Rockford Fosgate DETECT-A-FINGER RKC-502, DETECT-A-FINGER RKC-500 Series Installation Manual

INSTALLATION MANUAL FOR

DETECT-A-FINGER

®

DROP PROBE DEVICE

FOR RESISTANCE-TYPE SPOT WELDERS

Danger Sign

Sensing Probe

Assembly

Sensing Probe

Control Box

IMPORTANT: PLEASE REVIEW THIS ENTIRE
PUBLICATION BEFORE INSTALLING,
OPERATING OR MAINTAINING THIS DEVICE.

5795 Logistics Parkway • Rockford Systems, LLC, Illinois 61109-2695 • Toll-Free 1-800-922-7533 • Phone [phone]

Fax [phone] • Web Site www.rockfordsystems.com • E-Mail [e-mail]

Instruction Manual No. KSL-022

SECTION 1—IN GENERAL

Detect-A-Finger® Drop Probe Device-Welder

SECTION 1 - IN GENERAL .............................................. 2 - 8

SECTION 2 - INSTALLATION OF COMPONENTS ........ 9 - 16

Control Box ........................................................................ 9

Sensing Probe ............................................................ 10-11

Other Components That May Be Required ................ 12-15

Installation Considerations ............................................... 16

SECTION 3 - OPERATING PROCEDURES &

TROUBLESHOOTING ......................................................... 17-18

SECTION 4 - REPLACEMENT PARTS ............................... 19

SECTION 5 - ORDER FORM & RMA FORM ...................... 20

Safety Precautions

DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.

This safety alert symbol identies important safety messages in

this manual. When you see this symbol, be alert to the possibility of
personal injury, and carefully read the message that follows.

CAUTION

Efcient and safe machine operation depends on the development, implementation and enforcement of a safety

program. This program requires, among other things, the proper selection of point-of-operation guards and safety
devices for each particular job or operation, a thorough safety training program for all machine personnel, that includes
instruction on the proper operation of the machine, the point-of-operation guards and safety devices on the machine,
and a regularly scheduled inspection and maintenance program.

Rules and procedures covering each aspect of your safety program should be developed and published both in an

operator’s safety manual, as well as in prominent places throughout the plant and on each machine. Some rules or

instructions which must be conveyed to your personnel and incorporated into your program include:

CAUTION used without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property damage.

Never place your hands or any part of your body in this machine.

Never operate this machine without proper eye, face and body protection.

Never operate this machine unless you are fully trained, instructed, and have read the

instruction manual.

Never operate this machine if it is not working properly – stop operating and advise
your supervisor immediately.

Never use a foot switch to operate this machine unless a point-of-operation guard or
device is provided and properly maintained.

Never operate this machine unless two-hand trip, two-hand control or presence sensing
device is installed at the proper safety distance. Consult your supervisor should you
have any questions regarding the proper safety distance.

Never tamper with, rewire or bypass any control or component on this machine.

A company’s safety program must involve everyone in the company, from top management to operators, since only as a group can
any operational problems be identied and resolved. It is everyone’s responsibility to implement and communicate the information

and material contained in catalogs and instruction manuals to all persons involved in machine operation. If a language barrier or

insufcient education would prevent a person from reading and understanding various literature available, it should be translated,

read or interpreted to the person, with assurance that it is understood.

FOR MAINTENANCE AND INSPECTION ALWAYS REFER TO THE OEM’s (ORIGINAL
MACHINE MANUFACTURER’S) MAINTENANCE MANUAL OR OWNER’S MANUAL. If you do
not have an owner’s manual, please contact the original equipment manufacturer.

© 2018 Rockford Systems, LLC. All rights reserved. Not to be reproduced in whole or in part without written permission. Litho in U.S.A.

2 Call 1-800-922-7533

Rockford Systems, LLC

SECTION 1—IN GENERAL

Detect-A-Finger® Drop Probe Device-Welder

Safety References

OSH ACT AND FEDERAL REGULATIONS

Since the enclosed equipment can never overcome

a mechanical deciency, defect or malfunction in the

machine itself, OSHA (Occupational Safety and Health
Administration) has established certain safety regulations
that the employers (users) must comply with so that the
machines used in their plants, factories or facilities are

thoroughly inspected and are in rst-class operating

condition before any of the enclosed equipment is
installed.

1. U.S. Government—An Act—Public Law 91-596, 91st
Congress, S. 2193, December 29, 1970:

Duties

SEC. 5. (a) Each employer—

(1) SHALL FURNISH TO EACH OF HIS

EMPLOYEES EMPLOYzMENT AND A PLACE
OF EMPLOYMENT WHICH ARE FREE FROM
RECOGNIZED HAZARDS THAT ARE CAUSING
OR ARE LIKELY TO CAUSE DEATH OR SERIOUS
PHYSICAL HARM TO HIS EMPLOYEES;

(2) shall comply with occupational safety and

health standards promulgated under this Act.
(b) Each employee shall comply with occupational
safety and health standards and all rules, regulations,
and orders issued pursuant to this Act which are
applicable to his own actions and conduct.

2. OSHA 29 CFR Sections that an employer (user)

must comply with include:

1910.211 Denitions.

1910.212 General requirements for all machines.

1910.217 Mechanical power presses.

1910.219 Mechanical power-transmission apparatus.

3. OSHA 29 CFR 1910.147 The control of hazardous

energy (lockout/tagout).

4. OSHA Publication

“General Industry Safety and Health Regulations Part

1910,” Code of Federal Regulations, Subpart O

This publication can be obtained by contacting:

U.S. GOVERNMENT PRINTING OFFICE
P.O. BOX 979050

St. Louis, MO 63197-9000
[phone]

ANSI SAFETY STANDARDS FOR MACHINES

The most complete safety standards for machine tools
are published in the ANSI (American National Standards
Institute) B11 series. The following is a list of each ANSI
B11 Standard available at the printing of this publication.

B11–2008 General Safety Requirements
B11.1 Mechanical Power Presses
B11.2 Hydraulic Power Presses
B11.3 Power Press Brakes
B11.4 Shears
B11.5 Iron Workers
B11.6 Lathes
B11.7 Cold Headers and Cold Formers
B11.8 Drilling, Milling, and Boring Machines
B11.9 Grinding Machines
B11.10 Metal Sawing Machines
B11.11 Gear and Spline Cutting Machines
B11.12 Roll Forming and Roll Bending Machines
B11.13 Automatic Screw/Bar and Chucking Machines
B11.14 Withdrawn (Now see ANSI B11.18)
B11.15 Pipe, Tube and Shape Bending Machines
B11.16 Metal Powder Compacting Presses
B11.17 Horizontal Hydraulic Extrusion Presses
B11.18 Coil Processing Systems
B11.19 Performance Criteria for Safeguarding
B11.20 Integrated Manufacturing Systems
B11.21 Lasers
B11.22 CNC Turning Machines
B11.23 Machining Centers
B11.24 Transfer Machines
B11.TR1 Ergonomic Guidelines
B11.TR2 Mist Control Considerations
B11.TR3 Risk Assessment
B11.TR4 Programmable Electronic Systems (PES/PLC)
B11.TR5 Sound Level Measurement Guidelines
B11.TR7 Risk Assessment
R15.06 Robotic Safeguarding
B15.1 Mechanical Power Transmission Apparatus
B56.5 Guided Industrial Vehicles and Automated

Function of Manned Industrial Vehicles
B65.1 Printing Press Systems
B65.2 Binding and Finishing Systems
B65.5 Stand-Alone Patten Presses
B151.1 Horizontal (Plastic) Injection Molding Machines
B152.1 Hydraulic Die Casting Presses
B154.1 Rivet Setting Machines
B155.1 Packaging Machinery

01.1 Woodworking Machinery

These standards can be purchased by contacting:

ANSI—American National Standards Institute
25 West 43rd Street
New York, New York 10036
Phone: [phone]
www.ansi.org

(Continued on next page.)

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3

SECTION 1—IN GENERAL

Detect-A-Finger® Drop Probe Device-Welder

NATIONAL SAFETY COUNCIL SAFETY MANUALS

Other good references for safety on machine tools are

the National Safety Council’s Safety Manuals. These

manuals are written by various committees including
the Power Press, Forging and Fabricating Executive
Committee. Copies of the following publications are
available from their library:

• Power Press Safety Manual - 5th Edition

• Safeguarding Concepts Illustrated - 7th Edition

• Forging Safety Manual

These manuals can be obtained by contacting:

National Safety Council
1121 Spring Lake Drive
Itasca, IL 60143-3201
1-800-621-7615
www.nsc.org

OTHER SAFETY SOURCES

National Institute of Occupational Safety and
Health (NIOSH)
4676 Columbia Parkway
Cincinnati, OH 45226
Toll-Free: 1-800-35-NIOSH (1-800-356-4674)
Phone: [phone]
www.cdc.gov/niosh

OTHER SAFETY SOURCES (continued)

Robotic Industries Association (RIA)
900 Victors Way, Suite 140
P.O. Box 3724
Ann Arbor, MI 48106
Phone: [phone]
www.roboticsonline.com

NEMA (National Electrical Manufacturers
Association)
1300 North 17th Street, Suite 1847
Rosslyn, VA 22209
Phone: [phone]
www.nema.org

NFPA (National Fire Protection Association)
1 Batterymarch Park
Quincy, MA 02269-9101
Phone: [phone]
www.nfpa.org

For additional safety information and assistance in
devising, implementing or revising your safety program,
please contact the machine manufacturer, your state and
local safety councils, insurance carriers, national trade

associations and your state’s occupational safety and

health administration.

Warranty, Disclaimer and Limitation of Liability

Rockford Systems, LLC warrants that this product will be free from defects in material and workmanship for a period of 12 months from

the date of shipment thereof. ROCKFORD SYSTEMS LLC’S OBLIGATION UNDER THIS WARRANTY IS EXPRESSLY AND EXCLUSIVELY

LIMITED to repairing or replacing such products which are returned to it within the warranty period with shipping charges prepaid and
which will be disclosed as defective upon examination by Rockford Systems, LLC. This warranty will not apply to any product which will

have been subject to misuse, negligence, accident, restriction and use not in accordance with Rockford Systems, LLC’s instructions or

which will have been altered or repaired by persons other than the authorized agent or employees of Rockford Systems, LLC. Rockford

Systems, LLC’s warranties as to any component part is expressly limited to that of the manufacturer of the component part.

DISCLAIMER

The foregoing Warranty is made in lieu of all other warranties, expressed
or implied, and of all other liabilities and obligations on the part of
Rockford Systems, LLC, including any liability for negligence, strict liability,

or otherwise, and any implied warranty of merchantability or tness for a

particular purpose is expressly disclaimed.

4 Call 1-800-922-7533

WARRANTY

LIMITATION OF LIABILITY

Under no circumstances, including any claim of negligence, strict liability,
or otherwise, shall Rockford Systems, LLC be liable for any incidental or
consequential damages, or any loss or damage resulting from a defect in
the product of Rockford Systems, LLC.

Rockford Systems, LLC

Operator Safety Precautions Sign

Front

SECTION 1—IN GENERAL

Detect-A-Finger® Drop Probe Device-Welder

Accompanying this equipment is an
81⁄2” x 11” operator safety precautions
sign, Part No. KSC-000, for anyone
operating the machine where this
equipment will be installed. These
precautions are to be given to all
operators, including setup people,
maintenance personnel and
supervisors.

This sign should also be attached
to the machine, readily accessible

and visible to the operator. (A hole

in the corner of this precautions
sign is provided for attaching

purposes.) Additional copies of these

precautions are available. Please
call, write, fax, or use the order form
found on a later page in this manual.

Back

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When a language barrier or

insufcient education prevents a

person from reading or understanding
the contents of this operator safety
precautions sign, you should either
translate this information or have it
read or interpreted to the person. Make
sure that the person understands the
information. To order this sign in
Spanish, use Part No. KSC-000S; in
French, use Part No. KSC-000F.

These precautions must be reviewed
daily.

5

SECTION 1—IN GENERAL

Detect-A-Finger® Drop Probe Device-Welder

Danger Sign(s) to be Mounted on Machine

Accompanying this equipment is a 5” x 6” polyethylene danger sign, Part No. KSC-055. This sign MUST
BE PERMANENTLY MOUNTED IN A PROMINENT LOCATION on the machine where this equipment is
installed. This sign must be in a LOCATION THAT IS EASILY VISIBLE to the operator, setup person,
or other personnel who work on or around this machine. ALWAYS mount this sign with bolts or rivets
when installing the enclosed equipment.

If any danger sign becomes destroyed or unreadable, the sign must be replaced immediately. Contact factory for
replacement danger sign(s).

Never operate this machine unless the danger sign(s) is in place.

Part No. KSC-000 Operator
Safety Precations Sign

“M

echanical Power Press Safety

A copy of Booklet No. MPPS (Mechanical Power Press Safety) is available
upon request. This booklet is copied verbatim from the CFR (Code of Federal
Regulations) and contains all relevant sections of the OSHA standards concerning
power presses with which an employer (user) must comply. The enclosed
equipment must be installed, used and maintained to meet these standards.

Specically, any time a foot switch is used, a suitable point-of-operation
safeguard or device must be used to prevent bodily injury. In addition, every
press must be provided with a point-of-operation safeguard! Please review

this booklet before installing the enclosed equipment. If you are unfamiliar with
these detailed safety regulations, which include regulations on safeguarding
the point of operation properly, you may want to attend our regularly scheduled
machine safeguarding seminars. To obtain detailed information about these
training seminars, please call, fax, write, or check our Web site. Our telephone,
fax number, Web site, and mailing address are on the front cover of this manual.

” B

ooklet

Front Side

Part No. KSC-055 Danger Sign
(Foot) - Standard
Part No. KSC-055S - Spanish
Part No. KSC-055F - French

Reverse Side

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Rockford Systems, LLC