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Lazer Safe PCSS-A Series Technical Manual

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Summary of Contents for Lazer Safe PCSS-A Series

  • Page 2 This page has been left intentionally blank.
  • Page 3 LS-CS-M-046 PCSS-A Series Technical Manual Document Status Document Reference Code: LS-CS-M-046 Version: 1.25 Released: 12/09/2024 Page i Original Language Version: 1.25 Released: 12/09/2024...
  • Page 4 PCSS-A Series Technical Manual LS-CS-M-046 Document Revision History Date Manual Software Summary of Change Version Version 10/08/2012 1.00 Ax2.01.00 Initial release of publication 24/08/2012 1.01 Ax2.01.01 IO mapping changes to Down Enable options 4 and 6. 10/07/2013 1.02 Ax2.01.01 Updated guarding type compatibility table 7.3 for light guard type 1 and 3.
  • Page 5 LS-CS-M-046 PCSS-A Series Technical Manual Date Manual Software Summary of Change Version Version 20/03/2015 1.08 Ax2.10.00 (continued) Added Emergency Stop Option 19 Added notes for material sensing in Section 17. Updated kernel software interface. 17/04/2015 1.09 Ax2.12.01 Corrected special mode disparity codes...
  • Page 6 PCSS-A Series Technical Manual LS-CS-M-046 Date Manual Software Summary of Change Version Version 10/04/2019 1.15 Ax2.22.00 Updated Kernel Software Interface ANO2-15, DO1-82,83. Added Emergency Stop Options 23,24 (reserved). Added BLR-XL to Kernel Software Interface DO1-66. Updated Declaration of Conformity. 4/06/2019 1.16...
  • Page 7 LS-CS-M-046 PCSS-A Series Technical Manual Date Manual Software Summary of Change Version Version 29/04/2022 1.19 2.26.00 Updated DE option compatibility for Pre-Closing Ready DO1-43. Updated DE option compatibility for Pre-Pressing Ready DO1-37. Updated reference to PCSS Condition Code document in section 1-5.
  • Page 8 PCSS-A Series Technical Manual LS-CS-M-046 Date Manual Software Summary of Change Version Version 08/05/2024 1.23 2.30.00 Changed name for DO1/Ch 40 Table 7-5 to Adaptive Environment Sensing. Changed name for section 10.6.9 to Adaptive Environment Sensing. Changed name for B8 in Table 10-3 to Adaptive Environment Sensing.
  • Page 9 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 10 Related Documentation ......................2 Guide to Notes, Cautions and Warnings ..................2 Obtaining Technical Assistance ....................2 Introduction ..........................3 PCSS-A Series Hardware ......................5 Hardware Description ........................ 5 Alphanumeric Display Operation ....................7 Application Stop / Run Switch ..................... 9 Communication Ports .........................
  • Page 11 Guard Transmitter and Receiver Connections .............. 26 5.1.4 Laser Classification and Warnings ................26 5.1.5 Lazer Safe LZS-1, LZS-2, LZS-2-FG Transmitter / Receiver ........... 26 5.1.6 Lazer Safe IRIS, IRIS Plus and LZS-XL ................ 27 5.1.7 Light Guard Connections .................... 28 5.1.8...
  • Page 12 PCSS-A Series Technical Manual LS-CS-M-046 10.1 CNC/Guard/Counter Option Parameter ..................81 10.1.1 CNC Press Controller Parameter Options ..............81 10.1.2 CNC Press Controller Parameter (Option 0) ..............81 10.1.3 No CNC Press Controller Parameter (Option 1) ............81 10.2 Counting Method Function Options ................... 82 10.2.1...
  • Page 13 LS-CS-M-046 PCSS-A Series Technical Manual 10.6.22 Wrong Movement Direction Monitoring Disable ............95 10.6.23 Slow Speed Input Guard Muting – No CNC ..............95 10.6.24 Reserved – Bit 23 ...................... 95 10.6.25 Alternative Light Guard Type 3 ................... 95 10.6.26 Reserved – Bit 25 ...................... 95 10.6.27 Soft Stop Operation ....................
  • Page 14 PCSS-A Series Technical Manual LS-CS-M-046 11.28 Down Enable Option 28 ......................139 11.29 Down Enable Option 29 ......................141 11.29.1 Default OFF Control (Standard Configuration) ............141 11.29.2 Default ON Control (Alternate Configuration) ............141 11.29.3 Up-acting Machine ....................142 11.30...
  • Page 15 LS-CS-M-046 PCSS-A Series Technical Manual 12.7 Emergency Stop Option 7....................... 182 12.8 Emergency Stop Option 8....................... 182 12.8.1 Door Switches ......................182 12.8.2 Level Limit Switches ....................182 12.8.3 Emergency Stop Channels ..................182 12.8.4 Auxiliary Axis Contactor (Emergency Stop Output) ............. 182 12.9...
  • Page 16 PCSS-A Series Technical Manual LS-CS-M-046 13.3 Error Reset Option 3 ......................194 13.4 Error Reset Option 4 ......................194 13.5 Error Reset Option 5 ......................195 13.6 Error Reset Option 6 ......................195 13.7 Error Reset Option 7 ......................195 14 Valve Monitoring Safety Function Options ................
  • Page 17 Stopping Test Operation ..................255 17.3.6 Start-Up and Stopping Test Limits ................255 17.3.7 Lazer Safe LZS-1, LZS-2 and LZS-2-FG Systems ............255 17.3.8 Lazer Safe IRIS, IRIS Plus, LZS-XL Systems .............. 256 17.3.9 Light Guard System Types 1 and 2 ................256 17.3.10 Light Guard System Type 3 ..................
  • Page 18 17.5.4 Light Guard System Type 3 ..................262 17.5.5 PCSS Configuration without Guard and Counter ............263 17.6 Lazer Safe Guarding System Specific Operation Modes ............. 263 17.6.1 Normal Mode Operation ................... 263 17.6.2 Tray Mode Operation ....................264 17.6.3 Tray Mode Operation With CNC Up-Stand Height ............
  • Page 19 17.13.2 Lazer Safe Guarding Systems ................... 283 17.13.3 Lazer Safe LZS-2/LZS-2-FG Guarding System ............284 17.13.4 Lazer Safe IRIS, IRIS Plus, LZS-XL Guarding Systems ..........284 17.13.5 Light Guard System Types 1 and 2 ................286 17.13.6 Light Guard System Type 3 ..................286 17.13.7 PCSS Configuration without Guard and Counter ............
  • Page 20 PCSS-A Series Technical Manual LS-CS-M-046 This page has been left intentionally blank. Page xviii Original Language Version: 1.25 Released: 12/09/2024...
  • Page 21 Prerequisites To use Lazer Safe PCSS-A Series Technical Manual, you should be fully conversant with all critical safety aspects of the PCSS-A Series models and the press brake upon which it is to be installed. Document Organisation This manual is organised into the following chapters: 1.
  • Page 22 16. Auxiliary Connections 17. Operation 18. Specifications 19. EC Declaration of Conformity Related Documentation This manual (PCSS-A Series Technical Manual) should be used in conjunction with the following documents: • Lazer Safe PCSS Condition Codes (LS-RD-T-003). • Lazer Safe Bracket Installation Manual (LS-CS-M-026).
  • Page 23 It can be used in conjunction with the Lazer Safe LZS Operator Guarding to provide a highly effective and efficient single-supplier solution. It is also possible to use other types of light guard systems such as light curtains should a different guarding solution be required.
  • Page 24 PCSS-A Series Technical Manual LS-CS-M-046 Description PCSS-A0 & PCSS-A0 Plus PCSS-A1 & A2 LZS-1 (Planar Laser) LZS--1 (Planar Laser) LZS-2, LZS-2-FG (Block Laser) LZS-2, LZS-2-FG (Block Laser) Guard Systems Other Light Guard systems IRIS, IRIS-Plus, LZS-XL (Block Laser) Other Light Guard Systems...
  • Page 25 LS-CS-M-046 PCSS-A Series Technical Manual PCSS-A Series Hardware Hardware Description The PCSS-A series comprises a standard base unit housing the entire system with the motherboard containing: • Dual CPUs. • One shared RS-232 / USB serial port (CNC comms). •...
  • Page 26 PCSS-A Series Technical Manual LS-CS-M-046 Figure 3-3 overleaf shows the front panel layout of the PCSS-A0 and Figure 3-4 overleaf shows the front panel layout of the PCSS-A1 and PCSS-A2. Figure 3-3: PCSS-A0/PCSS-A0 Plus Front Panel (NOTE: PCSS-A0 Plus has both Y1 and Y2 connections) Page 6 Original Language Version: 1.25...
  • Page 27 LS-CS-M-046 PCSS-A Series Technical Manual Figure 3-4: PCSS-A1/A2 Front Panel Alphanumeric Display Operation The alphanumeric display on the front panel shows operational status and conditions of the PCSS. Upon powering up the PCSS unit, the status of each of the start-up checks is displayed as it is performed.
  • Page 28 PCSS-A Series Technical Manual LS-CS-M-046 The following is the structure of the information line that is scrolled across the first line of the PCSS display; PCSS_Ax Indicates the configured communications parameters as detailed below: A-B-C-EFG A: Number of data bits...
  • Page 29 LS-CS-M-046 PCSS-A Series Technical Manual Application Stop / Run Switch The Stop / Run switch located on the front panel allows an ISaGRAF user-defined application being run by the PCSS software to be stopped, while allowing the internal software safety function options selected to remain running.
  • Page 30 PCSS-A Series Technical Manual LS-CS-M-046 Expansion Bus Port (PCSS-A1/A2) Lazer Safe produces a range of accessory products that connect to the PCSS-A1/A2 Expansion Bus Port and extend the capabilities of the PCSS-A1 and PCSS-A2 safety controllers. The Expansion Bus pinout is shown in Figure 3-8.
  • Page 31 LS-CS-M-046 PCSS-A Series Technical Manual To ensure a totally safe application at all times, these hardware interrupts are hidden from the user application. As these cannot be reconfigured by any means, it is not possible to create an unsafe user application.
  • Page 32 PCSS-A Series Technical Manual LS-CS-M-046 PCSS-A Figure 3-10: Recommended PCSS-A Earthing Note: In order to support all possible earthing schemes, the earthing point for the PCSS-A case is isolated from all other system earths. Also, the cases of the D9 connectors (for the optical guards, encoders and serial communications) are not connected to any other system earths.
  • Page 33 LS-CS-M-046 PCSS-A Series Technical Manual • Access for service. • Clearance for connectors to allow easy connection or disconnection. • Location of adjacent ducting and height of ducting. • Visibility of the LED indicators. The recommended clearance measurements from the edge of the top cover when mounting the PCSS-A units are: •...
  • Page 34 LS-CS-M-046 The mounting dimensions when using this method of installation are shown in Figure 3-11. Figure 3-12: PCSS-A Series Mounting Dimensions Note: To ensure secure and stable mounting always use all four mounting feet supplied with the PCSS-A. Page 14 Original Language Version: 1.25...
  • Page 35 Figure 3-13. Figure 3-13: PCSS-A Series DIN Rail Mounting Option 3.9.3 External Enclosure IP Rating If the PCSS-A is not mounted in the control-cabinet, it should be mounted in a suitable enclosure on the press brake.
  • Page 36 PCSS-A Series Technical Manual LS-CS-M-046 Input /Output Module Description There are currently two types of PCSS-A with different input/output capabilities. These have been designed and developed for specific press brake applications, differing in their input and output configurations. Connections provided for each of these modules are arranged in a number of generic connector groups.
  • Page 37 LS-CS-M-046 PCSS-A Series Technical Manual Input / Output Types Each Lazer Safe I/O module variant contains a combination of digital inputs and outputs. These can be of the following types: • Standard inputs; • Standard outputs; • Pulsed inputs; and •...
  • Page 38 PCSS-A Series Technical Manual LS-CS-M-046 All dual outputs are labelled with the prefix “Y”, followed by the output number, “H” for the high side driver or “L” for the low side driver. For example, Y00H is the high side switch for output 00; Y00L is the low side switch for the same output.
  • Page 39 LS-CS-M-046 PCSS-A Series Technical Manual Power Supply Specifications Input points Input voltage 24 VDC ± 10% Input current 24 A 4.3.3 CN3 Connections CN3 has input connections for up, down and error reset switches on a 12-way removable terminal block. These are standard inputs (X00 – X11).
  • Page 40 PCSS-A Series Technical Manual LS-CS-M-046 Input / Output Module ISaGRAF Interface The Input / Output Module Interface for the PCSS provides an interface from the input and output module of the PCSS-A hardware to the kernel software safety functions and the ISaGRAF user application.
  • Page 41 LS-CS-M-046 PCSS-A Series Technical Manual PCSS-A I/O Specifications 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...
  • Page 42 PCSS-A Series Technical Manual LS-CS-M-046 This page has been left intentionally blank. Page 22 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 43 • The Guarding System. The high speed counters monitor machine movement, while the guarding system allows either a Lazer Safe transmitter/receiver, or a light guard, or a combination of both to be connected to the PCSS-A. Guard Operation The guard system interfaces with the Lazer Safe transmitter/receiver, or third party light guarding systems such as light curtains.
  • Page 44 The IRIS and IRIS Plus can be used where enhanced productivity and faster cycle times are required, reducing the slow speed distance of the machine down to 0mm. The IRIS Plus also performs real time angle measurement; refer to Lazer Safe IRIS Plus Optical Imaging System Technical Manual (LS-CS-M-082) for details.
  • Page 45 LS-CS-M-046 PCSS-A Series Technical Manual Transmitter Connector CN16 LC Test 2 Laser A Laser B Condition Indicator LC Test 1 0 VDC Figure 5-1: CN16 Guard Condition Lamp Indicator Connections Figure 5-2: CN16 Guard Condition LED Indicator Connection Figure 5-3: CN18 Guard Condition Lamp Indicator Connections...
  • Page 46 CN15 DB9 plug, and CN16 DB9 socket as shown in Figure 5-5 Figure 5-6 below. (The wire colours shown relate to a cable that can be provided by Lazer Safe on request). Page 26 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 47 Green Shield Shield Figure 5-6: Lazer Safe LZS-1, LZS-2, LZS-2-FG Transmitter Connections Refer to the appropriate Lazer Safe manual (available from http://www.lazersafe.com) for installation and alignment procedures. 5.1.6 Lazer Safe IRIS, IRIS Plus and LZS-XL Connections for the IRIS, IRIS Plus and LZS-XL transmitter/receiver units (PCSS-A1/A2 only)
  • Page 48 Black Shield Figure 5-8: Lazer Safe IRIS, IRIS Plus, LZS-XL Transmitter Connections Refer to the appropriate Lazer Safe manual (available from http://www.lazersafe.com) for installation and alignment procedures. Note: For historical reasons CN17 and CN18 are labelled 005 RX and 005 TX respectively.
  • Page 49 LS-CS-M-046 PCSS-A Series Technical Manual Figure 5-10: Light Guard Transmitter Connections (Linked Input Test Activation) Figure 5-11: Light Guard Transmitter Connections (Single Input Test Activation) The connections for the light guard transmitter of Type 1 that provides two inputs for activation...
  • Page 50 PCSS-A Series Technical Manual LS-CS-M-046 5.1.8 CN15 RX & CN16 TX Guard Specifications Inputs Input points (laser) Input points (light guard) 5 VDC  10% Input voltage (laser) 24 VDC  10% Input voltage (light guard) Voltage on (laser) 4.0 VDC...
  • Page 51 LS-CS-M-046 PCSS-A Series Technical Manual 5.1.9 CN17 RX & CN18 TX Guard Specifications Inputs Isolation Opto-coupler On display Red LED External connection DB9 socket Outputs Isolation Opto-coupler On display Red LED External connection DB9 plug Condition indicator output Output points...
  • Page 52 PCSS-A Series Technical Manual LS-CS-M-046 Counter Functionality The PCSS-A is equipped with a high speed counter to monitor the stopping distance, stopping time or speed of the pressing beam accurately. 5.2.1 Counter Operation The single counter component of the PCSS-A0 or the dual counter component of the PCSS- A0 Plus/A1/A2 interface to the optical encoders of the press brake.
  • Page 53 LS-CS-M-046 PCSS-A Series Technical Manual Figure 5-13: Encoder Shield Earthing 4-Pair 0.22 Brown Brown/White Blue Blue/White Orange Orange/White Internal Connection Green Green/White Shield to be earthed at a single point upon entry into the electrical cabinet Figure 5-14: Encoder 1 Input Connections...
  • Page 54 PCSS-A Series Technical Manual LS-CS-M-046 4-Pair 0.22 Green/White Internal Green Connection Orange/White Orange Blue/White Blue Brown/White Brown Figure 5-16: Encoder 1 Output Connections Encoder 2 OUT CN13 Socket 4-Pair 0.22 Green/White Internal Green Connection Orange/White Orange Blue/White Blue Brown/White Brown...
  • Page 55 LS-CS-M-046 PCSS-A Series Technical Manual Communications Connections ISaGRAF Host PC Communications During normal operation the connection between the PCSS-A and the host PC running the ISaGRAF workbench software is made via PCSS-A COM1 (CN10), an internal USB to serial converter, see Figure 6-1.
  • Page 56 PCSS-A Series Technical Manual LS-CS-M-046 Only the Communication Port option needs to be set to the appropriate serial port, all other options can remain at their default value. Note: Do not change the Target Slave Number from the default value of 1, otherwise the host PC will not be able to communicate with the PCSS-A.
  • Page 57 LS-CS-M-046 PCSS-A Series Technical Manual PCSS – COM2 CNC - COM PORT *RTS *CTS SHIELD - DB9 SHIELD DB9 PLUG * Optional, dependent upon CNC SOLDER BUCKET VIEW Figure 6-4: CNC to PCSS Serial Communications Connection (CN9A) All communication parameters are set in the ISaGRAF application, and are detailed in Chapter 8, CNC Press Controller Communications Interface.
  • Page 58 PCSS-A Series Technical Manual LS-CS-M-046 RUN LED State Description RESET PCSS CANopen communications is executing a reset. Single Flash STOPPED The PCSS is in the STOPPED state. Blinking PRE- The PCSS is in the PRE-OPERATIONAL state. OPERATIONAL OPERATIONAL The PCSS is in the OPERATIONAL state.
  • Page 59 LS-CS-M-046 PCSS-A Series Technical Manual PCSS Kernel Software Interface Kernel ISaGRAF Interface The Kernel Software Interface for the PCSS provides an interface between the kernel software safety functions and the ISaGRAF user application. The user application can write variables to the software kernel for configuration and control of the PCSS-A, and it can read variables from the kernel for use in controlling the user application.
  • Page 60 PCSS-A Series Technical Manual LS-CS-M-046 Changing the numbering in ISaGRAF Workbench version 3.x software can be performed by selecting Numbering in the Options menu of the I/O connection editor and ensuring the first number for Slots and Channels is set to zero and shown in Figure 7-2 below.
  • Page 61 Channel # Variable Name Description k_mode_sam Stop at mute mode k_mode_norm Normal mode (Lazer Safe guarding system only) k_mode_field Field muted mode k_mode_try Tray mode (Lazer Safe guarding system only) k_mode_go Guard only mode (light guard systems only)
  • Page 62 ACB medium tool detected k_acb_sml ACB small tool detected k_acb_stat ACB tool confirmation status k_setup_md Setup mode active k_mode_try2 Tray 2 mode (Lazer Safe guarding system only) k_mv_up_raw Unprocessed moving up signal k_angle_conf_slw Angle Confirmation Force Slow k_mode_tandem Tandem mode k_tandem_en...
  • Page 63 Start-up test static brake test request or k_hyd_tst_req Hydraulic valve test request (Down Enable Option 31) k_obst Guarding obstruction detected for Lazer Safe or light guard systems k_prp_tst or Proportional test active or k_dyn_tst_ok Dynamic brake test ok or...
  • Page 64 Emergency stop enable k_md_man Manual mode selected k_md_robot Robot mode k_md_norm Normal mode (Lazer Safe guarding system only) k_md_try Tray mode (Lazer Safe guarding system only) k_md_sam Stop at mute mode k_md_go Guard only mode (light guard systems only)
  • Page 65 Force repeat of start up tests k_lc_alt_brk Alternative light curtain mode enable k_lc_full Keep light curtains active for full stroke (including below the mute point) k_md_try2 Tray 2 mode (Lazer Safe guarding system only, No CNC) k_md_ba Enable BendAid support k_md_ex Enable ExSPSOE support k_md_tandem...
  • Page 66 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Variable Name Description SmartLink Brackets – restrict max continuous speed to 10mm/s k_bkt_limp_md k_tand_master Tandem mode master PCSS-A k_rt_angle_dis Disable default real time angle measurement for IRIS Plus k_alt_sut Alternative SUT distance 140/70mm for No CNC option...
  • Page 67 LS-CS-M-046 PCSS-A Series Technical Manual Kernel Interface Analogue Input (ANI) This section details the analogue input channel from the kernel software. Analogue inputs are passed from the kernel to the user application. Channel # Units Variable Name Description microns k_mu_pcss...
  • Page 68 PCSS-A Series Technical Manual LS-CS-M-046 Kernel Interface Analogue Output #1 (ANO) This section details the first analogue output channel to the kernel software. Analogue outputs are passed from the kernel to the user application. Channel # Units Variable Name Description...
  • Page 69 LS-CS-M-046 PCSS-A Series Technical Manual Kernel Interface Analogue Output #2 (ANO2) This section details the second analogue output channel to the kernel software. Analogue outputs are passed from the kernel to the user application. Channel # Units Variable Name Description...
  • Page 70 PCSS-A Series Technical Manual LS-CS-M-046 Each of the bits in ANO2, channel 30 set specific options for the Robot Mode Operation function enable value. The bits are detailed in Table 7-10 below. Bit # Description Low level hardware checks Stopping distance and time monitoring...
  • Page 71 LS-CS-M-046 PCSS-A Series Technical Manual CNC Press Controller Communications Interface The CNC Press Controller Communications Interface configures the transfer of information about the operation and bending cycle for the press brake from the CNC press controller to the PCSS, or from the PCSS to the CNC press controller. The communications is via the...
  • Page 72 CNC press controller or Lazer Safe to determine if the controller, and the version being used, are supported by the PCSS. The communications parameters must also be determined based on the requirements of the CNC press controller so these can be set during configuration of the PCSS.
  • Page 73 LS-CS-M-046 PCSS-A Series Technical Manual The CNC press controller communications interface also allows the operator of the machine to select the operator station that will be used, as well as the operator mode required to control the movement of the machine with the PCSS. The operator also has the alibility to select the type of guarding mode for each bend to be performed with the PCSS.
  • Page 74 The protocol option must be set to 0 when defining the ISaGRAF user application for this communications interface option. The LzsBus protocol is fully described in Lazer Safe PCSS Serial Protocol Specification (LS-CS-M-060). Note: The communication parameters defined during configuration of the PCSS in the...
  • Page 75 LS-CS-M-046 PCSS-A Series Technical Manual 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 or slow speed position...
  • Page 76 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Description 26-27 Reserved Foot Station 1 Foot Station 2 Foot Station 3 Foot Station 4 Table 8-6: PCSS operation parameters from the CNC (OperMode) 26-31 Note: The PCSS-A kernel software extracts this data directly from the incoming data stream;...
  • Page 77 LS-CS-M-046 PCSS-A Series Technical Manual ModBus ASCII Communications Interface Option ISaGRAF driver Driver name ser1__a11 Driver description Characteristics as shown below Channel # Description Protocol option (Set to 1 for ModBus ASCII) Baud rate option (0 = 9600; 1 = 19200; 2 = 38400; 3 = 57600; 4 = 76800;...
  • Page 78 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Units Description microns Reference Y1 microns Reference Y2 microns Pinching point 3 - 7 Reserved microns CNC mute or slow speed position microns Up-stand height 10 - 12 Reserved Count direction Y1 Count direction Y2...
  • Page 79 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Description Spare Spare Spare Spare Station 02 Mode 1foot - 1foot Mode 2hand - 1foot Mode 2hand - 2hand Mode 2 foot - 2 foot Mode 4hand - 2foot Mode 4hand - 4hand...
  • Page 80 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Units Description Block laser tool tip mode Block laser type Block laser default row Block laser default column Block laser tool tip row Block laser tool tip column Block laser top range Block laser bottom range...
  • Page 81 LS-CS-M-046 PCSS-A Series Technical Manual ModBus RTU Communications Interface Option ISaGRAF driver Driver name ser2__a7 Driver description Characteristics as shown below Channel # Description Protocol option (Set to 2 for ModBus RTU) Baud rate option (0 = 9600; 1 = 19200; 2 = 38400; 3 = 57600; 4 = 76800;...
  • Page 82 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Description ModBus Register 405001 - 405002 Spare Spare Spare Spare Station 02 Mode 1foot - 1foot Mode 2hand - 1foot Mode 2hand - 2hand Mode 2 foot - 2 foot Mode 4hand - 2foot...
  • Page 83 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Description ModBus Register 401001 - 401064 0 - 31 Spare Table 8-30: Write Generic Analogue inputs (gA_in_w) Channel # Description ModBus Register 403001 - 403002 0 - 31 Spare Table 8-31: Write Generic Digital inputs (gD_in_w)
  • Page 84 PCSS-A Series Technical Manual LS-CS-M-046 CANOpen Communications Interface Option (PCSS-A2) The CANOpen communications interface option requires a hardware interface only available in the PCSS-A2, refer to Section 6.2.2 for details. The PCSS acts as a CANOpen slave node, the ID number is set in the ComParam complex equipment, see Table 8-34.
  • Page 85 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Units Description Index:Sub Index microns Reference Y1 2000:01 RPDO1:1-4 microns Reference Y2 2000:02 RPDO1:5-8 microns Material thickness 2000:03 RPDO2:1-4 microns Die 01 height 2000:04 RPDO2:5-8 microns Die 02 height 2000:05 RPDO3:1-4 microns Punch 01 height...
  • Page 86 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Description Spare Down high speed Down low speed 5-14 Spare Condition changed 16-23 Spare Table 8-39: PCSS status to the CNC - 2082:01 TPDO2:1-4 (PCSS_ST) Channel # Description CNC OK Mute point Axis in position...
  • Page 87 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Description Index:Sub Index 2091:01 – 2091:04 TPDO19:1-4 – TPDO20:5-8 0-127 Spare Table 8-44: Generic digital outputs (gD_out) Description Index:Sub Index PCSS-A Kernel Version 2100:01 ISaGRAF Application Name 2100:02 Application Version 2100:03 Table 8-45: PCSS-A software versions Page 67 Original Language Version: 1.25...
  • Page 88 The protocol option must be set to 0 when defining the ISaGRAF user application for this communications interface option. The LzsBus protocol is fully described in Lazer Safe PCSS Serial Protocol Specification (LS-CS-M-060). Note: The communication parameters defined during configuration of the PCSS in the...
  • Page 89 LS-CS-M-046 PCSS-A Series Technical Manual 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 or slow speed position...
  • Page 90 PCSS-A Series Technical Manual LS-CS-M-046 Channel # Description 26-27 Reserved Foot Station 1 Foot Station 2 Foot Station 3 Foot Station 4 Table 8-51: PCSS operation parameters from the CNC (OperMode) 26-31 Note: The PCSS-A kernel software extracts this data directly from the incoming data stream;...
  • Page 91 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Description 0-31 FSoE digital inputs into the ISaGRAF application 32-63 Reserved FSoE digital inputs direct to the PCSS kernel software Table 8-57: FSoE Digital inputs (FSoE_DI) Channel # Description 0-31 FSoE digital outputs from the ISaGRAF application...
  • Page 92 PCSS-A Series Technical Manual LS-CS-M-046 This page has been left intentionally blank. Page 72 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 93 Valve Monitoring and • Down Switch. Special custom function options can also be developed by Lazer Safe to suit a manufacturer's requirements and the specific application of their press brake, if not already supported by the standard function options available.
  • Page 94 PCSS-A Series Technical Manual LS-CS-M-046 The I/O complex equipment for the Kernel Software Interface must be added within the I/O Connections editor of ISaGRAF, and output integer variables should then be defined for selection of each of the function options. Once these variables are defined, they can be...
  • Page 95 LS-CS-M-046 PCSS-A Series Technical Manual Identification of Selected Options When the configuration of the ISaGRAF application has been completed for the press brake, it is important to be able to easily identify which of the functions options have been selected and initialised by the PCSS software.
  • Page 96 PCSS-A Series Technical Manual LS-CS-M-046 In the latter case the option will be described by the bit number, and also by the decimal equivalent that can be used to calculate the final value of the option number. For example, to set bit 7, add 128 to the final guard/counter option number.
  • Page 97 LS-CS-M-046 PCSS-A Series Technical Manual Safety Function Option PCSS-A0 PCSS-A1 PCSS-A2 Comments Option Type Number or A0 Plus Down Enable Currently not supported Reserved Reserved Currently not supported Reserved Reserved Reserved Reserved Reserved Table 9-2 PCSS-A0/A0 Plus/A1/A2 Down Enable Safety Function Option Compatibility Page 77 Original Language Version: 1.25...
  • Page 98 PCSS-A Series Technical Manual LS-CS-M-046 Safety Function Option PCSS-A0 PCSS-A1 PCSS-A2 Comments Option Type Number or A0 Plus Error Reset Reserved - Same as Option 1 Reserved - Same as Option 3 Reserved Reserved Table 9-3 PCSS-A0/A0 Plus/A1/A2 Error Reset Safety Function Option Compatibility Page 78 Original Language Version: 1.25...
  • Page 99 LS-CS-M-046 PCSS-A Series Technical Manual Safety Function Option PCSS-A0 PCSS-A1 PCSS-A2 Comments Option Type Number or A0 Plus Valve Monitoring No inputs from valve monitors used Compatible DE option 4 and 6 Compatible DE option 5 Compatible DE option 4, 6 and 9...
  • Page 100 PCSS-A Series Technical Manual LS-CS-M-046 Safety Function Option PCSS-A0 PCSS-A1 PCSS-A2 Comments Option Type Number or A0 Plus Down Switch Table 9-5 PCSS-A0/A0 Plus/A1/A2 Down Switch Safety Function Option Compatibility Counting PCSS-A0 with PCSS-A0 with PCSS-A0 Plus/A1/A2 PCSS-A0 Plus/A1/A2 Method...
  • Page 101 A pushbutton connected to the Test Lock input (DO1, channel 19) is used by the operator to confirm the mute point. In the case of Lazer Safe guarding systems, the beam is lowered until an obstruction occurs, the operator confirms the position, and the PCSS-A then calculates an appropriate mute point above the obstruction.
  • Page 102 PCSS-A Series Technical Manual LS-CS-M-046 To select the no CNC press controller parameters option during the PCSS configuration, a CNC option value of 128 should be used to calculate the CNC/Counting/Guarding option selection variable value as described in Section 10.5. This will ensure that this option and the functionality required are initialised when the PCSS software is started.
  • Page 103 10.3 Guarding Type Function Options This option sets the type of guarding to be used with the PCSS-A; the Lazer Safe guarding system, OEM light guard systems, or no guarding system. The guarding type function option is selected during configuration of the PCSS, and is set by the value entered for the CNC/Counting/Guarding option;...
  • Page 104 PCSS software is started. 10.3.4 No Guard (Code 3) This option is selected when no Lazer Safe guard is used by PCSS, and in this situation may be used in combination with the no counting option as described in Section 10.2.3.
  • Page 105 LS-CS-M-046 PCSS-A Series Technical Manual 10.4 Light Guard Systems This section describes the options available for using OEM light guards (such as light curtains) with the PCSS-A. These may be used on their own, or in conjunction with Lazer Safe guarding systems.
  • Page 106 10.4.4 Light Guard Type 3 (Code 12) Light guard type 3 operates in the same manner as the Lazer Safe LZS-1 planar laser guarding systems, where a third party device is mounted on, and moves with, the pressing beam of the press brake. The protective field of this light guard device is positioned and aligned under the punch of the press brake to provide protection.
  • Page 107 LS-CS-M-046 PCSS-A Series Technical Manual 10.6 Guard/Counter Operation Option As well as the CNC/Counter/Guard Option selected as part of Section 10.5, there are also Operation Options that configure how the selected Counter/Guard systems behave during operation. These options are selected by setting the initial value for ANO channel 19 (Option Parameter 1) and ANO channel 18 (Option Parameter 2) in the ISaGRAF kernel software interface.
  • Page 108 PCSS-A Series Technical Manual LS-CS-M-046 Guard/Counter Operation Options 32-63 AN0 Channel 18 (Parameter 2 ) Decimal Description Force crawl on tool tip error. Force crawl during SmartLink Bracket operation. No Material Sensing Forced Crawl Speed Disable Reserved Reserved Reserved Reserved...
  • Page 109 When operating the PCSS with either Light Guard Type 1 or Type 2, down movement is restricted to crawl speed once the light guard has been muted. Unlike the Lazer Safe guarding systems or Light Guard Type 3, pressing speed is not allowed as the light guards cannot detect the surface of the material.
  • Page 110 LS-CS-M-046 10.6.5 Tray Mode Centre Obstruction Operation When using the Lazer Safe guarding system in Tray mode, crawl speed is enforced whenever a centre segment obstruction is detected, even if the obstruction of the centre segment is then removed, see Section 17.6.2.
  • Page 111 Functionally identical to the LZS-2, the LZS-2-FG has been modified specifically for use with folding machines, and the Lazer Safe folding machine mounting hardware. Depending upon the local authorities, it is possible that higher than normal bending speeds can be monitored by the PCSS-A.
  • Page 112 PCSS-A Series Technical Manual LS-CS-M-046 10.6.9 IRIS, IRIS Plus Adaptive Environment Sensing (AES) Operation On long machines it may be necessary to change the method used for guarding detection, to allow for minor laser beam movement. This can be due to environmental conditions, or mechanical factors that distort the laser beam.
  • Page 113 Limits can be set to ensure that the projecting material does not move at an unsafe speed. If the BSM mode is set (DO1 channel 41), and appropriate Lazer Safe imaging hardware is detected, then the PCSS-A (in conjunction with the CNC) will monitor the press brake bend speed.
  • Page 114 Parameter 1 variable. 10.6.19 No Material Sensing Disable Under normal operation of the Lazer Safe guarding system, the position of the mute point is calculated by the PCSS based on the expected obstruction position from the surface of the work material. This obstruction position is then confirmed during the mute setting stage, and...
  • Page 115 This option has been developed for specialised press machinery and not intended for use on press brakes. Do not select this or use this option unless specifically directed by Lazer Safe Customer Service. To select this option during the PCSS configuration, the value 16777216 should be used to calculate the initial value for the Guard Operation Option Parameter 1 variable.
  • Page 116 PCSS-A Series Technical Manual LS-CS-M-046 10.6.27 Soft Stop Operation On some machines, when the pressing beam is stopped in high speed by the PCSS-A (due to operator control or an obstruction), the sudden deactivation of the valves may result in excessive vibration and noise from the press brake.
  • Page 117 PCSS software is started. 10.6.35 No Material Sensing Forced Crawl Speed Disable Under normal operation of the Lazer Safe guarding system, the position of the mute point is calculated by the PCSS based on the expected obstruction position from the surface of the work material.
  • Page 118 PCSS-A Series Technical Manual LS-CS-M-046 This page has been left intentionally blank. Page 98 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 119 LS-CS-M-046 PCSS-A Series Technical Manual Down Enable Safety Function Options These options enable and control movement of the pressing beam when initiated by the operator of the press brake. The down enable function option to be selected will depend on the solenoid valve control strategy needed, which is based primarily on the hydraulic configuration of the press brake on which the PCSS is being installed.
  • Page 120 This makes sure that the energy from the inductive load at switch off is dissipated through the suppressor installed and not the PCSS output. Lazer Safe recommends varistor protection is fitted across all valve solenoids installed on the press brake when connected to the PCSS.
  • Page 121 LS-CS-M-046 PCSS-A Series Technical Manual This down enable option provides outputs for control of the following solenoid valves on the press brake. • High Speed Solenoids; • Prefill Solenoid; • Safety Solenoid and; • Proportional Solenoids Enable. 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.
  • Page 122 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 SAFETY SOLENOIDS AIO – Y03 PROPORTIONAL ENABLE AIO – Y06 Figure 11-2: Down Enable Option 1 Output Operation Should the soft stop operation be enabled as described in Section 10.6.27, the following...
  • Page 123 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 SAFETY SOLENOIDS AIO – Y03 PROPORTIONAL ENABLE AIO – Y06 Figure 11-3: Down Enable Option 2 Output Operation Should the soft stop operation be enabled as described in Section 10.6.27, the following...
  • Page 124 PCSS-A Series Technical Manual LS-CS-M-046 11.3 Down Enable Option 3 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Y03H 0VDC Y02L Solenoid Prefill Y02H Y01L Solenoids High Speed Y01H Y00L Solenoids Y00H...
  • Page 125 LS-CS-M-046 PCSS-A Series Technical Manual The prefill solenoid output is connected to a safety output on the PCSS and provided that: • There is no emergency stop condition; • The pressing beam is level; • The enable is set; and •...
  • Page 126 PCSS-A Series Technical Manual LS-CS-M-046 11.4 Down Enable Option 4 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Solenoid Safety Y03H 0VDC Y02L Solenoid Down Y02H Y01L Solenoid Solenoid High Speed Y01H...
  • Page 127 LS-CS-M-046 PCSS-A Series Technical Manual The outputs used on the PCSS for the solenoid valves on the press brake provided by this option are detailed below with the connections shown in Figure 11-6 for AIO. The operation of these solenoid valve outputs during up and down movement of the pressing beam is shown Figure 11-7.
  • Page 128 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE UP ENABLE DOWN LOW SPEED DOWN SOLENOID AIO – Y02 HIGH SPEED SOLENOIDS AIO – Y01 PRESSURE SOLENOID AIO – Y06 SAFETY SOLENOIDS AIO – Y03 UP SOLENOID AIO – Y09 Figure 11-7: Down Enable Option 4 Output Operation...
  • Page 129 LS-CS-M-046 PCSS-A Series Technical Manual The connections for the solenoid valve outputs provided by this option are shown in Figure 11-8 for AIO. The operation of these solenoid valve outputs during up and down movement of the pressing beam is shown in Figure 11-9.
  • Page 130 PCSS-A Series Technical Manual LS-CS-M-046 11.6 Down Enable Option 6 The connections for this down enable option are the same as shown in Figure 11-6 for down enable option 4. The operation of this option is also based on the down enable option 4, with the only difference being in the operation of the safety solenoid valve output and the high speed solenoid output.
  • Page 131 LS-CS-M-046 PCSS-A Series Technical Manual 11.7 Down Enable Option 7 The connections for this down enable option are the same as shown in Figure 11-1 for down enable option 1. The operation, however, is similar to down enable option 2, with the only difference being in the operation of the prefill solenoid valve output.
  • Page 132 PCSS-A Series Technical Manual LS-CS-M-046 Table 11-8 details the operation of the solenoids which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), then all solenoids are turned off for both start-up tests.
  • Page 133 LS-CS-M-046 PCSS-A Series Technical Manual Should the soft stop operation be enabled as described in Section 10.6.27, the following valves will be delayed in switching off until down movement comes to a complete stop. The proportional enable output will switch off immediately and can be used to perform a controlled decelerated stop.
  • Page 134 PCSS-A Series Technical Manual LS-CS-M-046 The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 135 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO - Y01 PREFILL SOLENOID AIO - Y02 SAFETY SOLENOIDS AIO - Y03 DOWN SOLENOIDS AIO - Y04 PROPORTIONAL ENABLE AIO - Y06 Figure 11-14: Down Enable Option 9 Output Operation...
  • Page 136 PCSS-A Series Technical Manual LS-CS-M-046 11.10 Down Enable Option 10 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Solenoids Unload Y04H 0VDC Y03L 0VDC Solenoids Safety Y03H 0VDC Y02L Solenoid Prefill Y02H Y01L Solenoids High Speed...
  • Page 137 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 SAFETY SOLENOIDS AIO - Y03 UNLOAD SOLENOIDS AIO - Y04 PROPORTIONAL ENABLE AIO - Y06 Figure 11-16: Down Enable Option 10 Output Operation...
  • Page 138 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 SAFETY SOLENOIDS AIO – Y03 PROPORTIONAL ENABLE AIO – Y06 Figure 11-17: Down Enable Option 11 Output Operation Should the soft stop operation be enabled as described in Section 10.6.27, the following...
  • Page 139 LS-CS-M-046 PCSS-A Series Technical Manual Table 11-13 details the operation of the outputs that will be turned off during the press brake start-up tests. Start-up Test 1 Start-up Test 2 Safe Torque Off Quickstop Brake Table 11-13: Down Enable Option 12 Start-up Test Operation...
  • Page 140 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 SAFETY SOLENOIDS AIO – Y03 PROPORTIONAL ENABLE AIO – Y06 Figure 11-19: Down Enable Option 14 Output Operation Should the soft stop operation be enabled as described in Section 10.6.27, the following...
  • Page 141 LS-CS-M-046 PCSS-A Series Technical Manual 11.15 Down Enable Option 15 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Solenoids Safety Y03H 0VDC Y02L Y02H Y01L Y01H Y00L Solenoids Y00H Proportional Enable Figure 11-20: Down Enable Option 15 (AIO Connections)
  • Page 142 PCSS-A Series Technical Manual LS-CS-M-046 The proportional enable output is used to enable the proportional solenoid on the press brake and is connected to a standard output. Once the pump is running, this output remains on when the down enable is on, the CNC press controller has initiated the up command after decompression or during decompression.
  • Page 143 LS-CS-M-046 PCSS-A Series Technical Manual The prefill solenoid output is connected to a safety output on the PCSS and provided that: • There is no emergency stop condition; • The pressing beam is level; • The enable is set; and •...
  • Page 144 PCSS-A Series Technical Manual LS-CS-M-046 11.19 Down Enable Option 19 IOA – CN1 IOA – CN2 Y05L 24VDC Solenoids Hold Y05H 24VDC Y04L 24VDC Solenoid Decompression Y04H 0VDC Y03L 0VDC Solenoids Safety Y03H 0VDC Y02L Solenoid Fill Y02H Y01L Solenoids...
  • Page 145 LS-CS-M-046 PCSS-A Series Technical Manual The high speed solenoid output is connected to a safety output on the PCSS and allows the control of the high speed solenoid valves on the press brake. If the down enable condition has been met but the down low speed condition has not been enabled, the high speed solenoid output will be switched on and the pressing beam can move down at high speed.
  • Page 146 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE HIGH SPEED SOLENOIDS AIO – Y01 FILLER SOLENOIDS AIO – Y02 DECOMPRESSION SOLENOID AIO – Y04 SAFETY SOLENOIDS AIO - Y03 HOLDING SOLENOIDS AIO – Y05 PROPORTIONAL ENABLE AIO - Y06 Figure 11-24: Down Enable Option 19 Output Operation...
  • Page 147 LS-CS-M-046 PCSS-A Series Technical Manual Table 11-18 details the operation of the solenoids which will be switched off during the press brake start-up tests. Note that alternate tests are performed if Down Enable Attribute Bit 1=1 (Table 11-1). Down Enable Attribute B1=0...
  • Page 148 PCSS-A Series Technical Manual LS-CS-M-046 • CNC controller has not yet been referenced; • Pressing of the material has begun; or • High speed disable distance before mute position has been reached. When this latched condition and the down enable condition are both set, then the down low speed condition will be enabled or set.
  • Page 149 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 DECOMPRESSION SOLENOID AIO - Y03 PROPORTIONAL ENABLE AIO - Y06 Figure 11-27: Down Enable Option 21 Output Operation Should the soft stop operation be enabled as described in Section 10.6.27, the high speed...
  • Page 150 PCSS-A Series Technical Manual LS-CS-M-046 11.22 Down Enable Option 22 IOA – CN1 IOA – CN2 Y05L 24VDC Solenoid Pressing Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Solenoids Safety Y03H 0VDC Y02L Solenoid Prefill Y02H Y01L Solenoids High Speed...
  • Page 151 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOIDS AIO – Y01 PREFILL SOLENOID AIO – Y02 PRESSING SOLENOID AIO – Y05 SAFETY SOLENOIDs AIO - Y03 PROPORTIONAL ENABLE AIO - Y06 Figure 11-29: Down Enable Option 22 Output Operation...
  • Page 152 PCSS-A Series Technical Manual LS-CS-M-046 The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 153 LS-CS-M-046 PCSS-A Series Technical Manual Should the soft stop operation be enabled as described in Section 10.6.27, the safety valve and proportional enable outputs will be delayed in switching off until down movement comes to a complete stop. As these outputs are delayed during the soft stop operation, it is essential that the down enable condition is passed to the CNC or press controller.
  • Page 154 PCSS-A Series Technical Manual LS-CS-M-046 The up enable condition is also controlled by this down enable option and although not physically connected to an output, is one of the conditions that must be met before up movement is allowed by the PCSS. This condition indicates that up movement of the pressing beam can occur due to the required conditions being met.
  • Page 155 LS-CS-M-046 PCSS-A Series Technical Manual Table 11-22 details the operation of the solenoids which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), then all solenoids are turned off for both start-up tests.
  • Page 156 PCSS-A Series Technical Manual LS-CS-M-046 11.26 Down Enable Option 26 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Solenoid Safety Y03H 0VDC Y02L Solenoid Prefill Y02H Y01L Solenoid Solenoid High Speed Y01H...
  • Page 157 LS-CS-M-046 PCSS-A Series Technical Manual The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 158 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOID AIO - Y01 PREFILL SOLENOID AIO - Y02 SAFETY SOLENOID AIO - Y03 DOWN SOLENOID AIO - Y04 or Y09 UP SOLENOID AIO - Y06 Figure 11-36: Down Enable Option 26 Output Operation...
  • Page 159 LS-CS-M-046 PCSS-A Series Technical Manual 11.28 Down Enable Option 28 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC STO Enable Y03H 0VDC Y02L Solenoids Y02H Y01L Solenoids High Speed Y01H Drive Enable...
  • Page 160 PCSS-A Series Technical Manual LS-CS-M-046 The outputs used on the PCSS for the solenoid valves on the press brake provided by this option are detailed below with the connections shown in Figure 11-37 for the AIO. The operation of these solenoid valve outputs during up and down movement of the pressing...
  • Page 161 LS-CS-M-046 PCSS-A Series Technical Manual To select down enable option 28 during the PCSS configuration, set the initial value for Down Enable Option Selection variable to 28 as described in Section 9.2. This will ensure that this option and all required outputs are initialised when the PCSS software is started.
  • Page 162 PCSS-A Series Technical Manual LS-CS-M-046 11.29.3 Up-acting Machine The Up-Acting Machine option is selected by setting Bit 5 of the Down Enable Attribute (see Table 11-1) in addition to Down Enable Option 29. Note: The Up-Acting Machine Option can only be selected when the Default On behaviour has been selected by setting Bit 3 of the Down Enable Attribute, see Section 11.29.2...
  • Page 163 LS-CS-M-046 PCSS-A Series Technical Manual The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 164 PCSS-A Series Technical Manual LS-CS-M-046 Table 11-25 details the operation of the solenoids, which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), then all solenoids are turned off for both start-up tests.
  • Page 165 LS-CS-M-046 PCSS-A Series Technical Manual 11.33 Down Enable Option 33 IOA – CN1 IOA – CN2 Y05L 24VDC Solenoids Holding Y05H 24VDC Y04L 24VDC Solenoid Decompression Y04H 0VDC Y03L 0VDC Solenoids Safety Y03H 0VDC Y02L Solenoid Prefill Y02H Solenoid Y01L...
  • Page 166 PCSS-A Series Technical Manual LS-CS-M-046 The outputs used for the solenoid valves on the press brake provided by this option are detailed below. The connections are shown in Figure 11-42 for the AIO. The operation of these outputs during up and down movement of the pressing beam is shown in Figure 11-43.
  • Page 167 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED DECOMPRESSION UP COMMAND SLOW SPEED INPUT PRE-CLOSING READY HIGH SPEED SOLENOIDS AIO - Y01 PREFILL SOLENOID AIO - Y02 SAFETY SOLENOIDS AIO - Y03 DECOMPRESSION SOLENOID AIO - Y04 HOLDING SOLENOIDS...
  • Page 168 PCSS-A Series Technical Manual LS-CS-M-046 To select down enable option 33 during the PCSS configuration, set the initial value for the Down Enable Option Selection variable to 33 as described in Section 9.2. This will ensure that this option and all required outputs are initialised when the PCSS software is started.
  • Page 169 LS-CS-M-046 PCSS-A Series Technical Manual When this latched condition and the down enable condition are both set, then the down low speed condition will be enabled or set. Additional specific conditions for this down enable option are also required in order to control...
  • Page 170 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN HIGH SPEED DOWN LOW SPEED PRE-CLOSING READY PRE-PRESSING READY MB1 or High Speed AIO - Y01 AIO - Y02 MB3 or Prefill AIO - Y04 AI O - Y12 and Y13 AIO - Y05...
  • Page 171 LS-CS-M-046 PCSS-A Series Technical Manual Table 11-27 details the operation of the solenoids which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), then all solenoids are turned off for both start-up tests.
  • Page 172 PCSS-A Series Technical Manual LS-CS-M-046 The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 173 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN HIGH SPEED DOWN LOW SPEED PRE-PRESSING READY YV1 or Safety AIO - Y01 AIO - Y05 AIO – Y03 YV4 or Down AIO - Y04 YV5 or Prefill AIO - Y02 Figure 11-47: Down Enable Option 35 Output Operation Note: Valve Monitoring Option 33 is provided specifically for this valve configuration.
  • Page 174 PCSS-A Series Technical Manual LS-CS-M-046 This down enable option provides outputs for control of the following solenoid valves on the press brake. • MB2 Solenoids; • MB3 or High Speed Solenoids; • MB4 or Safety Solenoids; • MB5 Solenoids; •...
  • Page 175 LS-CS-M-046 PCSS-A Series Technical Manual The MB3 or high speed solenoids are connected to safety output Y01 on the PCSS and will initially be active providing that: • Down enable is set; and • Pre-Closing Ready is reset. This output will then be switched off immediately at the end of decompression as received from the CNC press controller.
  • Page 176 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN HIGH SPEED DOWN LOW SPEED PRE-CLOSING READY PRE-PRESSING READY DECOMPRESSION UP COMMAND MB3 or HS AIO - Y01 AIO - Y02 MB4 or Safety AIO - Y03 AIO - Y04 AIO - Y05...
  • Page 177 LS-CS-M-046 PCSS-A Series Technical Manual The MB4 or safety solenoids use the safety output Y03 on the PCSS and will be enabled whenever the down enable is set, or the up command has been received from the CNC press controller after decompression.
  • Page 178 PCSS-A Series Technical Manual LS-CS-M-046 Note: Valve Monitoring Option 34 is provided specifically for this valve configuration. Refer Section 14.34 for details. Should the soft stop operation be enabled as described in Section 10.6.27, the following valves will be delayed in switching off until down movement comes to a complete stop. The down enable output from channel 7 of DI1 from the kernel software interface should be used to perform a controlled decelerated stop.
  • Page 179 LS-CS-M-046 PCSS-A Series Technical Manual This down enable option provides outputs for control of the following solenoid valves on the press brake. • MB1 or High Speed Down Solenoids; • MB3 or Prefill Solenoids; • MB4 Solenoids; • MB5 Solenoids; and •...
  • Page 180 PCSS-A Series Technical Manual LS-CS-M-046 The MB4 solenoids are connected to safety output Y02 on the PCSS. These valves will be switched on under the following conditions and the pressing beam will then move down in high speed. • The Pre-Pressing Ready condition has been set; and •...
  • Page 181 LS-CS-M-046 PCSS-A Series Technical Manual Table 11-30 details the operation of the solenoids which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), then all solenoids are turned off for both start-up tests.
  • Page 182 PCSS-A Series Technical Manual LS-CS-M-046 The down low speed condition is enabled when slow speed operation is required, but as with the down enable condition, it is not physically connected to an output. This condition is used to indicate that slow speed down movement is enabled. Any of the following variables being...
  • Page 183 LS-CS-M-046 PCSS-A Series Technical Manual DOWN ENABLE DOWN LOW SPEED HIGH SPEED SOLENOID AIO - Y01 PREFILL SOLENOID AIO - Y02 SAFETY SOLENOID AIO - Y03 UP SOLENOID AIO - Y06 DOWN SOLENOID AIO - Y09 Figure 11-54: Down Enable Option 38 Output Operation...
  • Page 184 PCSS-A Series Technical Manual LS-CS-M-046 11.40 Down Enable Option 40 IOA – CN1 IOA – CN2 Y05L 24VDC Y05H 24VDC Y04L 24VDC Y04H 0VDC Y03L 0VDC Drive Enable Y03H 0VDC Y02L Y02H Quickstop Y01L Enable Y01H Y00L Y00H Brake 0 VDC...
  • Page 185 LS-CS-M-046 PCSS-A Series Technical Manual The quickstop connected to output Y09 will be controlled similarly to the down enable condition, ensuring faster reaction time in stopping down movement when interfaced with the press brake control. In addition to the usual down enable conditions, I/O Channel 94 DO1 to the KSI must also be set to switch on the quickstop output.
  • Page 186 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED UP COMMAND BEAM MOVING STO ENABLE STO Enable Off Timer ANO (CH23) AIO - Y01 DRIVE ENABLE Drive Enable On Drive Enable Off Timer ANO (CH28) Timer ANO (CH31) AIO - Y03...
  • Page 187 LS-CS-M-046 PCSS-A Series Technical Manual Figure 11-58 below shows the operation of the start-up tests performed after the initial start- up of the PCSS and then usually after 24 hours of continuous operation. SUT 1 SUT 2 AIO – Y09...
  • Page 188 PCSS-A Series Technical Manual LS-CS-M-046 DOWN ENABLE DOWN LOW SPEED UP COMMAND STO ENABLE STO Enable Off Timer ANO (CH23) AIO - Y01 DRIVE ENABLE Drive Enable On Timer ANO (CH28) AIO - Y03 BRAKE Brake On Timer ANO (CH25)
  • Page 189 LS-CS-M-046 PCSS-A Series Technical Manual Figure 11-61 below shows the operation of the start-up tests performed after the initial start- up of the PCSS and then usually after 24 hours of continuous operation. SUT 1 SUT 2 AIO – Y09...
  • Page 190 PCSS-A Series Technical Manual LS-CS-M-046 This down enable option provides outputs for control of the following solenoid valves on the press brake. • Proportional Enable solenoids; • Safety Solenoids; • Prefill Solenoids, and; • High Speed Solenoids. The operation of all solenoid valve outputs for this down enable option is shown below in Figure 11-63.
  • Page 191 LS-CS-M-046 PCSS-A Series Technical Manual Note: As all outputs for this option are delayed during the soft stop operation when enabled, it is essential that an additional output from the PCSS-A is defined to trigger a stopping event. The down enable 2 condition from DI1 I/O channel 30 of the Kernel Software Interface can be used for this purpose.
  • Page 192 PCSS-A Series Technical Manual LS-CS-M-046 Table 11-34 details the operation of the solenoids, which will be switched off during the press brake start-up tests. Note that if Down Enable Attribute Bit 1=1 (Table 11-1), all solenoids are turned off for both start-up tests.
  • Page 193 LS-CS-M-046 PCSS-A Series Technical Manual Should the soft stop operation be enabled as described in Section 10.6.27, the following valves will be delayed in switching off until down movement comes to a complete stop. The proportional enable output will switch off immediately and can be used to perform a controlled decelerated stop.
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  • Page 195 LS-CS-M-046 PCSS-A Series Technical Manual Emergency Stop Safety Function Options The emergency stop function of the PCSS monitors the system and press brake conditions and will initiate an emergency stop when certain conditions are met. An emergency stop condition can occur if: •...
  • Page 196 PCSS-A Series Technical Manual LS-CS-M-046 12.1 Emergency Stop Option 1 12.1.1 Door Switches IOA – CN5 IOA – CN6 Door Switch - Left Door Switch - Right Door Switch - Rear Figure 12-1: Option 1 Door Switch (AIO Connections) Figure 12-1 for the AIO when monitoring the rear, left and right doors on the press brake using the functionality for emergency stop option 1.
  • Page 197 LS-CS-M-046 PCSS-A Series Technical Manual 12.1.2 Level Limit Switches Level Limit IOA – CN4 IOA – CN5 IOA – CN6 Level Limit Level Limit Level Limit 24 VDC Figure 12-2: Option 1 Level Limit (AIO Connections) Three inputs are provided for monitoring the level or parallelism of the pressing beam between the left side (Y1 axis) and the right side (Y2 axis) of the press brake.
  • Page 198 PCSS-A Series Technical Manual LS-CS-M-046 Table 12-3: Level Limit Switch Conditions The integrity of the level switches is also monitored. The Y1 and Y2 normally open level switches should never both be active at the same time, and if this occurs an error will be generated.
  • Page 199 LS-CS-M-046 PCSS-A Series Technical Manual 12.1.4 Auxiliary Axis Contactor (Emergency Stop Output) IOA – CN1 Y05L Y05H Y04L Y04H Y03L Y03H Y02L Y02H Y01L Y01H Y00L Auxiliary Axis Contactor (Emergency Stop) Y00H IOA – CN5 IOA – CN6 Auxiliary Axis Contactor Monitor...
  • Page 200 PCSS-A Series Technical Manual LS-CS-M-046 A normally closed (NC) contact from this contactor is also required to be connected to the safety input of the PCSS, as shown in Figure 12-4 for the AIO. This is important in monitoring that the changeover of this contactor occurs correctly. When an emergency stop condition happens, monitoring of the contactor is essential in confirming that the contact changeover occurs within an acceptable time limit to ensure that press brake operation is disabled.
  • Page 201 LS-CS-M-046 PCSS-A Series Technical Manual To select emergency stop option 2 during the PCSS configuration, set the initial value for the emergency stop option selection variable to 2 as described in Section 9.2. This will ensure that this option will be initialised and all required inputs and outputs are connected when the PCSS software is started.
  • Page 202 PCSS-A Series Technical Manual LS-CS-M-046 12.3.3 Emergency Stop Channels The operation of the emergency stop channels for the emergency stop option 3 is the same as for option 1 when using the AIO. Further information on the connections for the AIO and...
  • Page 203 LS-CS-M-046 PCSS-A Series Technical Manual A normally closed (NC) contact from this contactor is also required to be connected to the safety input of the PCSS, as shown in Figure 12-4 for the AIO. This is important in monitoring that the changeover of this contactor occurs correctly. When an emergency stop condition happens, monitoring of the contactor is essential in confirming that the contact changeover occurs within an acceptable time limit to ensure that press brake operation is disabled.
  • Page 204 PCSS-A Series Technical Manual LS-CS-M-046 Any other fault conditions detected by the PCSS software however will cause this output to switch off immediately. The timer delay for the switch off of this output can then be defined in the ISaGRAF application for I/O channel 23 of the ANO2 I/O board of the Kernel Software Interface.
  • Page 205 LS-CS-M-046 PCSS-A Series Technical Manual IOA – CN5 IOA – CN6 Door Switch - Left Door Switch - Right Door Switch - Rear IOA – CN4 24 VDC Figure 12-8: Option 13 Door Switch Standard Configuration (AIO Connections) Page 185 Original Language Version: 1.25...
  • Page 206 PCSS-A Series Technical Manual LS-CS-M-046 12.13.2 Door Switches (Alternate Configuration) IOA – CN5 IOA – CN6 Door Switch - Left Door Switch - Right Door Switch - Rear IOA – CN4 24 VDC Figure 12-9: Option 13 Door Switch Alternate Configuration (AIO Connections)
  • Page 207 LS-CS-M-046 PCSS-A Series Technical Manual 12.16 Emergency Stop Option 16 These options are reserved and not available for selection. 12.17 Emergency Stop Option 17 These options are reserved and not available for selection. 12.18 Emergency Stop Option 18 These options are reserved and not available for selection.
  • Page 208 PCSS-A Series Technical Manual LS-CS-M-046 12.19.2 Door Switches (Alternate Configuration) IOA – CN4 24 VDC IOA – CN5 IOA – CN6 Door Switch - Left Door Switch - Right Door Switch - Rear Figure 12-11: Option 19 Door Switch Alternate Configuration (AIO Connections)
  • Page 209 LS-CS-M-046 PCSS-A Series Technical Manual 12.20 Emergency Stop Option 20 These options are reserved and not available for selection. 12.21 Emergency Stop Option 21 Emergency Stop Option 21 is based upon Emergency Stop Option 3 with a modification to the rear door switch arrangement.
  • Page 210 PCSS-A Series Technical Manual LS-CS-M-046 12.21.4 Auxiliary Axis Contactor (Emergency Stop Output) The operation of the auxiliary axis contactor for the emergency stop option 21 is identical to Option 1, as shown in Section 12.1.4. Note that the deactivation of the auxiliary output may be delayed by up to 500ms via the Kernel Software Interface, ANO2 channel 23.
  • Page 211 LS-CS-M-046 PCSS-A Series Technical Manual 12.22.2 Delayed Auxiliary Axis Contactor (Emergency Stop Output) IOA – CN1 Y05L Delayed Auxiliary Axis Contactor (Emergency Stop) Y05H Y04L Y04H Y03L Y03H Y02L Y02H Y01L Y01H Y00L Y00H Figure 12-14: Delayed Auxiliary Axis Contactor Output (AIO Connections)
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  • Page 213 LS-CS-M-046 PCSS-A Series Technical Manual Error Reset Safety Function Options Most of the function options for the PCSS provide fault monitoring, which are then used to stop or limit the operation of the press brake. Any faults or inconsistent conditions that occur are usually latched on after the period of time defined for that particular function and option.
  • Page 214 PCSS-A Series Technical Manual LS-CS-M-046 13.3 Error Reset Option 3 IOA – CN3 Error Reset 1 Error Reset 2 24 VDC Figure 13-2: Error Reset Option 3 (AIO Connections) IOA – CN2 24VDC 24VDC 24VDC 0VDC 0VDC 0VDC Station 2 Indicator...
  • Page 215 LS-CS-M-046 PCSS-A Series Technical Manual 13.5 Error Reset Option 5 IOA – CN3 Error Reset 1 Error Reset 2 24 VDC Figure 13-4: Error Reset Option 5 (AIO Connections) This error reset option is intended for use with down switch options allowing 2 operator stations.
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  • Page 217 LS-CS-M-046 PCSS-A Series Technical Manual Valve Monitoring Safety Function Options The purpose of the safety options available in the PCSS for the valve monitoring function is to provide:- • An indication when all monitored valves are in the standby or idle state; and •...
  • Page 218 PCSS-A Series Technical Manual LS-CS-M-046 The state of the valve zero output from the valve monitoring function option can be checked by displaying the I/O channels for the DI1 I/O board of the Kernel Software Interface complex equipment in the I/O connection editor. I/O Channel 21 will show the valve zero output state...
  • Page 219 LS-CS-M-046 PCSS-A Series Technical Manual The valve monitoring function option selected should be based on the valve outputs for the down enable option chosen during configuration of the PCSS software and the valve monitoring required for the press brake. The valve monitoring option selection variable...
  • Page 220 PCSS-A Series Technical Manual LS-CS-M-046 ANO2 channel 21 is the valve monitor ON time, i.e. the minimum time that must elapse between turning on a valve and the valve monitor input changing state before an error condition is raised. If this value is zero, the default monitor time is applied (500ms). Any non- zero value is used by the kernel as the valve monitor ON time in milliseconds.
  • Page 221 LS-CS-M-046 PCSS-A Series Technical Manual Details of the fault conditions associated with this option are shown in Table 14-3. High Speed Prefill Safety Sol. Mon. Sol. Mon. Sol. Mon. Valve Fault Description Valve zero output set. Normal operating condition. High speed normal operating condition.
  • Page 222 PCSS-A Series Technical Manual LS-CS-M-046 14.3 Valve Monitoring Option 3 IOA – CN4 Valve Monitor – Safety Y2 Valve Monitor – Safety Y1 Valve Monitor – Prefill 24VDC 0VDC Figure 14-7: Valve Monitoring Option 3 (AIO Connections) Connections are provided to the standard inputs of the PCSS unit for monitoring prefill and...
  • Page 223 LS-CS-M-046 PCSS-A Series Technical Manual 14.4 Valve Monitoring Option 4 IOA – CN4 Valve Monitor – Proportional Y2 Valve Monitor – Proportional Y1 Valve Monitor – Low Speed Valve Monitor – High Speed Y2 Valve Monitor – High Speed Y1...
  • Page 224 PCSS-A Series Technical Manual LS-CS-M-046 To select valve monitoring option 4 during the PCSS configuration, set the initial value for the valve monitoring option selection variable to 4 as described in Sections 9.2 Figure 14-5. This will ensure that this option is initialised with all required inputs activated when the PCSS software is started.
  • Page 225 LS-CS-M-046 PCSS-A Series Technical Manual To select valve monitoring option 5 during the PCSS configuration, set the initial value for the valve monitoring option selection variable to 5 as described in Sections 9.2 Figure 14-5. This will ensure that this option is initialised with all required inputs activated when the PCSS software is started.
  • Page 226 PCSS-A Series Technical Manual LS-CS-M-046 Details of the fault conditions associated with this option are shown in Table 14-12. Safety Down Sol. Mon. Sol. Mon. Sol. Mon. Valve Fault Description Valve zero output set. Normal operating condition. Down movement normal operating condition.
  • Page 227 LS-CS-M-046 PCSS-A Series Technical Manual An example of the conditions for this valve monitoring option appears in Table 14-13. Crawl Prefill Safety Speed Sol. Mon. Sol. Mon. Sol. Mon. Valve Zero Description Crawl speed solenoid switched on. Prefill solenoid switched on.
  • Page 228 PCSS-A Series Technical Manual LS-CS-M-046 This option is used for monitoring the safety and high speed solenoid valves. Standard inputs on the PCSS unit are provided for monitoring normally closed contacts for connections to each of the solenoid valves as shown in Figure 14-12 for the AIO.
  • Page 229 LS-CS-M-046 PCSS-A Series Technical Manual This option is used for monitoring the safety and proportional solenoid valves. Standard inputs on the PCSS unit are provided for monitoring normally closed contacts for connections to each of the solenoid valves as shown in Figure 14-13 for the AIO.
  • Page 230 PCSS-A Series Technical Manual LS-CS-M-046 This option is used for monitoring the safety and down solenoid valves. Standard inputs on the PCSS unit are provided for monitoring normally open contacts for connections to each of the solenoid valves as shown in Figure 14-14 for the AIO.
  • Page 231 LS-CS-M-046 PCSS-A Series Technical Manual This option is used for monitoring the safety and high speed solenoid valves. Standard inputs on the PCSS unit are provided for monitoring normally closed contacts for connections to each of the solenoid valves as shown in Figure 14-15 for AIO.
  • Page 232 PCSS-A Series Technical Manual LS-CS-M-046 14.13 Valve Monitoring Option 13 IOA – CN4 Valve Monitor – Safety Y2 Valve Monitor – Safety Y1 24VDC 0VDC Figure 14-16: Valve Monitoring Option 13 (AIO Connections) This option is used for monitoring the safety valves. Standard inputs on the PCSS unit are...
  • Page 233 LS-CS-M-046 PCSS-A Series Technical Manual 14.14 Valve Monitoring Option 14 IOA – CN4 Valve Monitor – Safety Valve Monitor – Up/Down 24VDC 0VDC Figure 14-17: Valve Monitoring Option 14 (AIO Connections) This option is used for monitoring the safety, down and up solenoid valves on physical or...
  • Page 234 PCSS-A Series Technical Manual LS-CS-M-046 To select valve monitoring option 14 during the PCSS configuration, set the initial value for the valve monitoring option selection variable to 14 as described in Sections 9.2 Figure 14-5. This will ensure that this option is initialised with all required inputs activated when the PCSS software is started.
  • Page 235 LS-CS-M-046 PCSS-A Series Technical Manual Details of the fault conditions associated with this option are shown in Table 14-28. Holding Safety Decompression Valve Sol. Mon. Sol. Mon. Sol. Mon. Fault Description Valve zero output set. Normal operating condition. Down movement normal operating condition.
  • Page 236 PCSS-A Series Technical Manual LS-CS-M-046 14.16 Valve Monitoring Option 16 IOA – CN4 Valve Monitor – High Speed Y2-2 Valve Monitor – High Speed Y1-2 Valve Monitor – Low Speed Y2 Valve Monitor – Low Speed Y1 Valve Monitor – High Speed Y2-1 Valve Monitor –...
  • Page 237 LS-CS-M-046 PCSS-A Series Technical Manual Details of the fault conditions associated with this option are shown in Table 14-30. High Speed Prefill Proportional Sol. Mon. Sol. Mon. Sol. Mon. Valve Fault Description Valve zero output set. Normal operating condition. High speed normal operating condition.
  • Page 238 PCSS-A Series Technical Manual LS-CS-M-046 An example of the conditions for this valve monitoring option appears in Table 14-31. High Speed Prefill Sol. Mon. Sol. Mon. Valve Zero Description High speed solenoids switched on. Prefill solenoid switched on. All monitored valves are switched off.
  • Page 239 LS-CS-M-046 PCSS-A Series Technical Manual This option is used for monitoring the unload, prefill and safety valves on the press brake with standard inputs on the PCSS unit provided for monitoring normally closed contacts for each of the solenoid valves as shown in Figure 14-21 for AIO.
  • Page 240 PCSS-A Series Technical Manual LS-CS-M-046 14.22 Valve Monitoring Option 22 IOA – CN4 Valve Monitor – STO Enable Valve Monitor – High Speed Y2 Valve Monitor – High Speed Y1 24VDC 0VDC Figure 14-22: Valve Monitoring Option 22 (AIO Connections) This option is used for monitoring the high speed solenoid valves and STO enable.
  • Page 241 LS-CS-M-046 PCSS-A Series Technical Manual STO Enable High Speed Sol. Mon. Sol. Mon. Valve Fault Description Valve zero output set. Normal operating condition. Down movement normal operating condition. High speed movement normal operating condition. Solenoid valve switch off fault for all (as shown) or any monitored valves.
  • Page 242 PCSS-A Series Technical Manual LS-CS-M-046 An example of the conditions for this valve monitoring option can be seen in Table 14-37. Safety Proportional Sol. Mon. Sol. Mon. Valve Zero Description Safety solenoid switched on. Proportional solenoid switched on. All monitored valves are switched off.
  • Page 243 LS-CS-M-046 PCSS-A Series Technical Manual Prefill Safety Sol. Mon. Sol. Mon. Valve Zero Description Prefill solenoids switched on. Safety solenoids switched on All monitored valves are switched off. Legend: 0 = Off or Low, 1 = On or High and X = No effect.
  • Page 244 PCSS-A Series Technical Manual LS-CS-M-046 This option is used for monitoring the high speed solenoid valves. Standard inputs on the PCSS unit are provided for monitoring normally closed contacts for connections to each of the high speed solenoid valves as shown in Figure 14-25 for the AIO.
  • Page 245 LS-CS-M-046 PCSS-A Series Technical Manual This option is used for monitoring the holding and safety valves on the press brake with standard inputs on the PCSS unit provided for monitoring normally closed contacts for each of the solenoid valves as shown above in Figure 14-26 for AIO.
  • Page 246 PCSS-A Series Technical Manual LS-CS-M-046 STO1 STO2 Brake Sol. Mon. Sol. Mon. Sol. Mon. Valve Zero Description Servo 1 STO solenoid on Servo 2 STO solenoid on Brake release on All monitored valves are switched off. Legend: 0 = Off or Low, 1 = On or High and X = No effect.
  • Page 247 LS-CS-M-046 PCSS-A Series Technical Manual IOA – CN4 Valve Monitor – MB2 Y2 Valve Monitor – MB2 Y1 Valve Monitor – MB6 or Safety Y2 Valve Monitor – MB6 or Safety Y1 Valve Monitor – MB3 or Prefill Y2 Valve Monitor – MB3 or Prefill Y1 Valve Monitor –...
  • Page 248 PCSS-A Series Technical Manual LS-CS-M-046 14.33 Valve Monitoring Option 33 This valve monitoring option is to be used with Down Enable Option 35 (refer Section 11.35 for details) and monitors the down, prefill and safety valves on the press brake with standard...
  • Page 249 LS-CS-M-046 PCSS-A Series Technical Manual To select valve monitoring option 33 during the PCSS configuration, set the initial value for the valve monitoring option selection variable to 33 as described in Sections 9.2 Figure 14-5. This will ensure that this option is initialised with all required inputs activated when the PCSS software is started.
  • Page 250 PCSS-A Series Technical Manual LS-CS-M-046 Details of the fault conditions associated with this option for standard operation are shown in Table 14-50. High Speed Safety Valve Sol. Mon. Sol. Mon. Sol. Mon. Sol. Mon. Fault Description Valve zero output set. Normal operating condition.
  • Page 251 LS-CS-M-046 PCSS-A Series Technical Manual An example of the conditions for this valve monitoring option appears in Table 14-51. High Speed Prefill Safety Sol. Mon. Sol. Mon. Sol. Mon. Valve Zero Description High speed solenoids switched on. Prefill solenoids switched on.
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  • Page 253 LS-CS-M-046 PCSS-A Series Technical Manual Down Switch Safety Function Options The down switch options determine the number and the configuration of press brake operator stations, allowing multiple operators with a combination of foot and hand switches to control the down movement of the press brake.
  • Page 254 PCSS-A Series Technical Manual LS-CS-M-046 No delay is applied during the start-up tests, and all outputs are switched off as part of the typical start-up test process. However, the start-up tests may use a reduced stopping distance dependent on the distance defined for the stopping deceleration check. Any stopping deceleration distance over 15mm will reduce the distance allowed for checking the stopping performance during these tests.
  • Page 255 LS-CS-M-046 PCSS-A Series Technical Manual Channel # Description Station 02 Mode 1foot - 1foot Mode 2hand - 1foot Mode 2hand - 2hand Mode 2 foot - 2 foot Mode 4hand - 2foot Mode 4hand - 4hand Foot Station 1 Foot Station 2...
  • Page 256 PCSS-A Series Technical Manual LS-CS-M-046 15.4 Single/Dual Operator Modes It is possible to have either a single operator station or dual operator stations connected to the PCSS-A. The configuration of the operator station(s) can be modified from the CNC by selecting one of the operator modes supported by the option’s hardware (the option must...
  • Page 257 LS-CS-M-046 PCSS-A Series Technical Manual Any of the stations available to the option may be selected by setting the Foot Station 1 – Foot Station 4 bits, but no more than two stations may be selected at one time. The dual operator mode bit Station 02 (i.e.
  • Page 258 PCSS-A Series Technical Manual LS-CS-M-046 When a fault occurs, any further monitoring of the states for the control switches is disabled until the cause has been resolved and the fault condition has been reset using the method defined in the error reset option.
  • Page 259 LS-CS-M-046 PCSS-A Series Technical Manual 15.8 Down Switch Option 2 - Single Operator Foot and Hand Control IOA – CN5 IOA – CN6 IOA – CN3 Hand Button 1 - Right Hand Button 1 - Left Foot Pedal 1 - Down...
  • Page 260 PCSS-A Series Technical Manual LS-CS-M-046 To select down switch option 2 during the PCSS configuration, set the initial value for down switch option selection variable to 2 as described in Section 9.2. This will ensure that this option and all required inputs are initialised when the PCSS software is started.
  • Page 261 LS-CS-M-046 PCSS-A Series Technical Manual 15.10 Down Switch Option 4 - Dual Operator Foot and Hand Control IOA – CN5 IOA – CN6 IOA – CN3 Hand Button 2 - Right Hand Button 2 - Left Hand Button 1 - Right...
  • Page 262 PCSS-A Series Technical Manual LS-CS-M-046 This dual operator station option allows connections on the PCSS for both foot pedal and hand control shown IOA – CN5 IOA – CN6 IOA – CN3 Hand Button 2 - Right Hand Button 2 - Left...
  • Page 263 LS-CS-M-046 PCSS-A Series Technical Manual switches, the operator will need to release the hand switches to reset this timeout before another attempt can be made to control the press brake. Station Station Station Station Station Table 15-7: Down Switch Option 4 Permitted Compatible Modes...
  • Page 264 PCSS-A Series Technical Manual LS-CS-M-046 15.11 Down Switch Option 5 - Dual Operator Foot and Hand Control IOA – CN7 IOA – CN8 IOA – CN5 IOA – CN6 IOA – CN3 Hand Button 2 - Right Hand Button 2 - Left...
  • Page 265 LS-CS-M-046 PCSS-A Series Technical Manual Station Station Station Station Station Table 15-8: Down Switch Option 5 Compatible Operator Modes To select down switch option 5 during the PCSS configuration, set the initial value for down switch option selection variable to 5 as described in Section 9.2.
  • Page 266 PCSS-A Series Technical Manual LS-CS-M-046 If a single station mode is selected, then the 1 Foot – 1 Foot mode is selected and the corresponding station 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.
  • Page 267 LS-CS-M-046 PCSS-A Series Technical Manual Station Station Station Station Station Table 15-10: Down Switch Option 7 Compatible Operator Modes To select down switch option 7 during the PCSS configuration, set the initial value for down switch option selection variable to 7 as described in Section 9.2.
  • Page 268 PCSS-A Series Technical Manual LS-CS-M-046 15.15 Down Switch Option 9 – Three Operator Foot Control Only IOA – CN3 Foot Pedal 3 - Down Foot Pedal 2 - Down Foot Pedal 1 - Down 24 VDC IOA – CN5 IOA – CN6...
  • Page 269 LS-CS-M-046 PCSS-A Series Technical Manual 15.16 Down Switch Option 10 - Two Operator Foot Control Only IOA – CN3 Foot Pedal 2 - Down Foot Pedal 1 - Down 24 VDC IOA – CN5 IOA – CN6 Figure 15-10: Two Operator Foot Control (AIO Connections)
  • Page 270 PCSS-A Series Technical Manual LS-CS-M-046 Auxiliary Connections – Special Modes IOA – CN5 IOA – CN6 Special Mode Selection Figure 16-1: Special Mode Selection (AIO Connections) When a PCSS special mode of operation is to be selected with the press brake, it is necessary to activate the physical input.
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  • Page 272 PCSS-A Series Technical Manual LS-CS-M-046 Operation 17.1 PCSS Power-up When the power is applied to the PCSS, diagnostic checks of the hardware are performed before the ISaGRAF user application and the safety functions of the PCSS are initialised. Once the initial diagnostic hardware checks have been completed and the safety functions are initialised it will then be possible to begin operation of the press brake.
  • Page 273 LS-CS-M-046 PCSS-A Series Technical Manual The press brake must pass both start-up tests successfully before the system can enter normal operation. If either start-up test identifies a failure in the stopping performance limits, then this results in the start-up test having to be performed again until successfully passed.
  • Page 274 PCSS to indicate the failure. If the PCSS is configured with the LZS-2 Lazer Safe guarding system and the simulated stop occurs within the region below the mute 1 position but above the mute 2 position during deceleration, then a stopping distance failure will result in the condition code 7A89 being displayed by the PCSS.
  • Page 275 PCSS as detailed in the following sections. 17.3.7 Lazer Safe LZS-1, LZS-2 and LZS-2-FG Systems The stopping limit used with the LZS-1, LZS-2 and LZS-2-FG guarding systems is based on the stopping distance from the position from where the stop is triggered, until the position where down movement of the pressing beam stops, as measured by the position counters of the PCSS.
  • Page 276 I/O channel 13 in ANI I/O board of the Kernel Software Interface. 17.3.8 Lazer Safe IRIS, IRIS Plus, LZS-XL Systems As with the LZS-1 and LZS-2/LZS-2-FG, the stopping limit used with the IRIS, IRIS Plus and...
  • Page 277 Kernel Software Interface. 17.3.10 Light Guard System Type 3 The stopping limit used with the light guard type 3 system as with the Lazer Safe guarding system is also based on the stopping distance from the position where the stop is triggered until the position where down movement of the pressing beam stops as measured by the position counters of the PCSS.
  • Page 278 17.4.2 Lazer Safe Guarding System The position of the mute point when using the Lazer Safe guarding system is calculated by the PCSS based on the expected obstruction position from the surface of the material being used. This obstruction position is then confirmed during the setting of the mute point and the mute point is set 2 mm above the actual position of the obstruction from the surface of the material.
  • Page 279 This is not required if the forward counting method has been selected. Lazer Safe guarding system When a Lazer Safe laser guarding system has been installed, the PCSS system operation will also affect where the actual position of the obstruction is expected. The position...
  • Page 280 CNC press controller. When the PCSS is configured for both Lazer Safe and light guard systems, the confirmation of the position for the mute point will be dependent on the active guarding system selected at the beginning of the stroke or bend cycle.
  • Page 281 LS-CS-M-046 PCSS-A Series Technical Manual Note: In some situations where large die V widths are used with very thin material (less than 2mm) it is possible that the material is unable to be detected causing the down movement to stop and reporting the condition code 4203. The operator will still be allowed to move the pressing beam down after releasing the down switch but only in crawl speed with the 4257 condition code being reported.
  • Page 282 17.5.4 Light Guard System Type 3 Confirmation of the mute point position for the light guard type 3 is similar to the Lazer Safe Guarding System as described in Section 17.5.2. The mute is confirmed based on the actual position where the obstruction is detected from the surface of the material.
  • Page 283 CNC press controller, or a limit switch installed onto the press brake. 17.6 Lazer Safe Guarding System Specific Operation Modes 17.6.1 Normal Mode Operation When normal mode is selected on the CNC press controller, or as can be selected on the PCSS at top dead centre (TDC), the whole width of the laser beam (front, middle, rear) is activated for the detection of obstructions.
  • Page 284 PCSS-A Series Technical Manual LS-CS-M-046 Note: In some situations where large die V widths are used with very thin material (less than 2mm) it is possible that the material is unable to be detected causing the down movement to stop and reporting the condition code 4203. The operator will still be allowed to move the pressing beam down after releasing the down switch but only in crawl speed with the 4257 condition code being reported.
  • Page 285 LS-CS-M-046 PCSS-A Series Technical Manual Tray mode is not applicable when the No Counting/No Guarding options have been selected during configuration of the PCSS (as described in Section 10.5). There are several variants of Tray mode, covered in the next sections.
  • Page 286 PCSS-A Series Technical Manual LS-CS-M-046 If an outside obstruction does not occur at the programmed upstand height the beam is stopped, and the condition code 420E is displayed to indicate that no upstand has been detected. The operator must acknowledge this error with the down switch before normal operation can continue.
  • Page 287 LS-CS-M-046 PCSS-A Series Technical Manual This behaviour can be modified by selecting the Tray Mode Centre Obstruction Operation option, as described in Section 10.6.5. With this option selected, if an obstruction is detected by the centre segment at any point in the down stroke, the PCSS will cause the pressing beam to stop.
  • Page 288 1 and 2, with an additional monitoring function available. The PCSS is able to permanently monitor the mute point position in a similar way to the Lazer Safe guarding system, for any change to a different material thickness, which may result in a dangerously increased opening between punch and material.
  • Page 289 LS-CS-M-046 PCSS-A Series Technical Manual 17.7.3 Single Break Mode Operation - Light Guard System Types 1 & 2 Using the single break mode of operation allows the operator to initiate down movement on the press brake by briefly obstructing the light guard protective field once, when this mode has been enabled.
  • Page 290 PCSS-A Series Technical Manual LS-CS-M-046 The operator can enable the double break mode when the following procedure is performed: • The machine is at TDC, • The operator has selected the double break mode of operation and • Confirmation of the double break mode by the operator pressing the down switch.
  • Page 291 LS-CS-M-046 PCSS-A Series Technical Manual Note: As the mute and the slow speed position are not at the same point when using these systems, the lower slow speed position will be transferred between the CNC press controller and the PCSS. The slow speed position and subsequently the mute can then be raised from the CNC by the operator as required.
  • Page 292 PCSS-A Series Technical Manual LS-CS-M-046 17.8.3.1 Die V-width An analog parameter specifying the V-width measurement of the die in mm is also required prior to the commencement of the stroke at TDC. This analog value should be sent from the...
  • Page 293 Overview Automatic Cycle Start (ACS) is a selectable mode that improves productivity in specific types of bending without reducing the level of protection provided by the Lazer Safe IRIS or IRIS Plus guarding systems. ACS is a step mode that allows the press beam to cycle from mute point to mute point, only pausing momentarily at TDC.
  • Page 294 PCSS-A Series Technical Manual LS-CS-M-046 The following conditions apply while ACS mode is active. • Normal guarding is always in operation. If an obstruction occurs during closing the beam will stop, and the PCSS-A will then require the operator to initiate down movement and complete the bend with the foot pedal.
  • Page 295 LS-CS-M-046 PCSS-A Series Technical Manual 17.8.5.2 Tool Align Feedback Status Additional parameters are also available within the ISaGRAF application that provides feedback on the status of the tool align process. These include the following analogue values that identify where the tool tip has been found and the optimum tool position within the tool tip detection area.
  • Page 296 Stop-at-mute mode of operation can be selected either by the CNC press controller, or as connected to the PCSS when the operator has also selected any of the Lazer Safe or light guard modes. This allows the operator to move the pressing beam down until the mute point is reached, at which point the pressing beam will stop.
  • Page 297 LS-CS-M-046 PCSS-A Series Technical Manual 17.11 Special Modes Special modes allow the operator to configure the PCSS for specific operational purposes and can only be activated or deactivated at TDC. Any attempt to deactivate any special mode after leaving TDC will result in condition code 4300 being reported, and no further down movement permitted.
  • Page 298 PCSS-A Series Technical Manual LS-CS-M-046 Warning: In no other circumstances should this mode be engaged, as the operator would be unprotected, which could therefore result in serious injury. The appropriate precautions should be taken should this mode need to be activated.
  • Page 299 LS-CS-M-046 PCSS-A Series Technical Manual After the physical input has been activated for the special mode selection, the robot mode can be selected. Robot mode can then be activated by selecting the mode on the CNC press controller if communications to the PCSS has been established. Alternatively, setting the robot mode input to the Kernel Software Interface using I/O channel 10 of the DO1 I/O board.
  • Page 300 PCSS-A Series Technical Manual LS-CS-M-046 The physical input for the special mode selection must be activated to operate in this mode. The setup mode selection to the input to the Kernel Software Interface must also be activated. After the physical input has been activated for the special mode selection, the setup mode can be selected.
  • Page 301 ISaGRAF application for the variable connected to I/O channel 0 of the ANO2 I/O board of the Kernel Software Interface. 17.12.1 Lazer Safe LZS-1, LZS-2, LZS-2-FG Systems The stopping performance monitored when this guarding option is configured in the PCSS is based on distance.
  • Page 302 (whether LZS-1 or LZS-2) is then displayed on I/O channel 11 in the ANI I/O board of the Kernel Software Interface. 17.12.2 Lazer Safe IRIS, IRIS Plus, LZS-XL Systems The stopping performance monitored for the IRIS, IRIS Plus or LZS-XL by the PCSS is based on distance.
  • Page 303 The speeds monitored during operation of the press brake are detailed below in the following sections depending on the type of guarding system installed during configuration of the PCSS. When the PCSS is configured for both Lazer Safe and light guard systems, the speeds monitored will be dependent on the active guarding system selected.
  • Page 304 Y2 which will cause an emergency stop action of the PCSS to be triggered as described in Section 17.17. 17.13.4 Lazer Safe IRIS, IRIS Plus, LZS-XL Guarding Systems When these block laser systems are installed and configured with the PCSS, an additional two speed checks are performed, refer to Figure 17-8.
  • Page 305 LS-CS-M-046 PCSS-A Series Technical Manual 100% Speed Check 1 95% (or 75mm/s) Speed Check 2 65% (or 75mm/s) % of Maximum Closing Speed Slow Speed Slow Speed Point Slow Speed Point + Slow Speed Point + MSD + 3mm MSD + 3mm...
  • Page 306 An option is available in the PCSS software however which when configured allows pressing speed in the same manner as is possible with Lazer Safe guarding systems or light guard type 3. Further information on the configuration of this option can be found in Section 10.6.3.
  • Page 307 LS-CS-M-046 PCSS-A Series Technical Manual For a list of condition codes that result in the shutdown action being performed, please refer to the document "PCSS Condition Codes". 17.15 Stop Action A stop action usually occurs with a specific condition that results in the ISaGRAF application being halted.
  • Page 308 CNC press controller to cross reference the condition code displayed on the PCSS with the associated message to be displayed on the CNC press controller. Please contact Lazer Safe should you require the latest version of message files for specific CNC press controllers. Page 288 Original Language Version: 1.25...
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  • Page 310 PCSS-A Series Technical Manual LS-CS-M-046 Specifications 24 VDC  10% Supply voltage Current 1.25 A Max. (excludes output load current) Power consumption 30 W Max. (excludes output load power consumption) External power connection 12-way removable terminal block External dimensions 238 mm (L) x 225 mm (W) x 53 mm (D) PCSS enclosure rating Indoor use only.
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  • Page 312 PCSS-A Series Technical Manual LS-CS-M-046 EC Declaration of Conformity Page 292 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 313 LS-CS-M-046 PCSS-A Series Technical Manual Table 19-1: PCSS-A Guard and Encoder Options Table 19-2: Approved Guard with PCSS Combinations Table 19-3: Approved Hardware with PCSS Combinations Page 293 Original Language Version: 1.25 Released: 12/09/2024...
  • Page 314 PCSS-A Series Technical Manual LS-CS-M-046 Table 19-4: Approved Spare Parts Page 294 Original Language Version: 1.25 Released: 12/09/2024...

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