Pilz PSENvip E Operating Manual Download

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Change, maintenance

Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06

| 108

Change, maintenance

Tests are used for early identification of defects on the press brake and its safeguards.
They help to maintain a safe, working condition, i.e. to prevent accidents.
The test of the protective equipment consists of:

}

A function test using the test piece

and

}

a visual inspection

WARNING!
The press brake must be shut down immediately if the test reveals a

fault!
Failure to comply

could result in a

hazardous situation,

which could lead

serious injury and death

In this case, have the safety equipment checked by qualified staff.

Summary of Contents for PSENvip E

Page 1: ...PSENvip R PSENvip R LR PSENvip E Operating Manual 1003449 EN 06 Safe camera systems ...

Page 2: ...enta tion will be gratefully received Source code from third party manufacturers or open source software has been used for some components The relevant licence information is available on the Internet on the Pilz homepage Pilz PIT PMI PNOZ Primo PSEN PSS PVIS SafetyBUS p SafetyEYE SafetyNET p the spirit of safety are registered and protected trademarks of Pilz GmbH Co KG in some countries SD means...

Page 3: ...rotected field mode 25 4 2 1 2 Box bending protected field mode 26 4 2 1 3 Back gauge protected field mode 27 4 2 1 4 Box bending with back gauge protected field mode 28 4 3 Overrun 29 4 4 Overrun test 30 4 5 Muting end point productive version 31 4 6 Dynamic muting productive version 32 4 6 1 Standard interrupted press stroke 35 4 7 Braking ramp monitoring productive version 37 4 8 System cycle b...

Page 4: ... Connection diagram 80 7 Commissioning 81 7 1 Web interface 81 7 2 Initial commissioning 82 7 2 1 Align transmitter and receiver 83 7 2 1 1 Align transmitter 85 7 2 1 2 Position tool 88 7 2 1 3 Align receiver 89 7 2 2 Make adjustment during tool change 92 7 2 2 1 Tool detection 93 7 2 2 2 Adjustment in the web interface 97 7 2 3 Configure braking ramp monitoring 98 7 2 4 Test the function of the s...

Page 5: ...ng Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 5 11 Technical details 113 11 1 Safety characteristic data 115 12 Order reference 116 12 1 Device 116 12 2 Accessories 116 13 Attachment 118 13 1 Check list 118 ...

Page 6: ... of the special mod ule PSSu K F FAU B and PSSu K F FAU P If a description refers exclusively to one of the two versions the full product name will be used The versions of the PSSu K F FAU are described in a separate operating manual PSSu K F FAU B PSSu K F FAU P This operating manual is aimed at manufacturers company operators and personnel in volved in designing maintaining and operating press b...

Page 7: ...ardous situation that could lead to serious injury and death and indicates preventive measures that can be taken CAUTION This refers to a hazard that can lead to a less serious or minor injury plus material damage and also provides information on preventive measures that can be taken NOTICE This describes a situation in which the product or devices could be dam aged and also provides information o...

Page 8: ...e CNC or control system driving the press 1 3 2 Fig Components of the PSENvip Transmitter PSENvip E 2 Generates parallel beam 2 inputs for controlling the light source Receiver PSENvip R PSENvip R LR 1 Receives the light generated by the transmitter Sends image date to the special module PSSu K F FAU LED display for the status of the OSSD signal Special module PSSu K F FAU 3 Image evaluation of th...

Page 9: ...niversal Transmitter PSSu K F FAU Upper die Receiver Upper tool Lower tool Detection zone Transmitter Fig Whole system If the detection zone between transmitter and receiver is interrupted the PSSu K F FAU can shut down the safety outputs immediately The outputs that are shut down are defined in the PAS4000 user program There are 2 versions available for protected field monitoring The base version...

Page 10: ...un of 14 mm Productive version Danger zone is monitored either by Using the fixed muting end point The productive version of PSENvip operates as standard with the fixed muting end point of 4 mm With the fixed muting end point of 4 mm the protected field monitors the danger zone between upper tool and workpiece up to a remaining gap of 4 mm The control system PSSu PLC may mute the protective functi...

Page 11: ...mware version 2 0 the receiver PSENvip R PSENvip R LR is supported by a procedure for braking ramp monitoring For braking ramp monitoring by PSENvip a special module PSSu K F FAU P from Hardware version 3 and Firmware version 2 0 is required Certified blocks are available for the safety functions in the PAS4000 Library The blocks are exclusively intended for use with a fixed muting end point of 4 ...

Page 12: ...shing The protec ted field is around the tolerance zone behind the bending line Any parts of the body within the danger zone will only be detected behind the bending line There is a risk of injury from trapping or crushing 3 1 1 3 Hazards arising from incorrect handling of the workpiece PSENvip does not protect against hazards arising from incorrect handling of the workpiece When bending metal she...

Page 13: ...vip R PSENvip R LR PSENvip E 1003449 EN 06 13 Correct handling with flat workpieces Grip the metal sheet by the front corners Thumbs should be on top of the sheet palms should hold the sheet from below Fig Handling flat workpieces ...

Page 14: ...with box bending Hold the sheet on the right and left between the thumb and index finger As you hold the sheet do not reach with your hands into the box During the bending op eration fingers or hands can become crushed or trapped between the workpiece and up per tool Fig Handling box bending ...

Page 15: ...arded in compliance with the standards The front and rear bending lines are detected by the protected field on the PSENvip The front segments of the protected field are less than 15 mm away from the front bending line Under the following conditions this tool class must be evaluated in the PAS4000 user program after the PSENvip is switched on after a tool change after the control system is restarte...

Page 16: ...ion with the safety system The following safety guideline applies for press brakes with tools in this tool class WARNING Hazard areas that are not monitored by the PSENvip Additional hazard areas in zones that are not monitored by the PSENvip can lead to serious injuries fingers or hands being crushed or trapped Secure these zones with appropriate additional measures Carry out a hazard analysis Ra...

Page 17: ... by the PSENvip Fig Danger zone in unmonitored zone Example In unmonitored zones the use of tools which are not fully detected by the protec ted field on the PSENvip e g tools with a radius greater than 25 mm will lead to the risk of fingers or hands being crushed or trapped Fig Crush points when the tool is wider than the protected field ...

Page 18: ...he art and the applicable national European and international laws directives and standards It is the company s responsibility only to employ personnel who Are familiar with the basic regulations concerning health and safety accident prevention Have read and understood the information provided in the section entitled Safety Have a good knowledge of the generic and specialist standards applicable t...

Page 19: ... 3 2 5 Disposal In safety related applications please comply with the mission time TM in the safety related characteristic data When decommissioning please comply with local regulations regarding the disposal of electronic devices e g Electrical and Electronic Equipment Act ...

Page 20: ...AU If an object encroaches into the detection zone the two outputs on the PSSu K F FAU shut down and the LED on the receiver goes out A stop of the press stroke is initiated On the productive version safety functions must be implemented in the PAS4000 user pro gram in order to safeguard dynamic muting Certified Pilz blocks are available for this the PAS4000 Library CNC controller PSSu system with ...

Page 21: ...ok at the light from the trans mitter This could damage the eye If you do not use optical aids there is no danger to the eye The detection zone between transmitter and receiver is monitored and evaluated The pro tected field is the cross section of the detection zone It consists of several segments Fig Detection zone Legend 1 Light beam bundle 2 Illuminated target area 3 Protected field 4 Detectio...

Page 22: ... bending Reduced protected field front segments deactivated Bending with back gauge Reduced protected field rear segments deactivated Box bending with back gauge Reduced protected field front and rear segments deactivated Bending line Upper tool Illuminated target area Rear segments Workpiece Lower tool Adjustment line Front segments Central segments Fig Protected field definitions The height of t...

Page 23: ...ected field when the downward movement starts Acknowledgement of the reduced protected field when the protected field meets the workpiece Procedure Press stroke is started downward movement The press stroke begins in full protected field protected field mode Press stroke is stopped The press stroke is stopped as soon as the protected field meets the workpiece If necessary the operator can still al...

Page 24: ...Operating Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 24 Protected field mode Tool class Back gauge Rear segments blanked Yes No No The operation must be confirmed after each press stroke by operating a pushbutton ...

Page 25: ...p R PSENvip R LR PSENvip E 1003449 EN 06 25 4 2 1 1 Standard protected field mode The full protected field is available with standard protected field mode This protected field mode is applied for flat workpieces Fig Standard protected field mode ...

Page 26: ...anels must not encroach into the central segments If the middle or rear segments of the protected field are interrupted the outputs of the spe cial module PSSu K F FAU shut down 1 Fig Box bending protected field mode Legend 1 Front segments of protected field are blanked The box bending protected field mode is only active for one press stroke and must be ac knowledged by the operator before or dur...

Page 27: ...nd middle segments of the protected field are interrupted the outputs of the special module PSSu K F FAU shut down 1 Fig Back gauge protected field mode Legend 1 Rear segments of protected field are blanked The back gauge protected field mode is only active for one press stroke and must be ac knowledged by the operator before or during the press stroke WARNING Risk of injury due to reduced protect...

Page 28: ...nd the bending line The box s side panels must not encroach into the central segments If the middle segments of the protected field are interrupted the outputs of the special mod ule PSSu K F FAU shut down 1 2 Fig Box bending with back gauge protected field mode Legend 1 Rear segments of protected field are blanked 2 Front segments of protected field are blanked The box bending with back gauge pro...

Page 29: ... low A reduced protected field may lead to serious injury and death If you require a different overrun path than the factory set path then use the value indicated by the manufacturer on the nameplate of the press brake or a higher value If you enter a lower value for the overrun the protected field will also be reduced to an unpermitted level The overrun is measured each time the protected field i...

Page 30: ...esult of the overrun measurement is only relevant if the user carries out an overrun test The overrun test must be evaluated in the PAS4000 user program NOTICE The signal for the overrun measurement must be incorporated into the PAS4000 user program in such a way that the test complies with the press safety concept The test must be carried out after the control system is switched on for example so...

Page 31: ...g gap of 6 mm depending on the regulations of the country in which the PSENvip is operated and the requirements of the appropriate regulatory body Using a configured muting end point The productive version of PSENvip supports a configurable muting end point A value in the range 4 1 6 mm may be configured as the muting end point For the configuration please refer to the operating manual for the spe...

Page 32: ... are available in the PAS4000 Library for this purpose see online help for PAS4000 An advance measuring field is located below the protected field Dynamic muting is started as soon as the advance measuring field touches the workpiece Dynamic muting ensures that during the downward movement of the press the danger zone between upper tool and workpiece is monitored until the muting end point is reac...

Page 33: ...ield NOTICE When the muting end point is reached the protected field is interrupted and the PSENvip initiates a press stop via the OSSDs and the fast shutdown of the PSSu K F FAU P To prevent the press stopping fast shutdown must be deactivated in the safety system s user program thereby overriding the shutdown States of the OSSD mute signal The OSSD signal from the special module PSSu K F FAU con...

Page 34: ...l 1 Mute signal 1 LED OSSD lights LED Mute lights Full protected field active advance measur ing field touches workpiece OSSD signal 1 Mute signal 1 0 LED OSSD lights LED Mute off 1 Remaining gap with fixed muting end point 4 mm configured muting end point 4 1 6 mm OSSD signal 1 0 Mute signal 0 LED OSSD goes out LED Mute off 1 ...

Page 35: ...ected field during dynamic muting Procedure when advance measuring field is interrupted Downward movement Object interrupts advance meas uring field starts dynamic muting OSSD signal 1 Mute signal becomes 0 LED OSSD lights LED Mute goes out Control system initiates the stop ping of the press measuring field was not interrupted in the expected position pinch point Upper tool continues moving for th...

Page 36: ...ield during the dynamic mut ing Object interrupts the protected field to the side OSSD signal 1 0 Mute signal 1 LED OSSD goes out LED Mute lights Control system initiates the stop ping of the press stroke Upper tool continues moving for the overrun distance protected field interrupted Object is re moved Protected field cleared Press stroke can be resumed ...

Page 37: ...en coders The electronic modules PSSu E F INC and PSSu K F INC are available to record and evaluate the current position values safely Please refer to the operating manual of the electronic module you are using It is the task of the PAS4000 user program to monitor the monitoring curve for any violation using the safely determined current positions Braking ramp monitoring using PSENvip From Hardwar...

Page 38: ...ield is clear the OSSDSignal is 1 It switches to 0 if the protected field is interrupted Creep speed mode Signal that indicates creep speed mode to the safety system Status of protected field Free interrupted Signal System Init If the CNC signals to the PSSu K F FAU B that the press brake is at top dead centre or in an upward movement System Init 1 Signal from foot switch The press stroke is start...

Page 39: ...ed overrun 8 mm A press stroke with full protected field has the following states Press is at top dead centre Protected field Free Signal action Status Press Foot switch 0 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 System Init 1 OSSD 1 Creep speed 0 Downward movement rapid traverse Protected field Free Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 System Init 0 OSSD 1...

Page 40: ...ess is at bottom dead centre Protected field Interrupted Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 System Init 0 OSSD 0 Creep speed 1 Upward movement rapid traverse Protected field Free or interrupted Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 System Init 1 OSSD 0 or 1 Creep speed 0 Press is at top dead centre Protected fie...

Page 41: ...Function description Operating Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 41 Signal action Status Press Foot switch 0 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 System Init 1 OSSD 1 Creep speed 0 ...

Page 42: ...nding protected field mode the front segments of the protected field are blanked 4 8 2 1 Acknowledgement when starting at top dead centre The reduced protected field starts with an acknowledgement e g acknowledgement but ton when the downward movement is started at top dead centre TDC The following states are available Press is at top dead centre Protected field Free Signal action Status Press Foo...

Page 43: ... at bottom dead centre Protected field Interrupted Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 0 Creep speed 1 Upward movement rapid traverse Protected field Free or interrupted Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 Acknowledgement of ...

Page 44: ...ual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 44 Signal action Status Press Foot switch 0 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 Acknowledgement of re duced protected field pro tected field mode 0 System Init 1 OSSD 1 Creep speed 0 ...

Page 45: ...ollowing states are available Press is at top dead centre Protected field Free Signal action Status Press Foot switch 0 Acknowledgement of re duced protected field pro tected field mode 0 System Init 1 OSSD 1 Creep speed 0 Downward movement rapid traverse Full protected field active Protected field Free Signal action Status Press Foot switch 1 v 0 v 10 mm s Acknowledgement of re duced protected fi...

Page 46: ...via acknow ledgement Protected field Free Signal action Status Press Foot switch 1 v 10 mm s v 10 mm s v 0 Acknowledgement of re duced protected field pro tected field mode 0 1 System Init 0 OSSD 1 Creep speed 0 Downward movement creep speed Protected field Free Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 Acknowledgement of re duced protected field pro tected fi...

Page 47: ...reep speed 1 Upward movement rapid traverse Protected field Free or interrupted Signal action Status Press Foot switch 1 TDC SG BDC v 0 v 10 mm s v 10 mm s v 0 Acknowledgement of re duced protected field pro tected field mode 0 System Init 1 OSSD 0 or 1 Creep speed 0 Press is at top dead centre Protected field Free Signal action Status Press Foot switch 0 Acknowledgement of re duced protected fiel...

Page 48: ...e blanked On each press stroke the Reduced protected field protected field mode must be started via an acknowledge ment 4 8 4 System cycle in for box bending with back gauge press stroke The system cycle is the same as for box bending Please note that with box bending with back gauge protected field mode both the front and rear segments of the protected field are blanked On each press stroke the R...

Page 49: ...valuation field P Test piece vmax maximum closing speed x Set overrun y Measured overrun OverrunMeasurement Signal for overrun from the special module PSSu K F FAU see op erating manual of the PSSu K F FAU B PSSu K F FAU P Downward movement with maximum closing speed vmax Protected field Free Signal action Status Press OverrunMeasurement 0 P vmax x A Overrun measurement 0 Downward movement with ma...

Page 50: ...n measurement 0 evaluation field interrupted When the protected field is interrupted the PAS4000 user program must check whether the evaluation field was interrupted If the configured overrun has been exceeded the possibil ity of the press stroke continuing at fast closing speed 10 mm s must be excluded This can be achieved as follows for example Interlock Press stroke only possible at creep speed...

Page 51: ...hes to 0 if the protected field is interrupted Status of protected field Free interrupted Mute signal signals whether dynamic muting is activated or deactivated Dynamic muting starts when the advance measuring field touches the pinch point on the workpiece It ends when the tool centre point reaches the muting end point The signal is reset to 1 when the protected field is fully activated and the ad...

Page 52: ...E v 0 v 0 v 0 v 0 KP 4 1 6 mm Fig Definitions Legend TDC Top dead centre ME Muting end point 4 1 6 mm end of dynamic muting PP Pinch point BDC Bottom dead centre v 0 mm s Closing speed at top bottom dead centre v 0 mm s Downward movement v 0 mm s Upward movement Mute influences mute signal ...

Page 53: ...luding reserve advance measuring field Position Configured overrun 6 mm 2 mm Signal action Status Press Foot switch 0 v 0 TDC System Init 1 OSSD 1 Mute 1 Muting OSSD Inactive Monitoring of braking ramp Inactive Monitoring of pinch point Inactive Downward movement rapid traverse Protected field Free Dynamic muting Inactive Position Protected field height including reserve advance measuring field Po...

Page 54: ...of protected field Protected field Free Dynamic muting Active Position Protected field height including reserve advance measuring field Position Configured overrun 6 mm 2 mm 2 mm x number of muting stages Example for 2nd muting stage Position Configured overrun 4 mm Signal action Status Press Foot switch 1 System Init 0 OSSD 1 Mute 0 Muting OSSD Inactive Monitoring of braking ramp Active Monitorin...

Page 55: ...ield Interrupted Dynamic muting Inactive Position Frozen value Signal action Status Press Foot switch 1 ME v 0 System Init 0 OSSD 0 Mute 0 Muting OSSD Active Monitoring of braking ramp End Monitoring of pinch point Inactive Press is at bottom dead centre Protected field Interrupted Dynamic muting Inactive Position Frozen value Signal action Status Press Foot switch 1 v 0 BDC System Init 0 OSSD 0 M...

Page 56: ...ting OSSD Inactive Monitoring of braking ramp Inactive Monitoring of pinch point Inactive The foot switch may only be released during a safe upward movement Press is at top dead centre Protected field Free Dynamic muting Inactive Position Protected field height including reserve advance measuring field Position Configured overrun 6 mm 2 mm Signal action Status Press Foot switch 0 v 0 TDC System In...

Page 57: ...ted field are blanked 4 9 2 1 Acknowledgement when starting at top dead centre The reduced protected field starts with an acknowledgement e g acknowledgement but ton when the downward movement is started at top dead centre TDC The following states are available Press is at top dead centre Protected field Free Dynamic muting Inactive Position Protected field height including reserve advance measuri...

Page 58: ...ncluding reserve advance measuring field Position Configured overrun 6 mm 2 mm 2 mm from first muting stage Position Configured overrun 6 mm Signal action Status Press Foot switch 1 KP Acknowledgement of re duced protected field pro tected field mode 1 or 0 System Init 0 OSSD 1 Mute 1 0 Muting OSSD Inactive Monitoring of braking ramp Start Monitoring of pinch point Active Downward movement gradual...

Page 59: ... muting end point ME Protected field Interrupted Dynamic muting End Position Minimum protected field height including reserve without advance measuring field Position Configured overrun 0 4 mm rounded to mm Position value is frozen Signal action Status Press Foot switch 1 ME 4 1 6 mm Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 1 0 Mute 0 Muting OSSD Start...

Page 60: ...toring of pinch point Inactive Press is at bottom dead centre Protected field Interrupted Dynamic muting Inactive Position Frozen value Signal action Status Press Foot switch 1 Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 0 Mute 0 Muting OSSD End Monitoring of braking ramp Inactive Monitoring of pinch point Inactive Upward movement advance measuring field ...

Page 61: ...pinch point Inactive The foot switch may only be released during a safe upward movement Press is at top dead centre Protected field Free Dynamic muting Inactive Position Protected field height including reserve advance measuring field Position Configured overrun 6 mm 2 mm Signal action Status Press Foot switch 0 v 0 TDC Acknowledgement of re duced protected field pro tected field mode 0 System Ini...

Page 62: ...g field Position Configured overrun 6 mm 2 mm Signal action Status Press Foot switch 0 v 0 TDC Acknowledgement of re duced protected field pro tected field mode 0 System Init 1 OSSD 1 Mute 1 Muting OSSD Inactive Monitoring of braking ramp Inactive Monitoring of pinch point Inactive Downward movement rapid traverse Full protected field active Protected field Free Dynamic muting Inactive Position Pr...

Page 63: ...active Monitoring of braking ramp Inactive Monitoring of pinch point Inactive Downward movement is continued with reduced protected field start via acknow ledgement Protected field Free Dynamic muting Inactive Position Protected field height including reserve advance measuring field Position Configured overrun 6 mm 2 mm Signal action Status Press Foot switch 1 Acknowledgement of re duced protected...

Page 64: ... Protected field Free Dynamic muting Active Position Protected field height including reserve advance measuring field Position Configured overrun 6 mm 2 mm 2 mm x number of muting stages Example for 2nd muting stage Position Configured overrun 4 mm Signal action Status Press Foot switch 1 KP Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 1 Mute 0 Muting OSSD...

Page 65: ...g ramp Active Monitoring of pinch point Inactive Downward movement Protected field Interrupted Dynamic muting Inactive Position Frozen value Signal action Status Press Foot switch 1 ME 4 1 6 mm Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 0 Mute 0 Muting OSSD Active Monitoring of braking ramp End Monitoring of pinch point Inactive Press is at bottom dead c...

Page 66: ...cted field Free or interrupted Dynamic muting Inactive Position Frozen value Signal action Status Press Foot switch 1 or 0 Acknowledgement of re duced protected field pro tected field mode 0 System Init 0 OSSD 1 or 0 Mute 0 1 Muting OSSD Inactive Monitoring of braking ramp Inactive Monitoring of pinch point Inactive The foot switch may only be released during a safe upward movement Press is at top...

Page 67: ...PSENvip E 1003449 EN 06 67 Signal action Status Press Foot switch 0 v 0 TDC Acknowledgement of re duced protected field pro tected field mode 0 System Init 1 OSSD 1 Mute 1 Muting OSSD Inactive Monitoring of braking ramp Inactive Monitoring of pinch point Inactive ...

Page 68: ...m cycle for back gauge press stroke The system cycle is the same as for box bending Please note that with back gauge protec ted field mode the rear segments of the protected field are blanked On each press stroke the Reduced protected field protected field mode must be started via an acknowledge ment ...

Page 69: ...with back gauge press stroke The system cycle is the same as for box bending Please note that with box bending with back gauge protected field mode both the front and rear segments of the protected field are blanked On each press stroke the Reduced protected field protected field mode must be started via an acknowledgement ...

Page 70: ...data ready if you require support from Pilz if there is an error Settings Adjusting the settings the settings can be changed once a password has been entered The default user name is admin and the default password is psenvip Confirm your entry with Submit A new password can be entered The title of the web interface can be changed Access to the Tool Change and Adjustment options can be restricted t...

Page 71: ...transmitter and receiver must be maintained see Technical Details 113 WARNING A restricted field of vision or inadequate mounting will restrict the pro tected field A restricted protected field may lead to serious injury and death Ensure that the field of vision of the front lenses on the transmitter and re ceiver is not restricted Do not attach any other optical elements such as glass plastic sur...

Page 72: ... groove in which to insert the slot nut see diagram 14 0 3 7 0 3 15 0 2 8 3 0 2 1 17 0 5 4x ø15 4x ø8 4 32 5 71 5 115 35 35 27 A A B B Fig Dimensions of adapter plate with groove dimensions in mm The process for installing the transmitter and receiver is the same To install the system proceed as follows Fasten the adjustment plate and mounting plate as shown in the following diagram En sure that t...

Page 73: ...gend 1 Nut 2 Auxiliary adjustment plate 3 Adjustment plate 4 Flat washer 5 Mounting plate Viewed from the operator s side the receiver is installed on either the left or right hand bracket and then the transmitter on the other bracket Slide the nut slot on the adjustment plate into the groove on the bracket attached to the upper die ...

Page 74: ...Installation Operating Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 74 5 3 Dimensions 5 3 1 Transmitter Fig Dimensions Transmitter dimensions in mm ...

Page 75: ...ng Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 75 5 3 2 Receiver Fig Dimensions Receiver dimensions in mm 5 3 3 Fastening kit for the transmitter Fig Dimensions Fastening kit for the transmitter dimensions in mm ...

Page 76: ...Installation Operating Manual PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 76 5 3 4 Fastening kit for the receiver Fig Dimensions Fastening kit for the receiver dimensions in mm ...

Page 77: ...h the cable shield connection within the control cabinet e g on a bus bar We recommend you use Pilz ready made cable to connect the PSENvip see Order refer ences To use the PSENvip in accordance with the requirements of UL only use cables listed under Category Code CYJV Protect the cable from mechanical damage If the cable is not protected through the ma chine it should be laid in armoured hose La...

Page 78: ... K F FAU It is loc ated on the top of the receiver 1 3 2 4 Configuration PIn No Designation Cable colour 1 SerDes yellow 2 5V white 3 SerDes orange 4 GND blue We recommend you use Pilz ready made cable see Order references If you wish to make the connection cable yourself please use Category Cat5 cable STP star quad cable Cable with a diameter of AWG22 ...

Page 79: ...n M12 male connector is used to connect to the module PSSu K F FAU It is located on the top of the transmitter 1 2 3 4 Configuration Pin no Designation Cable colour 1 24 V DC brown 2 TRM_SYNC white 3 0 V blue 4 TRM_ON black Housing FE We recommend you use Pilz ready made cable see Order references ...

Page 80: ... PSENvip R PSENvip R LR PSENvip E 1003449 EN 06 80 6 4 Connection diagram 1 1 2 2 3 3 4 4 1 2 3 4 PSENvip E Mounting PSSu K F FAU SerDes GND 5 V SerDes 24 V TRM_SYNC 0 V TRM_ON PSENvip R PSENvip R LR FE Fig Connection diagram ...

Page 81: ...f the PSENvip when power is switched on is described under Operation INFORMATION When changing the tool follow the instructions provided under Initial com missioning Position tool Make adjustment during tool change 7 1 Web interface The web interface connects the CNC or PC to the special module PSSu K F FAU via an Ethernet interface INFORMATION The tool change and adjustment functions are only pos...

Page 82: ...t be installed correctly on the press brake see Installation 71 and electrically wired see Wiring 77 An upper tool must be fitted to the right and left hand edge of the press brake The supply voltage is present PSSu K F FAU CAUTION Have the protective equipment tested and certified before commis sioning for the first time Any machine safeguarded by the PSENvip must be tested and certified by quali...

Page 83: ...C C B Direction What A Move horizontally within the groove of the adjustment plate B Rotate on a horizontal plane within the slot holes of the adjustment plate C Move vertically by adjusting the nuts on the bolts Guidelines for the mechanical alignment of transmitter and receiver When making the alignment the nuts on the bolt connecting the PSENvip to the adjust ment plate should only be hand tigh...

Page 84: ...6 84 Push the screwdriver blade into the middle notch of the auxiliary adjustment plate and ad justment plate Rotate the screwdriver blade in the required direction You can use the left or right hand notch to rotate the transmitter or receiver even further to the left or right ...

Page 85: ...is screwed to a bracket Installation is described at the end of this chapter Attach an adjustment template with magnets to the upper tool The tip of the upper tool must sit in the notch on the stop of the adjustment template Align the alignment grid of the adjustment template to the contour of the upper tool Align the alignment grid on the upper tool Centre point of the upper tool in the notch on ...

Page 86: ...ig Receiver illuminated by transmitter If the illuminated target area does not enclose the receiver as shown in the diagram then you will need to realign the transmitter INFORMATION Carefully align the illuminated target area to the receiver This will make the adjustments in the following work stages easier ...

Page 87: ...racket using half length taper grooved dowel pins and cylin der head bolts see illustration 10 45 65 Ø 3 0 1 Ø 3 4 Ø 3 4 Ø 3 0 1 1 3 2 Fig Adjustment template to attach to bracket 1 Ø 3 mm DIN 1472 half length taper grooved dowel pin 2 M3 x 10 cylinder head bolts 3 Ø 3 mm DIN 1472 half length taper grooved dowel pin Attach the bracket to the upper tool clamp 1 Fig Adjustment template with bracket ...

Page 88: ... The distance from the bending line to the front segments of the protected field is 15 mm 15 mm Tool class 2 Semi circular tools For these tools we recommend alignment to the left hand bending line The distance from the front bending line of the tool to the front segments of the protected field is 15 mm The rear bending line of the tool is detected by the protected field The posi tion of the front...

Page 89: ...he alignment grid on the upper tool Centre point of the upper tool in the notch on the back stop Open the Adjustment menu in the web interface You will see the tool displayed with the bending lines and a template The example below shows a tool on which the bending line is approximately 7 mm to the left of centre Fig Incorrect adjustment The receiver is correctly aligned with the transmitter when T...

Page 90: ...e direction of the receiver as described in the section entitled Adjustment direc tions of transmitter and receiver until a correct adjustment image is displayed Remove the adjustment templates The correct adjustment image must correspond to the image shown in the following dia gram The bending line should be on the vertical guide The tool centre point should be aligned with the horizontal guide t...

Page 91: ...ver aligned incorrectly with transmitter the Out of range message will also appear Out of range Fig Checking the adjustment image with superimposed guide frame You can switch to the adjustment image without guide frame by pressing Cancel guide frame Exit the adjustment by selecting another option e g Operation The transmitter and receiver are now mechanically aligned NOTICE After you have aligned ...

Page 92: ...be exactly aligned to each other and to the centre point of the upper tool as described under Align transmitter and receiver The supply voltage must be present CAUTION The manufacturer or operator of the press must use appropriate measures to ensure safe selection of the Adjustment during tool change operating mode CAUTION The protective equipment must be tested following a tool change ad justment...

Page 93: ...warnings given under Tool shapes 15 Assignment to a tool class depends on Compliance with the requirement from EN 12622 whereby the protected field must safe guard areas lying 15 mm before the front bending line Full or partial detection of the upper tool via the protected field 15 mm 1 2 3 15 mm H3 V2 H2 V3 V1 H1 B1 Fig Classification of tools into tool classes ...

Page 94: ...ected by the PSENvip The front V1 or B1 and rear H1 or B1 bending lines are within the protected field The front segments of the protected field are at least 15 mm away from the front bending line These tools are safeguarded in compliance with the standards Example max 32 mm max 25 mm 15 mm 15 mm H H V V Fig Example for tool class 1 ...

Page 95: ...ls is fully detected by the PSENvip The front V2 and rear H2 bending lines are within the protected field The front segments of the protected field are less than 15 mm away from the front bend ing line These tools are not safeguarded in compliance with the standards Example 25 mm 15 mm H V Fig Example for tool class 2 ...

Page 96: ...3449 EN 06 96 Tool class 3 The contour of these tools is not fully detected by the PSENvip The front V3 and or rear H3 bending lines are within the protected field These tools are not safeguarded in compliance with the standards Example H V Fig Example for tool class 3 ...

Page 97: ...layed If the symbol appears on the display there is a problem with the lighting of the receiver by the transmitter Check that the transmitter and receiver are aligned correctly The illuminated target area must completely envelop the receiver If necessary realign the transmitter see Align transmitter 85 Remove any potential contamination on the lens of the transmitter or receiver The adjustment has...

Page 98: ...n register free of charge A valid E mail address is required for registration Name of the ZIP file PSENvip_OverrunCalculationTool_for_RampMonitoring_ Version zip e g PSENvip_OverrunCalculationTool_for_RampMonitoring_1_0_0 zip Contents of the ZIP file Excel tool PSENvip_OverrunCalculationTool_for_RampMonitoring_ Version xls e g PSENvip_OverrunCalculationTool_for_RampMonitoring_1_0_0 xls Operating m...

Page 99: ...nction test using test rod The test rod must be detected along the whole length of the detection zone The OSSD signal switches from 1 to 0 The LED on the receiver lights up red INFORMATION The following tests should be carried out 10 times during initial commission ing Function test with 10 mm and 15 mm test piece Position the 10 mm high section of the test piece on top of the lower tool Initiate ...

Page 100: ...piece Function test using the 35 mm test piece Move the press to top dead centre Position the 35 mm high section of the test piece on top of the lower tool Initiate a press stroke The test piece breaks the protected field The press stroke is stopped The upper tool should not touch the test piece WARNING The press brake must be shut down immediately if the test reveals a fault Failure to comply cou...

Page 101: ... self test various LEDs on the PSSu K F FAU change their status They are not lit constantly until the self test has elapsed The meaning of the LEDs is described in the operating manual PSSu K F FAU All outputs on the PSSu K F FAU are switched off INFORMATION During commissioning of a PSENvip with a new receiver data are trans ferred between the receiver and the special module PSSu K F FAU The tran...

Page 102: ...e protected field is clear The LED on the receiver lights up red if the protected field is interrupted It lights up green if the protected field is clear PSSu K F FAU The SUP LED lights up The meaning of the remaining LEDs is de scribed in the operating manual PSSu K F FAU B PSSu K F FAU P Examples for displaying the protected fields in the web interface Web interface Protected field mode Standard...

Page 103: ...cted field on each press stroke you will need to start the reduced protected field via an acknowledgement Use an acknowledgement button for the acknowledgement WARNING Risk of injury due to reduced protected field Around the bending line there is an increased risk of crushing and trapping of fingers or hands because with box bending protected field mode the front segments of the protec ted field a...

Page 104: ...stment is requested after a tool change via the Adjustment menu protected field monit oring is interrupted and The LED on the receiver lights up red The web interface shows the selected menu The symbol for the OSSD is red PSSu K F FAU The SUP LED goes out The meaning of the remaining LEDs is de scribed in the operating manual PSSu K F FAU B PSSu K F FAU P Once the adjustment Adjustment or tool cha...

Page 105: ...adjustment or tool change are stopped In the web interface all options except for Help and Service are inactive The symbol for the OSSD is red The message System in standby mode is displayed Transmitter and receiver are switched off The OSSD LED on the receiver will be off For tandem operation of presses it is now pos sible to remove and to re insert the receiver and the transmitter without an err...

Page 106: ...e g incorrect intensity too much scatter poor adjustment contamination Adjustment error detected tool does not match the referenced tool lack of tool adjustment following tool change Tool class communication error user program communication error no communication or faulty communication between user program and PSENvip invalid user program invalid CNC setting or faulty tool detection invalid mutin...

Page 107: ...uts on the PSSu K F FAU are shut down and the Err LED lights up red The transmitter is off and the receiver on the LED lights up red PSENvip is restar ted automatically The restart is carried out up to 3 times If the error is still present after wards PSENvip remains switched off The error is displayed via the web interface if pos sible and is reported to the PSSu system Remedy Rectify the error a...

Page 108: ...intain a safe working condition i e to prevent accidents The test of the protective equipment consists of A function test using the test piece and a visual inspection WARNING The press brake must be shut down immediately if the test reveals a fault Failure to comply could result in a hazardous situation which could lead to serious injury and death In this case have the safety equipment checked by ...

Page 109: ...ool over whole length of machine x with upper tool over whole length of machine After tool change x x x after Firmware up date x x x Carry out the test as described under Test the function of the safeguard INFORMATION This inspection may only be carried out by qualified personnel Visual inspection of transmitter and receiver for Condition of the installation and attachment Any damage on the housin...

Page 110: ...N 06 110 INFORMATION The inspection may only be carried out by appointed expert competent per son The result of these tests must be entered in the inspection book or in the machine file Any serious non conformances must be rectified before the press brake is returned to operation ...

Page 111: ... update or exchange of PSENvip and or compon ents on the PSENvip INFORMATION Before modifying a safe process a safe machine the impact of the modifica tion on the safety of the process machine must be analysed If the analysis has shown that safety functions need to be validated and tested after the modification then both the modification itself and the course of the entire process must be inspecte...

Page 112: ...g the lens Clean the lens as follows Remove the dust from the front lens using a soft brush Spray the front lens using an alcohol glass cleaner Do not allow drops to form on the lens Use a soft cloth to wipe across the whole of the front lens Remove any heavier dirt without scratching the front lens ...

Page 113: ...8 m Resolution of overrun 2 mm 2 mm Electrical data 584100 584101 584200 Supply voltage Voltage 5 V 5 V 24 V Kind DC DC DC Voltage tolerance 10 10 10 10 20 20 Output of external power supply DC 0 8 W 0 8 W 5 W Optical data 584100 584101 584200 Type of light source High Power LED Diameter of illuminated target area 70 mm Used wavelength range 510 550 nm 510 550 nm 510 550 nm Average service life LE...

Page 114: ...ed EMC EN 61000 6 4 EN 61496 1 EN 61000 6 4 EN 61496 1 EN 61000 6 4 EN 61496 1 Vibration In accordance with the standard EN 60068 2 6 EN 60068 2 6 EN 60068 2 6 Frequency 10 55 Hz 10 55 Hz 10 55 Hz Amplitude 0 35 mm 0 35 mm 0 35 mm Shock stress In accordance with the standard EN 60068 2 27 EN 60068 2 27 EN 60068 2 27 Acceleration 10g 10g 10g Duration 16 ms 16 ms 16 ms Protection type In accordance ...

Page 115: ...L IEC 61508 PFD EN ISO 13849 1 2015 TM year PL e Cat 4 SIL CL 3 3 30E 09 SIL 3 2 91E 04 20 All the units used within a safety function must be considered when calculating the safety characteristic data INFORMATION A safety function s SIL PL values are not identical to the SIL PL values of the units that are used and may be different We recommend that you use the PAScal software tool to calculate t...

Page 116: ...raight 584 572 PSEN op cable axial M12 4 p shield 5m Connection cable transmitter 5 m Connector M12 straight 630 304 PSEN op cable axial M12 4 p shield 10m Connection cable transmitter 10 m Connector M12 straight 630 305 PSEN op cable axial M12 4 p shield 20m Connection cable transmitter 20 m Connector M12 straight 630 270 PSEN op cable axial M12 4 p shield 30m Connection cable transmitter 30 m Co...

Page 117: ... E 1003449 EN 06 117 Product type Features Order no PSENvip MS Supporting arms for installing PSENvip on a press additional PSENvip MB 583 205 required 583 206 PSENvip MB Adapter pieces for mounting PSENvip AP on to any bracket 583 205 PSENvip TP Test piece 583 200 ...

Page 118: ...Not OK Notes 1 Check the category standards Does the category of the PSENvip match the cat egory required for the plant machine Have the standards applicable for the plant ma chine been considered 2 Check the ambient conditions for PSENvip Are the technical details of the PSENvip complied with 3 Check the wiring of the PSENvip Are all the electrical connections to the PSENvip wired correctly Do th...

Page 119: ... the switching elements that are connected to the outputs e g valves contactors monitored via feedback loops Does the wiring of the inputs and outputs match the circuit diagram 7 Check the effectiveness of the PSENvip during the hazardous movement Is the PSENvip effective throughout the whole of the hazardous movement of the plant machine Is the safety function tested in accordance with the instru...

Page 120: ...etyNET p THE SPIRIT OF SAFETY are registered and protected trademarks of Pilz GmbH Co KG in some countries We would point out that product features may vary from the details stated in this document depending on the status at the time of publication and the scope of the equipment We accept no responsibility for the validity accuracy and entirety of the text and graphics presented in this informatio...

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