....................................40<br />
SSC-3000 Press Control...................................38-48<br />
SSC-3000 Touch Screen/Display Kit.......................40<br />
SSC-3000 Expandable Options.........................44-56<br />
SSC-3000 Remote Operator Stations..............................41<br />
Subpanel, Hydraulic Power Press....................................60<br />
Subpanel, Hydraulic Press Brake....................................90<br />
Supervisory Control Station.....................33, 48, 63, 81, 93<br />
Survey Forms<br />
Full-Revolution Press........................................17-18<br />
CONTROL SYSTEMS | 139
Die Safety Blocks<br />
For Presses & Press Brakes<br />
www.rockfordsystems.com
Die Safety Blocks is a comprehensive catalog<br />
that features a complete l<strong>in</strong>e of die safety<br />
blocks and accessories for use whenever dies<br />
are be<strong>in</strong>g adjusted or repaired. These products<br />
can also satisfy lockout/tagout requirements<br />
for isolat<strong>in</strong>g mechanical energy.<br />
The alum<strong>in</strong>um die safety blocks featured <strong>in</strong><br />
the catalog are offered <strong>in</strong> several shapes and<br />
sizes. Products to choose from <strong>in</strong>clude:<br />
• X-shaped, U-shaped, and<br />
Octagonal Safety blocks<br />
• Adjustable Screw Devices for Use<br />
With Octagonal Safety Blocks<br />
• Wedges<br />
• Safety Block Holders<br />
• Electrical Interlock <strong>Systems</strong><br />
• Adjustable Safety Blocks<br />
The catalog also <strong>in</strong>cludes useful <strong>in</strong>formation<br />
on determ<strong>in</strong><strong>in</strong>g the size and number of die<br />
safety blocks to use.<br />
All products <strong>in</strong> this catalog are <strong>in</strong>tended and<br />
designed to meet the requirements of OSHA<br />
and ANSI safety standards.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong><br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.
Accord<strong>in</strong>g to OSHA 29 CFR 1910.217, “The employer sh<strong>all</strong> provide<br />
and enforce the use of safety blocks for use whenever dies are<br />
be<strong>in</strong>g adjusted or repaired <strong>in</strong> the press.” They are not required<br />
dur<strong>in</strong>g die sett<strong>in</strong>g unless die blocks are <strong>in</strong>cluded <strong>in</strong> your die sett<strong>in</strong>g<br />
procedure. They also satisfy the lockout/tagout requirements for<br />
isolat<strong>in</strong>g mechanical energy.<br />
Die safety blocks are placed between the die punch and holder with the<br />
mach<strong>in</strong>e stroke up. They are rated to support a static load. The static<br />
load represents the comb<strong>in</strong>ed weight of the press ram, ram comp<strong>one</strong>nts<br />
(ram-adjust assembly and connection rod[s] or pitman arm[s]), and the<br />
upper die.<br />
In some applications, as many as four safety blocks may be required.<br />
This is determ<strong>in</strong>ed by the size of the press bed and the weight the<br />
blocks must support. On larger presses, the total slide weight must then<br />
be distributed among the quantity of safety blocks required.<br />
The ram is usu<strong>all</strong>y adjustable; therefore, wedges or the adjustable<br />
screw device is offered to provide a proper fit. If the die takes up most<br />
of the space on the die set, it may be difficult to f<strong>in</strong>d a place to <strong>in</strong>sert<br />
the block. To avoid accident<strong>all</strong>y strok<strong>in</strong>g the press or leav<strong>in</strong>g the safety<br />
block <strong>in</strong> the die after use, an electrical power cut-off <strong>in</strong>terlock system<br />
should be used.<br />
Note: Electrical <strong>in</strong>terlock<strong>in</strong>g of die safety blocks to the mach<strong>in</strong>e’s motor<br />
and control circuits is required by ANSI B11.19.<br />
Electrical Power<br />
Cutoff System<br />
Die Safety Block<br />
Wedges<br />
Die Safety<br />
Block Holder<br />
U-Shaped Safety Block <strong>in</strong> Holder With Wedges<br />
and Electrical Power Cutoff System<br />
ALUMINUM DIE SAFETY BLOCK SYSTEM<br />
This high-strength die safety block is lightweight and comes <strong>in</strong> several sizes. The unique shape and mechanical properties of the 6063-T5 material<br />
have been calculated accord<strong>in</strong>g to str<strong>in</strong>gent structural alum<strong>in</strong>um design analysis standards to provide high strength.<br />
To determ<strong>in</strong>e the number of die safety blocks required, the static load each die safety block will support, and the length of each block, please follow<br />
the <strong>in</strong>structions below and on the next page.<br />
1. Determ<strong>in</strong><strong>in</strong>g the static load the die safety block(s) will support:<br />
The actual static load that the die safety block(s) will support is determ<strong>in</strong>ed by add<strong>in</strong>g the actual weights of the press slide and slide<br />
comp<strong>one</strong>nts (ram-adjustment assembly, connection rod[s] or pitman arm[s], and the upper die).<br />
If this weight cannot be determ<strong>in</strong>ed, an approximate static load can be calculated us<strong>in</strong>g the <strong>in</strong>formation and formulas on the next page.<br />
SHUT HEIGHT, 3 (DIE SPACE), ON MECHANICAL<br />
POWER PRESSES AND LOCATION OF SLIDE<br />
(BETWEEN 1 AND 2 ) WHEN APPLYING DIE<br />
SAFETY BLOCKS<br />
A Slide Adjustment<br />
B Mach<strong>in</strong>e Stroke<br />
A B<br />
SLIDE<br />
PUNCH<br />
OBI<br />
PRESS<br />
FRAME<br />
1 S.U.A.U. - Stroke Up - Adjustment Up<br />
2 S.U.A.D. - Stroke Up - Adjustment Down<br />
3 S.D.A.U. - Stroke Down - Adjustment Up<br />
SHUT HEIGHT<br />
4 S.D.A.D. - Stroke Down - Adjustment Down<br />
1<br />
2<br />
3<br />
4<br />
A<br />
Die<br />
Safety<br />
Block<br />
Location<br />
HOLDER<br />
DIE<br />
SET<br />
DIE SAFETY BLOCK LOCATION—<br />
PLACE BETWEEN THE DIE<br />
PUNCH AND HOLDER.<br />
BOLSTER<br />
BED<br />
2 | DIE SAEETY BLOCKS
Allow 2000 pounds of static load for each cubic foot displaced <strong>in</strong> the press bed area (front to back x right to left) multiplied by the shut height (die<br />
space) of the press. Note: When us<strong>in</strong>g this formula, the calculated approximated static load has a safety factor of two (2).<br />
FORMULAS:<br />
Press Bed Area (sq <strong>in</strong>) x Shut Height (<strong>in</strong>) = Cubic Feet Displaced<br />
Cubic Inches/Cubic Feet (Constant)<br />
(1728 cu <strong>in</strong>/cu ft)<br />
Cubic feet displaced x 2000 lb/cubic foot =Total Static Load<br />
EXAMPLE:<br />
(Press Bed Area) (Shut Height)<br />
48 <strong>in</strong> by 96 <strong>in</strong> x 24 <strong>in</strong> = 110,592 = 64 cu ft<br />
1728 cu <strong>in</strong>/cu ft 1728<br />
64 cubic feet displaced x 2000 lb/cu ft = 128,000 lb static load<br />
2. Determ<strong>in</strong><strong>in</strong>g the Die Safety Block Length<br />
With the mach<strong>in</strong>e at the top of its stroke; stroke up — adjustment up (S.U.A.U. – see previous page), measure the space between the upper<br />
and lower die set plates (not the distance between the bolster and slide). This gives the maximum safety block length. To determ<strong>in</strong>e the stroke<br />
up — adjustment down (S.U.A.D. – see previous page) measurement, subtract the ram adjustment from the S.U.A.U. figure. This provides the<br />
m<strong>in</strong>imum length of the die safety block.<br />
Total Length of Die Safety Block Required ___________”<br />
EXCEPTIONS<br />
A. If wedges will be used, subtract 1½” maximum. This is an <strong>all</strong>owance for variation <strong>in</strong> the stopp<strong>in</strong>g po<strong>in</strong>t of the crankshaft or adjustment of the ram.<br />
Total Length of Die Safety Block Required ____________”<br />
B. When an adjustable screw is added to an octagonal safety block, the m<strong>in</strong>imum length of the alum<strong>in</strong>um portion of the safety block is as follows:<br />
For sm<strong>all</strong> and medium safety blocks<br />
2½” plus the size of the adjustable screw device<br />
For large safety blocks<br />
3” plus the size of the adjustable screw device<br />
When an adjustable screw device is added to an octagonal safety block and the screw is <strong>all</strong> the way <strong>in</strong>side of the safety block, it will add 2” to<br />
the over<strong>all</strong> length of sm<strong>all</strong> and medium safety blocks and 21/2” to the over<strong>all</strong> length of large safety blocks. Therefore, subtract 2” for<br />
sm<strong>all</strong> or medium blocks and 2½” for large blocks to determ<strong>in</strong>e the length of the alum<strong>in</strong>um portion of the die block.<br />
Example: If the m<strong>in</strong>imum over<strong>all</strong> length of the sm<strong>all</strong> or medium safety block required is 10½” with any size adjustable screw device, the alum<strong>in</strong>um<br />
portion of the safety block would be 8½” (10½” - 2” = 8½”).<br />
Example: If the m<strong>in</strong>imum over<strong>all</strong> length of the large safety block required is 16” with any size adjustable screw device, the alum<strong>in</strong>um portion of<br />
the safety block would be 13½” (16” - 2½” = 13½”).<br />
Total Length of the Alum<strong>in</strong>um Portion of the Die Safety Block ___________”<br />
3. Determ<strong>in</strong><strong>in</strong>g the Size of the Die Safety Block<br />
The size of the die safety block (sm<strong>all</strong>, medium, large) is determ<strong>in</strong>ed by <strong>one</strong> or both of the follow<strong>in</strong>g factors:<br />
A. The size of the block itself and the area available <strong>in</strong> the die. (See static load charts.)<br />
B. The static load capacity of the block (sm<strong>all</strong>, medium, large) versus the total static load be<strong>in</strong>g supported. (See static load charts.)<br />
DIE SAEETY BLOCKS | 3
X-SHAPED SAFETY BLOCKS<br />
To determ<strong>in</strong>e the number of safety blocks required, the static load each<br />
safety block will support, and the length of each block, please refer to<br />
pages 2-3.<br />
The X-shaped safety blocks can be furnished four different ways:<br />
A) Cut to length with a hole and p<strong>in</strong> for an <strong>in</strong>terlock<br />
cha<strong>in</strong> or wedges<br />
B) Cut to length only<br />
C) In a n<strong>in</strong>e-foot length<br />
SMALL<br />
LARGE<br />
A 4” 5¾”<br />
B 1” 1¼”<br />
SMALL<br />
LARGE<br />
WEIGHT OF BLOCKS<br />
0.681 lb/<strong>in</strong><br />
1.250 lb/<strong>in</strong><br />
D) Cut to length with a hole and p<strong>in</strong> for an <strong>in</strong>terlock cha<strong>in</strong> or<br />
wedges and a base plate <strong>in</strong>st<strong>all</strong>ed (order base plate<br />
separately; see page 6)<br />
MAXIMUM APPROXIMATE STATIC<br />
LOAD<br />
PER BLOCK IN POUNDS (TONS)*<br />
BLOCK LENGTH SMALL LARGE<br />
1”-24” 97,000 (48) 203,000 (101)<br />
24½”-30” 90,000 (45) 189,000 (94)<br />
30½”-36” 86,000 (43) 171,000 (85)<br />
36½”-42” 84,000 (42) 169,000 (84)<br />
42½”-48” 73,000 (36) 165,000 (82)<br />
48½”-54” 71,000 (35) 146,000 (73)<br />
54½”-60” 69,000 (34) 144,000 (72)<br />
*The approximate static loads shown <strong>in</strong> this chart have<br />
a built-<strong>in</strong> safety factor of two.<br />
SMALL<br />
LARGE<br />
WAY FURNISHED† PART NO. PART NO.<br />
A KTS-609 KTS-610<br />
B KTS-605 KTS-606<br />
C KTS-608 KTS-608<br />
D KTS-635 KTS-636<br />
†Powder coat<strong>in</strong>g available on request—please consult the factory.<br />
U-SHAPED SAFETY BLOCKS<br />
4 | DIE SAEETY BLOCKS<br />
A<br />
C<br />
SMALL MEDIUM LARGE<br />
A 4 5 ∕8” 5½” 6¾”<br />
B 4” 4 7 ∕8” 5½”<br />
C 2 5 ∕8” 3¼” 4¼”<br />
B<br />
To determ<strong>in</strong>e the number of safety blocks required, the static load each<br />
safety block will support, and the length of each block, please refer to<br />
pages 2-3.<br />
The U-shaped safety blocks can be furnished three different ways:<br />
A) Cut to length with a hole and p<strong>in</strong> for an <strong>in</strong>terlock cha<strong>in</strong> or wedges<br />
B) Cut to length only<br />
C) In a n<strong>in</strong>e-foot length<br />
SMALL<br />
MEDIUM<br />
LARGE<br />
WEIGHT OF BLOCKS<br />
0.638 lb/<strong>in</strong><br />
0.879 lb/<strong>in</strong><br />
1.17 lb/<strong>in</strong><br />
Copyright © 2018 by <strong>Rockford</strong> <strong>Systems</strong>, LLC. All rights reserved. Not to be reproduced <strong>in</strong> whole or <strong>in</strong> part without written permission. LITHO IN U.S.A.<br />
BLOCK<br />
LENGTH<br />
MAXIMUM APPROXIMATE STATIC LOAD<br />
PER BLOCK IN POUNDS (TONS)*<br />
SMALL MEDIUM LARGE<br />
1”-24” 88,500 (44) 126,000 (63) 169,500 (84)<br />
24½”-30” 87,000 (43) 123,000 (61) 166,000 (83)<br />
30½”-36” 84,000 (42) 120,500 (60) 162,000 (81)<br />
36½”-42” 81,500 (40) 117,500 (58) 159,000 (79)<br />
42½”-48” 79,000 (39) 114,000 (57) 156,000 (78)<br />
48½”-54” 76,500 (38) 112,000 (56) 152,000 (76)<br />
54½”-60” 74,000 (37) 108,500 (54) 148,500 (74)<br />
*The approximate static loads shown <strong>in</strong> this chart have<br />
a built-<strong>in</strong> safety factor of two.<br />
WAY<br />
FURNISHED†<br />
SMALL MEDIUM LARGE<br />
PART NO. PART NO. PART NO.<br />
A KTS-561 KTS-562 KTS-563<br />
B KTS-564 KTS-565 KTS-566<br />
C KTS-554 KTS-555 KTS-556<br />
†Powder coat<strong>in</strong>g available on request—<br />
please consult the factory.
B<br />
OCTAGONAL SAFETY BLOCKS<br />
A<br />
A<br />
B<br />
To determ<strong>in</strong>e the number of safety blocks required, the static load each<br />
safety block will support, and the length of each block, please refer to<br />
pages 2-3.<br />
The octagonal safety blocks can be furnished four different ways:<br />
A) Cut to length with a hole and p<strong>in</strong> for an <strong>in</strong>terlock cha<strong>in</strong><br />
and with an adjustable screw device and/or base plate<br />
<strong>in</strong>st<strong>all</strong>ed (order adjustable screw device and/or base plate<br />
separately; see below and page 6)<br />
B) Cut to length with a hole and p<strong>in</strong> for an <strong>in</strong>terlock<br />
cha<strong>in</strong> or wedges<br />
C) Cut to length only<br />
D) In a n<strong>in</strong>e-foot length<br />
SMALL MEDIUM LARGE<br />
A 5 5 ∕8 5½” 6¾”<br />
B 3½” 4¼” 5¼”<br />
SMALL<br />
MEDIUM<br />
LARGE<br />
WEIGHT OF BLOCKS<br />
0.833 lb/<strong>in</strong><br />
1.12 lb/<strong>in</strong><br />
1.58 lb/<strong>in</strong><br />
MAXIMUM APPROXIMATE STATIC LOAD<br />
PER BLOCK IN POUNDS (TONS)*<br />
BLOCK LENGTH SMALL MEDIUM LARGE<br />
1”-24” 190,000 (95) 275,500 (137) 289,500 (144)<br />
24½”-30” 173,000 (86) 258,000 (129) 258,000 (129)<br />
30½”-36” 169,500 (84) 244,000 (122) 245,000 (122)<br />
36½”-42” 164,500 (82) 232,000 (116) 234,500 (117)<br />
42½”-48” 158,000 (79) 226,500 (113) 223,500 (111)<br />
48½”-54” 155,500 (77) 226,000 (113) 211,000 (105)<br />
54½”-60” 155,000 (77) 218,500 (109) 210,500 (105)<br />
*The approximate static loads shown <strong>in</strong> this chart<br />
have a built-<strong>in</strong> safety factor of two.<br />
SMALL MEDIUM LARGE<br />
WAY FURNISHED† PART NO. PART NO. PART NO.<br />
A KTS-589 KTS-590 KTS-591<br />
B KTS-592 KTS-593 KTS-594<br />
C KTS-595 KTS-596 KTS-597<br />
D KTS-599 KTS-600 KTS-601<br />
†Powder coat<strong>in</strong>g available on request—please consult the factory.<br />
ADJUSTABLE SCREW DEVICE—FOR USE WITH<br />
OCTAGONAL SAFETY BLOCKS ONLY<br />
This heavy-duty steel screw device is added to the octagonal shaped<br />
safety blocks. These screws are needed to prevent any space<br />
between the block and die when various dies are used or when the<br />
slide is adjusted.<br />
Adjustable<br />
Screw<br />
ADJUSTABLE SCREW DEVICE<br />
OCTAGONAL SAFE-<br />
TY BLOCK SIZE<br />
SMALL<br />
INCHES OF<br />
ADJUST-<br />
MENT<br />
PART<br />
NO.<br />
MAXIMUM APPROXIMATE STATIC<br />
LOAD PER ADJUSTABLE SCREW<br />
EVICE IN POUNDS (TONS)*<br />
2” KTS-574 106,000 (53)<br />
4” KTS-584 102,500 (51)<br />
6” KTS-625 98,500 (49)<br />
8” KTS-626 94,500 (47)<br />
10” KTS-627 91,000 (45)<br />
12” KTS-622 87,500 (43)<br />
2” KTS-575 73,000 (36)<br />
4” KTS-585 70,000 (35)<br />
MEDIUM<br />
6” KTS-628 67,000 (33)<br />
8” KTS-629 64,000 (32)<br />
10” KTS-630 61,000 (30)<br />
12” KTS-623 58,000 (29)<br />
6” KTS-598 189,000 (94)<br />
Note: If an adjustable screw device is mounted to an octagonal safety<br />
block, you must use the approximate static loads shown <strong>in</strong> the chart.<br />
This is because the adjustable screw devices will not hold as heavy a<br />
static load as the octagonal safety blocks by themselves.<br />
LARGE<br />
*The approximate static loads shown <strong>in</strong> this<br />
chart have a built-<strong>in</strong> safety factor of two.<br />
8” KTS-631 181,000 (90)<br />
10” KTS-632 174,000 (87)<br />
12” KTS-624 167,000 (83)<br />
DIE SAEETY BLOCKS | 5
SAFETY BLOCK BASE<br />
SAFETY WEDGES<br />
These wedges prevent hazardous<br />
movement of the press slide if a space<br />
is created between the block and die<br />
when various dies are used or when<br />
the slide is adjusted. All cut-to-length<br />
wedges are furnished with a 24” cha<strong>in</strong>.<br />
Available <strong>in</strong> alum<strong>in</strong>um or hardwood.<br />
This safety block base can be added<br />
to U-shaped, octagonal-shaped, and<br />
X-shaped safety blocks. The base adds<br />
stability to help prevent the die block from<br />
tipp<strong>in</strong>g over. Available <strong>in</strong> 1⁄2” thick steel<br />
or alum<strong>in</strong>um.<br />
Safety Block Base<br />
STEEL BASES FOR U-SHAPED AND OCTAGONAL-SHAPED SAFETY BLOCKS<br />
PART NO. DESCRIPTION DIMENSIONS<br />
STL-053 MINI BASE 6” X 6”<br />
STL-049 SMALL BASE 8 5 ∕8” X 8 5 ∕8”<br />
STL-050 MEDIUM BASE 9½” X 9½”<br />
STL-051 LARGE BASE 10¾” X 10¾”<br />
STEEL BASES FOR X-SHAPED SAFETY BLOCKS<br />
PART NO. DESCRIPTION DIMENSIONS<br />
STL-057 SMALL X-BASE 4” X 4”<br />
STL-058 LARGE X-BASE 6” X 6”<br />
ALUMINUM BASES FOR OCTAGONAL-SHAPED SAFETY BLOCKS<br />
PART NO. DESCRIPTION DIMENSIONS<br />
KTS-638 SMALL BASE 6” X 6”<br />
KTS-640 MEDIUM BASE 8” X 8”<br />
KTS-641 LARGE BASE 10” X 10”<br />
ALUMINUM BASES FOR X-SHAPED SAFETY BLOCKS<br />
PART NO. DESCRIPTION DIMENSIONS<br />
KTS-637 SMALL X-BASE 4” X 4”<br />
KTS-639 LARGE X-BASE 6” X 6”<br />
PART NO.<br />
KTS-571<br />
KTS-572<br />
KTS-573<br />
KTS-570<br />
KTS-642<br />
SAFETY WEDGES FOR SAFETY BLOCKS<br />
DESCRIPTION<br />
Two-Piece Alum<strong>in</strong>um<br />
Safety Wedges<br />
6” ALUMINUM WEDGE FOR SMALL BLOCKS<br />
7” ALUMINUM WEDGE FOR MEDIUM BLOCKS<br />
8” ALUMINUM WEDGE FOR LARGE BLOCKS<br />
ALUMINUM WEDGE MATERIAL IN A 9’ LENGTH<br />
HARDWOOD WEDGE FOR ALL BLOCK SIZES<br />
HOLDERS<br />
These holders are designed to accept<br />
U-shaped, octagonal, X-shaped, and<br />
adjustable safety blocks. They are<br />
constructed of heavy-gauge steel and<br />
pa<strong>in</strong>ted safety orange. The holders<br />
attach easily to the mach<strong>in</strong>e with two<br />
1⁄4” fasteners. A strap is furnished<br />
with each holder to keep the block<br />
<strong>in</strong> place. Safety wedges can also be<br />
stored <strong>in</strong> the holders.<br />
PART NO.<br />
LIFTING HANDLE—PART NO. KTS-633<br />
The alum<strong>in</strong>um lift<strong>in</strong>g handle is a convenient option<br />
for <strong>all</strong> safety blocks that are used frequently.<br />
ELECTRICAL INTERLOCK SYSTEMS<br />
Accord<strong>in</strong>g to ANSI B11.19, safety blocks “sh<strong>all</strong> be <strong>in</strong>terlocked with the<br />
mach<strong>in</strong>e to prevent actuation of hazardous motion of the mach<strong>in</strong>e.” The<br />
follow<strong>in</strong>g <strong>in</strong>terlock systems will satisfy this requirement. The <strong>in</strong>terlock<br />
must be <strong>in</strong>terfaced <strong>in</strong>to the control system so that when the plug is<br />
pulled, the power to the ma<strong>in</strong> drive motor and control is disconnected.<br />
If the mach<strong>in</strong>e has a mechanical energy source, such as a flywheel, it<br />
must come to rest before the die block can be <strong>in</strong>serted. The <strong>in</strong>terlock<br />
system is available <strong>in</strong> a yellow plug with <strong>one</strong> contact or an orange plug<br />
with two contacts. The <strong>in</strong>terlock system <strong>in</strong>cludes the plug, a 24” long<br />
cha<strong>in</strong>, a receptacle, and an electrical mount<strong>in</strong>g box.<br />
Part No. KTS-518<br />
One-contact <strong>in</strong>terlock system<br />
with 24” cha<strong>in</strong><br />
Part No. KTS-533<br />
Two-contact <strong>in</strong>terlock system<br />
with 24” cha<strong>in</strong><br />
HOLDERS<br />
DESCRIPTION<br />
KTS-003 8” X 8” X 14”<br />
KTS-005 10½” X 10½” X 14”<br />
KTS-019 10½” X 10½” X 24”<br />
KTS-020 12” X 12” X 30”<br />
KTS-518<br />
6 | DIE SAEETY BLOCKS
WARNING LABELS—<br />
PART NO. KST-323 ENGLISH<br />
PART NO. KST-323S–SPANISH<br />
The warn<strong>in</strong>g label illustrated to the right is provided with <strong>all</strong> safety<br />
blocks and should be affixed directly to each safety block. If a safety<br />
block is not t<strong>all</strong> enough for the label to fit, affix it to a prom<strong>in</strong>ent location<br />
on the mach<strong>in</strong>e. All personnel operat<strong>in</strong>g or work<strong>in</strong>g around the mach<strong>in</strong>e<br />
must be required to read, understand, and adhere to <strong>all</strong> warn<strong>in</strong>gs on<br />
this label. If the label becomes destroyed or unreadable, it MUST be<br />
replaced. Contact the factory immediately for a replacement label and<br />
do not operate the equipment until the warn<strong>in</strong>g label is <strong>in</strong> place.<br />
MAXIMUM LOAD LABEL—PART NO. KST-330<br />
The maximum load label shown to the right is provided with <strong>all</strong> safety<br />
blocks and is affixed directly to each safety block. If the label becomes<br />
destroyed or unreadable, contact the factory for a replacement label.<br />
The maximum load <strong>in</strong> tons should be written legibly on the label <strong>in</strong><br />
permanent marker based on the maximum load chart.<br />
ADJUSTABLE DIE SAFETY BLOCKS<br />
These adjustable safety blocks feature a tough<br />
m<strong>all</strong>eable-iron bell-bottom base, a convenient<br />
handle for lift<strong>in</strong>g, and precision-cut acme<br />
threads for easy adjustment and extra rigidity.<br />
The adjust<strong>in</strong>g screw can be easily adjusted<br />
up or down by hand. Turn<strong>in</strong>g holes are also<br />
provided <strong>in</strong> the screw neck to facilitate the use<br />
of a turn<strong>in</strong>g bar, if required.<br />
Safety Block <strong>in</strong> Use on<br />
a Power Press<br />
PART NO.<br />
CAPACITY<br />
IN TONS<br />
*Does not have a handle.<br />
LENGTH<br />
CLOSED<br />
SCREW<br />
ADJUSTMENT<br />
+ +<br />
LENGTH SCREW<br />
ADJUSTMENT UP<br />
BASE<br />
DIAMETER<br />
WEIGHT IN<br />
POUNDS<br />
SAFETY BLOCK HOLDER<br />
PAR NO.<br />
KTS-520* 10 6¾” 1¼” 8” 4 7 ∕8” 8 KTS-003<br />
KTS-521 10 8¾” 3½” 12¼” 5 5 ∕8” 10 KTS-003<br />
KTS-522 10 12¾” 7¼” 20” 6½” 13 KTS-003<br />
KTS-523 20 9½” 2¾” 12¼” 6 3 ∕8” 18 KTS-003<br />
KTS-524 20 11½” 4½” 16” 6 5 ∕8” 22 KTS-003<br />
KTS-525 20 17½” 9½” 27” 7¾” 35 KTS-005<br />
KTS-526 24 11¾” 3¼” 15” 7¼” 31 KTS-005<br />
KTS-527 24 15¾” 6½” 22¼” 7 7 ∕8” 40 KTS-005<br />
KTS-528 24 21¾” 12” 33¼” 9¼” 56 KTS-005<br />
DIE SAEETY BLOCKS | 7
Mach<strong>in</strong>e<br />
<strong>Safeguard<strong>in</strong>g</strong><br />
Sem<strong>in</strong>ars<br />
www.rockfordsystems.com
Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong> Sem<strong>in</strong>ars gives a<br />
complete overview of our 2 1/2-day mach<strong>in</strong>e<br />
safeguard<strong>in</strong>g sem<strong>in</strong>ar.<br />
We have been educat<strong>in</strong>g <strong>in</strong>dividuals on<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g s<strong>in</strong>ce the company was<br />
started. Sem<strong>in</strong>ars take place at our tra<strong>in</strong><strong>in</strong>g<br />
center <strong>in</strong> <strong>Rockford</strong>, Ill<strong>in</strong>ois.<br />
This monthly sem<strong>in</strong>ar covers safeguard<strong>in</strong>g for<br />
fabricat<strong>in</strong>g mach<strong>in</strong>es, cutt<strong>in</strong>g mach<strong>in</strong>es, and<br />
large work envelopes.<br />
The sem<strong>in</strong>ar expla<strong>in</strong>s how to safeguard<br />
mach<strong>in</strong>es to meet OSHA and ANSI standards<br />
and best safety practices.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our<br />
sole focus for over 45 years. We stand<br />
committed to the prevention of <strong>in</strong>juries and<br />
fatalities. Our mission is to enhance the longterm<br />
health and quality of life of workers <strong>in</strong><br />
high-risk occupations, while improv<strong>in</strong>g the<br />
bottom l<strong>in</strong>e of the organizations we serve by<br />
<strong>in</strong>creas<strong>in</strong>g compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g<br />
costs and improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong>
Quotes from Past Participants<br />
—The sem<strong>in</strong>ar has a lot of <strong>in</strong>formation on the safety of<br />
presses. Any<strong>one</strong> with a press operation needs to attend<br />
—It was what I expected<br />
—very <strong>in</strong>formative<br />
—Instructors are very knowledgeable<br />
—I thoroughly enjoyed the sem<strong>in</strong>ar and picked up a lot of<br />
very valuable <strong>in</strong>formation<br />
—Excellent presentation<br />
—Best tra<strong>in</strong><strong>in</strong>g I’ve had <strong>in</strong> years<br />
—The hands-on experience was great<br />
—This sem<strong>in</strong>ar is, perhaps, the most comprehensive<br />
coverage that I have heard on this subject. The course<br />
is a “must” for any<strong>one</strong> <strong>in</strong>volved <strong>in</strong> mach<strong>in</strong>ery guard<strong>in</strong>g<br />
or operational set-up<br />
ROCKFORD SYSTEMS’ QUALIFICATIONS<br />
For many years <strong>Rockford</strong> <strong>Systems</strong> has been educat<strong>in</strong>g corporations throughout the world on<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g. Every year, hundreds of people attend these sem<strong>in</strong>ars. Participants<br />
come from a variety of areas <strong>in</strong>clud<strong>in</strong>g manufactur<strong>in</strong>g, distribution, aerospace, <strong>in</strong>surance,<br />
government, and consult<strong>in</strong>g. They <strong>in</strong>clude safety directors, plant managers, ma<strong>in</strong>tenance<br />
and eng<strong>in</strong>eer<strong>in</strong>g personnel, setup people, safety specialists, loss-control eng<strong>in</strong>eers, and<br />
safety consultants. Sem<strong>in</strong>ar <strong>in</strong>structors are very knowledgeable and have many years of<br />
experience <strong>in</strong> the mach<strong>in</strong>e tool <strong>in</strong>dustry.<br />
MACHINE SAFEGUARDING SEMINAR OVERVIEW<br />
Accord<strong>in</strong>g to safety standards, when a mach<strong>in</strong>e creates a hazard to operators and other<br />
employees <strong>in</strong> the mach<strong>in</strong>e area, it must be safeguarded. <strong>Rockford</strong> <strong>Systems</strong> offers a mach<strong>in</strong>e<br />
safeguard<strong>in</strong>g sem<strong>in</strong>ar to teach people <strong>in</strong> positions of responsibility how to safeguard the<br />
po<strong>in</strong>t of operation and other mach<strong>in</strong>e hazards to meet these safety standards.<br />
This 2½-day sem<strong>in</strong>ar expla<strong>in</strong>s how to <strong>in</strong>terpret the performance language of both OSHA<br />
(Occupational Safety and Health Adm<strong>in</strong>istration) and ANSI (American National Standards<br />
Institute) standards. Specific mach<strong>in</strong>e safeguard<strong>in</strong>g situations are also discussed. Another<br />
section of the mach<strong>in</strong>e safeguard<strong>in</strong>g sem<strong>in</strong>ar provides basic safeguard<strong>in</strong>g guidel<strong>in</strong>es for<br />
other metalwork<strong>in</strong>g mach<strong>in</strong>es us<strong>in</strong>g the ANSI B11-series safety standards.<br />
Sem<strong>in</strong>ars comb<strong>in</strong>e classroom discussion with demonstrations of mach<strong>in</strong>es under power.<br />
Hands-on experience with these mach<strong>in</strong>es and visual aids, <strong>in</strong>clud<strong>in</strong>g slides and videos, are<br />
also used. These teach<strong>in</strong>g methods enable the participants to <strong>in</strong>terpret the OSHA and ANSI<br />
standards as they relate to their specific mach<strong>in</strong>e applications and production requirements.<br />
DAY-TO-DAY OUTLINE OF SAFEGUARDING SEMINAR<br />
Day 1<br />
8:00 a.m. to 5:00 p.m.<br />
• Welcome, Introduction, and Objectives of Sem<strong>in</strong>ar<br />
• Brief History of ANSI, OSHA, and NFPA-79<br />
• Risk Reduction<br />
• OSHA 29 CFR 1910.211, Def<strong>in</strong>itions<br />
• OSHA 29 CFR 1910.212, General Requirements for<br />
All Mach<strong>in</strong>es and Auxiliary Equipment<br />
• OSHA 29 CFR 1910.217 Mechanical<br />
Power Presses<br />
• ANSI B11.1-2009 Mechanical Power Presses<br />
• Full-Revolution-Clutch Identification and<br />
Control Requirements<br />
• Part-Revolution-Clutch Identification and Control<br />
Requirements<br />
• Control Reliability and Brake Monitor<strong>in</strong>g<br />
• Electrical Comp<strong>one</strong>nt Requirements (NFPA-79)<br />
• Hand-Feed<strong>in</strong>g Tools<br />
• Po<strong>in</strong>t-Of-Operation <strong>Safeguard<strong>in</strong>g</strong>—Guards,<br />
Devices, Methods<br />
• Design, Construction, Sett<strong>in</strong>g, and Feed<strong>in</strong>g of Dies<br />
• Inspection and Ma<strong>in</strong>tenance Records<br />
• Instruction to Operators<br />
• Reports of Injuries<br />
• Mechanical Power-Transmission Apparatus<br />
(OSHA 1910.219)<br />
Day 2<br />
8:00 a.m. to 5:00 p.m.<br />
• ANSI B11.2 Hydraulic Power Presses<br />
• ANSI B11.3 Power Press Brakes<br />
• ANSI B11.4 Shears<br />
• ANSI B11.5 Iron Workers<br />
• ANSI B11.6 Lathes (Manu<strong>all</strong>y Operated)<br />
• ANSI B11.7 Cold Header and Cold Formers<br />
• ANSI B11.8 Drill<strong>in</strong>g, Mill<strong>in</strong>g, and Bor<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.9 Gr<strong>in</strong>d<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.10 Metal Saw<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.11 Gear Cutt<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.12 Roll Form<strong>in</strong>g and Roll<br />
Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.13 Automatic Screw/Bar and<br />
Chuck<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.14 Coil Slitt<strong>in</strong>g Mach<strong>in</strong>es/<strong>Systems</strong><br />
Withdrawn—See ANSI B11.18<br />
• ANSI B11.15 Pipe, Tube, and Shape<br />
Bend<strong>in</strong>g Mach<strong>in</strong>es<br />
• ANSI B11.16 Metal Powder Compact<strong>in</strong>g Presses<br />
• ANSI B11.17 Horizontal Hydraulic Extrusion Presses<br />
• ANSI B11.18 Coil Process<strong>in</strong>g <strong>Systems</strong><br />
• ANSI B11.19 <strong>Safeguard<strong>in</strong>g</strong> Methods (Criteria)<br />
• ANSI B11.20 Integrated Manufactur<strong>in</strong>g (Cells)<br />
• ANSI B11.21 Mach<strong>in</strong>e Tools Us<strong>in</strong>g<br />
Laser Process<strong>in</strong>g (Cutt<strong>in</strong>g)<br />
• ANSI B11.22 CNC Turn<strong>in</strong>g Centers and Lathes<br />
• ANSI B11.23 Mach<strong>in</strong><strong>in</strong>g Centers—CNC Mills,<br />
Drills, Bor<strong>in</strong>g<br />
• ANSI B11.24 Transfer Mach<strong>in</strong>es<br />
• ANSI/SPI B151.1 Horizontal<br />
(Plastic Injection Mold<strong>in</strong>g Mach<strong>in</strong>es)<br />
Day 2 (Cont<strong>in</strong>ued)<br />
• BS ISO 14137 and JIS B6360 Electrical<br />
Discharge (EDM) Mach<strong>in</strong>es<br />
• ANSI B152.1 Hydraulic Die<br />
Cast<strong>in</strong>g Presses<br />
• ANSI/RIA R15.06–1999 & 2012 Robots<br />
and Large Work Envelopes<br />
• OSHA 1910.147 Control of Hazardous<br />
Energy Lockout/Tagout<br />
Day 3<br />
8:00 a.m. to 10:00 a.m.<br />
• Mach<strong>in</strong>e Demonstrations<br />
SEMINAR MATERIALS<br />
Each person attend<strong>in</strong>g this sem<strong>in</strong>ar receives<br />
a variety of <strong>in</strong>formation regard<strong>in</strong>g mach<strong>in</strong>e<br />
safeguard<strong>in</strong>g which <strong>in</strong>cludes repr<strong>in</strong>ts of the<br />
follow<strong>in</strong>g:<br />
• OSHA 29 CFR 1910.211, 1910.212,<br />
1910.217, and 1910.219<br />
• Charts and graphs for future reference<br />
• <strong>Safeguard<strong>in</strong>g</strong> product catalogs<br />
• U.S. Department of Labor memorandums<br />
• Mechanical Power Press Safety<br />
Information Card<br />
• Safety Distance Guide Slide Chart<br />
• Fold<strong>in</strong>g, Acrylic Copolymer OSHA and ANSI<br />
Guard-Open<strong>in</strong>g Scales<br />
• Lam<strong>in</strong>ated function-test<strong>in</strong>g checklists<br />
for safeguards<br />
2 | MACHINE SAFEGUARDING SEMINARS
SEMINAR REGISTRATION FORM<br />
2 1 ⁄2-Day “Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong>” Sem<strong>in</strong>ar $995.00/person<br />
Registration for the dates of<br />
Company Name<br />
Address L<strong>in</strong>e 1<br />
Address L<strong>in</strong>e 2<br />
City State/Prov<strong>in</strong>ce/Region ZIP/Postal Code<br />
Ph<strong>one</strong> Ext. Fax<br />
E-Mail Address<br />
Registrants:<br />
Name Title/Position T-Shirt Size<br />
Name Title/Position T-Shirt Size<br />
Name Title/Position T-Shirt Size<br />
Name/Title of person mak<strong>in</strong>g registration<br />
Ph<strong>one</strong><br />
Payment Options—Fees are payable <strong>in</strong> advance us<strong>in</strong>g any of the follow<strong>in</strong>g forms of payment:<br />
Check enclosed payable to <strong>Rockford</strong> <strong>Systems</strong>, LLC Check amount<br />
Invoice company Purchase Order No.<br />
Bill<strong>in</strong>g Address:<br />
Br<strong>in</strong>g<strong>in</strong>g check to sem<strong>in</strong>ar.<br />
Attn:<br />
Br<strong>in</strong>g<strong>in</strong>g credit card to sem<strong>in</strong>ar. Charge to: American Express Visa MasterCard<br />
Card No.<br />
Exp. Date<br />
Cardholder’s Name<br />
Signature<br />
Enrollments are limited and are taken on a first-come, first-served basis.<br />
Maximum class size is 24 people. Please c<strong>all</strong>, mail, e-mail, or fax us to<br />
make your reservation.<br />
By Ph<strong>one</strong>: C<strong>all</strong> toll-free 1-800-922-7533<br />
By Mail: Complete and mail the above form to:<br />
Sem<strong>in</strong>ar Registrar<br />
<strong>Rockford</strong> <strong>Systems</strong>, LLC<br />
5795 Logistics Parkway<br />
<strong>Rockford</strong>, IL 61109<br />
By E-mail: Complete and send form at our Web site<br />
www.rockfordsystems.com<br />
By Fax: Send copy of completed form to: 815-874-7890<br />
Substitutions may be made at any time. Please notify sem<strong>in</strong>ar<br />
registrar with any changes.<br />
On-Site Custom Sem<strong>in</strong>ars: We can present a shorter version of<br />
this sem<strong>in</strong>ar at your company. Please c<strong>all</strong> us for details.<br />
MACHINE SAFEGUARDING SEMINARS | 3
<strong>Safeguard<strong>in</strong>g</strong><br />
Reference Sheets<br />
For Industrial Mach<strong>in</strong>es<br />
www.rockfordsystems.com<br />
4 | ROCKFORD SYSTEMS TURNKEY SOLUTIONS
<strong>Safeguard<strong>in</strong>g</strong> Reference Sheets outl<strong>in</strong>e required<br />
mach<strong>in</strong>e safeguard<strong>in</strong>g follow<strong>in</strong>g OSHA 1910<br />
standards and ANSI B-11 requirements on an<br />
<strong>in</strong>dividual mach<strong>in</strong>e basis: Gr<strong>in</strong>ders, Lathes,<br />
Press Brakes, Power Presses and Robots. Please<br />
enjoy these handy sheets for a comprehensive<br />
view of mach<strong>in</strong>e safeguard<strong>in</strong>g compliance.<br />
At <strong>Rockford</strong> <strong>Systems</strong>, we are experts at<br />
mach<strong>in</strong>e guard<strong>in</strong>g because it has been our sole<br />
focus for over 45 years. We stand committed<br />
to the prevention of <strong>in</strong>juries and fatalities. Our<br />
mission is to enhance the long-term health<br />
and quality of life of workers <strong>in</strong> high-risk<br />
occupations, while improv<strong>in</strong>g the bottom l<strong>in</strong>e<br />
of the organizations we serve by <strong>in</strong>creas<strong>in</strong>g<br />
compliance, reduc<strong>in</strong>g risk, lower<strong>in</strong>g costs and<br />
improv<strong>in</strong>g productivity.<br />
Industrial Mach<strong>in</strong>e Safety <strong>Solutions</strong>
DEMYSTIFYING DIE SAFETY BLOCKS<br />
Die safety blocks are c<strong>all</strong>ed by many names: safety blocks,<br />
ram blocks, die blocks or prop blocks. Regardless of the<br />
term, die safety blocks <strong>all</strong> have the same purpose: provide<br />
protection to any<strong>one</strong> work<strong>in</strong>g <strong>in</strong> the die area from a freef<strong>all</strong><strong>in</strong>g<br />
upper die/slide. This <strong>all</strong>-too-common accident<br />
happens <strong>in</strong> the event of a brake or counterbalance failure, broken pitman<br />
or adjust<strong>in</strong>g screw, or a sudden loss of hydraulic<br />
pressure on presses. While die safety blocks are<br />
on the surface simple devices, there are many<br />
factors to consider <strong>in</strong> choos<strong>in</strong>g what type of to<br />
use, as well as how many to use or where to put<br />
them. As a result many organizations struggle<br />
with this topic.<br />
OSHA REGULATIONS<br />
Die safety blocks are required by OSHA CFR 29, Subpart O, 1910.217<br />
(d)(9)(iv) Mechanical Power Presses which states, “The employer sh<strong>all</strong><br />
provide and enforce the use of safety blocks for use whenever dies are<br />
be<strong>in</strong>g adjusted or repaired <strong>in</strong> the press.” OSHA does not require the use<br />
of safety blocks dur<strong>in</strong>g die sett<strong>in</strong>g; however, companies may <strong>in</strong>clude them<br />
dur<strong>in</strong>g die sett<strong>in</strong>g procedures as a best safety practice. Proper use of<br />
die safety blocks also satisfies OSHA’s lockout/tagout requirements for<br />
controll<strong>in</strong>g mechanical energy.<br />
Anytime an employee needs to put their hands <strong>in</strong><br />
the die area of a press or is required to work on<br />
the die, they must follow OSHA regulations without<br />
exception. At no time should the employee make<br />
any adjustments or service with<strong>in</strong> the die space<br />
area without tak<strong>in</strong>g proper protection measures that<br />
meet OSHA and ANSI requirements. Regardless of<br />
how time-consum<strong>in</strong>g, the company is responsible—<br />
and liable—for these procedures <strong>in</strong> a press shop.<br />
With the press motor off and the flywheel at rest (for mechanical<br />
presses), safety blocks are placed between the die punch and holder<br />
with the mach<strong>in</strong>e stroke up. The number of safety blocks is determ<strong>in</strong>ed<br />
by the size of the press bed and the weight the blocks must support. On<br />
larger presses, the total slide weight must then be distributed among the<br />
quantity of safety blocks required. In some applications, as many as four<br />
safety blocks may be required.<br />
The ram is usu<strong>all</strong>y adjustable; therefore, wedges or the adjustable screw<br />
device is offered to provide a proper fit. If the die takes up most of the<br />
space on the die set, it may be difficult to f<strong>in</strong>d a place to <strong>in</strong>sert the block.<br />
To avoid accident<strong>all</strong>y strok<strong>in</strong>g the press or leav<strong>in</strong>g the safety block <strong>in</strong> the<br />
die after use, an electrical power cut-off <strong>in</strong>terlock system should be used.<br />
Accord<strong>in</strong>g to ANSI B11.19-2003, safety blocks “sh<strong>all</strong> be <strong>in</strong>terlocked with<br />
the mach<strong>in</strong>e to prevent actuation of hazardous motion of the mach<strong>in</strong>e.”<br />
The electrical <strong>in</strong>terlock system for die safety blocks must be<br />
<strong>in</strong>terfaced <strong>in</strong>to the control system so that when the plug is pulled,<br />
the power to the ma<strong>in</strong> drive motor and control is disconnected. If<br />
2 | QUICK REFERENCE SHEETS<br />
GOT DIE SAFETY BLOCKS?<br />
the mach<strong>in</strong>e has a mechanical energy source, such as a flywheel, it must<br />
come to rest before the die block can be <strong>in</strong>serted.<br />
DIE SAFETY BLOCK CALCULATIONS<br />
Three factors need to be determ<strong>in</strong>ed to guide your selection of safety<br />
blocks: static load, block length and block size.<br />
1. Determ<strong>in</strong>e Static Load<br />
The actual static load that the die safety block(s) will support is determ<strong>in</strong>ed<br />
by add<strong>in</strong>g the actual weights of the press slide and slide comp<strong>one</strong>nts<br />
(ram-adjustment assembly, connection rod[s] or pitman arm[s], and the<br />
upper die).<br />
If this weight cannot be determ<strong>in</strong>ed, an approximate static load can<br />
be calculated us<strong>in</strong>g the formula below. Allow 2000 pounds of static load<br />
for each cubic foot displaced <strong>in</strong> the press bed area (front to back x right<br />
to left) multiplied by the shut height (die space) of the press. Note: When<br />
us<strong>in</strong>g this formula, the calculated approximated static load has a safety<br />
factor of two (2).<br />
Allow 2000 pounds of static load for each cubic foot displaced <strong>in</strong> the<br />
press bed area (front to back x right to left) multiplied by the shut height<br />
(die space) of the press. Note: When us<strong>in</strong>g this formula, the calculated<br />
approximated static load has a safety factor of two (2).<br />
Static Load Formula:<br />
1<br />
1 S.U.A.U. - Stroke Up - Adjustment Up<br />
2 S.U.A.D. - Stroke Up - Adjustment Down<br />
3 S.D.A.U. - Stroke Down - Adjustment Up<br />
SHUT HEIGHT<br />
4 S.D.A.D. - Stroke Down - Adjustment Down<br />
• (Press Bed Area (sq <strong>in</strong>) x Shut Height (<strong>in</strong>))/(Cubic Inches/Cubic<br />
Feet (1728 cu <strong>in</strong>/cu ft constant))<br />
• Cubic feet displaced x 2000 lb/cubic foot = Total Static Load<br />
Example:<br />
• Press Bed Area = 48 <strong>in</strong> x 96 <strong>in</strong><br />
• Shut Height = 24 <strong>in</strong><br />
• (48 x 96 x 24)/1728 or 110,592/1728 = 64 cu ft<br />
• 64 cubic feet displaced x 2000 lb/cu ft = 128,000 Total Cubic<br />
Static Load<br />
2. Determ<strong>in</strong>e Block Length<br />
A Slide Adjustment<br />
B Mach<strong>in</strong>e Stroke<br />
2<br />
With the mach<strong>in</strong>e at the top of its stroke; stroke up—adjustment up<br />
(S.U.A.U.), measure the space between the upper and lower die set<br />
plates (not the distance between the bolster and slide). This gives the<br />
maximum safety block length.<br />
A<br />
3<br />
B<br />
4<br />
A<br />
Die<br />
Safety<br />
Block<br />
Location<br />
SLIDE<br />
PUNCH<br />
HOLDER<br />
BOLSTER<br />
BED<br />
DIE<br />
SET<br />
OBI<br />
PRESS<br />
FRAME
GET SAFEGUARDING!<br />
To determ<strong>in</strong>e the stroke up—adjustment down (S.U.A.D. measurement,<br />
subtract the ram adjustment from the S.U.A.U. figure. This provides the<br />
m<strong>in</strong>imum length of the die safety block.<br />
Total Length of Die Safety Block Required ___________”<br />
EXCEPTIONS:<br />
1. If wedges will be used, subtract 11/2” maximum. This is an <strong>all</strong>owance<br />
for variation <strong>in</strong> the stopp<strong>in</strong>g po<strong>in</strong>t of the crankshaft or adjustment of<br />
the ram.<br />
Total Length of Die Safety Block Required ____________”<br />
1. When an adjustable screw is added to an octagonal safety block,<br />
the m<strong>in</strong>imum length of the alum<strong>in</strong>um portion of the safety block is<br />
as follows:<br />
When an adjustable screw device is added to an octagonal safety block<br />
and the screw is <strong>all</strong> the way <strong>in</strong>side of the safety block, it will add 2” to<br />
the over<strong>all</strong> length of sm<strong>all</strong> and medium safety blocks and 21/2” to the<br />
over<strong>all</strong> length of large safety blocks. Therefore, subtract 2” for sm<strong>all</strong> or<br />
medium blocks and 21/2” for large blocks to determ<strong>in</strong>e the length of the<br />
alum<strong>in</strong>um portion of the die block.<br />
Example:<br />
• If the m<strong>in</strong>imum over<strong>all</strong> length of the sm<strong>all</strong> or medium safety block<br />
required is 101/2” with any size adjustable screw device, the<br />
alum<strong>in</strong>um portion of the safety block would be 81/2” (101/2” –<br />
2”= 81/2”).<br />
Example:<br />
• If the m<strong>in</strong>imum over<strong>all</strong> length of the large safety block required is<br />
16” with any size adjustable screw device, the alum<strong>in</strong>um portion<br />
of the safety block would be 131/2” (16” – 21/2”=<br />
131/2”).<br />
Total Length of the Alum<strong>in</strong>um Portion of the Die Safety Block<br />
___________”<br />
3. Determ<strong>in</strong>e Block Size<br />
The size of the die safety block (sm<strong>all</strong>, medium, large) is determ<strong>in</strong>ed by<br />
<strong>one</strong> or both of the follow<strong>in</strong>g factors:<br />
1. The size of the block itself and the area available <strong>in</strong> the die.<br />
2. The static load capacity of the block (sm<strong>all</strong>, medium, large) versus<br />
the total static load be<strong>in</strong>g supported.<br />
ROCKFORD SYSTEMS CAN HELP<br />
<strong>Rockford</strong> <strong>Systems</strong> offers a variety of die safety<br />
blocks, electrical <strong>in</strong>terlock systems, accessories<br />
and operator safety resources. Our l<strong>in</strong>e of highstrength,<br />
alum<strong>in</strong>um wedge die safety blocks that are<br />
lightweight and come <strong>in</strong> several shapes (x-shape,<br />
u-shape, octagon shape) and sizes (sm<strong>all</strong>, medium,<br />
large) to meet every press application. The unique Wedge Safety Blocks<br />
shape and mechanical properties of the 6063-T5 alum<strong>in</strong>um have been<br />
calculated accord<strong>in</strong>g to str<strong>in</strong>gent structural alum<strong>in</strong>um design analysis<br />
standards to provide high strength. Blocks are sold <strong>in</strong> standard 9’ lengths<br />
or can be cut to any size.<br />
<strong>Rockford</strong> <strong>Systems</strong> also offers adjustable die safety blocks. These<br />
adjustable die safety blocks feature a tough m<strong>all</strong>eable-iron bell-bottom<br />
base. The blocks also have a convenient handle for lift<strong>in</strong>g and precisioncut<br />
acme threads for easy adjustment and extra rigidity. The adjust<strong>in</strong>g<br />
screw can be easily adjusted up or down by hand. Turn<strong>in</strong>g holes are also<br />
provided <strong>in</strong> the screw neck to faciliDie Block-Octagon Static Loadtate the<br />
use of a turn<strong>in</strong>g bar, if required.<br />
All <strong>Rockford</strong> <strong>Systems</strong> static load charts, (see example below) are found<br />
on www.rockfordsystems.com on die block product pages.<br />
Die Block Electrical<br />
Interlock System<br />
Unlike most competitors, <strong>Rockford</strong> <strong>Systems</strong> offers<br />
electric<strong>all</strong>y <strong>in</strong>terlocked systems. The <strong>in</strong>terlock system<br />
is available <strong>in</strong> a yellow plug with <strong>one</strong> contact (KTS518)<br />
or an orange plug with two contacts (KTS533). The<br />
electrical <strong>in</strong>terlock system for die safety blocks<br />
<strong>in</strong>cludes the plug, a 24-<strong>in</strong>ch long cha<strong>in</strong>, a receptacle,<br />
and an electrical mount<strong>in</strong>g box.<br />
Additional die block accessories available from <strong>Rockford</strong> <strong>Systems</strong><br />
<strong>in</strong>clude lift<strong>in</strong>g handles, holders and bases. Our octagon shape safety<br />
block comes with an optional heavy-duty steel, adjustable screw device<br />
to prevent any space between the block and die when various dies are<br />
used or when the slide is adjusted.<br />
DANGER SIGN FOR DIE SAFETY BLOCKS<br />
Don’t forget to post the appropriate danger signs near <strong>all</strong> mach<strong>in</strong>ery <strong>in</strong><br />
the plant. The purpose of danger signs is to warn personnel of the danger<br />
of bodily <strong>in</strong>jury or death. The suggested procedure for mount<strong>in</strong>g this sign<br />
is as follows:<br />
1. Sign must be clearly visible to the operator and other personnel<br />
2. Sign must be at or near eye level<br />
3. Sign must be PERMANENTLY fastened with bolts or rivets<br />
Please c<strong>all</strong> 1-800-922-7533 or visit www.rockfordsystems.com for<br />
more <strong>in</strong>formation.<br />
QUICK REFERENCE SHEETS | 3
GOT GUARD OPENING SCALES? GET SAFEGUARDING!<br />
HOW TO USE A GUARD OPENING SCALE<br />
Po<strong>in</strong>t-of-operation barrier guards are<br />
essential safeguard<strong>in</strong>g equipment for<br />
hazardous <strong>in</strong>dustrial processes and<br />
mach<strong>in</strong>ery such as presses, pumps,<br />
motors and drills. When properly<br />
<strong>in</strong>st<strong>all</strong>ed the barriers prevent a person from plac<strong>in</strong>g any part of their body<br />
<strong>in</strong>to the po<strong>in</strong>t of operation by reach<strong>in</strong>g through, over, under or around the<br />
guards to access a hazard. However, because barrier guards are typic<strong>all</strong>y<br />
constructed out of materials such as wire mesh, expanded metal, rods,<br />
or hairp<strong>in</strong>s, most have open<strong>in</strong>gs that present the potential for <strong>in</strong>juries if<br />
a person reached through them. As a result, whether the guard is fixed,<br />
adjustable, movable, or <strong>in</strong>terlocked, any open<strong>in</strong>gs must be measured for<br />
compliance with Table O-10 of OSHA 29 CFR 1910.217 (Mechanical<br />
Power Presses), current ANSI/CSA standards, or International<br />
standard ISO 13857 to determ<strong>in</strong>e the safe distance from the hazard.<br />
The critical role of measur<strong>in</strong>g barrier open<strong>in</strong>gs f<strong>all</strong>s on a simple but often<br />
misunderstood tool: the Guard Open<strong>in</strong>g Scale. Also known as “gotcha<br />
sticks,” Guard Open<strong>in</strong>g Scales mimic the human hand and forearm. Over<br />
the past 70 years they’ve proven to be the most accurate means of<br />
ensur<strong>in</strong>g any open<strong>in</strong>g <strong>in</strong> a barrier guard will not <strong>all</strong>ow a hazardous<br />
z<strong>one</strong> to be accessed.<br />
HISTORY OF THE GUARD OPENING SCALE<br />
The history of the Guard Open<strong>in</strong>g Scale dates back to 1948. It was then<br />
that Liberty Mutual Insurance, jo<strong>in</strong>ed with the Writ<strong>in</strong>g Committee for the<br />
ANSI B11.1 Safety Standard on Mechanical Power Presses, eng<strong>in</strong>eered a<br />
stair-step shaped measurement tool to determ<strong>in</strong>e guard-open<strong>in</strong>g size vs.<br />
guard distance to the nearest Po<strong>in</strong>t of Operation hazard. A rash of <strong>in</strong>juries<br />
to mechanical power press operators who reached through barriers and<br />
suffered lacerations, amputations and crushed limbs prompted Liberty<br />
Mutual’s actions. Although Guard Open<strong>in</strong>g Scales were first designed for<br />
po<strong>in</strong>t of operation guards on mechanical power presses, they are now often<br />
used on other mach<strong>in</strong>es as well.<br />
Orig<strong>in</strong><strong>all</strong>y, the recommended dimensions used for the scale were based<br />
upon “average-size hands,” which at the time were a woman’s size 6<br />
glove. ANSI <strong>in</strong>corporated these dimensions from Liberty Mutual <strong>in</strong>to its<br />
1971 revision of the ANSI B11.1 safety standard for mechanical power<br />
presses. In 1995, however, a study entitled “A Review of Mach<strong>in</strong>e-<br />
Guard<strong>in</strong>g Recommendations” was conducted by Donald Vaillancourt and<br />
Stover Snook of Liberty Mutual Research to establish whether the 1948<br />
draw<strong>in</strong>gs were consistent with current hand size data, <strong>in</strong> particular as the<br />
data relates to women and m<strong>in</strong>orities who have become more prevalent<br />
<strong>in</strong> manufactur<strong>in</strong>g. Vaillancourt and Snook suggested several important<br />
4 | QUICK REFERENCE SHEETS<br />
modifications <strong>in</strong>clud<strong>in</strong>g mov<strong>in</strong>g the glove size from a woman’s size 6 to<br />
a size 4. Draw<strong>in</strong>gs from the study have been adopted <strong>in</strong> several current<br />
ANSI B11-series safety standards for mach<strong>in</strong>e tools as well as <strong>in</strong> the ANSI/<br />
zz R15.06 safety standard for <strong>in</strong>dustrial robots and robot systems. OSHA <strong>in</strong><br />
Table O-10 of OSHA 29 CFR 1910.217 did not, on the other hand, offici<strong>all</strong>y<br />
adopt the draw<strong>in</strong>gs.<br />
OSHA VS. ANSI GUARD OPENING SCALES<br />
OSHA Compliance Officers are usu<strong>all</strong>y limited to us<strong>in</strong>g OSHA’s own scale,<br />
which is referenced by CFR 1910.217, Table 0-10. The ANSI scale is more<br />
likely to be used by Insurance Loss Control Eng<strong>in</strong>eers <strong>in</strong> manufactur<strong>in</strong>g<br />
plants where sm<strong>all</strong>er hand sizes tend to dom<strong>in</strong>ate the employee population.<br />
Let’s look at the differences <strong>in</strong> the two designs:<br />
Note that the OSHA scale locks on the 3rd<br />
stair-step on the entrance side, and that<br />
the tip of the scale does not reach the die,<br />
mean<strong>in</strong>g the test is “passed” for that open<strong>in</strong>g<br />
size at that distance away. Also note that the ANSI scale locks on the last<br />
stair-step on the entrance side, and that the tip of the scale goes past the<br />
die, mean<strong>in</strong>g that the test is “failed” for that open<strong>in</strong>g size at that distance<br />
away. That problem can be fixed <strong>in</strong> <strong>one</strong> of two ways; move the guard a little<br />
further away from the die, or make the adjustable guard open<strong>in</strong>g a little<br />
sm<strong>all</strong>er, or some comb<strong>in</strong>ation of those two.<br />
USING A GUARD OPENING SCALE<br />
Double-h<strong>in</strong>ged design to<br />
<strong>all</strong>ow fold<strong>in</strong>g <strong>in</strong>to thirds<br />
A Guard Open<strong>in</strong>g Scale is a two-dimensional representative of an average<br />
sized f<strong>in</strong>ger, hand and arm. Of course, the human body is not twodimensional<br />
but three-dimensional, thus mak<strong>in</strong>g its correct use critic<strong>all</strong>y<br />
important. Follow these simple <strong>in</strong>structions for proper measurements.<br />
First, place the scaled side perpendicular to the sm<strong>all</strong>est dimension<br />
<strong>in</strong> a hole <strong>in</strong> the barrier guard material and attempt to <strong>in</strong>sert it towards<br />
the hazard. If properly designed, the barrier guard will stop the tip from<br />
access<strong>in</strong>g the hazard area. When multiple open<strong>in</strong>gs of various sizes exist<br />
<strong>in</strong> a barrier guard, each must be tested with the tool. The maximum<br />
guard open<strong>in</strong>g that OSHA <strong>all</strong>ows is a 6-<strong>in</strong>ch open<strong>in</strong>g at 31.5 <strong>in</strong>ches<br />
away. For most people that’s armpit to f<strong>in</strong>gertip. Also, the open<strong>in</strong>gs<br />
should always be measured empty, not with any material <strong>in</strong> place. This<br />
is based on the logic that personnel may put a hand through the guard<br />
open<strong>in</strong>g without material tak<strong>in</strong>g up a portion of the space. Remember<br />
that Safety Inspectors won’t cut a plant operator any slack because the<br />
guard happens to be adjustable. Adjustable guard open<strong>in</strong>gs must be<br />
measured the same as fixed guard open<strong>in</strong>gs.<br />
Guard Open<strong>in</strong>g Scale Comparison<br />
Please c<strong>all</strong> 1-800-922-7533 or visit rockfordsystems.com<br />
for more <strong>in</strong>formation.
GOT LATHES? GET SAFEGUARDING!<br />
SAFEGUARDING LATHES<br />
Lathes are often overlooked when Risk Assessments are conducted<br />
to determ<strong>in</strong>e appropriate “Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong>.” OSHA regulations<br />
consider lathes to be a 1910.212 mach<strong>in</strong>e, say<strong>in</strong>g to the employer,<br />
“One or more methods of mach<strong>in</strong>e guard<strong>in</strong>g sh<strong>all</strong> be provided to protect<br />
the operator and other employees <strong>in</strong> the mach<strong>in</strong>e area from hazards<br />
such as those created by po<strong>in</strong>t of operation, <strong>in</strong>go<strong>in</strong>g nip po<strong>in</strong>ts, rotat<strong>in</strong>g<br />
parts, fly<strong>in</strong>g chips, and sparks” … but 1910.212 requirements are<br />
vague because they cover such a wide variety of mach<strong>in</strong>ery. Therefore, a<br />
reference to someth<strong>in</strong>g more detailed, like ANSI B11.6 on metalwork<strong>in</strong>g<br />
lathes, is required for specific safeguard<strong>in</strong>g alternatives.<br />
From a practical standpo<strong>in</strong>t, the rotat<strong>in</strong>g chuck (work-holder) cannot be<br />
fully enclosed, unlike gears, sprockets, or cha<strong>in</strong>s which can and usu<strong>all</strong>y<br />
are completely covered, often by the mach<strong>in</strong>e’s manufacturer. However,<br />
that same lathe manufacturer may provide no safeguard<strong>in</strong>g at or near<br />
the po<strong>in</strong>t of operation.<br />
H<strong>in</strong>ged chuck-shields are <strong>one</strong> of the<br />
most common methods to protect<br />
lathe operators from the rotat<strong>in</strong>g workholder.<br />
Their purpose is to prevent an<br />
operator from <strong>in</strong>advertently com<strong>in</strong>g <strong>in</strong><br />
contact with the chuck, which often<br />
results <strong>in</strong> entanglement with it, result<strong>in</strong>g<br />
<strong>in</strong> serious <strong>in</strong>jury or even death. Chuck<br />
Chuck-Shields<br />
shields are commerci<strong>all</strong>y available<br />
from numerous providers. They may be<br />
constructed of metal, polycarbonate, or<br />
some comb<strong>in</strong>ation of materials. When<br />
not <strong>in</strong> use, they need to be swung up<br />
out of the way, so most are h<strong>in</strong>ged.<br />
Although U.S. Safety Standards and Regulations do not require chuckshields<br />
to be electric<strong>all</strong>y <strong>in</strong>terlocked, some European manufacturers offer<br />
that feature. With electric<strong>all</strong>y <strong>in</strong>terlocked shields, when the lathe chuck<br />
shield is lifted up, the positive contacts on the microswitch open, send<strong>in</strong>g<br />
a stop signal to the mach<strong>in</strong>e control. The mach<strong>in</strong>e will not start up aga<strong>in</strong><br />
until the emergency stop button has been reset.<br />
Another type of protection commonly<br />
used on lathes is a chip/coolant<br />
shield. These are often useful when<br />
the operator’s personal protective<br />
equipment (PPE) does not adequately<br />
control the waste product com<strong>in</strong>g<br />
off of the cutt<strong>in</strong>g tool. If chips strike<br />
the operator <strong>in</strong> the upper body or Chip/Coolant Shield<br />
accumulate on the floor creat<strong>in</strong>g a slip-trip hazard, a chip/coolant shield<br />
is often suggested to supplement the operator’s PPE. OSHA’s 1910.219<br />
addresses the need to cover rotat<strong>in</strong>g comp<strong>one</strong>nts to prevent the operator’s<br />
hair and cloth<strong>in</strong>g from gett<strong>in</strong>g entangled, dragg<strong>in</strong>g them <strong>in</strong>to the mach<strong>in</strong>e.<br />
These rotat<strong>in</strong>g comp<strong>one</strong>nts <strong>in</strong>clude the lead screw, feed rod, traverse rod,<br />
and camshaft, <strong>in</strong> the lower front portion of the lathe.<br />
In April 2011, a lathe’s horizontal rotat<strong>in</strong>g comp<strong>one</strong>nts took the life of<br />
a 22-year old female student at Yale University’s Sterl<strong>in</strong>g Chemistry<br />
Laboratory. While work<strong>in</strong>g very late at night by herself, her hair became<br />
entangled <strong>in</strong> that part of the mach<strong>in</strong>e, result<strong>in</strong>g <strong>in</strong> asphyxiation. (Google;<br />
Yale Lathe Fatality)<br />
Telescopic metal sleeves are available to cover a lathe’s horizontal<br />
rotat<strong>in</strong>g comp<strong>one</strong>nts, although many manufactur<strong>in</strong>g companies elect<br />
not to use them. Accord<strong>in</strong>g to feedback from OSHA Compliance Officers<br />
and Insurance Loss Control Inspectors, <strong>one</strong> of the most common<br />
lathe accidents results from the misuse of the standard chuck wrench<br />
furnished by the lathe manufacturer.<br />
When the lathe is not be<strong>in</strong>g used, a<br />
typical (unsafe) storage place for the<br />
chuck-wrench is <strong>in</strong> the chuck. At some<br />
po<strong>in</strong>t <strong>in</strong> time, the operator turns the lathe<br />
on without check<strong>in</strong>g to see where the<br />
chuck wrench is located, which sends it<br />
fly<strong>in</strong>g. This has caused serious accidents,<br />
<strong>in</strong>clud<strong>in</strong>g the loss of eyes. Spr<strong>in</strong>g-loaded, Self-Eject<strong>in</strong>g Chuck Wrench<br />
self-eject<strong>in</strong>g chuck wrenches are a solution to this problem because they<br />
won’t stay <strong>in</strong> the chuck by themselves. They are available <strong>in</strong> a number<br />
of sizes.<br />
Many older lathes also need updates to br<strong>in</strong>g them up to code with<br />
electrical standards like NFPA 79. The two most common updates are<br />
for: 1) magnetic motor-starters to provide dropout protection, (a.k.a. antirestart),<br />
and 2) ma<strong>in</strong> power disconnects that lock only <strong>in</strong> the OFF position.<br />
As with any mach<strong>in</strong>e, provision for Lockout/Tagout is always important.<br />
Danger and Warn<strong>in</strong>g signs, depict<strong>in</strong>g specific hazards on lathes are also<br />
available.<br />
To see these and other lathe safeguard<strong>in</strong>g products, please c<strong>all</strong><br />
1-800-922-7533 or visit our website.<br />
QUICK REFERENCE SHEETS | 5
SAFEGUARDING STANDARDS FOR BENCH<br />
AND PEDESTAL GRINDERS<br />
Gr<strong>in</strong>ders are <strong>one</strong> of the most frequently<br />
cited mach<strong>in</strong>es dur<strong>in</strong>g OSHA mach<strong>in</strong>esafety<br />
<strong>in</strong>spections. This is frequently<br />
due to improperly adjusted work rests<br />
and tongue guards on bench/pedestal<br />
gr<strong>in</strong>ders, as well as a lack of r<strong>in</strong>g test<strong>in</strong>g<br />
for the gr<strong>in</strong>d<strong>in</strong>g wheels.<br />
OSHA 29 CFR SubPart O 1910.215 is a “mach<strong>in</strong>e specific” (vertical)<br />
regulation with a number of requirements, which if left unchecked, are<br />
often cited by OSHA as violations. ANSI B11.9-2010 (Gr<strong>in</strong>ders) and ANSI<br />
B7.1 2000 (Abrasive Wheels) also apply.<br />
WORK RESTS AND TONGUE GUARDS<br />
OSHA specifies that work rests must be kept adjusted to with<strong>in</strong> 1/8-<br />
<strong>in</strong>ch of the wheel, to prevent the workpiece from be<strong>in</strong>g jammed between<br />
the wheel and the rest, result<strong>in</strong>g <strong>in</strong> potential wheel breakage. Because<br />
gr<strong>in</strong>ders run at such a high RPM, wheels actu<strong>all</strong>y explode when they<br />
break, caus<strong>in</strong>g very serious <strong>in</strong>jury, like bl<strong>in</strong>dness and even death.<br />
In addition, the distance between the gr<strong>in</strong>d<strong>in</strong>g wheel and the adjustable<br />
tongue guard (also known as a “spark arrestor”) must never exceed 1/4-<br />
<strong>in</strong>ch. Because the wheel wears down dur<strong>in</strong>g use, both these dimensions<br />
must be regularly checked/adjusted.<br />
“Gr<strong>in</strong>der safety gauges” can be used dur<strong>in</strong>g the <strong>in</strong>st<strong>all</strong>ation, ma<strong>in</strong>tenance,<br />
and <strong>in</strong>spection of bench/pedestal gr<strong>in</strong>ders to make sure the work rests<br />
and tongue guards comply with OSHA’s 1910.215 regulation and ANSI<br />
standards. Wait until the wheel has completely stopped and the Gr<strong>in</strong>der<br />
is properly “Locked Out” before us<strong>in</strong>g a “gr<strong>in</strong>der safety gauge”. Gr<strong>in</strong>der<br />
coast-down time takes several m<strong>in</strong>utes, which tempts employees to use<br />
the “gr<strong>in</strong>der safety gauge” while the wheel is still rotat<strong>in</strong>g. This practice<br />
is very dangerous because it can cause wheel breakage.<br />
Where gr<strong>in</strong>ders are concerned, personal protective equipment (PPE)<br />
usu<strong>all</strong>y means a full face-shield, not just safety glasses. You cannot be too<br />
careful with a mach<strong>in</strong>e that operates at several thousand RPM.<br />
GOT GRINDERS?<br />
RING TESTING<br />
OSHA says that you must “r<strong>in</strong>g test” gr<strong>in</strong>d<strong>in</strong>g<br />
wheels before mount<strong>in</strong>g them to prevent the<br />
<strong>in</strong>advertent mount<strong>in</strong>g of a cracked gr<strong>in</strong>d<strong>in</strong>g wheel.<br />
R<strong>in</strong>g test<strong>in</strong>g <strong>in</strong>volves suspend<strong>in</strong>g the gr<strong>in</strong>d<strong>in</strong>g<br />
wheel by its center hole, then tapp<strong>in</strong>g the side<br />
R<strong>in</strong>g Test<strong>in</strong>g<br />
of the wheel with a non-met<strong>all</strong>ic object. This<br />
should produce a bell t<strong>one</strong> if the wheel is <strong>in</strong>tact. A thud, or a crackedplate<br />
sound <strong>in</strong>dicates a cracked wheel. NEVER mount a cracked wheel.<br />
For larger gr<strong>in</strong>ders, gr<strong>in</strong>d<strong>in</strong>g wheels are laid flat on a vibration-table, with<br />
sand evenly spread over the wheel. If the wheel is cracked, the sand<br />
moves away from the crack.<br />
To prevent crack<strong>in</strong>g a wheel dur<strong>in</strong>g the mount<strong>in</strong>g procedure, employees<br />
must be very carefully tra<strong>in</strong>ed <strong>in</strong> those procedures. This starts with<br />
mak<strong>in</strong>g sure the wheel is properly matched to that particular gr<strong>in</strong>der,<br />
us<strong>in</strong>g proper blotters and spacers, and know<strong>in</strong>g exactly how much<br />
pressure to exert with a torque-wrench, just to mention a few th<strong>in</strong>gs.<br />
This OSHA-compliant “Wheel-Cover” <strong>all</strong>ows no more than 90 degrees<br />
(total) of the wheel left exposed. (65<br />
degrees from horizontal plane to the top of<br />
wheel-cover). Never exceed these wheelcover<br />
maximum open<strong>in</strong>g dimensions.<br />
Larger wheel-cover open<strong>in</strong>gs create a<br />
wider pattern of fly<strong>in</strong>g debris should the<br />
wheel explode. A well-recognized safety<br />
precaution on bench/pedestal gr<strong>in</strong>ders is<br />
to stand well off to the side of the wheel<br />
Wheel Cover<br />
for the first full m<strong>in</strong>ute before us<strong>in</strong>g the mach<strong>in</strong>e. Accidents have shown<br />
that gr<strong>in</strong>d<strong>in</strong>g wheels are most likely to shatter/explode dur<strong>in</strong>g that first<br />
m<strong>in</strong>ute.<br />
There is an OSHA Instruction Standard #STD 1-12.8 October 30, 1978<br />
address<strong>in</strong>g the conditional and temporary removal of the “Work Rest”<br />
for use only with larger piece parts based on the condition that “Side<br />
Guards” are provided.<br />
Gr<strong>in</strong>der Gauge 1/8 Work Rest Gr<strong>in</strong>der Gauge 1/4 Tongue Guard<br />
Remember, you must DOCUMENT any and <strong>all</strong> safety requirements set<br />
forth by OSHA, as that is their best evidence that safety procedures are<br />
re<strong>all</strong>y be<strong>in</strong>g followed.<br />
6 | QUICK REFERENCE SHEETS
This sign does not cover <strong>all</strong> dangers<br />
Do not remove or cover this sign—See back for mount<strong>in</strong>g<br />
BENCH GRINDER SAFETY GAUGE<br />
The bench gr<strong>in</strong>der safety gauge is laser-cut,<br />
Grade 5052 alum<strong>in</strong>um with H32 hardness.<br />
The safety yellow, durable powder-coated<br />
gauge has silk-screened text and graphics.<br />
The bench gr<strong>in</strong>der safety gauge measures<br />
2 3/4-<strong>in</strong>ches wide by 2 1/4-<strong>in</strong>ches high by<br />
.1000-<strong>in</strong>ches thick and has a 1/4-<strong>in</strong>ch hole<br />
for attachment to the bench gr<strong>in</strong>der.<br />
STANDARD MOUNT GRINDER SHIELDS<br />
These standard mount gr<strong>in</strong>der shields are available <strong>in</strong> various sizes for<br />
protection from the swarf of bench or pedestal gr<strong>in</strong>ders. The frames<br />
are constructed of re<strong>in</strong>forced fiber nylon or heavy cast alum<strong>in</strong>um. Each<br />
shield is furnished with a threaded support rod. The transparent portion<br />
of the standard mount gr<strong>in</strong>der shields is made of high-impact resistant<br />
polycarbonate to m<strong>in</strong>imize scratch<strong>in</strong>g and provide durability.<br />
DOUBLE-WHEEL AND SINGLE-WHEEL<br />
BENCH GRINDER SHIELDS<br />
Double-wheel bench gr<strong>in</strong>der shields<br />
provide protection for both wheels of the<br />
gr<strong>in</strong>der with <strong>one</strong> cont<strong>in</strong>uous shield. The<br />
durable shield is made of clear, 3/16-<strong>in</strong>chthick<br />
polycarbonate and measures 18-<br />
<strong>in</strong>ch x 6-<strong>in</strong>ch. A special shield bracket<br />
adds stability to the top of the shield. The<br />
s<strong>in</strong>gle-wheel bench gr<strong>in</strong>der shield is made<br />
Gr<strong>in</strong>der Safety Gauge<br />
Direct-Mount or Magnetic-Mount<br />
Bench Gr<strong>in</strong>der Shields<br />
with Flexible Arms<br />
of clear, 3/16-<strong>in</strong>ch-thick polycarbonate and measures 6-<strong>in</strong>ch x 6-<strong>in</strong>ch.<br />
This sturdy, impact-resistant shield is designed for use when a s<strong>in</strong>gle<br />
wheel needs safeguard<strong>in</strong>g. These shields have a direct-mount base that<br />
attaches directly to the gr<strong>in</strong>der table or pedestal.<br />
ELECTRICALLY-INTERLOCKED GRINDER AND<br />
TOOL GRINDER SHIELDS<br />
GET SAFEGUARDING!<br />
These electric<strong>all</strong>y-<strong>in</strong>terlocked gr<strong>in</strong>der<br />
and tool gr<strong>in</strong>der shields are ideal for<br />
s<strong>in</strong>gle- and double-wheel gr<strong>in</strong>ders.<br />
When the heavy-duty shield is swung<br />
out of position, the positive contacts on<br />
the microswitch open, send<strong>in</strong>g a stop Electric<strong>all</strong>y-Interlocked Gr<strong>in</strong>der<br />
signal to the mach<strong>in</strong>e control. The safety microswitch electrical wires are<br />
furnished with a protective sheath and connect to the safety circuit of the<br />
mach<strong>in</strong>e that switches off the control to the movement of the gr<strong>in</strong>d<strong>in</strong>g<br />
wheel. All safety micro switches are mounted <strong>in</strong> an enclosed hous<strong>in</strong>g<br />
with an enclosure rat<strong>in</strong>g of IP 67. The multi-adjustable, hexagonal steel<br />
arm structure <strong>all</strong>ows easy mount<strong>in</strong>g on the most diverse gr<strong>in</strong>ders. A<br />
versatile clamp <strong>all</strong>ows horizontal and vertical adjustment of the shield. All<br />
electric<strong>all</strong>y-<strong>in</strong>terlocked gr<strong>in</strong>der and tool gr<strong>in</strong>der shields consist of a high<br />
impact-resistant, transparent polycarbonate shield with an alum<strong>in</strong>um<br />
profile support and provide operator protection from fly<strong>in</strong>g chips and<br />
coolant.<br />
SINGLE-PHASE DISCONNECT SWITCH AND<br />
MAGNETIC MOTOR STARTER<br />
This s<strong>in</strong>gle-phase unit is designed for<br />
motors that have built-<strong>in</strong> over-loads. Typical<br />
applications for these comb<strong>in</strong>ations <strong>in</strong>clude<br />
sm<strong>all</strong>er crimp<strong>in</strong>g mach<strong>in</strong>es, gr<strong>in</strong>ders, drill<br />
presses, and <strong>all</strong> types of saws. The 115-V,<br />
15-A disconnect switch and non-revers<strong>in</strong>g<br />
magnetic motor starter are housed <strong>in</strong> a<br />
NEMA-12 enclosure. Enclosure size is 8” x<br />
6” x 3-1/2”. It <strong>in</strong>cludes a self-latch<strong>in</strong>g red<br />
emergency-stop palm button and a green motor control start push<br />
button. It can be used on mach<strong>in</strong>es with 115-V and is rated up to 1/2 HP<br />
maximum. The disconnect switch has a rotary operat<strong>in</strong>g handle which is<br />
lockable <strong>in</strong> the off position only. This meets OSHA and ANSI standards.<br />
DANGER SIGN FOR CUTTING AND<br />
TURNING MACHINES<br />
S<strong>in</strong>gle-Phase<br />
Disconnect Switch<br />
Don’t forget to post the appropriate danger signs near <strong>all</strong> mach<strong>in</strong>ery <strong>in</strong><br />
the plant. The purpose of danger signs is to warn personnel of the danger<br />
of bodily <strong>in</strong>jury or death. The suggested procedure for mount<strong>in</strong>g this sign<br />
is as follows:<br />
1. Sign must be clearly visible to the operator and other personnel<br />
2. Sign must be at or near eye level<br />
3. Sign must be PERMANENTLY fastened with bolts or rivets<br />
Please c<strong>all</strong> 1-800-922-7533 or visit www.rockfordsystems.com<br />
for more <strong>in</strong>formation.<br />
QUICK REFERENCE SHEETS | 7<br />
MOVING SAW BLADE<br />
You are expose<br />
parts that w<br />
f<strong>in</strong>gers or limbs<br />
NEVER place your<br />
part of y<br />
the saw<br />
NEVER operate this<br />
cloth<strong>in</strong>g<br />
long ha<br />
ALWAYS use a hand t<br />
wear pro<br />
equipme<br />
FAILURE to obey will<br />
f<strong>in</strong>gers o
SAFEGUARDING MECHANICAL POWER PRESSES<br />
Mechanical power presses (a.k.a.<br />
punch presses, stamp<strong>in</strong>g presses,<br />
flywheel presses), have existed <strong>in</strong> the<br />
United States s<strong>in</strong>ce 1857. They were<br />
orig<strong>in</strong><strong>all</strong>y designed as either fullrevolution<br />
or part-revolution, both of<br />
which still exist, although the latter<br />
currently represents an estimated<br />
90 percent of the roughly 300,000<br />
mechanical power presses be<strong>in</strong>g<br />
used <strong>in</strong> the U.S. today.<br />
GOT MECHANICAL POWER PRESSES?<br />
This blog will address part-revolution<br />
presses only. These are often<br />
referred to as “air clutch” presses,<br />
made by dozens of manufacturers. The idea of safety for these mach<strong>in</strong>es<br />
has existed s<strong>in</strong>ce 1922, when the first ANSI B11.1 Safety Standard was<br />
developed. The latest version, ANSI B11.1-2009 is the 10th update of<br />
that standard. This is gener<strong>all</strong>y considered to conta<strong>in</strong> the “Best Safety<br />
Practices” for press users.<br />
In the early 1970’s, OSHA promulgated a “mach<strong>in</strong>e specific regulation”<br />
for mechanical power presses, their CFR SubPart O, 1910.217. Very few<br />
changes have been made to that regulation s<strong>in</strong>ce then. Keep <strong>in</strong> m<strong>in</strong>d<br />
that OSHA’s 1910.217 Regulation was taken from ANSI B11.1 us<strong>in</strong>g a<br />
version that was freshly updated for OSHA <strong>in</strong> 1971. ANSI has updated<br />
their B11.1 four times s<strong>in</strong>ce that time. Every update adds new, more<br />
str<strong>in</strong>gent requirements than the previous version.<br />
Although many companies have long s<strong>in</strong>ce met the basic OSHA<br />
requirements for their presses, a significant number of those shops have<br />
yet to make updates to meet the latest ANSI B11.1 Standard. When OSHA<br />
regulations came 46 years ago, press control systems were primarily<br />
relay-logic systems, designed to meet OSHA’s <strong>in</strong>itial requirement for<br />
“Control Reliability” and “Brake Monitor<strong>in</strong>g.”<br />
Press control systems manufactured <strong>in</strong> the mid 1980’s and beyond have<br />
been mostly solid-state, designed to meet the ANSI Standard concept for<br />
the “Performance of Safety Related Functions.” One of the advantages<br />
to solid-state controls are the features built-<strong>in</strong>to them. Two of these<br />
are a: built-<strong>in</strong> “Stopp<strong>in</strong>g Performance Monitor” and built-<strong>in</strong> “Stop Time<br />
Measurement,” which prevents users from hav<strong>in</strong>g to use a portable<br />
device to determ<strong>in</strong>e “Safety Distance” when apply<strong>in</strong>g Light Curta<strong>in</strong> and<br />
Two-hand Control devices.<br />
Mechanical Power Presses require some comb<strong>in</strong>ation of guards and/<br />
or devices to reduce or elim<strong>in</strong>ate exposure to hazards at the “po<strong>in</strong>t of<br />
operation” where the dies close. <strong>Safeguard<strong>in</strong>g</strong> alternatives <strong>in</strong>clude:<br />
Po<strong>in</strong>t-of-Operation Guards, Awareness Barriers, Light Curta<strong>in</strong>s, and Two-<br />
Hand Controls.<br />
1) Po<strong>in</strong>t-of-Operation Guards<br />
Po<strong>in</strong>t-Of-Operation Guards are typic<strong>all</strong>y used for cont<strong>in</strong>uous operations<br />
where coil-stock feeds <strong>in</strong>to the press as it operates <strong>in</strong> an un<strong>in</strong>terrupted<br />
mode of operation.<br />
By OSHA’s def<strong>in</strong>ition, a guard<br />
must prevent people from<br />
ANSI and OSHA Guard Open<strong>in</strong>g Scales<br />
reach<strong>in</strong>g over, under, through, or<br />
around it. (OUTA is an acronym easy to remember; This guard keeps<br />
you “OUTA” here.) Guards must meet <strong>one</strong> of two measurement scales<br />
(the OSHA guard open<strong>in</strong>g scale or the ANSI/CSA guard open<strong>in</strong>g scale),<br />
to ensure that a sm<strong>all</strong> hand can’t reach far enough through any open<strong>in</strong>g<br />
to get hurt.<br />
To discourage misuse, h<strong>in</strong>ged or slid<strong>in</strong>g guard sections are often<br />
electric<strong>all</strong>y <strong>in</strong>terlocked, so that they rema<strong>in</strong> <strong>in</strong> position (closed) dur<strong>in</strong>g<br />
press operations. Without <strong>in</strong>terlocks, movable sections can easily be left<br />
open, whether <strong>in</strong>tentional or not, leav<strong>in</strong>g Operators and others <strong>in</strong> the area<br />
unprotected.<br />
Guard Interlocks are attached to h<strong>in</strong>ged or mov<strong>in</strong>g guard sections, s<strong>in</strong>ce<br />
access to the po<strong>in</strong>t-of-operation is most often made through those<br />
open<strong>in</strong>gs. Interlock attachment is best accomplished with tamperresistant<br />
fasteners to discourage cheat<strong>in</strong>g the switch.<br />
Many older guards use simple lever-arm or push-button switches. Not<br />
only are these switches easy to cheat with tape or wire, they are also<br />
spr<strong>in</strong>g-operated, leav<strong>in</strong>g them subject to failure it the spr<strong>in</strong>g breaks.<br />
Newer switches are free of spr<strong>in</strong>gs, and use actuators with a unique<br />
geometry, mak<strong>in</strong>g them much more difficult to defeat.<br />
2) Awareness Barriers (for low-level hazards only)<br />
Another common method of safeguard<strong>in</strong>g on coil-fed presses is an<br />
“Awareness Barrier” (A/B). They should completely surround press<br />
auxiliary equipment with rail<strong>in</strong>gs, cha<strong>in</strong>s, or cables, suspended on floor<br />
stations. Although they don’t provide the same level protection as a<br />
guard, they do help to limit access to hazards on auxiliary equipment like<br />
coil-payoffs, feeds, straighteners, etc.<br />
Awareness Barriers are considered superior to just a yellow l<strong>in</strong>e on the<br />
floor, because to get beyond the A/B requires an <strong>in</strong>tentional act and some<br />
physical contact with them. This means the person is well aware that<br />
they are enter<strong>in</strong>g a hazard area, contrary to their safety tra<strong>in</strong><strong>in</strong>g. Auxiliary<br />
equipment may also require that <strong>in</strong>go<strong>in</strong>g rolls are covered to prevent<br />
entanglement with long hair or loose cloth<strong>in</strong>g.<br />
Awareness barriers should also have several<br />
Danger or Warn<strong>in</strong>g signs attached to them<br />
specify<strong>in</strong>g what the hazards are <strong>in</strong> go<strong>in</strong>g<br />
beyond the A/Bs. Examples of sign verbiage<br />
might <strong>in</strong>clude: mov<strong>in</strong>g coil stock, <strong>in</strong>go<strong>in</strong>g<br />
p<strong>in</strong>ch po<strong>in</strong>ts, sharp edges, tripp<strong>in</strong>g hazard, etc.<br />
8 | QUICK REFERENCE SHEETS
GET SAFEGUARDING!<br />
3) Light Curta<strong>in</strong>s<br />
Light Curta<strong>in</strong>s have been around s<strong>in</strong>ce the mid-1950’s. They consist of<br />
a vertic<strong>all</strong>y mounted transmitter and receiver with closely spaced beams<br />
of <strong>in</strong>fra-red light, creat<strong>in</strong>g a flat sens<strong>in</strong>g-field. When f<strong>in</strong>gers, hands, or<br />
arms that reach through that sens<strong>in</strong>g-field, the press cycle is prevented<br />
or stopped to avoid operator <strong>in</strong>jury.<br />
One of the reasons that presses make a good application for light curta<strong>in</strong>s<br />
is that they can be stopped mid-cycle very quickly. Light curta<strong>in</strong>s can be<br />
used for either s<strong>in</strong>gle or cont<strong>in</strong>uous applications. The only th<strong>in</strong>g that light<br />
curta<strong>in</strong>s don’t provide is “impact protection” should someth<strong>in</strong>g break <strong>in</strong><br />
the po<strong>in</strong>t of operation and be ejected <strong>in</strong> the operator’s direction. Where<br />
that’s an issue, poly carbonate shields or guards may be appropriate.<br />
Like any safeguard<strong>in</strong>g device, light curta<strong>in</strong>s should be “function-tested”<br />
before every operat<strong>in</strong>g shift to ensure that they are cont<strong>in</strong>u<strong>in</strong>g to provide<br />
protection. Make/model specific “function-test procedures” are usu<strong>all</strong>y<br />
available on each light curta<strong>in</strong> manufacturer’s website.<br />
4) Two-Hand Controls<br />
Two-Hand Controls are considered a safer means of cycl<strong>in</strong>g a press than<br />
a foot-switch because both hands must be <strong>in</strong> a safe position to use them.<br />
When cycl<strong>in</strong>g a press with a foot switch, hands can be anywhere. When<br />
operat<strong>in</strong>g a press <strong>in</strong> the s<strong>in</strong>gle-cycle mode of operation, it’s possible to<br />
use a two-hand control as a safeguard<strong>in</strong>g device as well. This requires<br />
that they meet a list of rules <strong>in</strong> both OSHA and ANSI.<br />
Also required by OSHA on Mechanical<br />
Power Presses is an electric<strong>all</strong>y <strong>in</strong>terlocked<br />
“Safety Block” whenever dies are be<strong>in</strong>g<br />
adjust<strong>in</strong>g or repaired while they are <strong>in</strong> the<br />
press. The <strong>in</strong>terlock is required because<br />
safety blocks are very seldom designed<br />
to hold the full work<strong>in</strong>g-force of the press<br />
(please refer to our Die Safety Blocks blog<br />
for additional <strong>in</strong>formation).<br />
Die Safety Block<br />
Mechanical Power Presses require two types of OSHA <strong>in</strong>spections:<br />
1) Periodic and regular (typic<strong>all</strong>y quarterly) <strong>in</strong>spections of the<br />
press parts, auxiliary equipment, and safeguards...<br />
(don’t forget to document)<br />
2) Weekly <strong>in</strong>spections of; clutch/brake mechanism, anti-repeat<br />
feature...along with other items (don’t forget to document)<br />
OSHA requires tra<strong>in</strong><strong>in</strong>g (<strong>in</strong> 1910.217) for any<strong>one</strong> who cares for, <strong>in</strong>spects,<br />
ma<strong>in</strong>ta<strong>in</strong>s, or operates mechanical power presses.<br />
ANSI B11.1-2009, requires tra<strong>in</strong><strong>in</strong>g for “<strong>all</strong> (people) associated with<br />
press production systems, <strong>in</strong>clud<strong>in</strong>g operators, die setters, ma<strong>in</strong>tenance<br />
personnel, supervisors, which must also <strong>in</strong>clude (OSHA) 1910.147<br />
Lockout/Tagout.”<br />
Please c<strong>all</strong> 1-800-922-7533 or visit rockfordsystems.com for<br />
more <strong>in</strong>formation.<br />
Two-Hand Control on a Press<br />
Ten of the basic requirements for a two-hand control be<strong>in</strong>g used as a<br />
safeguard<strong>in</strong>g device (<strong>in</strong> the s<strong>in</strong>gle-cycle mode of operation) <strong>in</strong>clude:<br />
1) Protection from un<strong>in</strong>tended operation<br />
2) Located to require the use of both hands (no elbow & f<strong>in</strong>ger tips)<br />
3) Concurrently operated (actuation with<strong>in</strong> half-second of each other)<br />
4) Hold<strong>in</strong>g-time dur<strong>in</strong>g the downstroke (hazardous portion of cycle)<br />
5) Anti-repeat (push and release both actuators for each s<strong>in</strong>gle cycle)<br />
6) Interrupted stroke protection (for <strong>all</strong> operat<strong>in</strong>g stations)<br />
7) Separate set of two-hand controls for each operator<br />
8) Mounted at a calculated “Safety Distance” from nearest hazard<br />
9) Control system to meet “Performance of Safety Related Functions”<br />
10) Stopp<strong>in</strong>g Performance Monitor is also required<br />
When runn<strong>in</strong>g high-production operations, don’t forget to consider<br />
ergonomics when choos<strong>in</strong>g and <strong>in</strong>st<strong>all</strong><strong>in</strong>g two-hand controls. Several<br />
manufacturers of low-force and no-force actuators are on the market.<br />
QUICK REFERENCE SHEETS | 9
PRESS BRAKE SAFEGUARDING BASICS<br />
Press Brakes are currently a hot topic <strong>in</strong> the “Mach<strong>in</strong>e <strong>Safeguard<strong>in</strong>g</strong>”<br />
arena. OSHA regulations consider press brakes to be a 1910.212<br />
mach<strong>in</strong>e, say<strong>in</strong>g to the employer; “<strong>one</strong> or more methods of mach<strong>in</strong>e<br />
guard<strong>in</strong>g sh<strong>all</strong> be provided to protect the operator and other employees<br />
<strong>in</strong> the mach<strong>in</strong>e area from hazards such as those created by po<strong>in</strong>t<br />
of operation, <strong>in</strong>-go<strong>in</strong>g nip po<strong>in</strong>ts, rotat<strong>in</strong>g parts, fly<strong>in</strong>g chips, and<br />
sparks”...1910.212 requirements are good place to start, but they<br />
leave out the details of exactly how to go about safeguard<strong>in</strong>g any<br />
particular mach<strong>in</strong>e. Therefore, a reference to an ANSI Standard like<br />
B11.3 on press brakes is often used to identify specific safeguard<strong>in</strong>g<br />
alternatives. ANSI B11.3 may however need some help from ANSI<br />
B11.19 on safeguard<strong>in</strong>g methods, to provide a complete picture of<br />
how to go about protect<strong>in</strong>g people.<br />
Older press brakes, like those manufactured <strong>in</strong> the mid-1980’s and<br />
before, were mechanical (flywheel-type) mach<strong>in</strong>es, some of which are<br />
still <strong>in</strong> use today. Because the stopp<strong>in</strong>g times on mechanical press<br />
brakes are long, equ<strong>all</strong>y long light curta<strong>in</strong> safety-distances result, mak<strong>in</strong>g<br />
that safeguard<strong>in</strong>g device impractical <strong>in</strong> many cases.<br />
Press brakes manufactured after the mid-1980’s are much more likely<br />
to be hydraulic. Hydraulic press brakes <strong>all</strong>ow for a wider variety of<br />
safeguard<strong>in</strong>g options than mechanical press brakes do, and offer faster<br />
stopp<strong>in</strong>g-times, result<strong>in</strong>g <strong>in</strong> closer safety-distances where light curta<strong>in</strong>s<br />
or two-hand controls are used.<br />
New Control System on a Mechanical Press Brake<br />
GOT PRESS BRAKES?<br />
A common method of safeguard<strong>in</strong>g press brakes is with a vertic<strong>all</strong>y<br />
mounted <strong>in</strong>fra-red light curta<strong>in</strong>. Hydraulic press brakes <strong>all</strong>ow for short<br />
stopp<strong>in</strong>g times so that a light curta<strong>in</strong> can be mounted relatively close to<br />
the dies.<br />
Infra-red<br />
Two-Hand Controls<br />
Light Curta<strong>in</strong><br />
Two-hand controls on press brakes are often used <strong>in</strong> the sequencemode<br />
of operation where the actuators br<strong>in</strong>g the mach<strong>in</strong>e down and stop<br />
before the dies close, <strong>all</strong>ow<strong>in</strong>g just enough die-space to feed the part.<br />
The part is placed <strong>in</strong> the rema<strong>in</strong><strong>in</strong>g die-open<strong>in</strong>g, then a foot-switch is<br />
used to make the bend and return the mach<strong>in</strong>e to its full-open position.<br />
Safety distance is required for both light curta<strong>in</strong>s, and two-hand controls.<br />
That distance must be calculated with a stop-time measurement (STM)<br />
device on a quarterly basis. STM read<strong>in</strong>gs must be documented to show<br />
safety <strong>in</strong>spectors.<br />
ANSI B11.3 which was updated <strong>in</strong> 2012, offers<br />
two completely new categories of protection for<br />
hydraulic press brakes: Active Optical Protective<br />
Devices (lasers) and Safe Speed <strong>Safeguard<strong>in</strong>g</strong>.<br />
Active Optical Protective Devices (AOPDs) detect<br />
hands and f<strong>in</strong>gers <strong>in</strong> a danger area. The biggest<br />
attraction for AOPDs are for jobs where the<br />
operator must hand hold sm<strong>all</strong> parts up close Laser Scanner<br />
to the dies. A unique feature of AOPDs is that they are designed to be<br />
mounted with zero safety distance, unlike light curta<strong>in</strong>s that must be<br />
mounted at a calculated safety-distance, as outl<strong>in</strong>ed <strong>in</strong> ANSI B11.3. Safe<br />
Speed <strong>Safeguard<strong>in</strong>g</strong> is based on a ram speed of 10mm per second or<br />
less, provid<strong>in</strong>g that speed is carefully monitored. Aga<strong>in</strong>, these two new<br />
methods of protection can only be applied to hydraulic press brakes (and<br />
potenti<strong>all</strong>y Servo-Drive Press Brakes).<br />
The Lazersafe Sent<strong>in</strong>el Plus is the most<br />
advanced guard<strong>in</strong>g solution available<br />
designed specific<strong>all</strong>y for hydraulic press<br />
brakes. The Lazersafe ties directly <strong>in</strong>to the<br />
mach<strong>in</strong>e’s exist<strong>in</strong>g hydraulic and electric<br />
control circuits, provid<strong>in</strong>g a Category 4<br />
solution. The Lazersafe is CE rated and<br />
<strong>all</strong>ows mach<strong>in</strong>e operators to hold workpieces<br />
Lazersafe Sent<strong>in</strong>el Plus<br />
Press Brake Guard<strong>in</strong>g System<br />
with<strong>in</strong> 20mm of the po<strong>in</strong>t of operation. Encoder feedback ensures that<br />
the speed and position of the tool<strong>in</strong>g is cont<strong>in</strong>uously monitored, and a<br />
4.3” HMI provides mach<strong>in</strong>e operators immediate feedback of <strong>all</strong> vital<br />
functions. The Lazersafe Sent<strong>in</strong>el Plus is compatible with a wide variety<br />
10 | QUICK REFERENCE SHEETS
of mach<strong>in</strong>es and tool<strong>in</strong>g types, material thickness and easily <strong>all</strong>ows for<br />
box shapes to be formed.<br />
The backs of press brakes cannot be left<br />
wide open. Two hazards exist often exist<br />
here. The first is reach<strong>in</strong>g the dies from<br />
the back. The second is the possibility of a<br />
multi-axis back gauge mov<strong>in</strong>g and creat<strong>in</strong>g<br />
p<strong>in</strong>ch po<strong>in</strong>ts. As to exactly what is required<br />
on the back of equipment often depends on<br />
local OSHA <strong>in</strong>terpretation. The very least, an awareness barrier, like a<br />
rail<strong>in</strong>g, cha<strong>in</strong>, or cable with a “Danger” or “Warn<strong>in</strong>g” sign, complete with<br />
Pictograms, not just verbiage.<br />
For local OSHA <strong>in</strong>terpretations that won’t<br />
accept awareness barriers, a full perimeter<br />
guard may be the answer for the back of<br />
a press brake. That guard can either be<br />
bolted <strong>in</strong>to position, or if it’s movable, an<br />
electrical <strong>in</strong>terlock switch can be <strong>in</strong>st<strong>all</strong>ed<br />
to make sure it stays closed.<br />
GET SAFEGUARDING!<br />
Perimeter Guard<br />
As with any <strong>in</strong>dustrial mach<strong>in</strong>e, Lockout/Tagout on Press Brakes must<br />
strive for “Zero Energy State” to and with<strong>in</strong> each piece of equipment<br />
us<strong>in</strong>g both locks and tags.<br />
Also menti<strong>one</strong>d <strong>in</strong> the ANSI standard is die safety blocks; please see our<br />
related blog post on “Demystify<strong>in</strong>g Die Safety Blocks”.<br />
Please c<strong>all</strong> 1-800-922-7533 or visit rockfordsystems.com for<br />
more <strong>in</strong>formation.<br />
QUICK REFERENCE SHEETS | 11
PLAYING IT SAFE WITH ROBOTICS<br />
Robotics is a grow<strong>in</strong>g field as more and more companies are <strong>in</strong>corporat<strong>in</strong>g<br />
<strong>in</strong>dustrial automation <strong>in</strong>to their production processes. In just the first n<strong>in</strong>e<br />
months of 2016, 23,985 robots were ordered from North American<br />
companies, many of which require mach<strong>in</strong>e guard<strong>in</strong>g equipment to<br />
maximize productivity and safety. Robots are used for replac<strong>in</strong>g humans<br />
who were perform<strong>in</strong>g unsafe, hazardous, highly repetitive, and unpleasant<br />
tasks. They are utilized to accomplish many different types of application<br />
functions such as material handl<strong>in</strong>g, assembly, arc weld<strong>in</strong>g, resistance<br />
weld<strong>in</strong>g, mach<strong>in</strong>e tool load/unload functions, pa<strong>in</strong>t<strong>in</strong>g/spray<strong>in</strong>g, etc.<br />
POTENTIAL HAZARDS<br />
Studies <strong>in</strong>dicate that many robot <strong>in</strong>juries occurr<strong>in</strong>g <strong>in</strong> robotic automation<br />
typic<strong>all</strong>y occur dur<strong>in</strong>g non-rout<strong>in</strong>e operat<strong>in</strong>g conditions, such as<br />
programm<strong>in</strong>g, ma<strong>in</strong>tenance, repair, test<strong>in</strong>g, setup, or adjustment when<br />
the worker may temporarily be with<strong>in</strong> the robot’s work<strong>in</strong>g envelope.<br />
As stated by OSHA, mechanical hazards<br />
might <strong>in</strong>clude workers collid<strong>in</strong>g with<br />
equipment, be<strong>in</strong>g crushed, or trapped<br />
by equipment, or be<strong>in</strong>g <strong>in</strong>jured by f<strong>all</strong><strong>in</strong>g<br />
equipment comp<strong>one</strong>nts. For example,<br />
a worker could collide with the robot’s<br />
arm or peripheral equipment as a result Non-Safeguarded Robots<br />
of unpredictable movements, comp<strong>one</strong>nt malfunctions, or random<br />
program changes. The worker could be <strong>in</strong>jured by be<strong>in</strong>g trapped<br />
between the robot’s arm and other peripheral equipment or be<strong>in</strong>g<br />
crushed by peripheral equipment as a result of be<strong>in</strong>g impacted by the<br />
robot <strong>in</strong>to this equipment.<br />
Mechanical hazards also can result from the mechanical failure of<br />
comp<strong>one</strong>nts associated with the robot or its power source, drive<br />
comp<strong>one</strong>nts, tool<strong>in</strong>g or end-effector, and/or peripheral equipment. The<br />
failure of gripper mechanisms with resultant release of parts, or the<br />
failure of end-effector power tools such as gr<strong>in</strong>d<strong>in</strong>g wheels, buff<strong>in</strong>g<br />
wheels, deburr<strong>in</strong>g tools, power screwdrivers, and nut runners are a few<br />
of the possibilities.<br />
Human errors can result <strong>in</strong> hazards both to personnel and equipment.<br />
Errors <strong>in</strong> programm<strong>in</strong>g, <strong>in</strong>terfac<strong>in</strong>g peripheral equipment, connect<strong>in</strong>g<br />
<strong>in</strong>put/output sensors, can <strong>all</strong> result <strong>in</strong> unpredictable movement or action<br />
by the robot which can result <strong>in</strong> personnel <strong>in</strong>jury or equipment breakage.<br />
Human errors <strong>in</strong> judgment frequently<br />
result from <strong>in</strong>correctly activat<strong>in</strong>g the teach<br />
pendant or control panel. The greatest<br />
human judgment error results from<br />
becom<strong>in</strong>g so familiar with the robot’s<br />
redundant motions that personnel are<br />
too trust<strong>in</strong>g <strong>in</strong> assum<strong>in</strong>g the nature of Non-Safeguarded Robot<br />
these motions and place themselves <strong>in</strong><br />
hazardous positions while programm<strong>in</strong>g or perform<strong>in</strong>g ma<strong>in</strong>tenance<br />
with<strong>in</strong> the robot’s work envelope.<br />
GOT ROBOTICS?<br />
SAFEGUARDING AUTOMATION CELLS<br />
Robots <strong>in</strong> the workplace are gener<strong>all</strong>y associated with the mach<strong>in</strong>e<br />
tools or process equipment. Robots are mach<strong>in</strong>es, and as such, must<br />
be safeguarded <strong>in</strong> ways similar to those presented for any hazardous<br />
remotely controlled mach<strong>in</strong>e, f<strong>all</strong><strong>in</strong>g under the general duty clause<br />
or OSHA 1910.212(a)(1) or 1910.212(a)(3)ii. Refer to https://www.<br />
osha.gov/SLTC/robotics/standards.html and OSHA’s compliance<br />
directive on robotics STD 01-12-002 at https://www.osha.gov/<br />
pls/oshaweb/owadisp.show_document?p_table=DIRECTIVES&p_<br />
id=170 for more <strong>in</strong>formation.<br />
Various techniques are available to<br />
prevent employee exposure to the<br />
hazards which can be imposed by<br />
robots. The most common technique<br />
is through the <strong>in</strong>st<strong>all</strong>ation of perimeter<br />
guard<strong>in</strong>g with <strong>in</strong>terlocked gates. A critical<br />
parameter relates to the manner <strong>in</strong> which<br />
the <strong>in</strong>terlocks function. Of major concern<br />
Robotics Packag<strong>in</strong>g Cell<br />
Courtesy: Banner Eng<strong>in</strong>eer<strong>in</strong>g<br />
is whether the computer program, control circuit, or the primary power<br />
circuit, is <strong>in</strong>terrupted when an <strong>in</strong>terlock is activated. The various <strong>in</strong>dustry<br />
standards should be <strong>in</strong>vestigated for guidance; however, it is gener<strong>all</strong>y<br />
accepted that the primary motor power to the robot should be <strong>in</strong>terrupted<br />
by the <strong>in</strong>terlock.<br />
Although ANSI standards are guidel<strong>in</strong>es, many U.S. <strong>in</strong>dustry experts<br />
experts agree that ANSI standards provide the best guidel<strong>in</strong>es for<br />
safeguard<strong>in</strong>g mach<strong>in</strong>ery that doesn’t have a vertical OSHA requirement.<br />
ANSI/RIA R15.06-2012 is the most recent U.S. Standard on Industrial<br />
Robots, which requires that perimeter guards conta<strong>in</strong> the robot<br />
automation. These guards are required to have a 12-<strong>in</strong>ch sweep and a<br />
60-<strong>in</strong>ch height (ANSI/RIA R15.06-1999). However, CSA 2003 cite best<br />
practices at a 6-<strong>in</strong>ch (.15m) sweep and a 72-<strong>in</strong>ch (1.8m) height.<br />
When a robot is to be used <strong>in</strong> a workplace, the employer should<br />
accomplish a comprehensive operational safety/health hazard analysis<br />
and then devise and implement an effective safeguard<strong>in</strong>g system<br />
which is fully responsive to the situation. In general, the scale of the<br />
automation cell will drive the scale of the safeguard<strong>in</strong>g. (Various effective<br />
safeguard<strong>in</strong>g techniques are described <strong>in</strong> ANSI B11.19-2010.)<br />
12 | QUICK REFERENCE SHEETS
ROCKFORD SYSTEMS CAN HELP<br />
Dur<strong>in</strong>g <strong>Rockford</strong> <strong>Systems</strong> Onsite<br />
Risk Assessments and Onsite<br />
Mach<strong>in</strong>e Surveys, we f<strong>in</strong>d <strong>one</strong> of<br />
the most common problems with<br />
robotics is the failure to accurately<br />
calculate safety distances, typic<strong>all</strong>y<br />
used <strong>in</strong> regard to the <strong>in</strong>st<strong>all</strong>ation<br />
of safety mats. Robots make rapid<br />
and wide-reach<strong>in</strong>g moves. The<br />
goal is to stop a robot before it can<br />
hurt some<strong>one</strong>.<br />
Any robot that moves more that 10 <strong>in</strong>ches per second must be safeguarded<br />
adequately. Safe distance is determ<strong>in</strong>ed by the follow<strong>in</strong>g Robotics Industry<br />
Associations (RIA) formula with the follow<strong>in</strong>g parameters:<br />
DS= 63 <strong>in</strong>ches per second (IPS) X(TS+ TC+ TR) + DPF<br />
DPF= 1.2 m (48 <strong>in</strong>.)<br />
Where:<br />
DS= m<strong>in</strong>imum safe distance<br />
TS= stopp<strong>in</strong>g time of device<br />
TC= worst stopp<strong>in</strong>g time of control system<br />
TR= response time of safeguard<strong>in</strong>g device <strong>in</strong>clud<strong>in</strong>g <strong>in</strong>terface<br />
GET SAFEGUARDING!<br />
Robotics P<strong>all</strong>etizer and<br />
Stretch Wrapper Cell<br />
Courtesy: Banner Eng<strong>in</strong>eer<strong>in</strong>g<br />
DPF= maximum travel distance toward a hazard once some<strong>one</strong> has<br />
entered the field<br />
So the total horizontal space to be protected is 48 <strong>in</strong>. plus 63 IPS,<br />
multiplied by the total time delay between detection of a person <strong>in</strong> the<br />
protected area and the actual time it takes for the robot to stop.<br />
It’s imperative that the automation cell and <strong>all</strong> aspects of mach<strong>in</strong>e use be<br />
identified and considered when select<strong>in</strong>g and implement<strong>in</strong>g a robotics<br />
safeguard<strong>in</strong>g. Ultimately, the best type of protective measure will be the<br />
device or system that provides maximum protection, with m<strong>in</strong>imal impact<br />
on normal mach<strong>in</strong>e operation.<br />
Please c<strong>all</strong> 1-800-922-7533 or visit www.rockfordsystems.com for<br />
more <strong>in</strong>formation.<br />
QUICK REFERENCE SHEETS | 13
NOTES
NOTES
5795 Logistics Parkway, <strong>Rockford</strong>, Ill<strong>in</strong>ois 61109 United States<br />
1-800-922-7533 | 815-874-7891<br />
www.rockfordsystems.com<br />
RSTKS/0119