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Lazer Safe PCSS-F Series Technical Manual

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PCSS-F SERIES
Technical Manual
Additions
LS-CS-M-023
27 Action Road, Malaga WA 6090, Australia
PO Box 2368, Malaga WA 6944, Australia
+61 8 9249 4388
+61 8 9249 6011
info@lazersafe.com

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Summary of Contents for Lazer Safe PCSS-F Series

  • Page 1 PCSS-F SERIES Technical Manual Additions LS-CS-M-023 27 Action Road, Malaga WA 6090, Australia PO Box 2368, Malaga WA 6944, Australia +61 8 9249 4388 +61 8 9249 6011 info@lazersafe.com...
  • Page 2 PCSS-F Additions Technical Manual LS-CS-M-023 Document Reference Code: LS-CS-M-023 Version: 1.02 Released: 03/12/2013 Date Manual Software Summary of Change Version Version 01/01/2008 0.01 Initial release of addendum. 14/01/2008 0.02 Updated Option Compatibility Table to match latest kernel release. 17/01/2008 0.03 Changed communications protocol to ser4_a8.
  • Page 3 Copyright in this documentation is owned by Lazer Safe Pty Ltd. No part of this document may be reproduced or copied in any form or by any means (graphic, electronic, or mechanical including photocopying, recording, taping, or information storage and retrieval systems) without the written permission of Lazer Safe Pty Ltd.

  • Page 4: Table Of Contents

    PCSS-F Additions Technical Manual LS-CS-M-023 About This Manual ..................1-1 Document Objectives ......................1-1 Guide to Notes, Cautions and Warnings................1-1 Obtaining Technical Assistance ................... 1-1 FIO04 Input / Output Module ..............2-1 CN1 Connections ....................... 2-1 CN2 Connections ....................... 2-1 CN3 Connections .......................

  • Page 5: About This Manual

    The PCSS-F Additions Technical Manual provides specific information on the hardware used by Trumpf. Note: This symbol indicates helpful information that helps you make better use of your Lazer Safe product. Caution: This symbol alerts you to situations that could result in equipment damage. Warning: This symbol indicates danger.

  • Page 7: Fio04 Input / Output Module

    24 VDC Supply 24VDC 24VDC 0 VDC Supply 0VDC 0 VDC Supply 0VDC Figure 2-1: PCSS-F Series I/O Module Power Connections Power Supply Specifications Input points Input voltage 24 VDC ± 10% Input current 15 A total CN2 has connections for outputs to control the solenoid valves on the press brake via a 7way removable terminal block.

  • Page 8: Cn1 Connections

    PCSS-F Additions Technical Manual LS-CS-M-023 Connections on CN5 are provided for Door and Emergency Stop switches on the press brake via an 8-way removable terminal block. Three pulsed input combinations (X10 to X13 / P10 to P13) are available for these connections. A 24 VDC connection is also available for energising when switched to the standard input.
  • Page 9 LS-CS-M-023 PCSS-F Additions Technical Manual Standard Input Specifications Input voltage 24 VDC ± 10% Input current 15 mA Voltage on 14 VDC minimum Voltage off 12 VDC maximum Delay on 0.02 ms Delay off 0.02 ms Isolation Opto-coupler On display Red LED Output supply voltage 24 VDC ±...

  • Page 11: Cnc Press Controller Communications Interface

    LS-CS-M-023 PCSS-F Additions Technical Manual ISaGRAF driver Driver name ser4__a9 Driver description Characteristics as shown below Channel # Description Protocol options (4 = LzsBus2) Baud rate option (0 = 9600; 1 = 19200; 2 = 38400; 3 = 57600; 4 = 76800;...
  • Page 12 PCSS-F Additions Technical Manual LS-CS-M-023 Channel # Units Description microns Reference Y1 microns Reference Y2 microns Material thickness microns Die 01 height microns Die 02 height microns Punch 01 height microns Punch 02 height microns Tool reference microns CNC Mute position microns Upstand height microns...
  • Page 13 LS-CS-M-023 PCSS-F Additions Technical Manual Channel # Description CNC OK CNC TDC CNC Mute CNC Axis in Position CNC Moving Up Spare CNC 2 Station CNC Hydraulics On Spare Spare Foot Station 1 Foot Station 2 Foot Station 3 Foot Station 4 CNC Referenced CNC Decompression CNC Hydraulic Start...
  • Page 14 PCSS-F Additions Technical Manual LS-CS-M-023 Channel # Description 0-127 Spare Table 3-10: Generic Digital inputs (gD_in) Channel # Description 0-127 Spare Table 3-11: Generic Digital outputs (gD_out) Page 3-4 Original Language Version: 1.02 Released: 03/12/2013...

  • Page 15: Pcss Safety Function Options

    PCSS software is started. Note: Lazer Safe recommends varistor protection is fitted across all valves installed on the press brake when connected to the PCSS. Whilst resistor/capacitor and diode protection solutions are available, varistor protection provides superior reaction time and suppression capabilities to generated valve voltages and transients compared to other protection solutions.
  • Page 16 PCSS-F Additions Technical Manual LS-CS-M-023 The down enable condition from the down enable option is not physically connected to an output but is one of the conditions that must be met before down movement is allowed by the PCSS. This condition used from the down enable option indicates that the down switch has been pressed and that down movement of the pressing beam can occur due to the required safety conditions being met.

  • Page 17: Down Enable Option 17

    LS-CS-M-023 PCSS-F Additions Technical Manual It is also possible to have an additional delay when the proportional pressure output is switched off from the PCSS by using a variable connected to I/O channel 23 of the ANO board for the Kernel Software Interface.
  • Page 18 PCSS-F Additions Technical Manual LS-CS-M-023 FIO04 – CN3 Y04H Brake Set Y2-2 Y04L 24VDC Figure 4-4: Down Enable Option 17 (CN3 - FIO04 Connections) This down enable option provides outputs for control of the following devices on the press brake: •...
  • Page 19 LS-CS-M-023 PCSS-F Additions Technical Manual The quick stop condition is enabled during up and down movement during normal operation or when the static brake tests are performed on the machine. When the beam is moving down and the dynamic brakes tests are active the quick stop condition is disabled for determining the stopping performance of the mechanical brakes during down movement.
  • Page 20 PCSS-F Additions Technical Manual LS-CS-M-023 4.1.2.2 Option Selection To select down enable option 17 during the PCSS configuration, set the initial value for Down Enable Option Selection Variable to 17 as described the PCSS F Series Technical Manual. This will ensure that this option and all required outputs are initialised when the PCSS software is started.

  • Page 21: Emergency Stop Function Options

    LS-CS-M-023 PCSS-F Additions Technical Manual The emergency stop function of the PCSS monitors system and press brake conditions and will initiate an emergency stop when certain conditions are met. An emergency stop condition can occur if: • The emergency stop enable from the ISaGRAF user application has not been enabled via the Kernel Software Interface (an input has been provided on channel 8 of the DO1 board);...
  • Page 22 PCSS-F Additions Technical Manual LS-CS-M-023 If either left or right doors are opened, machine operation is possible but the pressing beam will only operate in slow speed while the side door remains open. When this situation occurs, mid- stroke on down movement, the operator is required to release the down switch control and operate the down control switch again to move the pressing beam again;...
  • Page 23 LS-CS-M-023 PCSS-F Additions Technical Manual Standard inputs on the PCSS unit are used for monitoring the normally open (NO) contact left and right side level limit switches. Either of these switch contacts are normally set to close when the pressing beam is out of level to the left or the right side but should never occur on both at the same time.
  • Page 24 PCSS-F Additions Technical Manual LS-CS-M-023 Left NO Right NO Press NC Operator Action Description Open Open Closed Normal operation. Level within acceptable limits. Closed Open Closed No down movement allowed. Out of level left. Move up to re-level. Open Closed Closed No down movement allowed.
  • Page 25 LS-CS-M-023 PCSS-F Additions Technical Manual Channel 1 Channel 2 Switches Switches Emergency Stop Description Closed Closed Normal operating condition. Open Open Valid emergency stop detected. Emergency stop condition. Closed Open Fault with switch states detected. Emergency stop condition. Open Closed Fault with switch states detected.
  • Page 26 PCSS-F Additions Technical Manual LS-CS-M-023 4.2.1.5 ON Switch Monitor FIO04 – CN5 On Switch 24VDC Figure 4-11: Option 6 ON Switch (CN5 - FIO04 Connections) The ON switch, as illustrated in for the FIO04, is used to control the emergency Figure 4-11 stop circuit of the press brake.

  • Page 27: Emergency Stop Option 7

    LS-CS-M-023 PCSS-F Additions Technical Manual Two robot gate switch channels are provided on the PCSS unit for connection to the press brake as shown in for the FIO04 module. When the robot gate switch contacts Figure 4-12 connected to both of these inputs are opened, an emergency stop condition is invoked by the PCSS, preventing any further operation of the press brake but up movement of the press is still allowed.
  • Page 28 PCSS-F Additions Technical Manual LS-CS-M-023 The state of these inputs will determine how or if the press brake can be operated when used in this application. If both the left and right doors are open, an emergency stop situation would be invoked by the PCSS and no movement of the pressing beam would occur.
  • Page 29 LS-CS-M-023 PCSS-F Additions Technical Manual Two emergency stop channel safety inputs are provided on the PCSS unit for connection to the press brake as shown in for the FIO04 module. When the emergency stop switch Figure 4-14 contacts connected to both of these inputs are opened, an emergency stop condition is invoked by the PCSS, preventing any further operation of the press brake.
  • Page 30 PCSS-F Additions Technical Manual LS-CS-M-023 4.2.2.4 Brake Switch Monitors This option monitors the switches for the mechanical brakes and is comprised of two separate feedbacks from the brake unit, one an electrical monitor and the other a mechanical monitor as shown in below.
  • Page 31 LS-CS-M-023 PCSS-F Additions Technical Manual 4.2.2.5 CNC brake activation This option monitors allows an external input to activate the emergency brakes by applying 24V to this input. During brake activation the enable and quick stop signals will remain true. Removing 24V from this input disables the brakes immediately. The physical connection is made to X29 as shown in below Figure 4-16...
  • Page 32 PCSS-F Additions Technical Manual LS-CS-M-023 4.2.2.7 Enable Monitors This option monitors enables and monitors the outputs required to drive and stop the press. Two enable outputs are required to allow movement of the pressing beam as shown in below. Figure 4-18 FIO04 –...

  • Page 33: Error Reset Option 4

    LS-CS-M-023 PCSS-F Additions Technical Manual 4.2.2.9 Option Selection To select emergency stop option 7 during the PCSS configuration, set the initial value for the emergency stop option selection variable to 7. This will ensure that this option is initialised with all required inputs activated when the PCSS software is started.

  • Page 34: Error Reset Option 6

    PCSS-F Additions Technical Manual LS-CS-M-023 FIO04 – CN4 Station 1 Indicator 0VDC Station 2 Indicator 0VDC 24VDC Figure 4-21: Error Reset Option 4 (CN4 - FIO04 Output Connections) This error reset option is intended for use with down switch options allowing two operator stations.
  • Page 35 LS-CS-M-023 PCSS-F Additions Technical Manual 4.3.3 Error Reset Option 6 FIO04 – CN4 Error Reset 1 Error Reset 2 0VDC 0VDC 24VDC FIO04 – CN10 Error Reset 3 Error Reset 4 24VDC 0VDC 0VDC Figure 4-23: Error Reset Option 6 (CN4 - FIO04 Input Connections) Page 4-25 Original Language Version: 1.02 Released: 03/12/2013...
  • Page 36 PCSS-F Additions Technical Manual LS-CS-M-023 FIO04 – CN4 Station 1 Indicator 0VDC Station 2 Indicator 0VDC 24VDC FIO04 – CN10 Station 3 Indicator Station 4 Indicator 24VDC 0VDC 0VDC Figure 4-24: Error Reset Option 6 (CN4 - FIO04 Output Connections) This error reset option is intended for use with down switch options allowing four operator stations.

  • Page 37: Valve Monitoring Option 12

    LS-CS-M-023 PCSS-F Additions Technical Manual 4.4.1 Valve Monitoring Option 12 FIO04 – CN7 Valve Monitor – High Speed Y1 Valve Monitor – High Speed Y2 Valve Monitor – Prefill Valve Monitor – Proportional Y1-1 Valve Monitor – Proportional Y1-2 Valve Monitor – Proportional Y2-1 Valve Monitor –...

  • Page 38: Down Switch Function Options

    PCSS-F Additions Technical Manual LS-CS-M-023 The down switch options available can be selected in the PCSS during configuration with the ISaGRAF user application and it is then possible to connect for different operator station foot and hand control combinations as detailed below in the following sections. The press brake can also be configured for single or dual operator station by physically removing or adding the second station by changing the electrical connections dependent on the down switch option selected during the configuration of the PCSS.
  • Page 39 LS-CS-M-023 PCSS-F Additions Technical Manual FIO04 – CN9 Hand Button 1 – Left Hand Button 1 – Right Hand Button 2 – Left Hand Button 2 – Right 24VDC 0VDC FIO04 – CN10 24VDC 0VDC 0VDC Figure 4-27: Dual Operator Foot Control (CN9/10 - FIO04 Connections) The connections in this option allow dual operator station with foot pedal control on each as shown in for the FIO04 module.

  • Page 40: Down Switch Option 6 - Four Operator Foot Control Only

    PCSS-F Additions Technical Manual LS-CS-M-023 4.5.2 Down Switch Option 6 - Four Operator Foot Control Only FIO04 – CN4 Foot Pedal – Down 1 Foot Pedal – Down 2 0VDC 0VDC 24VDC FIO04 – CN9 Foot Pedal – Down 3 Foot Pedal –...
  • Page 41 LS-CS-M-023 PCSS-F Additions Technical Manual B12-31 Station Station Station Station Station 2H-F If a single station mode is selected then the 1 Foot – 1 Foot mode is selected and the corresponding station B8 to B11 is selected by the CNC. If the mode selected on the CNC is the 2 Foot - 2 Foot dual operator mode, both operator stations will be allowed to initiate down movement, when two corresponding stations B8 to B11 are selected by the CNC.
  • Page 43 LS-CS-M-023 PCSS-F Additions Technical Manual FIO04 – CN8 Special Mode 24VDC Figure 5-1: Special Mode Selection (CN8 - FIO04 Connections) When a PCSS special mode of operation is to be selected with the press brake, it is necessary to activate the physical input. The special mode input connection is shown in Figure 5-1 the FIO04.

  • Page 44: Kernel Operation

    PCSS-F Additions Technical Manual LS-CS-M-023 In addition to the stopping performance monitoring is a continuous check performed to ensure that the press break is not moving when the down switch is released. For down enable option 17 where down movement is detected for more than a distance of 80um while the down switch is released then the 7A83 condition code will be displayed by the PCSS to indicate the stopping movement failure for Y1 or 7A84 condition code if there is a stopping movement failure on Y2 and an emergency stop will then be triggered.

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