Pilz PSENvip RL D P Set Operating Manual Download

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System Connections

Operating Manual PSENvip RL D P Set
1001641-EN-09

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bComEnd

JMPC END

RESTORE:

FALSE

bAcknowledgeToolChangeA0

bAcknowledgeToolTypeA1

bAcknowledgeToolTypeA2

TRUE

bStartCom

bToolValid

END:

END_FUNCTION_BLOCK

Summary of Contents for PSENvip RL D P Set

Page 1: ...PSENvip RL D P Set Operating Manual 1001641 EN 09 Safe camera systems...

Page 2: ...be made for the user s internal purposes Suggestions and comments for improving this documenta tion will be gratefully received Pilz PIT PMI PNOZ Primo PSEN PSS PVIS SafetyBUS p SafetyEYE SafetyNET p...

Page 3: ...s 16 3 3 1 Use of qualified personnel 17 3 3 2 EMCD 17 3 3 3 Warranty and liability 17 3 3 4 Safety during commissioning installation and operation 17 3 3 5 Disposal 17 4 Function description 18 4 1 O...

Page 4: ...on wiring 57 6 2 Connections 59 6 2 1 Receiver 59 6 2 2 Transmitter 61 6 2 3 Supply voltage 61 6 2 4 Connection between transmitter and receiver 61 6 2 5 Connection diagram 62 7 Commissioning 63 7 1...

Page 5: ...5 Tool change 88 8 2 6 Error messages 88 8 2 7 Cleaning the front lenses 88 9 Diagnostics and Troubleshooting 90 9 1 Error Management 90 9 1 1 Minor errors 90 9 1 2 Major errors 91 9 1 3 Fatal errors...

Page 6: ...valid for the PSENvip from Version 1 0 year of construction 2014 1 2 Overview of documentation 1 Introduction The introduction is designed to familiarise you with the contents structure and specific o...

Page 7: ...hat can be taken WARNING This warning must be heeded It warns of a hazardous situation that could lead to serious injury and death and indicates preventive measures that can be taken CAUTION This refe...

Page 8: ...0 m Inputs 1 input for setup mode 1 input for signalling when the press brake is at top dead centre 2 inputs for controlling the protected field mode Protected field can be adapted to a range of bendi...

Page 9: ...er Upper die Safety control system CNC Receiver Lower tool Detection zone Upper tool Transmitter Fig Whole system 2 1 Scope of supply PSENvip RL D P Set complete set Order reference Description PSENvi...

Page 10: ...In the PSS 4000 user program safety functions must be implemented to safe guard the dynamic muting of PSENvip Monitoring of the pinch point Monitoring of the press braking ramp Definition of a safe p...

Page 11: ...ending with back gauge protected field mode the protected field is reduced This means there can only be limited protection against trapping and crushing The protec ted field is around the tolerance zo...

Page 12: ...x bending and or back gauge bending mode the protected field is partly blanked Around the bending line there is an increased risk of crushing and trapping of fingers or hands Correct handling with fla...

Page 13: ...trapped between the workpiece and up per tool Fig Handling box bending 3 1 3 Categories SIL The PSENvip may only be used with an automation system PSS 4000 from Pilz with SIL 3 of EN 61508 and PL e o...

Page 14: ...tchover point at high closing speed Tool class 2 These tools cannot be safeguarded in compliance with the standards The front and rear bending lines are detected by the protected field on the PSENvip...

Page 15: ...y out a hazard analysis Raise the switchover point which initiates braking at low speed It must be placed even higher than the position used for tools of tool class 2 The switchover point must be moni...

Page 16: ...press brakes EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 2 Safety of machinery Safety related parts of control systems...

Page 17: ...to the specific application Approved personnel must be familiar with how to use and test ESPE and be authorised by the ESPE operator to do this 3 3 2 EMCD The PSENvip is designed for use in an indust...

Page 18: ...s into the detection zone both output signal switching devices OSSD1 OSSD2 on the PSENvip will switch to the OFF state The safety system will use these signals to initiate stopping of the press stroke...

Page 19: ...n Power Off System Init Protected field mode Acknowledge ment of reduced protected field Inputs Outputs PSENvip receiver PSENvip transmitter CNC controller Protected field mode Setup Foot switch E STO...

Page 20: ...uminated target area The lens on the receiver only de tects light that runs parallel to the optical axis This guarantees stability against diffused light NOTICE Do not use optical aids e g lenses to l...

Page 21: ...to initiate stopping of the press stroke 4 2 Protected field The protected field consists of several segments The front and rear segments viewed from the operator s side can be deactivated This provid...

Page 22: ...e with the corresponding inputs and outputs is ex plained in this chapter in the section entitled System cycle 4 2 1 Dynamic muting An advance measuring field is located below the protected field If i...

Page 23: ...are deactivated before the upper tool enters the protec ted field NOTICE The control system may only override the safety function from a remaining gap of 6 mm Signal statuses of the outputs Mute1 Mut...

Page 24: ...e meas uring field starts dynamic muting OSSD1 OSSD2 1 Mute1 Mute2 1 0 Safety system initiated the stop ping of the press measuring field was not interrupted in the expected position pinch point 2 Upp...

Page 25: ...efer to chapter 11 Technical Details for more information about the input area of the overrun Details on how to enter the overrun are described in Chapter 7 Commis sioning section entitled Enter overr...

Page 26: ...tains the inputs for controlling the light source 1 2 3 4 Fig Transmitter and receiver 1 Display 2 Receiver 3 LED OSSD status 4 Transmitter 4 4 2 Transmitter The top of the transmitter has a 4 pin M12...

Page 27: ...ty tests are requested by an external control system before these 2 minutes have elapsed The best time to do this is when the OSSDs are already switched off due to the position within the press stroke...

Page 28: ...r communication with the programmable safety system See Communication with a programmable safety system in this section 4 4 3 2 Outputs OSSD1 OSSD2 in accordance with EN 61496 1 type 4 Two safe output...

Page 29: ...checked via regular on tests Test pulses for outputs that are switched off see Technical Details Outputs that are switched off are switched on for the duration of the test pulse The load must not swit...

Page 30: ...icates the status of the protected field Green The protected field is clear Red Protected field is interrupted 1 Fig LED on receiver 1 OSSD LED 4 4 3 4 Key display and function The PSENvip receiver ha...

Page 31: ...ey when confirming the entered overrun and making adjustments during a tool change MODE Call up the operating modes tool change and adjustment during initial commissioning The DIAGNOSTICS menu is also...

Page 32: ...vip is not in the status SYSTEM OK or NORMAL OPERATION Operating state State Description NORMAL OPERA TION One of the protected field modes is activated See Chapter 8 Operation SETUP This is the opera...

Page 33: ...s under Safety This is the case with tool classes 2 and 3 User programs that do not support communication with the PSENvip can be used if you only intend to safeguard tools of tool class 1 This is the...

Page 34: ...safety system X1 6 Output Mute1 Tool class PSENvip PLC Bit 1 The PSENvip sends Bit 1 of the detected tool class to the safety sys tem X2 6 Output Mute2 Tool class PSENvip PLC Bit 2 The PSENvip sends B...

Page 35: ...s max 200 ms 1 The PSENvip starts communication Activate 0 1 pulse edge Tool class PLC PSENvip Bit 1 2 Bits can have any status 2 The safety system is ready for communication PLC Ready 0 1 pulse edge...

Page 36: ...t 2 0 7 The safety system ends communication PLC Ready 1 0 pulse edge Tool class PLC PSENvip Bit 1 2 0 or 1 depending on the original status INFORMATION The requirements of the user program in the saf...

Page 37: ...ing Front segments blanked Yes Yes No Back gauge Rear segments blanked Yes No No The operation must be confirmed after each press stroke by operating a pushbutton 4 5 1 Standard protected field mode T...

Page 38: ...s side panels must not encroach into the central segments If the central or rear segments of the protected field are interrupted the OSSDs switch to the OFF state 1 Fig Box bending protected field mod...

Page 39: ...front and central segments of the protected field are interrupted the OSSDs switch to the OFF state 1 Fig Back gauge protected field mode Legend 1 Rear segments of protected field are blanked The bac...

Page 40: ...are behind the bending line The box s side panels must not encroach into the central segments If the central segments of the protected field are interrupted the OSSDs switch to the OFF state 1 2 Fig...

Page 41: ...o each other during initial commissioning The vertical and horizontal alignment is performed using templates and is displayed on the re ceiver In this operating mode The protected field is inactive Th...

Page 42: ...ovement Foot switch Start stop press stroke System Init Press brake is at top dead centre OSSD Output signal switching devices of the PSENvip Protected field Free interrupted Mute 1 2 signals whether...

Page 43: ...t Mute 1 2 Segment switches outputs Mute 1 and Mute 2 4 7 1 System cycle for standard press stroke Inputs on the PSENvip receiver Protected field mode 1 0 Protected field mode 2 0 Power Off 0 1 Status...

Page 44: ...0 Dynamic muting Start 4 Status Downward movement Tool centre point reaches the 8 mm point v 0 KP 8 mm Foot switch 1 System Init 0 OSSD 1 Protected field Free Mute 1 2 0 Dynamic muting Active 5 Status...

Page 45: ...ess is at bottom dead centre v 0 BDC Foot switch 1 System Init 0 OSSD 0 Protected field Interrupted Mute 1 2 0 Dynamic muting Inactive 8 Status Upward movement Advance measuring field is cleared v 0 F...

Page 46: ...button and then release 1 Status Press is at top dead centre TDC v 0 Foot switch 0 System Init 1 OSSD 0 Protected field Free Mute 1 2 0 Dynamic muting Inactive 2 Status Downward movement v 0 Foot swit...

Page 47: ...Free Mute 1 2 0 Dynamic muting Active 5 Status Downward movement Tool centre point reaches the 6 mm point v 0 6 mm 6 mm Foot switch 1 System Init 0 OSSD 1 0 Muting of the OSSD in steps 5 to 8 in the s...

Page 48: ...omatically the operator can release the foot switch System Init 1 OSSD 1 or 0 Protected field Free or interrupted Mute 1 2 0 1 Dynamic muting Inactive Continue with step 1 4 7 3 System cycle for back...

Page 49: ...uts on the PSENvip receiver Protected field mode 1 1 Protected field mode 2 1 Acknowledgement of reduced protected field Press pushbutton and then release The system cycle is the same as for box bendi...

Page 50: ...ed with the respective front lenses aligned in parallel to each other The distance between the transmitter and receiver may not be greater than the value stated in the Technical Details CAUTION Ensure...

Page 51: ...a corresponding groove in which to insert the slot nut see Fig 5 1 14 0 3 7 0 3 15 0 2 8 3 0 2 1 17 0 5 4x 15 4x 8 4 32 5 71 5 115 35 35 27 A A B B Fig Dimensions of adapter plate with groove dimensio...

Page 52: ...justment plate Flat washer Fig Installing the transmitter and receiver Viewed from the operator s side the receiver is installed on the left hand bracket and the transmitter on the right hand bracket...

Page 53: ...Installation Operating Manual PSENvip RL D P Set 1001641 EN 09 53 5 3 Dimensions 5 3 1 Transmitter 80 55 168 115 5 142 5 52 112 52 Fig Transmitter dimensions dimensions in mm...

Page 54: ...EN 09 54 5 3 2 Receiver 55 137 228 115 5 112 52 142 5 52 112 MODE ESC Fig Receiver dimensions dimensions in mm 5 3 3 Fastening kit for the transmitter 97 6 8 36 5 9 46 20 162 13 6 72 Fig Dimensions o...

Page 55: ...stallation Operating Manual PSENvip RL D P Set 1001641 EN 09 55 5 3 4 Fastening kit for the receiver 156 36 5 9 76 20 13 6 8 162 72 Fig Dimensions of the fastening kit for the receiver dimensions in m...

Page 56: ...itter and receiver are available as accessories for order no see Chapter 11 Technical Details Details about installation can be found in the diagram below 1 2 3 4 5 Fig Bracket for transmitter and rec...

Page 57: ...eristic C 4 A or 6 A depending on the inrush current Please refer to the recommendations of the power supply manufacturer WARNING Electric shock Safe electrical isolation must be ensured for the exter...

Page 58: ...s should be linked Only the following pro tected field modes are possible Standard protected field mode switch open both inputs 0 Box bending with back gauge protected field mode switch closed both in...

Page 59: ...scription Colour 1 Activate Output Start communication with safety system White 2 24 VDC Input 24 VDC supply voltage Brown 3 Protected field mode 1 Input setting of protected field modes Green Tool cl...

Page 60: ...nitiation of a press stroke with reduced protected field Green 4 System Init Input the press is at top dead centre Yellow 5 OSSD2 Output OSSD2 Grey 6 Mute2 Output dynamic muting Pink Tool class PSENvi...

Page 61: ...M12 connector X3 on the transmitter Pin no Designation Description Colour 1 24 V DC Input 24 V DC supply voltage brown 2 TRM_SYNC Input signal to control the intensity of the light source white 3 0 V...

Page 62: ...p Bit 1 Protected field mode 2 Tool class PLC PSENvip Bit 2 OSSD 1 Mute 1 Tool class PSENvip PLC Bit 1 1 2 3 4 5 6 7 8 1 2 3 4 24 V DC 0 V Power Off Setup PLC Ready Acknowledgement System Init OSSD 2...

Page 63: ...ceiver Tracking the adjustment line to the tip of the upper tool Entering the overrun Performing the function test using the test piece The tool change adjustment involves Tracking the adjustment line...

Page 64: ...ustment templates and the information on the display provide support when aligning the transmitter and receiver Please note the different cut outs around the cross hair on the two adjustment templates...

Page 65: ...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 tightened There are three notches o...

Page 66: ...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 Al...

Page 67: ...apes The correct adjustment of the upper tool also depends on the tool shape The tools are di vided into tool classes in the Tool Change menu INFORMATION You must comply with the tool class informatio...

Page 68: ...he rear bending line of the tool is detected by the protected field The posi tion of the front bending line must be considered in the hazard analysis 15 mm Tool class 2 Stamp For these tools we recomm...

Page 69: ...ntour of the upper tool Align the alignment grid on the upper tool Centre point of the upper tool in the notch on the back stop Fig Attach the adjustment template to the receiver Press the MODE key Us...

Page 70: ...outs around the cross hair see section entitled Adjustment templates This makes it easier to evaluate the adjustment direction required by the transmitter and receiver Adjust the direction of the rec...

Page 71: ...isplay Apart from the areas around the tool centre point the guide frame should be clear of objects The following diagram illustrates a valid and an an invalid adjustment image In the case of an inval...

Page 72: ...sage appears this can lead to false stops during operation In this case you must cor rect the adjustment If you comply with the specifications for the required protected field size and the overrun is...

Page 73: ...receiver you will still need to carry out the step for Adjustment during tool change see section entitled Adjustment during tool change 7 2 2 Adjustment template with bracket An adjustment template sc...

Page 74: ...tool change CAUTION The manufacturer or operator of the press must ensure safe selection of the Adjustment during tool change operating mode with appropriate meas ures CAUTION The protective equipmen...

Page 75: ...ANGE operating mode the PSENvip detects the contour of the tool and as signs it to a tool class Assignment to a tool class depends on Compliance with the requirement from EN 12622 whereby the protecte...

Page 76: ...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...

Page 77: ...ected 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 Tool class 3 The...

Page 78: ...ection on the PSENvip display 7 3 3 Make adjustment during tool change To achieve optimum results the tool should be aligned to an appropriate bending line dur ing initial commissioning see section en...

Page 79: ...range bar the following symbol appears 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...

Page 80: ...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 h...

Page 81: ...can exit the menu at any time without confirming the entry by pressing ESC In this case the previous value for the overrun will be retained NOTICE Once the overrun has been entered you will have to p...

Page 82: ...st during initial commissioning The machine manufacturer must perform a function test on the safeguard before putting the press brake into service During this test the press brake must be fully config...

Page 83: ...ures on the press brake must be checked at least once a year by an appointed expert competent person to ensure they are in a safe condition The result of these tests must be entered in the inspection...

Page 84: ...be detected along the whole length of the detection zone The OSSDs switch to the OFF state The LED on the receiver lights up red INFORMATION The following tests must be run on the left and right hand...

Page 85: ...piece Function test using the 35 mm test piece Start up the press Position the 35 mm high section of the test piece on top of the lower tool Initiate a press stroke The test piece interrupts the advan...

Page 86: ...the self test has been carried out Switch on the supply voltage A self test runs while the start screen is displayed on screen An error message will appear if an error is detected INFORMATION Informa...

Page 87: ...available protected field modes also depends on the se lected tool class Please refer also to the section entitled Protected field modes under Function Description WARNING Risk of injury due to reduce...

Page 88: ...ion entitled Adjustment during tool change Carry out a function test using the test piece See Chapter 7 Commissioning section entitled Function test of the safety device INFORMATION Generally you shou...

Page 89: ...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 90: ...iggered An error identifier is shown on the display of the PSENvip receiver see Error messages in this chapter The error plus some additional diagnostic data is entered in a special data area on the P...

Page 91: ...supply voltage off and then on again 9 1 3 Fatal errors Possible causes Major system defect Error during self test Reaction of the PSENvip The PSENvip switches to a FATAL state It remains in a safe co...

Page 92: ...P Internal error STOP 1 Restart the PSENvip Switch supply voltage off and then on again 2 Change the receiver Wiring error Wiring error 1 Restart the PSENvip Switch supply voltage off and then on agai...

Page 93: ...r Initial commis sioning 6 Change receiver and or transmitter Toll size exceeded or Communication error with safety system Tool size exceeded or Communication error with safety system 1 Use smaller to...

Page 94: ...c block 2 Diagnostic data 3 Data in hex 9 3 1 Diagnostic blocks and diagnostic data The System Data diagnostic block contains the following diagnostic data Type The type of PSENvip SW Version The soft...

Page 95: ...EN 09 95 The Log Data diagnostic block contains the following diagnostic data Log data Log book data Press the MODE button to access the next diagnostic block Press the keys to access the diagnostic...

Page 96: ...ly possible when the press speed is re duced accordingly If for example the brake ramp is launched too late the PSS 4000 stops the press Determining of a safe position and a safe speed of the upper to...

Page 97: ...cation sequence Please note The PSENvip switches to a RUN state if the user program fails to react to the communic ation request via the PSENvip once a timeout of 200 ms has elapsed As a result tools...

Page 98: ...press is at top dead centre TDC each press stroke must be acknowledged before it is initiated Only after this acknowledgement are the OSSDs switched on enabling rapid traverse for the press Program ex...

Page 99: ...n between PSENvip and PSS4000 CAL RisingFlagE0 clk bStartToolChangeE0 q bToolchangeFlag LD bToolchangeFlag S bStartCom Waiting for the communication start LDN bStartCom ORN bStartToolChangeE0 JMPC RES...

Page 100: ...ENDDATATRANSFER TOOL01 LD TRUE STN bAcknowledgeToolTypeA1 ST bAcknowledgeToolTypeA2 LD UINT 1 ST uiToolTypePSENvip JMP ENDDATATRANSFER TOOL02 LD TRUE ST bAcknowledgeToolTypeA1 STN bAcknowledgeToolTyp...

Page 101: ...ating Manual PSENvip RL D P Set 1001641 EN 09 101 LD bComEnd JMPC END RESTORE LD FALSE ST bAcknowledgeToolChangeA0 ST bAcknowledgeToolTypeA1 ST bAcknowledgeToolTypeA2 LD TRUE R bStartCom R bToolValid...

Page 102: ...measuring field Sheet thickness 2 mm Required penetration depth From side 1 6 mm From top or bottom 1 6 mm Transmitter s electrical data Number of inputs 2 Supply voltage 24 VDC Tolerance range 20 V...

Page 103: ...Mute in accordance with EN 61496 1 type 4 Signal level at 0 0 VDC 3 V 2 V in accordance with EN 61496 Signal level at 1 UB 1 VDC 11 V 30 V in accordance with EN 61496 Residual current at 0 signal Max...

Page 104: ...Transmitter 115 5 mm x 112 mm x 168 mm Receiver 115 5 mm x 112 mm x 228 mm Weight Transmitter 1700 g Receiver 2900 g The standards valid on 2010 03 apply Safety characteristic data Unit Operating mod...

Page 105: ...for transmitter re ceiver 583 202 PSENvip AT mag Adjustment templates with magnets 583 203 PSENvip AT mech Adjustment templates for bracket mounting 583 204 PSENvip MB Set of adapter plates for trans...

Page 106: ...g 8 pin screened 5 m for re ceiver 630 314 PSEN op cable axial M12 8 p screening 10 m Straight plug 8 pin screened 10 m for receiver 630 315 PSEN op cable axial M12 8 p screening 30 m Straight plug 8...

Page 107: ...otes 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...

Page 108: ...tching 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 th...

Page 109: ...Attachment Operating Manual PSENvip RL D P Set 1001641 EN 09 109 12 2 EC declaration of conformity...

Page 110: ...XXXX en 0X 2021 01 Printed in Germany Pilz GmbH Co KG 2021 Support Technical support is available from Pilz round the clock Pilz develops environmentally friendly products using ecological materials a...

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