LS CS M 026 Bracket Installation Manual

Bracket Installation Manual
LS-CS-M-026
Document Status
Document Reference Code:
Version:
Released:
LS-CS-M-026
0
02/07/2008
Document Revision History

Date
Version
Summary of Change
02/07/2008
New manual
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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Released: 02/07/2008
LS-CS-M-026
Table of Contents
1
About This Manual ........................................................................................4
1.1
1.2
1.3
1.4
1.5
Document Organisation .......................................................................................................... 4

Document Objectives.............................................................................................................. 4
Related Documentation .......................................................................................................... 4
Guide to Notes, Cautions and Warnings ................................................................................. 4
Obtaining Technical Assistance .............................................................................................. 4
2
3
General Overview .........................................................................................5

Bracket models .............................................................................................6
3.1
3.2
3.2.1
Vertical brackets ..................................................................................................................... 6

Horizontal adaptors ................................................................................................................ 7
General purpose bracket conversion ..............................................................................................7
Bracket selection ..........................................................................................9
4.1
4.2
Vertical bracket selection ....................................................................................................... 9

Horizontal adaptor selection and mounting position ............................................................. 9
Before you start ..........................................................................................13
5.1
5.2
5.3
Components .......................................................................................................................... 13
Additional components ......................................................................................................... 15
Tools required ....................................................................................................................... 15
Horizontal adaptor installation ...................................................................16
6.1
6.2
End mount straight and off-set............................................................................................. 16

General purpose straight and off-set.................................................................................... 16
Vertical bracket installation ........................................................................17
7.1
7.2
7.3
7.3.1
7.3.2
7.4
7.4.1
7.5
7.5.1
7.5.2
7.6
Fitting vertical bracket to end mount horizontal adaptors................................................... 17

Fitting vertical bracket to general purpose horizontal adaptors .......................................... 17
STD 610 & 730 mounting plate............................................................................................. 18
Mounting plate assembly ............................................................................................................ 18
Fit the mounting plate to the vertical bracket................................................................................ 19
LITE 380 & 500 integrated mounting plate .......................................................................... 19
Integrated mounting plate assembly ............................................................................................ 19
Cable installation .................................................................................................................. 20
LITE 380 & 500 ......................................................................................................................... 20
STD 610 & 730.......................................................................................................................... 21
Metric adjustment guide decal ............................................................................................. 23
Bracket operation and maintenance ...........................................................24
8.1
8.2
8.3
Locking handle...................................................................................................................... 24
Latch mechanism .................................................................................................................. 24
Bracket maintenance ............................................................................................................ 24
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About This Manual

This chapter contains information about this manual, containing the following elements:
1.1
Document Organisation
Document Objectives
Related Documentation
Guide to Notes, Notice and Cautions
Obtaining Technical Assistance.
Document Organisation
This manual is organised into the following chapters:
1.2
1.
About This Manual (this chapter)
2.
General Overview
3.
Bracket Models
4.
Bracket Selection
5.
Before You Start
6.
Horizontal Adaptor Installation
7.
Vertical Bracket Installation
8.
Bracket Operation and Maintenance
Document Objectives
This manual provides information about the installation of brackets systems for Lazer Safe LZS
Series of press brake operator guarding systems.
1.3
Related Documentation
This manual should be used in conjunction with the following documents:
1.4
Technical manual reference guides for the related LZS Series guarding system
Quick reference guides for the related LZS Series guarding system
Guide to Notes, Cautions and Warnings

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 or a situation that could cause bodily injury.
1.5
Obtaining Technical Assistance

For technical support contact your supplier or email customerservice@lazersafe.com.au
detailing your specific requirements.
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General Overview
The Lazer Safe bracket system is designed for mounting the Lazer Safe Series of press brake
guarding systems to the press brake. The bracket system consists of a pair of adjustable vertical
brackets and horizontal mounting adaptors. The horizontal mounting adaptors are fixed to the upper
beam of the press brake to provide a mounting point for the vertical brackets. The laser transmitter
and receiver units of the Lazer Safe guarding system are fitted to mounting plates located at the
bottom of each vertical bracket.
The bracket system allows the laser transmitter and receiver to be adjusted to different positions to
suit various tool sizes. It also provides stability and minimises vibration on the guarding system when
the machine is in operation. The high level of adjustment accuracy in the bracket linear bearing
ensures precise alignment of the laser transmitter and receiver is maintained throughout the entire
adjustment range of the brackets.
The bracket system is supplied in a number of options for both the vertical bracket and the horizontal
adaptor to suit most applications. This manual provides information for the assembly and installation
of each bracket system.
Horizontal adaptor
Vertical bracket
Receiver
Upper
beam
Laser
Transmitter
Punch
Die
Figure 1
Warning
When installing the bracket system care must be taken to ensure sufficient clearance
between the brackets and any other part of the machine that may present a trapping
hazard and potential injury.
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Bracket models
There are four vertical bracket models and three horizontal adaptors available in four
configurations. These can be used in various combinations to suit most press brake
applications.
3.1
Vertical brackets
The four vertical brackets available are LITE 380, LITE 500, STD 610 and STD 730. Refer to
Table 1 and Figure 2 for details of each model.
Linear
bearing and
rail for
accuracy and
stability
Free sliding
mechanism
Locking clamp
and handle for
quick
adjustment
Latch
mechanism to
hold bracket
clear during tool
change
Enclosed
housing for
cable and
terminal
connections
Horizontal
adjustment
range
Vertical
adjustment
range
20.0mm
244.0mm
20.0mm
354.0mm
40.0mm
348.0mm
40.0mm
468.0mm
LITE
380
LITE
500
STD
610
STD
730
Table 1
Vertical bracket
STD 610
STD 730
Vertical bracket
LITE 380
LITE 500
Figure 2
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3.2
Horizontal adaptors
There are three types of horizontal adaptor available and provide four different mounting
options. The required horizontal adaptor will depend on the mounting position on the upper
beam of the press brake. The horizontal adaptors include End mount straight, End mount
off-set and General purpose (can be configured for straight or off-set application). Refer to
Figure 3 and Figure 4.
Figure 3
General purpose
straight
General purpose
off-set
Figure 4
3.2.1
General purpose bracket conversion

The general purpose bracket can be configured for either straight or off-set application. The
general purpose bracket is supplied as standard in the straight configuration. To convert the
bracket to the off-set configuration, simply unscrew and remove the flange from the end of the
bracket and fix it to the opposite end (refer to Figure 5).
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Figure 5
Note
There are two versions of the general purpose horizontal bracket available to suit
either the STD or LITE vertical brackets. The mounting position for both versions is
the same and only the flange component is different to suit the STD or LITE bracket.
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Bracket selection
When selecting a vertical bracket system you must ensure that the bracket option allows
sufficient clearance for tool change and sufficient vertical adjustment range to suit the tools
that will be used on the machine. Vertical brackets are available in various lengths for both
STD and LITE versions.
4.1
Vertical bracket selection

For LZS-003, LZS-003-HS & LZS-004 Laser transmitter and receiver
STD 610
STD 730
LITE 380
LITE 500
Vertical adjustment
range
348.0mm
468.0mm
244.0mm
354.0mm
Horizontal adjustment
range
40.0mm
40.0mm
20.0mm
20.0mm
Maximum punch
height*
309.95mm
429.95mm
205.95mm
315.95mm
Table 2
For LZS-005 Block Laser transmitter and receiver Guarding only model
STD 610
STD 730
LITE 380
LITE 500
Vertical adjustment
range
range
Maximum punch
height*
348.0mm
468.0mm
244.0mm
354.0mm
40.0mm
40.0mm
20.0mm
20.0mm
313.0mm
433.0mm
209.0mm
319.0mm
Table 3
For LZS-005 Block Laser transmitter and receiver - Angle Confirmation model
STD 610
STD 730
LITE 380
LITE 500
Vertical adjustment
range
range
Maximum punch
height*
348.0mm
468.0mm
244.0mm
354.0mm
40.0mm
40.0mm
20.0mm
20.0mm
294.0mm
414.0mm
190.0mm
300.0mm
Table 4
* Note Maximum punch height
This is an approximate guide only as dimensions will vary depending on the guarding
system laser to punch distance setting that is configured by the machine
manufacturer for OEM systems or by the installer during installation of a retrofit
system. The listed dimensions are applicable only when the horizontal adaptors are
mounted to allow minimum clearance. Listed dimensions are based on horizontal
adaptors manufactured and supplied by Lazer Safe. Punch height refers to overall
height of the tool. Refer to section 4.2.
4.2
Horizontal adaptor selection and mounting position

The following tables detail the minimum mounting position for each horizontal adaptor when
used with various combinations of vertical bracket and guarding system transmitter and
receiver. All dimensions are referenced from the top edge of the upper tool holder and
include a 5mm clearance tolerance. This ensures that there is sufficient clearance for the
upper tool to be removed from either end of the machine when the vertical brackets are
locked in their upper most position.
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Note
To maintain a symmetrical appearance the horizontal adaptors can be mounted at
the same position. For example both A and B brackets can be mounted at the B
position. This will allow sufficient clearance for both brackets and will keep the
brackets level with respect to each other. Please note however that the A bracket will
lose a small amount of vertical adjustment although this is suitable for most
applications.
:
Mounting position for LZS-003, LZS-003-HS & LZS-004 Laser transmitter

and receiver
STD 610 & 730
Minimum mounting position in mm
Diagram
LITE 380 & 500
End mount straight
Figure 6
254.2
277.6
193.2
216.8
End mount off-set
Figure 7
144.2
167.6
106.0
106.8
General purpose straight
Figure 8
231.2
254.6
170.2
193.8
General purpose off-set
Figure 9
121.2
144.6
60.2
83.8
Table 5
Mounting position for LZS-005 Block Laser transmitter and receiver

Guarding only model
STD 610 & 730
Diagram
LITE 380 & 500
End mount straight
Figure 6
281.5
281.5
220.7
220.7
End mount off-set
Figure 7
171.5
171.5
110.7
110.7
Figure 8
258.5
258.5
197.7
197.7
Figure 9
148.5
148.5
87.7
87.7
Table 6
Mounting position for LZS-005 Block Laser transmitter and receiver Angle Confirmation model
STD 610 & 730
Diagram
LITE 380 & 500
End mount straight
Figure 6
298.5
298.5
237.7
237.7
End mount off-set
Figure 7
188.5
188.5
127.7
127.7
Figure 8
275.5
275.5
214.7
214.7
Figure 9
165.5
165.5
104.7
104.7
Table 7
Note
The laser transmitter must always be mounted on the left side of the press brake and
the receiver on the right.
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Figure 6
Figure 7
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Figure 8
Figure 9
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Before you start

Before commencing installation ensure that you have all the required components and
tools.
5.1
Components
Refer to the following tables for a complete list of supplied components.
Vertical bracket kit for LITE 380
ID
Component
1
Vertical bracket left
2
Vertical bracket right
3
TX/RX Mounting hardware
M6 nut (6)
M6 locking nut (6)
M6 flat washer (12)
Product code
0018023100
0018023200
0011170200
Qty
1
1
1
Table 8
Vertical bracket kit for LITE 500
ID
Component
1
2
3
M6 nut (6)
M6 locking nut (6)
M6 flat washer (12)
Product code
0018023300
0018023400
0011170200
Qty
1
1
1
Table 9
Vertical bracket kit for STD 610
ID
Component
Product code
1
0018022100
2
0018022200
3
Mounting plate
0041010000
4
0011170200
M6 nut (6)
M6 locking nut (6)
M6 flat washer (12)
5
Metric adjustment guide decal set 1000mm 0036001900
Qty
1
1
2
1
Cable tie 100mm x 2mm black
0038015000
Protective tubing for cable 500mm
0041010300
Table 10
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Vertical bracket kit for STD 730

ID Component
1
2
Product code
0018022300
0018022400
Qty
1
1
0041010000
0011170200
2
1
5
6
Mounting plate
M6 nut (6)
M6 locking nut (6)
M6 flat washer (12)
Metric adjustment guide decal set 1000mm
Cable tie 100mm x 2mm black
0036001900
0038015000
1
6
Protective tubing for cable 500mm
0041010300
3
4
Table 11
Horizontal adaptor kit end mount straight
ID Component
Product code Quantity
1 End mount straight bracket
0019010800
2
2 Bracket accessories kit
0019013000
1
M8 x 20mm socket head cap screw (4)
Table 12
Horizontal adaptor kit end mount off-set
ID Component
1 End mount off-set bracket
0019011000
2
0019013000
1
Table 13
Horizontal adaptor kit general purpose suits LITE 380 & 500
ID Component
1 General purpose bracket
0019010900
2
0019013100
1
M8 internal tooth washer (4)
M8 flat washer (4)
Table 14
Horizontal adaptor kit general purpose suits STD 610 & 730
ID Component
1 General purpose bracket
0019011600
2
0019013100
1
M8 internal tooth washer (4)
M8 flat washer (4)
Table 15
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5.2
Additional components
Additional components may be required for some bracket installations. This may include items
such as cable glands, cable ties, terminal strips, extension cables, conduit, etc. These items
are not supplied with the bracket kits or LZS Series guarding systems and should be sourced
separately.
5.3
Tools required
Refer to Table 16 for a list of tools required for bracket installation. Please note that the listed
tools are not supplied with any Lazer Safe bracket kits.
Item #
1
2
3
4
5
6
7
8
Tools required for bracket installation

Electric drill
Drill bits and taps to suit M8 and M12 hole sizes
Wire cutters
Flat blade terminal screw driver
10mm open ended spanner
Metric Allen key set
Tape measure
Spirit level
Table 16
Warning
Ensure that adequate body and eye protection is used during bracket installation
where the use of power tools is required. Failure to do so may result in injury.
Warning
While care is taken to remove all sharp edges during the bracket manufacturing
process care should be exercised during installation when hands are placed inside
the bracket cover.
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Horizontal adaptor installation

Refer to section 4.2 for the mounting position required for each horizontal adaptor. Drill and
tap four mounting holes per adaptor as instructed.
Note
When using the LITE 380 and LITE 500 brackets ensure the horizontal adaptor is
positioned as close to the centre of the bending line as possible as the brackets have
a limited amount of horizontal adjustment range once installed.
6.1
End mount straight and off-set

1. Drill and tap four M8 mounting holes.
2. Secure the bracket to the machine with the supplied M8 x 20mm socket head cap
screws.
3. Check that the bracket is level then tighten the screws.
Figure 10
6.2
General purpose straight and off-set

1. Drill and tap four M12 mounting holes
2. Secure the bracket to the machine with the supplied M12 x 50mm socket head cap
screws and M12 flat and internal tooth washers.
3. Check that the bracket is level then tighten the screws.
Figure 11
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LS-CS-M-026
Vertical bracket installation

The vertical brackets are supplied pre-assembled and only need to be fitted to the
horizontal adaptors.
7.1
Fitting vertical bracket to end mount horizontal adaptors

1. Secure the vertical bracket to the horizontal adaptor with the supplied M6 x 20mm
socket head cap screws.
2. Check that the vertical bracket is level then tighten the screws.
Figure 12
7.2
Fitting vertical bracket to general purpose horizontal adaptors

1. Secure the vertical bracket to the horizontal adaptor with the supplied M6 x 20mm
socket head cap screws.
2. Check that the vertical bracket is level then tighten the screws.
Figure 13
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7.3
STD 610 & 730 mounting plate

When using the STD 610 & 730 brackets, mounting plates are used to attach the guarding
system transmitter and receiver to the vertical bracket. They are also used to adjust and
align the guarding system for correct operation. Refer to Figure 14 and Figure 15. If using
the LITE 380 & 500 brackets then the mounting plate is integrated into the bracket and not
supplied as a separate component. Refer to section 7.4 for assembly instructions.
7.3.1
Mounting plate assembly

1. Fit a M6 nut to each of the threaded posts on the top of the transmitter and receiver.
Make sure that each nut is fitted with equal spacing from the top of the transmitter and
receiver housing. This will ensure quicker and more accurate adjustment of the
guarding system.
2. Fit a flat washer to each threaded post.
3. Fit the mounting plates.
5. Fit and secure the mounting plates with the M6 locking nuts.
Figure 14
Figure 15
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LS-CS-M-026
7.3.2
Fit the mounting plate to the vertical bracket

Once the mounting plates have been fitted to the transmitter and receiver the complete
assembly is then fitted to the vertical bracket.
1. Loosen the rectangular nut on the mounting plate.
2. Slide the mounting plate into the groove on the bottom of the vertical bracket.
3. Secure the mounting plate by tightening the screw.
Figure 16
7.4
LITE 380 & 500 integrated mounting plate

The LITE 380 & 500 vertical brackets feature integrated mounting plates. The transmitter and
receiver are fitted to each bracket as shown in Figure 17 and Figure 18.
7.4.1
Integrated mounting plate assembly

1. Fit a M6 nut to each of the threaded posts on the top of the transmitter and receiver.
Make sure that each nut is fitted with equal spacing from the top of the transmitter and
receiver housing. This will ensure quicker and more accurate adjustment of the
guarding system.
3. Fit the transmitter and receiver to the bottom of each bracket.
5. Fit and secure the transmitter and receiver with the M6 locking nuts.
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LS-CS-M-026
Figure 17
Figure 18
7.5
Cable installation
After the mounting plates have been fitted to the vertical brackets the cables for the transmitter
and receiver need to be installed. The cable installation procedure will vary depending on the
type of cable supplied with the transmitter and receiver and the vertical bracket model used.
7.5.1
LITE 380 & 500

1. Place the cable along the flat side of the bracket.
2. Secure the cable with three cable ties.
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Secure cable with

three cable ties
Transmitter/receiver
cable
Figure 19
7.5.2
STD 610 & 730

1. Remove the terminal cover plate from the top of each vertical bracket
2. Fit cable gland to the hole on the lower end of the vertical bracket.
3. Insert the transmitter and receiver cables into the cable glands.
4. Slide the protective cable tube over the cable then place inside the back of the bracket
cover.
5. Secure the protective cable tube and cable with the three supplied cable ties.
6. Fit a cable gland to the hole in the top of each vertical bracket
7. Insert the transmitter and receiver cables into the cable glands.
8. If an extension cable is required then a terminal strip can be used to terminate the main
cable and the extension cable. Place the terminal strip in the cavity at the top of the
bracket then replace the terminal cover plate.
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LS-CS-M-026
Terminal
cover plate
Protective
cable tube
Cable exits the bracket

via a cable gland
Secure protective
cable tube and
cable with three
cable ties
Cable from transmitter or

receiver enters the bracket
via a cable gland
Figure 20
Figure 21
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LS-CS-M-026
7.6
Metric adjustment guide decal

The STD 610 and STD 730 brackets are supplied with a set of metric adjustment guides. The
guides are self adhesive and should be fixed to the inside front edge of each bracket. The
guides can be used as a reference when adjusting the bracket vertical position and setting up
the laser transmitter and receiver to various tool heights.
1. Trim the decal to suit the length of the bracket.
2. Peel off the decal backing and fix the decal to the inside front edge of the bracket. The
marker on the bracket clamp is used as a reference point when adjusting the bracket
vertical position. Refer to Figure 22.
Figure 22
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Bracket operation and maintenance

The initial set-up of each bracket system will vary slightly depending on the guarding system
that has been fitted. Refer to the appropriate guarding system technical manual and reference
guides for set-up information.
8.1
Locking handle
Each bracket features a locking handle and clamp assembly that is used to secure the bracket
vertical position. The clamp assembly is designed so that a minimum amount of clamping force
is required to hold the bracket in position. It is important that the handle not be over tightened
as it is designed to break in order to avoid damage to the clamp assembly that can occur
through excessive force. When operating the handle only a quarter to half turn is required to
secure the bracket.
Warning
When adjusting the bracket handle ensure that the bottom of the bracket is held
firmly with your free hand to prevent the bracket from free falling when the clamp is
released.
Caution
Excessive force on the bracket handle will result in the handle breaking. Do not apply
excessive force when operating the handle. The handle should only be operated by
hand and the use of tools or implements to tighten the handle must be avoided.
8.2
Latch mechanism
STD 610 and STD 730 brackets feature a latch mechanism. The latch is used to lock the
bracket in the upper position during tool change. After tool change the bracket is unlatched and
returned to its original position. The locking handle can then be adjusted and the bracket
vertical position moved to suit the replacement tool if necessary.
8.3
Bracket maintenance
The following maintenance procedure is recommended once every two months.
1. Using a soft cloth clean the linear rail and wipe away any grease and dirt that may have
accumulated along the rail.
2. Apply a small amount of lubricant to the grease nipple of the linear bearing. The
recommended lubricant is AS2-Shell.
3. Slide the bracket up and down several times along the full range of vertical movement.
4. Wipe away any excess lubricant.
5. Check that each bracket is level then tighten all mounting screws.
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Bracket Installation Manual

Bracket Installation Manual

Document Revision History

Bracket Installation Manual

About This Manual ........................................................................................4

Document Organisation .......................................................................................................... 4

General Overview .........................................................................................5

Vertical brackets ..................................................................................................................... 6

Bracket selection ..........................................................................................9

Vertical bracket selection ....................................................................................................... 9

Before you start ..........................................................................................13

Horizontal adaptor installation ...................................................................16

End mount straight and off-set............................................................................................. 16

Vertical bracket installation ........................................................................17

Fitting vertical bracket to end mount horizontal adaptors................................................... 17

Bracket operation and maintenance ...........................................................24

Bracket Installation Manual

About This Manual

About This Manual (this chapter)

Before You Start

Horizontal Adaptor Installation

Vertical Bracket Installation

Bracket Operation and Maintenance

Guide to Notes, Cautions and Warnings

Obtaining Technical Assistance

Bracket Installation Manual

Bracket Installation Manual

Bracket Installation Manual

General purpose bracket conversion

Bracket Installation Manual

Bracket Installation Manual

Vertical bracket selection

Horizontal adaptor selection and mounting position

Bracket Installation Manual

Mounting position for LZS-003, LZS-003-HS & LZS-004 Laser transmitter

LITE 380 & 500

End mount straight

End mount off-set

General purpose straight

General purpose off-set

Mounting position for LZS-005 Block Laser transmitter and receiver

LITE 380 & 500

End mount straight

End mount off-set

General purpose straight

General purpose off-set

LITE 380 & 500

End mount straight

End mount off-set

General purpose straight

General purpose off-set

Bracket Installation Manual

Bracket Installation Manual

Bracket Installation Manual

Before you start

Cable tie 100mm x 2mm black

Protective tubing for cable 500mm

Bracket Installation Manual

Vertical bracket kit for STD 730

Protective tubing for cable 500mm

Bracket Installation Manual

Tools required for bracket installation

Bracket Installation Manual