LZS-003-HS Operation Manual Dual Laser Version 1 10 EN

LZS-003-HS Operation Manual
Dual Laser Version

LS-CS-M0005-EN LZS-003-HS Operation Manual – Dual Laser Version
Document Status
Document Reference Code: LS-CS-M0005-EN
Version: 1.10
Released: 24/07/2007
Document Revision History

Date Version Summary of Change
10/01/2007 1.08 New error code display sequence information added.
4/07/2007 1.09 New software version eliminates use of magnetic card. Mute point set-up and
material sensing test improved functionality.
24/07/2007 1.10 Language settings added to parameter settings
Copyright Information
"Lazer Safe", "LZS", "LZS-003", LZS-003-SS4", "LZS-003-SS6", "LZS-003-HS", "PCSS" and "Press Control Safety System" are
trademarks of Lazer Safe Pty Ltd.
The content of this manual is supplied for informational use only, is subject to change without notice and should not be construed
as a commitment by Lazer Safe Pty Ltd. Lazer Safe Pty Ltd assumes no responsibility or liability for any errors, inaccuracies or
omissions that may appear within this publication.
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.
Lazer Safe's copyright in this document is protected by Australian copyright laws (including the Copyright Act 1948
(Commonwealth)) and by international copyright treaties.
© 2005-7 Lazer Safe Pty Ltd. All rights reserved.
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Version 1.10 Released: 24/07/2007
Table of Contents
1 About This Manual ......................................................................................... 1
1.1 Document Organisation .......................................................................................................... 1
1.2 Document Objectives .............................................................................................................. 1
1.3 Technical Competence Requirements ..................................................................................... 1
1.4 Related Documentation .......................................................................................................... 1
1.5 Guide to Notes, Notice and Cautions ...................................................................................... 1
1.6 Obtaining Technical Assistance .............................................................................................. 2
2 Critical Safety Information ............................................................................ 3
2.1 Proper Use of the LZS-003-HS ................................................................................................ 3
2.2 Special Warnings .................................................................................................................... 3
3 General Overview........................................................................................... 4
3.1 Key Benefits ............................................................................................................................ 4
3.2 System Operation ................................................................................................................... 4
3.2.1 LZS-003-HS High Speed Dual Laser Model ....................................................................................... 4
3.2.2 Setup ........................................................................................................................................... 5
3.2.3 Mute Point .................................................................................................................................... 5
3.2.4 Normal Mode................................................................................................................................. 6
3.2.5 Tray / Box Mode ............................................................................................................................ 6
3.2.6 Field Muted Mode .......................................................................................................................... 7
3.2.7 Stop at Mute Point ......................................................................................................................... 7
3.3 Tool Change ............................................................................................................................ 7
3.4 Closed Loop Design ................................................................................................................. 8
4 Transmitter & Receiver Adjustment............................................................... 9
4.1 Adjusting the laser to punch distance .................................................................................... 9
4.2 Adjusting the receiver for tray/box bending ........................................................................ 10
5 Operating the LZS-003-HS ........................................................................... 13
5.1 Operator Controls ................................................................................................................. 13
5.1.1 Operator Panel ............................................................................................................................ 13
5.1.2 LZS-003-HS Controller .................................................................................................................. 14
5.2 System Start-up .................................................................................................................... 14
5.3 Start-up Test ......................................................................................................................... 15
5.4 Setting the Mute Point .......................................................................................................... 17
5.5 Selecting Tray / Box Mode .................................................................................................... 20
5.6 Returning From Tray / Box Mode to Normal Mode ............................................................... 21
5.7 Selecting Field Muted Mode .................................................................................................. 22
5.8 Returning From Field Muted Mode to Normal Mode ............................................................. 23
5.9 Selecting Stop at Mute Point Mode ....................................................................................... 24
5.10 Disengage Stop at Mute Point Mode ..................................................................................... 26
6 Operator Instruction and Demonstration .................................................... 27
6.1 Equipment Identification ...................................................................................................... 27
6.2 Starting the System .............................................................................................................. 27
6.3 Mute Point Setting ................................................................................................................ 27
6.4 Operation in Normal Mode .................................................................................................... 28
6.5 Tray / Box mode ................................................................................................................... 28
6.6 Field Muted Mode .................................................................................................................. 28
6.7 Stop at Mute Point ................................................................................................................ 28
6.8 Setting Laser Position ........................................................................................................... 29
6.9 Back Gauge Interference ...................................................................................................... 29
6.10 Running the System .............................................................................................................. 29
6.11 Customer Sign Off – Training Completed ............................................................................. 29
7 Parameter Programming with the 1003-03 Operator Panel ........................ 30
7.1 Using the Keypad in Parameter Programming Mode ............................................................ 30
7.2 Entering Parameter Programming Mode .............................................................................. 31
7.3 Selecting the Parameter to be Programmed ........................................................................ 32
7.4 New Password....................................................................................................................... 34
7.5 Field Muted Button Functionality.......................................................................................... 36
7.6 Mute Stop Button Functionality ............................................................................................ 38
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7.7 Crawl Distance ...................................................................................................................... 39

7.8 Language............................................................................................................................... 40
7.9 Exit ........................................................................................................................................ 40
8 Error and Condition Codes ........................................................................... 41
8.1 LZS-003-HS Controller Display Codes................................................................................... 41
8.2 Condition Codes .................................................................................................................... 41
8.2.1 Controller Condition Code Display.................................................................................................. 41
8.2.2 1003-03 Operator Panel Conditions ............................................................................................... 42
8.3 Understanding Error Codes................................................................................................... 43
8.4 Initial Start-Up Test .............................................................................................................. 44
8.4.1 Initial Start-Up Test Faults............................................................................................................ 44
8.5 Mute Point Set-up ................................................................................................................. 45
8.5.1 Mute Point Set-up Faults .............................................................................................................. 45
8.6 Condition Codes .................................................................................................................... 46
8.7 Error Codes for LZS-003-HS.................................................................................................. 47
8.7.1 Primary Display Error Codes ......................................................................................................... 47
8.7.2 Secondary Display Error Codes ..................................................................................................... 49
9 Glossary of Terms ........................................................................................ 53
9.1 Abbreviations ........................................................................................................................ 53
10 Specifications ............................................................................................... 54
10.1 Circuits .................................................................................................................................. 54
10.2 Circuit Load Conditions and Contact Impedances (interfacing to 24 V systems) ................ 55
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1 About This Manual

This chapter contains information about this manual, containing the following elements:
• Document Organisation
• Document Objectives
• Technical Competence Requirements
• Prerequisites
• Related Documentation
• Guide to Notes, Notice and Cautions
• Obtaining Technical Assistance.
1.1 Document Organisation

This manual is organised into the following chapters:
1. About This Document (this chapter)
2. Critical Safety Information
3. General Overview
4. Transmitter & Receiver Adjustment
5. Operating the LZS-003-HS
6. Operator Instruction and Demonstration
7. Parameter Programming with the Operator Panel
8. Error and Condition Codes
9. Glossary of Terms
10. Specifications
1.2 Document Objectives

This manual provides information on the operation of Lazer Safe's LZS-003-HS press brake
operator guarding system.
1.3 Technical Competence Requirements

All operators of the LZS-003-HS equipment should be trained to use it and the press brake
upon which it is installed in a manner that complies with established safety practices.
1.4 Related Documentation

This manual should be used in conjunction with;
• The Operation Manual for your press brake
• The Lazer Safe Transmitter and Receiver Alignment Manual
1.5 Guide to Notes, Notice and Cautions

Note:
This symbol indicates helpful information that helps you make better use of your
Lazer Safe product.
Caution
This symbol alerts you to situations that could result in equipment damage
Warning
This symbol indicates danger. You are in a situation that could cause bodily injury.
Before you work on any equipment, be aware of the hazards involved with electrical
circuitry and be familiar with standard practices for preventing accidents. To see
translations of the warnings that appear in this publication, refer to the translated
Page 1
safety warnings that accompanied this device.
1.6 Obtaining Technical Assistance

For technical support with the LZS-003-HS, email customerservice@lazersafe.com.au detailing
your specific requirements.
Page 2
2 Critical Safety Information

2.1 Proper Use of the LZS-003-HS
The LZS-003-HS is designed to protect hands and fingers in the area close to the edge of the
punch. When installed correctly and safety instructions are observed fully, the LZS-003-HS
permits safe manipulation close to the punch, as well as offering effective protection while tools
close at high speed.
Please note these general safety notices:
• The LZS-003-HS is designed exclusively for installation and operation on hydraulic press
brakes, or press brakes that comply with the statutory machine safety and accident
prevention rules and regulations valid for the place where the press brake is operated, in
particular after the LZS-003-HS has been installed.
• The LZS-003-HS must be installed either in the press brake factory, or by specialist
technicians trained by Lazer Safe (or its authorised representatives).
• The operator must be fully conversant with the operation of the press brake and the risks
associated with it, as well as the operation of the LZS-003-HS guarding system.
• The alignment of the protective equipment for punches of different lengths should be
performed by a die setter (or someone with equivalent specialist expertise) trained in all
relevant aspects of operating the press brake and the LZS-003-HS guarding system.
• Suitable protective equipment must be worn by the operator at all times.
2.2 Special Warnings

To ensure the highest possible degree of safety in operating a press brake fitted with the LZS-
003-HS, it is important to note the following special warnings.
Warning: AVOID FAST, ERRATIC MOVEMENTS AS TOOLS CLOSE
When the tools close at high speed (above mute point) towards a static (fixed)
obstruction, there will be less than maximum protection at the point where the laser
detects the obstruction. For example, if a small obstruction, such as a finger, is
rapidly and erratically pushed between punch and obstruction immediately before the
laser senses the static obstruction, the finger might be touched.
Warning: NO PROTECTION BETWEEN MUTE POINT AND WORKPIECE

In Normal mode, the LZS-003-HS protects until the laser is within 2mm of the
material surface. Even though this gap is too small for a finger to be inserted, always
exercise care.
Warning: NO PROTECTION IN FIELD MUTED MODE

In Field Muted mode, the optical sensing is deactivated. Although the LZS-003-HS
ensures that the machine does not exceed crawl speed in this mode, particular
caution must still be exercised.
The LZS-003-HS Operator Panel requires a password to enable the Field Muted
mode button. The password should only be available to suitably trained personnel.
Field Muted mode should only be used by suitably trained personnel and only
in exceptional circumstances (changing tools, maintenance, etc.)
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3 General Overview
The Lazer Safe LZS-003-HS is a guarding system for hydraulic press brakes that provides a
highly effective solution for both operator safety and machine productivity.
The system comprises the following components:
• LZS-003-HS Controller
• Operator Panel
• Optical Encoder
• Laser Transmitter / Receiver pair
• Brackets for mounting the Transmitter and Receiver
The LZS-003-HS can be installed either at the time of manufacture or as a retrofit to a press
brake already in service.
3.1 Key Benefits

• Delivers comprehensive operator protection at
close proximity to work piece.
• Allows tools to close at high speed, increasing
productivity.
• Complex shapes can be achieved with the "Tray /
Box" and "Field Muted" modes of operation.
• Encoder feedback provides closed-loop monitoring
of speed and stopping distance of the press beam.
• A flat band of continuous laser light detects
obstructions as small as 4mm while remaining
vibration tolerant.
The LZS provides protection at close
• The mute point is automatically determined, easily proximity to work-piece.
set and continuously monitored.
• The rear section of laser is easily muted to ignore the back gauge in "up-close" situations.
• Failure detection is performed by real-time monitoring of the process under control.
3.2 System Operation

The transmitter and receiver are mounted on the upper beam of the press brake, allowing the
operator to remain close to the work-piece as the tools close at high speed. Hands and fingers
are protected by a continuous band of laser light that senses the zone below the punch. If an
obstruction is detected the beam movement is stopped. The punch cannot make contact with
the obstruction.
The LZS-003-HS system continuously monitors the critical speeds and stopping distance of the
moving member of the machine. If the crawl speed is exceeded and / or the stopping distance
is exceeded, the LZS-003-HS controller will issue a stop command to the machine. There is no
need for a separate stopping distance monitor.
3.2.1 LZS-003-HS High Speed Dual Laser Model
For press brakes with a high closing speed (150 mm / sec or faster) the LZS-003-HS is
recommended (Figure 3-1). This model features a transmitter with two parallel lasers that are
4mm and 14mm below the punch. The lower laser (laser B) triggers the deceleration of the
press to bending speed while the higher laser (laser A) continues to provide protection.
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Laser to punch
distance
Laser A 4mm
Laser B 14mm
Mute point
Figure 3-1: LZS-003-HS Dual Laser
3.2.2 Setup
During setup the laser is set at a distance of 14mm below the tip of the punch. When using the
LZS-003-HS dual laser only the lower laser (Laser B) is switched on during set-up.
Laser B to
punch distance
14mm
Mute point
2mm
Figure 3-2: Laser to punch distance / Mute point distance
3.2.3 Mute Point

The Mute point must first be established so that the LZS-003-HS will not treat the material
being formed as an obstruction. The Mute point is automatically set at 2.0mm above the
surface of the material as the tools close for the first stroke. This mute point set-up can be
initiated whenever the material thickness is substantially changed.
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3.2.4 Normal Mode

If no obstruction is detected, the tools close at high speed until the laser reaches the mute point
and continue at pressing speed with the sensing functions muted, bending the material until
finished.
In normal mode, the entire width of the laser (front, middle and rear) is activated for recognition
of obstructions. As the punch moves towards the work piece, the laser will detect obstructions
ahead of the tip of the punch until it reaches the mute point, thereby covering the range where
the beam is allowed to travel at high speed. When an obstruction is detected, the beam stops.
The punch will not touch the obstruction.
Should the operator decide to continue with the stroke, the foot switch will have to be
depressed again. The tools will begin to close. If however the obstruction has not been
removed and is still detected the cycle will be completed in crawl speed with the sensing
function muted. This feature is important for jobs where the shape of the work piece will
obstruct the laser.
Mute Mute Mute

point point point
Figure 3-3 Normal Mode operation
3.2.5 Tray / Box Mode

When making boxes or trays, two opposing side walls are bent first. The work piece is then
turned horizontally so the remaining two side walls can be bent. The two previously bent side
walls now obstruct the front section of the laser and cause the system to mistake them for a
dangerous obstruction. In this situation, if the system is in Normal Mode, the beam will come
to a stop and wait for operation of the foot switch. Then, if the work piece is kept in place and
the foot switch is depressed it will only be possible for the tools to close at crawl speed and
time will be lost.
The LZS-003-HS Tray / Box Mode eliminates this lost time by allowing the beam to continue in
high speed to the mute point only after stopping at the top of the side wall. The foot switch
must be depressed to resume closing of the tools. The front, centre and rear sections of the
laser are active from the top of the stroke to the top of the side wall. Upon reaching the side
wall, the front and rear sections of the laser are deactivated for the remainder of the stroke.
The centre section of the laser remains active until the mute point is reached, unless an
obstruction is detected. If an obstruction is detected by the centre section, the beam will stop
and continuation of the stroke to the mute point will only be possible in crawl speed.
Tray / Box Mode may also be used to ignore interference from the back gauge. In Tray / Box
Mode, the back gauge will then be treated like the work piece side wall as described above. In
this case, both front and rear sections are muted from the top of the back gauge, but the centre
section always remains active.
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Once selected, Tray / Box Mode will remain active while the machine is operating. If the
machine is idle for ten minutes, the LZS-003-HS will automatically switch back to Normal
Mode.
Mute Mute Mute

point point point
Figure 3-4 Tray / Box Mode operation
3.2.6 Field Muted Mode

WARNING: NO PROTECTION IN FIELD MUTED MODE
In this mode, protection from the laser is muted for the entire stroke of the beam and therefore
does not provide protection. The LZS-003-HS however maintains all its other safety functions.
For example, it continues to monitor that the closing of the tools occurs at crawl speed and
stops the machine if that speed is exceeded.
The Field Muted Mode should only be used in cases where no alternative mode with activated
protection exists. It is recommended that the Field Muted Mode only be activated by
supervisory personnel. Field Muted Mode can be locked and password protected.
3.2.7 Stop at Mute Point
The auxiliary Mute Stop mode may be engaged to cause the beam to always stop at the mute
point. It is particularly useful when the back gauge is set close to the die causing the rear
section of the laser to be interrupted. The rear section of the laser is muted within the area
10.0mm above the material to clear back gauge obstructions.
3.3 Tool Change

When changing the tools the transmitter and receiver can be easily moved clear so that the
punch can be removed from either end of the machine. To realign the transmitter and receiver
each is moved quickly back into position. The laser is adjusted to the correct distance from the
punch tip with the aid of an alignment tool. The receiver is simply positioned so that the laser
strikes any where in the 40mm window reception area. In most tool changes the receiver does
not require any adjustment if the punch depth changes by less than 20mm. After the tool
change is complete the mute point is then quickly and easily reset during the first stroke.
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3.4 Closed Loop Design

The closed-loop design of the LZS-003-HS enables monitoring of the stopping distance of the
moving beam every time it stops. If the stopping distance limit is exceeded, an emergency
stop signal is issued and the machine is shut down.
The LZS-003-HS surveys the effect of failures of hydraulic valves, failures of electrical
components, and failures in the machine controller software in relation to the actions of the
parts of the machine that pose risk to the operator.
Figure 3-5 Closed loop design
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4 Transmitter & Receiver Adjustment

Note:
Refer to the Transmitter and Receiver Alignment Manual for more detailed
information.
4.1 Adjusting the laser to punch distance

Prior to operating the LZS-003-HS system, it is necessary to check the laser to punch distance.
When the LZS-003-HS system is powered up the laser to punch distance setting of 14mm will
be displayed on the top line of the LCD Operator Panel.
To check the laser to punch distance;
1. Power-up the LZS-003-HS system and check the laser to punch distance setting on the
LCD Operator Panel. It will be displayed as 14mm.
2. Set the LZS-003-HS to Normal Mode (default start-up mode) and check that the laser is
on.
3. Place the TX Alignment Magnet on the end of the punch with the punch tip aligned with
the 14mm laser to punch mark (Figure 4-1).
4. Loosen the vertical bracket locking handle and adjust the vertical position of the laser
so that it is positioned inside the window on the TX Alignment Magnet (Figure 4-2).
Figure 4-1: TX Alignment Magnet (set to 14mm)
Figure 4-2: Vertical bracket locking handle
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4.2 Adjusting the receiver for tray/box bending

When using Tray Mode the front and rear sensors are muted after sensing the work-piece up-
stand. The middle sensor remains active and provided it remains unobstructed the stroke can
be completed in high speed. The middle sensor must be positioned approximately 1mm behind
the centre line of the punch to avoid being obstructed by the up-stand (Figure 4-3).
Figure 4-3: Receiver middle sensor position
To adjust the receiver position;

1. Place the RX Alignment Magnet on the end of the punch with the punch tip aligned
with the 14mm laser to punch mark (Figure 4-4). A 4mm portion of the laser will be
visible on the receiver window.
2. Unlock the slider mechanism screw (A) (Figure 4-5).
3. Move the front to back slider mechanism of the receiver forward until it reaches the
front limit (Figure 4-5 & Figure 4-6).
4. Move the front to back slider mechanism of the receiver towards the rear of the
machine until the LCD Operator Panel shows the middle sensor as being clear.
5. Lock the slider mechanism screw (A) (Figure 4-5).
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LASER ALIGNMENT MAGNET
FIT TO RECEIVER END OF PUNCH
14m m
8m m 9mm
6m m 7mm
4m m 5mm
POSITION LASER INSIDE WINDOW
Figure 4-4: RX Alignment Magnet (set to 14mm)
Figure 4-5: Slider Mechanism Adjustment
Page 11
Figure 4-6: Middle sensor adjustment
Page 12
5 Operating the LZS-003-HS

5.1 Operator Controls
5.1.1 Operator Panel
The instructions in this section refer to various controls on the LZS-003-HS Operator Panel,
which is shown in Figure 5-1:
Main display
Mute lamp "Laser beam

clear" indicator
LEDs
Operating mode indicator LEDs
Figure 5-1: LZS-003-HS Operator Panel
Indicator States
The various indicators can have multiple states.
The Mute lamp's states are illustrated throughout this manual as follows:
Off
On
Flashing (slow)
Flashing (fast)
The states of the operating mode and "laser beam clear" indicator LEDs are illustrated
throughout this manual as follows:
Off
On
Flashing
Note:
In all operations, the display text "READY TO BEND" is replaced by the word
"BENDING" when the down pedal is pressed and the tool is in motion.
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5.1.2 LZS-003-HS Controller

The LZS-003-HS Controller is usually mounted on the side of the press brake. It has a two
digit LED display that also provides important status information on the operation of the LZS-
003-HS. The left-hand digit is referred to as the Secondary Digit and the right-hand digit as
the Primary Digit. The LZS-003-HS Controller is shown in Figure 5-2:
Figure 5-2: LZS-003-HS Controller
Note:
Section 8 contains detailed information on error codes.
5.2 System Start-up

When the LZS-003-HS system is powered-up the controller will perform a self test. During the
self test the LCD Operator Panel will display software version information and the controller will
cycle various numbers on the two segment display. After the self test is complete the controller
display will show 01 and the LCD Operator panel display will scroll the LZS-003-HS system
software version and laser to punch distance setting across the top line of the display.
The laser to punch distance setting will be displayed as 14mm. Check that the laser is aligned
14mm below the punch.
Note:
Refer to Section 4 or the Transmitter and Receiver Alignment Manual for detailed
information regarding alignment and laser to punch settings.
Once the laser to punch distance has been checked press the SET button as indicated on the
LCD Operator Panel display. Proceed with the Start-up test.
Page 14
5.3 Start-up Test

Once started, the LZS-003-HS will perform a start-up test to check the systems emergency
stop function and stopping performance of the press brake. Check the following prior to
commencing the start-up test:
• Open the tools to a minimum opening of 50mm.
• Check the transmitter and receiver are correctly aligned.
• Check the laser to punch distance.
• Check that the laser clear indicator LEDs are all on.
Note:
Refer to Section 4 or the Transmitter and Receiver Alignment Manual for detailed
information regarding alignment and laser to punch settings.
To commence the test, press the down pedal as indicated on the display. The beam will move
a short distance then stop.
Note:
After the start-up test is complete it may be necessary to restart the hydraulic pump.
Figure 5-3: Start-up test display
If the test completes successfully, the mute point will be set next. Press the down pedal to
continue, as shown in the following diagram. See Section 5.4 Setting the Mute Point.
Figure 5-4: Initial mute point setting
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If the start-up test generates an error, the display will show the following:
Figure 5-5: Error detected display.

(Note: the first line of the text display scrolls the message "Error detected,
emergency stop activated".)
In this situation, the press brake is shut down and cannot be operated until the error condition
is corrected. The error code is displayed on the LZS-003-HS Controller's two digit display -
consult Section 8 for detailed information.
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5.4 Setting the Mute Point

Prior to setting the mute point place a sample piece of material on top of the die.
¾ Place a sample piece of material on top of the die. The material should be the same
thickness as the material that will be used during bending as the laser will detect the
surface of the material when setting the mute point. See Figure 5-6.
Figure 5-6: Material placement on the die.
Note:
In addition to being set immediately after the start-up test, the mute point must
always be reset in any of the following situations:
• After changing from Normal mode or Tray mode to Field Muted mode.
• After changing from Field Muted mode to Normal mode or Tray mode.
• When material thickness changes.
• When the tools are changed.
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To set the mute point, press the SET button. The Ready to Set LED will be on. If in Normal
mode, the display will show:
Figure 5-7: Setting the mute point (step 1)
Press the foot pedal to close the tools. When the laser detects the material the beam will stop
and the message in Figure 5-8 will be displayed. Release the foot pedal.
Note:
During mute point set-up the LZS-003-HS system uses the front and middle sensors
of the receiver to detect the material. When setting the mute point the rear sensor
must remain unobstructed. If a rear sensor obstruction occurs the beam will stop.
Release the foot pedal and press again. The beam will move a further 2mm. If the
front or middle sensors do not detect the material then the mute point can not be set.
The beam must then be retracted, the SET button pressed and the mute point set-up
repeated.
Figure 5-8: Setting the mute point (step 2)
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Press the SET button to confirm. The Ready to Set LED will be off and the Mute Set LED will
be on. The display will show:
Figure 5-9: Mute point set
The mute point is now set.

The beam may now be driven further down, or retracted.
Note:
Retraction may occur automatically after the punch has been moved downwards, to
the bottom dead centre.
The system may now be operated.
Page 19
5.5 Selecting Tray / Box Mode

In order to select Tray / Box mode, the system must first be in Normal mode (the default start-
up mode), as shown in Figure 5-10. The laser must also be above the mute point and clear of
any obstructions.
Figure 5-10: Normal mode panel display
Press the Guard Mode button - the display will change as shown:
Figure 5-11: Mode change confirmation
Press the SET button - the display will change as follows to confirm Tray / Box mode and the
Tray LED will be on:
Figure 5-12: Indication of Tray / Box mode selection
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Tray / Box mode is now activated.

Notes:
• The setting of the Mute point is stored in memory. For a new setting, perform the same
procedure for Mute Point setting as described for Normal Mode (Section 5.4).
• When setting the mute point in Tray / Box mode, the front and middle sensors of the laser
receiver find the reference position. However, if the rear sensor is obstructed first, there
will be no 2 mm tolerance zone.
5.6 Returning From Tray / Box Mode to Normal Mode

The LZS-003-HS automatically returns to Normal mode from Tray / Box mode after 10 minutes
of inactivity. It can also be returned to Normal mode by a procedure identical to that described
previously:
Press the Guard Mode button - the display will change as shown:
Press the SET button - the display will change as follows to confirm Normal mode:
Figure 5-14: Indication of Normal mode selection
Normal mode is now activated.
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5.7 Selecting Field Muted Mode

Note:
The availability of this mode depends on the setting of the relevant operating
parameter. See Section 7 for more detailed information.

To select Field Muted mode, press the Field Muted button. The display will show:
Press the SET button to confirm. The display will show:
Figure 5-16: Selecting Field Muted Mode
At this stage a manual mute point can be set anywhere in the stroke.
• Press the foot pedal to close the tools.
• Release the foot pedal at the desired mute point position.
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Press the SET button to confirm the mute point. The display will show:
Figure 5-17: Indication of Field Muted mode selection.

(Note: the first line of the text display scrolls the message "Crawl speed due to field
muted mode")
5.8 Returning From Field Muted Mode to Normal Mode

To return to Normal mode from Field Muted mode, press the Guard Mode button. The display
will show:
Figure 5-18: Change from Field Muted mode
After pressing the SET button, the mute point must be reset. Repeat the steps in section 5.4
Setting the Mute Point.
Figure 5-19: Reset mute point after mode change

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Confirm the new mute point by pressing the SET button:
Figure 5-20: Mute point confirmation
After pressing the SET button, the system is returned to Normal mode:
Figure 5-21: Indication of Normal mode selection
Normal mode is now activated.
5.9 Selecting Stop at Mute Point Mode

Note:
The availability of this mode depends on the setting of the relevant operating
parameter. See Section 7 for more detailed information.
To select Stop at Mute Point mode (in Normal Mode, Tray / Box Mode or Field Muted Mode),
press the Mute Stop button. Depending on the current mode, the display will appear as shown
in either Figure 5-22 or Figure 5-23.
Page 24
Figure 5-22: Selecting Stop at Mute Point Mode (in conjunction with Normal mode)
Figure 5-23: Selecting Stop at Mute Point Mode (in conjunction with Tray / Box mode)
Note:
"Stop at Mute Point" also mutes the rear beam for an increased height above mute
point. This prevents the back gauge from interrupting the rear beam when the back
gauge is set to less than 20 mm.
Page 25
5.10 Disengage Stop at Mute Point Mode

To disengage Stop at Mute Point mode, press the Mute Stop button. The display will show:
Figure 5-24: Disengage Stop at Mute Point Mode (Normal Mode)
Figure 5-25: Disengage Stop at Mute Point Mode (Tray / Box Mode)
Page 26
6 Operator Instruction and Demonstration

Lazer Safe Ref #: __________________
Instructor's Name: _________________ Company: _______________________
Signature: ________________________ Date: ___________________________
Ensure that the responsible person - Operator, Foreman or Manager (whoever the company
designates as responsible) reads and understands the manual (translate if necessary).
It is suggested that the manual be given to this person as the installation is started so they will
have read the manual by the time the installation is completed.
6.1 Equipment Identification

Component Model Serial Number Notes
LZS-003-HS Controller
Transmitter
Receiver
Operator Panel
6.2 Starting the System

Refer to Section 5.2 for a detailed description.
• Demonstrate and explain the start-up test. Demonstrate the stopping test during start-up
and explain how it tests the safety stopping performance of the machine and either passes
or shuts the machine down with an error. Explain the 30 hour test if the machine is run
continually for 30 hours.
• Explain how the transmitter and receiver operate. Demonstrate how the receiver detects
the laser in segments (using a 4 mm Allen key is usually convenient). Show how blocking
the laser like this is indicated on the operator panel lights (front, middle, and rear sensors
clear or not clear).
6.3 Mute Point Setting

Refer to Section 5.4 for a detailed description.
• Highlight the purpose of the mute point. Explain that the laser detects obstructions
2mm above the surface of the material that you have set mute from. Explain how a change
in material thickness will be detected if it is greater than 2mm.
• Get the operator to demonstrate setting and resetting the mute point. Make sure the
process outlined in Section 5.4 is understood.
• Ensure that it is understood that the mute point is set from the front and middle sensors.
Page 27
6.4 Operation in Normal Mode

• Ensure that it is understood what happens when the system runs in normal mode.
• The process must be understood and demonstrated.
• Demonstrate the difference between front, middle and rear sensor obstructions with regard
to the pressing beam retract function (if operational).
• Ensure it is understood that the laser is muted after one or two obstructions (depending on
operation) and that the Mute lamp remains permanently lit to indicate this status. Explain
the sensor blanking function of the receiver rear sensors.
6.5 Tray / Box mode

Refer to Sections 5.5 and 5.6 for detailed descriptions.
• Explain and demonstrate how this process is useful in box and tray type bending.
• Get the operator to go into and come out of Tray / Box mode themselves.
• Explain that the mute point is retained when switching from normal to Tray / Box mode.
Also get them to change mute point in Tray / Box mode.
• Make sure they understand that the front and rear sensors are muted after an obstruction,
but if the middle sensor is obstructed the laser will be muted for the remainder of the stroke.
• Make sure the operator is aware of the 10 minute time limit set into Tray / Box mode and
that it ensures the machine cannot be left permanently in Tray / Box mode.
6.6 Field Muted Mode

• Demonstrate this function and ensure the operator understands that the laser protection will
be switched off and the machine will only operate in crawl speed while being used in this
mode.
• Explain that the system will still monitor the machine speed and stopping performance.
Make sure the operator is aware that a responsible person should have access to the
password for enabling the field-muted mode button.
• Show how to switch back to normal mode and explain that the mute point must be reset.

6.7 Stop at Mute Point

• Explain the stop at mute function. Show how the rear sensor is muted 10 mm above the
material to provide extra clearance for any back-gauge interference.
Page 28
6.8 Setting Laser Position

Refer to Section 4 or the Transmitter Receiver Alignment Manual for a detailed description.
• Explain and demonstrate how to adjust the Transmitter and Receiver height.
• Get the operator to adjust the brackets and check the alignment of the laser.
• Demonstrate how the laser target is used to set the distance of the laser from the punch
ensuring that it is parallel.
• Ensure the operator is aware that to view the laser striking the receiver, a small section of
the laser can be obstructed to brighten the intensity.
• Explain that if the laser is not correctly aligned, the mute point can be inaccurately detected
when bending and that errors codes can be generated.
6.9 Back Gauge Interference

• Ensure that the operator understands the effect of the back gauge on the rear sensor
section. If an obstruction occurs, the system will react by stopping the machine.
• Establish if the back gauge or any processes they are performing may cause interference.
• Explain that approximately 10 mm of the rear sensor can be blocked by the back gauge
without an obstruction to be detected.
6.10 Running the System

• Have the operator perform each of the main functions.
• Using each mode of the system have the operator bend some test pieces of material and
also making sure to utilise the Tray / Box mode for a demonstration of the operation during
box bending.
• Ensure the operator is aware of each mode they are in and the status of the LCD and
indicator LEDs, including the Mute lamp during each mode.
6.11 Customer Sign Off – Training Completed
Company Name: __________________ Date: ___________________________
Names of Company Representatives: Signatures of Company Representatives:

________________________________ ________________________________
________________________________ ________________________________
________________________________ ________________________________
________________________________ ________________________________
________________________________ ________________________________
________________________________ ________________________________
Page 29
7 Parameter Programming with the 1003-03 Operator Panel

The LZS-003-HS can be programmed with a number of operational parameters to suit
individual user requirements.
These parameters are:
New password
To ensure that changes are made only by authorised personnel, the LZS-003-HS requires
entry of a four digit password to enter the programming mode. This password can and should
be changed from the factory default password
Field Muted button functionality
This option determines behaviour of the Field Muted button, controlling access to the Field
Muted mode.
Mute Stop button functionality
This option determines behaviour of the Mute Stop button, controlling access to the Stop at
Mute Point mode.
Crawl distance
This option allows you to set the distance above the work piece that the press brake travels at
crawl (slow) speed.
Language selection
This option allows to you to select the different language options installed.
Note:
Pressing the Lazer Safe button at any time exits the Parameter Programming mode
when no change has been made to the parameter currently being edited.
The options for each of the parameter programming methods are described in the following
sections.
7.1 Using the Keypad in Parameter Programming Mode

In Parameter Programming mode, the Operator Panel keypad is used to make menu selections
and enter parameter values. In this mode, the functionality of the buttons differs from normal
operation. These differences are summarised in the following diagram and table:
Figure 7-1: Keypad button functionality in Parameter Programming mode
Button Function
Field Muted Moves menu selection up or increments value (depending on context)
Guard Mode Moves menu selection down or decrements value (depending on context)
Mute Stop Moves cursor to next digit (where applicable)
SET Accepts the current menu selection or value entered (depending on context)
Note:
Each button's LED is illuminated whenever the button is active.
Page 30
7.2 Entering Parameter Programming Mode

To enter the Parameter Programming mode, press the Lazer Safe logo (directly above the
Mute lamp). You will immediately be required to enter a four digit password, as shown in the
following figure:
Figure 7-2: Password entry
Warning
The factory default password for entering Parameter Programming mode is 1234.
For maximum safety, it is strongly recommended that the password be changed
when the LZS-003-HS is installed. See Section 7.4 for detailed information on
changing the password.
To enter the password:

1. Press the Field Muted button to increment the current digit (highlighted with an
underscore) or press the Guard Mode button to decrement it.
2. When the correct value for that digit is displayed, press the Mute Stop button to select the
next digit.
3. Repeat Steps 1 and 2 until all four password digits have been entered. At any time, you
can go back to previous digits by pressing the Mute Stop button until it "scrolls" back to the
position you wish to change.
4. Press the SET button to accept the value entered.
If you have entered the password correctly, the display will allow you access the parameter
programming functions. If the password is entered incorrectly, the LZS-003-HS will return to
normal operating mode.
Page 31
7.3 Selecting the Parameter to be Programmed

Once the password has been correctly entered, the display shows:
Figure 7-3: Set New password
Pressing the Guard Mode button scrolls to the next parameter, as shown in the following
figures. Press SET to accept your selection.
If you go past the parameter you wish to set, press the Field Muted button to move "up" a
menu item.
Figure 7-4: Set Field Muted button functionality
Figure 7-5: Set Mute Stop button functionality
Page 32
Figure 7-6: Set crawl distance
Figure 7-7: Set Language
Figure 7-8: Exit parameter programming
Page 33
7.4 New Password

As described in the previous section, it is strongly recommended that you change the
parameter programming password as soon as the LZS-003-HS is installed. This specifically
prevents unauthorised access to Field Muted mode, in which there is no laser protection.
Note:
For your convenience, it is important to record the new password and save it in a
safe place. If you lose the password, the operator panel must be returned to Lazer
Safe or your authorised distributor / installer to have the default password restored.
After entering this programming parameter, the display shows:
Figure 7-9: Enter new password
To enter a new password:

next digit.
3. Repeat Steps 1 and 2 until all four password digits have been entered. At any time, you
can go back to previous digits by pressing the Mute Stop button until it "scrolls" back to the
position you wish to change.
4. Press the SET button to accept the value entered.
Once all four digits have been re-entered, you will be prompted to re-enter the password to
confirm it, as shown:
Figure 7-10: Re-enter new password

Page 34
The process for re-entering the new password is identical to the process described above. If
the new password is re-entered correctly and confirmed, the display will return to the main
Parameter Programming menu.
If it is entered incorrectly, the following display is shown:
Figure 7-11: New password not accepted
If the new password has not been accepted, press the SET button to return to the main
Parameter Programming menu. If you wish, you can attempt changing the password again by
selecting the New Password option.
Page 35
7.5 Field Muted Button Functionality

This parameter allows to you to select the functionality of the Field Muted button in press
brake operation.
The three options available are:

Option Functionality
The button is enabled and the operator can enter Field Muted mode at any
Enabled
time.
Disabled-On The button is disabled and the system is locked into Field Muted mode.
Disabled-Off The button is disabled and the system is locked out of Field Muted mode.
On entering this parameter's menu, the display shows:
Figure 7-12: Field Muted button functionality - option 1
Pressing the Guard Mode button successively displays the other options for this parameter.
Press SET to accept your selection.
If you go past the option you wish to set, press the Field Muted button to move "up" a menu
item.
Page 36
Page 37
7.6 Mute Stop Button Functionality

This parameter allows to you to select the functionality of the Mute Stop button in press brake
operation.
The three options available are:
Option Functionality
The button is enabled and the operator can enter Stop at Mute Point mode at
Enabled
any time.
Disabled-On The button is disabled and the system is locked into Stop at Mute Point
mode.
Disabled-Off The button is disabled and the system is locked out of Stop at Mute Point
mode.
Figure 7-15: Mute Stop button functionality - option 1
Pressing the Guard Mode button successively displays the other options for this parameter.
Press SET to accept your selection.
If you go past the option you wish to set, press the Field Muted button to move "up" a menu
item.
Page 38
7.7 Crawl Distance

This parameter allows to you to select the Crawl Distance (in mm, using two digits).
Caution:
This parameter is set by your supplier and should only be changed by trained
personnel. An incorrect crawl distance setting will result in speed errors being
detected by the LZS-003-HS controller which will prevent normal operation of the
press brake.
Figure 7-18: Set crawl distance
The default setting is 5mm for dual laser systems.

To enter a new crawl distance:
next digit, and repeat Step 1.
3. Press the SET button to accept the value entered. The display returns to the main
Parameter Programming menu.
Page 39
7.8 Language
This parameter allows to you to select the different languages installed.
Figure 7-19: Set Language
7.9 Exit
Press the SET button when this option is displayed on the main Parameter Programming menu
to exit Parameter Programming mode.
Page 40
8 Error and Condition Codes

8.1 LZS-003-HS Controller Display Codes
The LZS-003-HS controller displays error and condition codes on the two segment display
located on the front of the controller box. The right side digit displays the primary processor
codes and the left side digit displays the secondary processor codes.
Secondary Primary
processor processor
display display
Figure 8-1: Layout of controller display
8.2 Condition Codes

8.2.1 Controller Condition Code Display
Condition codes are displayed during normal operation. These codes ranging from 00 to 07
indicate various steps during initial set-up and mute point setting. They also indicate minor
problems that can be rectified by the operator reinitiating part of the set-up procedure.
Secondary Primary
Condition Code
Display Display
0 0 System operational
0 1 Start-up or 30 hour test
0 2 Mode changed
0 3 Obstruction during mute point set-up
0 4 Confirm mute point
0 5 Ambient light detected or receiver not connected
0 6 Start time exceeded
0 7 No material sensed after the mute point
Table 8-1
Note:
Refer to detailed description in this section for more information about condition
codes and operator actions required.
Page 41
8.2.2 1003-03 Operator Panel Conditions

The Operator Panel is programmed to display a range of messages about operational
conditions on its two line screen. The first line displays the description of the condition and the
second line displays the required action (if any). These are summarised in Table 8-2:
Display Line 1 (Condition) Display Line 2 (Action Required)
System Power-up Press 'SET'
Confirm Mute? Press 'SET'
Mode Change? Press 'SET'
Obstruction during mute point setup Press 'SET'
Ambient light present Press 'SET'
Start-up test1 complete Down / Up pedal
Receiver clear / obstruction status error Receiver line check error
No movement detected on down command Press 'SET'
No material sensed below mute point Return to top
No movement detected with down command active Release down pdl
Opening too small for start-up test prs 'SET' for 2s
Down stroke stopped by first obstruction in normal mode Release down pdl
Down stroke stopped by second obstruction in normal mode Release down pdl
Down stroke stopped by outside obstruction in tray mode Release down pdl
Down stroke stopped by centre obstruction in tray mode Release down pdl
Down stroke stopped at mute point in 'stop at mute' mode Release down pdl
Crawl speed due to field muted mode LASER INACTIVE
Crawl speed due to second obstruction in normal mode -
Crawl speed due to centre obstruction in tray mode -
Crawl speed due to open tools with protection off -
Crawl speed due to no start-up test being performed RESET MACHINE
Error detected, emergency stop activated Check Error Code
Do Start-up Test1 Press down pedal
Set new mute pnt Press down pedal
Unrecognised Error Code -
Table 8-2: Operator panel condition codes
Abbreviations
The following abbreviations are used for conciseness in some of the above messages:
Abbreviation Meaning
pdl Pedal
pnt Point
prs Press
s Seconds
Table 8-3
Page 42
8.3 Understanding Error Codes

In the event of an emergency shut down the LZS-003-HS will display error codes on the two-
segment display. Error codes are displayed as primary (right segment) and secondary (left
segment) codes and have two parts to each. The display will cycle through the four error code
numbers automatically and will continue to repeat until the LZS-003-HS controller is reset. The
display sequence is as follows;
• Both displays show --
• Secondary display shows - Primary display shows 1st number
• Secondary display shows - Primary display shows 2nd number
• Both displays show --
• Secondary display shows 1st number. Primary display shows -
• Secondary display shows 2nd number. Primary display shows -
• Both displays show -- then sequence is repeated
Note:
Section 8.7 contains detailed explanations of all error codes.
Example 1
Secondary Primary Secondary Primary

processor processor processor processor
display display display display
Primary 1st number Primary 2nd number
This indicates primary error code 8/2 – Stopping distance exceeded
Example 2
Secondary Primary Secondary Primary

processor processor processor processor
display display display display
Secondary 1st number Secondary 2nd number
This indicates secondary error code 1/3 – Crawl speed exceeded
In Example 1, the error is displayed on the primary display. The secondary display will
generally show an error code that is not listed. This error should be ignored as the error
causing the emergency shut down is reported on the primary display. The same applies for the
secondary error code in Example 2.
To reset the LZS-003-HS system after an error code has been displayed, the power supply
must be isolated for five seconds.
Note:
When reading the error codes a point (.) will sometimes appear after the secondary
digit. It is important to make note of this when referring to the error code section.
Page 43
8.4 Initial Start-Up Test
SEC PRI
Step Initial start-up test Operation Condition Cause of Fault / Action Required
Display Display
1 Start machine 0 1 Normal ¾ Continue to step 2.
2 Press SET button 0 0 Normal ¾ Continue to step 3.

¾ Check that transmitter and
receiver are aligned and laser is
0 3 Fault
clear of any obstructions. Press
SET button.
3 Press foot pedal Beam travels short distance then ¾ Continue to mute point set-up
stops. Hydraulic pump may be 0 0 Normal Section 8.5.
shut down.
Beam travels short distance then ¾ No encoder movement detected
stops. 0 1 Fault during secondary stopping
TEST. See fault 1.
Beam does not move ¾ Start time exceeded. No
movement detected within 1
0 1 Fault
second of the approach input
turning on. See fault 1.
Beam travels short distance then ¾ No approach input signal to LZS-
8/2 Fault
stops. System shuts down. 003 controller. See fault 2.
Beam travels short distance then ¾ No approach input signal to LZS-
9./1 Fault
stops. System shuts down. 003 controller. See fault 2.
Beam travels and stops when ¾ No approach input signal to LZS-
0 3 Fault
laser is obstructed 003 controller. See fault 2.
Beam travels and does not stop. ¾ Stopping distance error -
8/2 Fault
System shuts down. Secondary Stop. See fault 3.
Beam travels and does not stop. ¾ Stopping distance error -
9./1 Fault
System shuts down. Secondary Stop. See fault 3.
System shuts down when beam ¾ Reverse encoder A and B
8/2 Fault
is retracted channels
System shuts down when beam ¾ Reverse encoder A and B
9./1 Fault
is retracted channels
8.4.1 Initial Start-Up Test Faults
Fault Description Check
1 No encoder movement detected ¾ Check encoder wiring connections to the LZS-003 controller.
during initial start-up TEST.
¾ Reverse encoder A and B channels
¾ Check mechanical operation of the encoder. Check the optical encoder sprocket is firmly
secured to the encoder shaft. Check the optical encoder chain and spring travel.
¾ Replace the encoder
2 No approach input signal to LZS-003 ¾ Refer to the LZS-003-HS Installation Manual

controller.
3 Stopping distance error - Secondary ¾ Machine has exceeded the maximum allowable stopping distance.
Stop
¾ SEC 1 & 2 contacts not connected in best location to ensure adequate stopping distance.
¾ SEC 1 & 2 contacts not connected where they will cause the machine to stop.
¾ Reduce machine approach speed to allow stopping within maximum allowable limit
Page 44
8.5 Mute Point Set-up
SEC PRI Cause of Fault / Action

Step Setting the mute point Operation Condition
Display Display Required
1 After initial start-up restart

hydraulic pump (if
applicable)
2 Place sample material on

die
3 Check operator interface Mute lamp is off. 0 0 Normal ¾ Continue to step 5.

panel indicators
Mute lamp is flashing. ¾ Laser obstructed.
Press SET button to
0 3 Condition
reset (00 should be
displayed).
4 Press foot pedal to drive Beam travels and stops when laser ¾ Continue to step 6.
0 0 Normal
punch toward material detects material
Beam travels and stops when laser ¾ Stopping distance

8/2 Fault
detects material error. See fault 1.
Beam travels and stops when laser ¾ Stopping distance

9/1 Fault
detects material error. See fault 1.
5 Release foot pedal Mute lamp is flashing 0 4 Normal ¾ Continue to step 7.
Mute lamp is off. ¾ Material not detected.

0 0 Condition
See fault 2.
6 Press SET button to Mute lamp is on. ¾ Mute point is set.

0 0 Normal
confirm mute point
8.5.1 Mute Point Set-up Faults
Fault Description Cause of Fault / Action Required
1 Stopping distance error ¾ Machine has exceeded the maximum allowable stopping distance.
¾ EN 1 & 2 contacts not connected in best location to ensure adequate stopping distance.
¾ EN 1 & 2 contacts not connected where they will cause the machine to stop.
¾ Reduce machine approach speed to allow stopping within maximum allowable limit
2 Material not detected ¾ Press foot pedal again. Beam will move additional 2mm to detect material.
¾ Material must be detected by middle sensor to set mute point.
¾ Check that front and rear laser sections remain clear above material when setting mute point.
Page 45
8.6 Condition Codes
Secondary Primary
Condition Description Action Required
Display Display
0 0 Normal Indicates normal operation. ¾ None (if mute point is already set).
0 1 Start-up or 30 hour test System requires initial start-up test

¾ Refer to initial set-up.
to be performed.
0 2 Mode changed Operating mode has been ¾ Press SET button to confirm mode
changed. change.
0 3 Obstruction during mute Laser has been obstructed during ¾ Check laser is clear of any
point set-up mute point set-up or beam has obstructions.
been retracted during mute point
set-up. ¾ Press SET button. Code will reset
to 00. Continue with mute point set-
up.
0 4 Confirm mute point Laser has detected material and ¾ Press SET button to confirm mute
requires mute point confirmation. point. Refer to mute point setting.
0 5 Ambient light detected Receiver has detected ambient ¾ Check laser is clear of any
light or receiver is not connected. obstructions.
¾ Press SET button to reset code to
00. Mute point must be reset.
0 6 Start time exceeded The beam has not moved within 1

¾ Release machine foot pedal and
second of the LZS-003-HS
repress to reset code to 00.
receiving an approach input.
Beam approach starts then stops. ¾ Check mechanical operation of the

encoder.
¾ Check the optical encoder sprocket
is firmly secured to the encoder
shaft.
¾ Check the optical encoder chain and
spring travel.
¾ Check encoder wiring connections
to the LZS-003-HS controller.
¾ Replace the encoder.
0 7 No material sensed after The front or middle receiver ¾ Retract beam to reset code to 00.
mute point sensors have not detected material
below the mute point. ¾ Check laser is aligned parallel with
the punch.
¾ Reset the mute point.
Page 46
8.7 Error Codes for LZS-003-HS
8.7.1 Primary Display Error Codes
Primary Approach
Display Input
8 OFF Stopping The beam has not stopped moving ¾ No approach input signal to LZS-003 controller.
distance within 100ms during the initial start-up Refer to the LZS-003-HS Installation Manual
2 ON exceeded test or the stopping distance has
exceeded 13.5mm during mute point ¾ Check that the correct encoder sprocket is
setting. installed.
¾ Check mechanical operation of the encoder.
¾ Check sprocket is firmly secured to encoder
shaft.
¾ Check chain/spring travel.
¾ Check SEC 1/2 and EN 1/2 contacts are
connected where they will cause the machine to
stop.
¾ Check SEC 1/2 and EN 1/2 contacts are
connected in best location to ensure adequate
stopping distance.
¾ Machine approach speed must be reduced to
allow stopping within maximum allowable limit.
8 OFF Stopping The stopping distance had exceeded ¾ No approach input signal to LZS-003 controller.
distance 13.5mm with laser B active or 8.5mm Refer to the LZS-003-HS Installation Manual
3 ON exceeded with laser B muted.
¾ Check that the correct encoder sprocket is
installed.
shaft.
¾ Check EN 1/2 contacts are connected where they
will cause the machine to stop.
¾ Check EN 1/2 contacts are connected in best
location to ensure adequate stopping distance.
8 OFF Stopping The stopping distance has exceeded ¾ No approach input signal to LZS-003 controller.
distance 13.5mm close to the mute point. Refer to the LZS-003-HS Installation Manual
4 ON exceeded
installed
shaft.
¾ Check EN 1/2 contacts are connected where they
will cause the machine to stop.
9 OFF EN1 contact The EN1 contact has not been closed ¾ Check all interface connections and wiring.
closing by the secondary processor or the EN1
7 ON disparity contact has not been closed properly ¾ Check that the current through the contact has
when the secondary processor has not exceeded its rating.
commanded it to.
¾ Replace the LZS-003 controller.
Page 47
Primary Approach
Display Input
9 OFF EN1 contact The voltage across EN1 is not high ¾ Check that there is > 10v AC/DC across EN1
opening enough when the contact is opened. when it opens. Refer to the LZS-003-HS
8 ON disparity Installation Manual
¾ Check that no contacts in series with EN1 open
within 10ms of EN1 opening.
¾ Check all interface connections and wiring.
¾ Check all contacts in series with EN1.
9 OFF SEC2 The SEC2 contact has not been closed by ¾ Check all interface connections and wiring.
contact the secondary processor or the SEC2
9 ON closing contact has not been closed properly ¾ Check that the current through the contact has
disparity when the secondary processor has not exceeded its rating.
commanded it to. ¾ Replace the LZS-003 controller.
9 OFF SEC2 The voltage across SEC2 is not high ¾ Check that there is > 10v AC/DC across SEC2
contact enough when the contact is opened. when it opens. Refer to the LZS-003-HS
A ON opening Installation Manual
disparity
¾ Check that no contacts in series with SEC2
open within 10ms of SEC2 opening.
¾ Check all contacts in series with SEC2.
A OFF Receiver The receiver test voltage is incorrect. ¾ Check all connections and wiring between the
bias error receiver and LZS-003 controller.
1 ON
¾ Check that the receiver shield is connected to
the LZS-003 controller.
¾ Replace the receiver.
B OFF Counter The encoder count has exceeded ¾ Check mechanical operation of the encoder.
overflow 1750mm during beam retract.
2 ON ¾ Check sprocket is firmly secured to encoder
shaft.
¾ Check all connections between the encoder and
LZS-003 controller.
B OFF Counter The encoder count has exceeded ¾ Check mechanical operation of the encoder.
overflow 1750mm during beam approach.
3 ON ¾ Check sprocket is firmly secured to encoder
shaft.
¾ Check all connections between the encoder and
LZS-003 controller.
C OFF Mute lamp No current detected through the mute ¾ Check all connections and wiring between the
failure lamp when it is switched on or off. operator panel and the LZS-003 controller.
2 ON
¾ Check that there are no shorts between the
mute + & mute - terminals on CN12.
¾ Replace the operator panel.
Page 48
8.7.2 Secondary Display Error Codes
Secondary Approach
Display Input
1 OFF Crawl speed Speed has exceeded 20mm/s when ¾ Restart system and reset mute point.
exceeded laser A mutes in normal mode.
3 ON ¾ Check that the change of speed point is set
above the mute point to allow the machine to
decelerate to 20mm/s before laser A reaches
the mute point.
¾ Check the machine mute point is set high
enough.
¾ Check the change of speed point is set high
enough using the LZS-003 dip switch or
parameter settings.
installed.
shaft.
¾ Check machine crawl speed is 20mm/s or
less.
1 OFF Crawl speed Crawl speed has exceeded 20mm/s ¾ Check that the correct encoder sprocket is
exceeded after laser A has been muted. installed.
4 ON
shaft.
¾ Check machine pressing speed is 20mm/s or
less.
1 OFF 50% speed Speed has exceeded 50% of maximum ¾ Check that the change of speed point is set
check approach speed or 84mm/s when laser above the mute point to allow the machine to
5 ON exceeded A is 5mm from the mute point. decelerate to >50% of maximum approach
speed or 84mm/s when laser A is 5mm from
the mute point.
exceeded during forced crawl in field muted mode installed.
6 ON before a mute point has been set.
shaft.
less.
exceeded during forced crawl in normal mode. installed.
7 ON
shaft.
less.
1. OFF 80% speed Speed has exceeded 80% of maximum ¾ Check that the change of speed point is set
check approach speed or 134mm/s when laser above the mute point to allow the machine to
3 ON exceeded B is muted. decelerate to >80% of maximum approach
speed or 134mm/s when laser B reaches the
mute point.
Page 49
Secondary Approach
Fault Description Possible Cause of Fault and Action
Display Input
1. OFF Crawl speed Crawl speed has exceeded the ¾ Check that the change of speed point is set to
exceeded maximum allowable limit of 10mm/s allow the machine to decelerate to 10mm/s
2 ON when the mute input is on. before the mute input is switched on.
installed
shaft.
less.
1. OFF Crawl speed Crawl speed has exceeded 10mm/s ¾ Check that the correct encoder sprocket is
exceeded during forced crawl in field muted mode installed.
4 ON before the initial start-up test has been
performed. ¾ Check mechanical operation of the encoder.
shaft.
less.
exceeded during forced crawl in field muted installed.
6 ON mode.
shaft.
less.
installed.
exceeded during forced crawl in tray mode or the installed.
7 ON speed has exceeded 20mm/s when
laser A is muted in tray mode. ¾ Check mechanical operation of the encoder.
shaft.
less.
¾ Check machine pressing speed is 20mm/s or
less.
9 OFF Stopping The stopping distance had exceeded ¾ No approach input signal to LZS-003
distance 13.5mm with laser B active or 8.5mm controller. Refer to the LZS-003-HS Installation
1 ON exceeded with laser B muted. Manual
installed.
shaft.
¾ Check EN 1/2 contacts are connected where
they will cause the machine to stop.
Page 50
Secondary Approach
Display Input
9. OFF Stopping The stopping distance had exceeded ¾ No approach input signal to LZS-003 controller.
distance 20mm during the initial start-up test. Refer to the LZS-003-HS Installation Manual
1 ON exceeded
installed.
shaft.
¾ Check EN 1/2 contacts are connected where
they will cause the machine to stop.
A. OFF EN2 contact The EN2 contact has not been closed ¾ Check all interface connections and wiring.
closing by the secondary processor or the
2 ON disparity EN2 contact has not been closed ¾ Check that the current through the contact has
properly when the secondary not exceeded its rating.
processor has commanded it to. ¾ Replace the LZS-003 controller.
A. OFF EN2 contact The voltage across EN2 is not high ¾ Check that there is > 10v AC/DC across EN2
opening enough when the contact is opened. when it opens. Refer to the LZS-003-HS
3 ON disparity Installation Manual
¾ Check that no contacts in series with EN2 open
within 10ms of EN2 opening.
¾ Check all contacts in series with EN2.
B OFF SEC1 The SEC1 contact has not been ¾ Check all interface connections and wiring.
contact closed by the secondary processor or
1 ON closing the SEC1 contact has not been ¾ Check that the current through the contact has
disparity closed properly when the secondary not exceeded its rating.
processor has commanded it to. ¾ Replace the LZS-003 controller.
B OFF SEC1 The voltage across SEC1 is not high ¾ Check that there is > 10v AC/DC across SEC1
contact enough when the contact is opened. when it opens. Refer to the LZS-003-HS
2 ON opening Installation Manual
disparity
¾ Check that no contacts in series with SEC1
open within 10ms of SEC1 opening.
¾ Check all contacts in series with SEC1.
C. OFF Receiver Middle receiver sensor test failure. ¾ Check all connections and wiring between the
test failed receiver and LZS-003 controller.
2 ON
¾ Check that the receiver shield is connected to
the LZS-003 controller.
Page 51
Secondary Approach
Display Input
D OFF Receiver The receiver test voltage is incorrect. ¾ Check all connections and wiring between
test failed the receiver and LZS-003 controller.
1 ON
¾ Check that the receiver shield is connected
to the LZS-003 controller.
D. OFF Receiver Front or rear sensor test failure. ¾ Check all connections and wiring between
test failed the receiver and LZS-003 controller.
2 ON
¾ Check that the receiver shield is connected
to the LZS-003 controller.
Page 52
9 Glossary of Terms
Term Description
Approach The closing movement of the tools
Approach signal A signal from the press brake controller to the LZS-003-HS controller to
indicate that the foot pedal has been pressed to allow the tools to close
Approach speed The closing of the tools in high speed >10mm/s
Beam / pressing The moving member of the press brake
beam
Crawl speed The closing of the tools in slow speed ≤10mm/s
Die Bottom tool of the press brake
Field muted Operating mode of the LZS-003-HS where the laser is muted and the
mode closing of the tools is possible in crawl speed only
Mute Disabling of the protective laser field
Mute point The point where the protective laser field is disabled
Normal mode Operating mode of the LZS-003-HS
Punch Top tool of the press brake
Retract The opening movement of the tools
Stopping The distance measured by the LZS-003-HS of the closing of the tools
distance when a stop command is issued
Tray / Box mode Operating mode of the LZS-003-HS used for bending tray and box
shaped parts
Table 9-1: Glossary of terms
9.1 Abbreviations
Abbreviations
CNC Crawl normally closed output contact of the LZS-003-HS controller
CNO Crawl normally open output contact of the LZS-003-HS controller
EN1 / EN2 Enable 1 / Enable 2 output contacts of the LZS-003-HS controller
mm/s Millimetres per second
ms milliseconds
pdl pedal
pnt point
PRI Primary
prs press
RX Receiver
s seconds
SEC Secondary
SEC1 / SEC2 Secondary 1 / Secondary 2 output contacts of the LZS-003-HS controller
TX Transmitter
Table 9-2: Abbreviations
Page 53
10 Specifications
Functional
Equipment Type: Electro sensitive Protective Equipment (ESPE) to EN954-1: 1997 Category 4 for
Hydraulic Press Brakes
Level of Protection: Equivalent to Clause 5.3.2.(f) - prEN 12622 (1996)
Optical Range: 15 m net (distance between windows of laser sender and receiver)
Vertical Adjustment 300 mm standard, other lengths available
Range:
Protective Functions: 1. Recognition of interruptions in sections of a flat band of laser light which runs
both in parallel and in a fixed position to and ahead of the edge of the punch.
2. Monitors stopping distance.
3. Monitors press brake beam high speed.
4. Monitors press brake beam low speed.
5. Monitors mute point position.
6. Forces press into a safe condition upon detection of fault.
Response Time: 12 ms from interruption of light beam until opening of relay contacts (both
paths).
Laser Classification: Class 1 (IEC 60825-1).
System Structure: Two-channel computer system with mutually independent processing of input
signals, exchange of parity data and reciprocal monitoring of output data in
accordance with requirement classes 5 and 6-DIN V VDE 0801-/A1 (principles of
computers in safety related systems) congruent with EN 954 Category 4. LZS has
been EC type examined to the requirements of IEC 61496-1, -2 for a Type 4 ESPE.
TUV registration number 08/205/B1-PM01700.
Environmental
Degree of Protection: IP54 (all system units)
Operating Temperature: 0 to 55 ºC
Storage Temperature: -30 to 75ºC
Humidity Class: E
Electrical
Supply Voltage: 115 V (-15%, 60 Hz) to 230 V (+30%, 50 / 60 Hz)
Nominal Supply Current 0.05 A
Safety Output: 4 Normally Closed contacts (2 primary & 2 secondary)
Auxiliary Output: 1 Normally Closed contact
Contact Rating: 5 A resistive, 2 A inductive @ 24 VDC; minimum load 10 mA @ 5 VDC
Isolation: All contact paths are isolated.
Table 10-1
10.1 Circuits
Output Contact Contact Specification
EN1 Enable 1 1 isolated contact path, EN 954 Category 4 (if in series with EN2)
EN2 Enable 2 1 isolated contact path, EN 954 Category 4 (if in series with EN1)
SEC1 Secondary 1 1 isolated contact path, EN 954 Category 4 (if in series with SEC2)
SEC2 Secondary 2 1 isolated contact path, EN 954 Category 4 (if in series with SEC1)
AUX Auxiliary output 1 isolated contact path (functionally identical with EN-circuits)
CNO Crawl speed (positive logic) 1 isolated contact path
CNC Crawl speed (negative logic) 1 isolated contact path
RETR Retract beam 1 isolated contact path
MUTE Mute lamp (state) 1 isolated contact path
Table 10-2
Page 54
10.2 Circuit Load Conditions and Contact Impedances (interfacing

to 24 V systems)
Contact Impedance Load current, Minimum

Load current,
Output inductive load, permissible
ohmic load,
Contact cosϕ = 0,4; load current
OPEN CLOSED cosϕ = 1
L/R = 7 ms at 5 V=
EN1 7 kΩ 0 kΩ 10 A 5A 100 mA
EN2 7 kΩ 0 kΩ 10 A 5A 100 mA
SEC1 7 kΩ 0 kΩ 10 A 5A 100 mA
SEC2 7 kΩ 0 kΩ 10 A 5A 100 mA
AUX ∞ kΩ 0 kΩ 10 A 5A 100 mA
CNO ∞ kΩ 0 kΩ 10 A 5A 100 mA
CNC ∞ kΩ 0 kΩ 10 A 5A 100 mA
RETR ∞ kΩ 0 kΩ 10 A 5A 100 mA
MUTE ∞ kΩ 0 kΩ 10 A 5A 100 mA
Table 10-3
Nominal Voltage of System to be Interfaced : 24V DC or 24V AC.
Note
Specifications are subject to change without notice.
Page 55

LZS-003-HS Operation Manual Dual Laser Version 1 10 EN

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7.7 Crawl Distance ...................................................................................................................... 39

1 About This Manual

1.1 Document Organisation

1.2 Document Objectives

1.3 Technical Competence Requirements

1.4 Related Documentation

1.5 Guide to Notes, Notice and Cautions

safety warnings that accompanied this device.

1.6 Obtaining Technical Assistance

2 Critical Safety Information

2.2 Special Warnings

Warning: NO PROTECTION BETWEEN MUTE POINT AND WORKPIECE

Warning: NO PROTECTION IN FIELD MUTED MODE

3.1 Key Benefits

3.2 System Operation

Figure 3-1: LZS-003-HS Dual Laser

Figure 3-2: Laser to punch distance / Mute point distance

3.2.3 Mute Point

3.2.4 Normal Mode

Mute Mute Mute

Figure 3-3 Normal Mode operation

3.2.5 Tray / Box Mode

Mute Mute Mute

Figure 3-4 Tray / Box Mode operation

3.2.6 Field Muted Mode

3.3 Tool Change

3.4 Closed Loop Design

Figure 3-5 Closed loop design

4 Transmitter & Receiver Adjustment

4.1 Adjusting the laser to punch distance

Figure 4-1: TX Alignment Magnet (set to 14mm)

Figure 4-2: Vertical bracket locking handle

4.2 Adjusting the receiver for tray/box bending

Figure 4-3: Receiver middle sensor position

To adjust the receiver position;

LASER ALIGNMENT MAGNET

FIT TO RECEIVER END OF PUNCH

POSITION LASER INSIDE WINDOW

Figure 4-4: RX Alignment Magnet (set to 14mm)

Figure 4-5: Slider Mechanism Adjustment

Figure 4-6: Middle sensor adjustment

5 Operating the LZS-003-HS

Mute lamp "Laser beam

Operating mode indicator LEDs

Figure 5-1: LZS-003-HS Operator Panel

5.1.2 LZS-003-HS Controller

Figure 5-2: LZS-003-HS Controller

5.2 System Start-up

5.3 Start-up Test

Figure 5-3: Start-up test display

Figure 5-4: Initial mute point setting

Figure 5-5: Error detected display.

5.4 Setting the Mute Point

Figure 5-6: Material placement on the die.

Instructor's Name: _ Company: _______

Signature: Date: ___

Company Name: Date: _________