Operating Manual PSENvip RL D P Set Operating Manual PSENvip RL D P Set PSENvip RL D P Set Safe camera systems Operating Manual — No.
Preface This document is a translation of the original document. All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made for internal purposes. Suggestions and comments for improving this documentation will be gratefully received. 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 Secure Digital.
Contents Contents Contents Chapter 1 Chapter 2 Chapter 3 Page Introduction 1.1 Validity of the documentation 1.2 Overview of documentation 1.3 Definition of symbols 1-2 1-3 1-5 Overview 2.1 Scope of supply 2-3 Safety 3.1 3.1.1 3.1.2 3.1.2.1 3-1 3-2 3-2 3-2 3.1.2.2 3.1.2.3 3.1.2.4 3.1.3 3.1.4 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.
Contents 4.4.3.3 4.4.3.4 4.4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.7 4.7.1 4.7.2 4.7.3 4.7.4 Chapter 5 Chapter 6 2 4-16 4-17 4-20 4-24 4-24 4-25 4-26 4-27 4-28 4-28 4-28 4-28 4-30 4-31 4-34 4-37 4-37 Installation 5.1 General requirements 5.2 Install transmitter and receiver 5.3 Dimensions 5.3.1 Transmitter 5.3.2 Receiver 5.3.3 Fastening kit for the transmitter 5.3.4 Fastening kit for the receiver 5.3.5 Bracket for transmitter and receiver 5-1 5-2 5-4 5-4 5-5 5-5 5-6 5-7 Wiring 6.1 6.
Contents 7.2.1.2 7.2.1.3 7.2.1.4 7.2.1.5 7.2.1.6 7.2.2 7.3 7.3.1 7.3.2 7.3.3 7.4 7.5 7.5.1 7.5.1.1 7.5.1.2 7.5.1.3 7.5.1.4 7.5.1.5 7.5.
Contents Chapter 11 Chapter 12 4 Technical details 11.1 Technical details 11.2 Order reference 11-1 11-3 Attachment 12.1 Check list 12.2 EC declaration of conformity 12-1 12-4 Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
1 Introduction 1000 Einführung_PSENvip 1Introduction This operating manual contains information about the intended operation of the PSENvip. The PSENvip is a camera-based protection system for press brakes. This operating manual is aimed at manufacturers, company operators and personnel involved in designing, maintaining and operating press brakes, which are to be safeguarded using the PSENvip. This operating manual is not an instruction manual for the press brake that is safeguarded using the PSENvip.
1 Introduction 1.1 Validity of the documentation 1.1 Gltigkeit Validity 1100 Einf 1of theder documentation Dokumentation This documentation is valid for the product PSENvip RL D P Set. It is valid until new documentation is published. Einfuehrung_Doku_ab_Version_2.0_2012 This documentation is valid for the PSENvip from Version 2.2/year of construction 2013. 1-2 Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.
1 Introduction 1.2 Overview of documentation 1.2 Overview 1200 Einführung_Übersicht 1of documentation 1 Introduction The introduction is designed to familiarise you with the contents, structure and specific order of this manual. 2 Overview This chapter provides information on the PSENvip's most important features. 3 Safety This chapter must be read as it contains important information on safety and intended use.
1 Introduction 1.2 Overview of documentation 10 System Connections This chapter describes how the PSENvip is connected to the press brake's programmable safety system. 11 Technical Details 12 Appendix 1-4 Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
1 Introduction 1.3 Definition of symbols 1.3 Definition 1300 Einfhrung 1of Zeichen symbols Information that is particularly important is identified as follows: DANGER! This warning must be heeded! It warns of a hazardous situation that poses an immediate threat of serious injury and death and indicates preventive measures that can be taken.
1 1-6 Introduction Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
2 Overview 2000 Overview Uebersicht_Allgemein 2- The PSENvip is a camera-based protection and measuring system (electrosensitive protective equipment) for press brakes. It consists of a transmitter and receiver. The PSENvip monitors the detection zone between the transmitter and receiver below the moving upper tool.
2 Overview Tool detection Automatic detection of tool contour during tool change Assignment of tool to a tool class Uebersicht_Gesamtsystem The whole system consists of: Press brake Numerical controller (CNC) Programmable safety system PSENvip (transmitter and receiver) CNC Safety control system Upper die Transmitter Lower tool Receiver Upper tool Fig. 2-1: 2-2 Whole system Pilz GmbH & Co.
2 Overview 2.1 Scope of supply 2.1 Scope 2100 Grundlagen 2of supply PSENvip RL D P Set: complete set Order reference Description PSENvip RL D P PSENvip receiver, left, with display and dynamic muting PSENvip T PSENvip transmitter PSENvip AT mag Adjustment templates with magnets PSENvip AP Set of adjustment plates for transmitter/receiver PSENvip TP Test piece in accordance with EN 12622, Annex H DVD with operating manuals Pilz GmbH & Co.
2 2-4 Overview Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
3 Safety 3.1 Intended use Safety 3.1 3000 Intended 3100 Sicherheit_Bestimm_Allg 3use The PSENvip is exclusively designed for stationary use on press brakes. As electrosensitive protective equipment (ESPE), the PSENvip meets the requirements of a type 4 ESPE in accordance with EN 61496-1. The PSENvip safeguards the danger zone below the moving upper tool. Danger zones outside of the protected field are not protected.
3 Safety 3.1 Intended use 3.1.1 Approvals Sicherheit_Zulassungen 3Approvals 4 4 4 3.1.2 Safety during operation Safety during operation Sicherheit_Betrieb_Allg 3- Intended use also includes awareness of the hazards that arise during operation, against which the PSENvip does not provide protection. 3.1.2.
3 Safety 3.1 Intended use 3.1.2.3 Hazards arising from incorrect handling of the workpiece Hazards arising from incorrect handling of the workpiece Sicherheit_Betrieb_Handhabung_Werkstueck_falsch 3- The PSENvip does not protect against hazards arising from incorrect handling of the workpiece.
3 Safety 3.1 Intended use Sicherheit_Betrieb_Handhabung_Werkstueck_richtig 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. 3-1: 3-4 Handling flat workpieces Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
3 Safety 3.1 Intended use Correct handling 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 operation, fingers or hands can become crushed or trapped between the workpiece and upper tool. Fig. 3-2: Handling box bending Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
3 Safety 3.1 Intended use 3.1.3 Categories / SIL Categories / SIL Sicherheit_Kategorien_P_Variante 3- The PSENvip may only be used with an automation system PSS 4000 from Pilz with SIL 3 of EN 61508 and PL e of EN ISO 13849-1. Please note: To achieve the corresponding category or SIL, the whole system including all safety-related components (parts, devices, user program etc.) must be included in the assessment.
3 Safety 3.1 Intended use The following safety guideline applies for press brakes with tools in this tool class. WARNING! Crushing and trapping of fingers or hands! There may be additional hazard areas in zones that are not monitored by the PSENvip. In these zones there is an increased risk of crushing and trapping of fingers or hands.
3 Safety 3.1 Intended use Please also note the following guidelines in danger zones in areas that cannot be detected and monitored by the safeguard. Example: Upper tool with a danger zone outside the zone monitored by the PSENvip Fig. 3-3: Danger zone in unmonitored zone Example: In unmonitored zones, the use of tools which are not fully detected by the protected field on the PSENvip (e.g.
3 Safety 3.2 Standards Sicherheit_Normen 33200 Standards 3.2 To use the PSENvip correctly you will need to have a good knowledge of the relevant standards and directives.
3 Safety 3.3 Safety guidelines 3.3 Safety 3300 Sicherheit_Sicherheitsrichtlinien_Allgemein 3guidelines Failure to keep to these guidelines will render all warranty and liability claims invalid: All health and safety / accident prevention regulations for the particular area of application must be observed. Before using the unit it is necessary to perform a safety assessment in accordance with the Machinery Directive 2006/42/EC.
3 Safety 3.3 Safety guidelines 3.3.3 Warranty and liability Warranty Sich 3Gewhrleistung and liability All claims to warranty and liability will be rendered invalid if: The product was used contrary to the purpose for which it is intended Damage can be attributed to not having followed the guidelines in the manual Operating personnel are not suitably qualified Any type of modification has been made (e.g. exchanging components on the PCB boards, soldering work etc.). 3.3.
3 3-12 Safety Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
4 Function description 4.1 Overview 4.1 4000 Function Funktion_Ueberblick_P_Variante 44100 Overview description The PSENvip is a camera-based protection system for press brakes. It consists of a transmitter and receiver, which are fixed to the moving part of the press brake, the upper die. The detection zone between the transmitter and receiver monitors the immediate danger zone below the moving upper tool. The detection zone moves with the upper die, providing mobile safeguarding of the danger zone.
4 Function description 4.1 Overview Other safety devices (safety valves, prefill valve, contactor for E- STOP) The following overview shows the fundamentals of the whole system. The signals from the PSENvip transmitter and receiver are explained in the sections below.
4 Function description 4.1 Overview INFORMATION Some inputs and outputs on the receiver are also used for communication with the safety system (see section entitled "Communication with the safety system"). If communication is not required, protected field mode can also be controlled directly via the CNC controller. Funktion_PSS_4000 The motion sequence of the press is monitored by the automation system PSS 4000.
4 Function description 4.1 Overview 1 4 3 2 Fig. 4-3: Definitions Key: 1: Light beam bundle 2: Illuminated target area 3: Protected field 4: Detection zone Funktion_Schutzfeld_allgemein The shape and size of the protected field depend on the bending function and the machine-dependent overrun. A reduced protected field is possible for box bending and/or back gauge mode (for the size of the protected field please see "Protected field" section and the chapter entitled "Technical Details").
4 Function description 4.2 Protected field 4.2 Protected 4200 Funktion_Schutzfeld 4field The protected field consists of several segments. The front and rear segments (viewed from the operator's side) can be deactivated.
4 Function description 4.2 Protected field INFORMATION Please note that the central segments are 1 mm behind the bending line. With box bending you must ensure that the side panels of the box do not encroach into this area. Funktion_Schutzfeld_Hinweise The two following sections explain the basic mode of action of the protected field during a press stroke (interrupted and uninterrupted).
4 Function description 4.2 Protected field 3. The advance measuring field is used to hold the protected field stationary at the pinch point on the workpiece. The segment division is optimised for the dynamic muting process. 4. The respective upper segments are deactivated before the upper tool enters the protected field. NOTICE The control system may only override the safety function from a remaining gap of 6 mm.
4 Function description 4.2 Protected field The signal statuses of the outputs Mute1/Mute2 and OSSD1/OSSD2 when interrupting the protected field by side intervention or interruption of the advance measuring field before reaching the plate are described in section entitled "Standard interrupted press stroke". 4.2.
4 Function description 4.2 Protected field Side intervention with full protected field or reduced protected field during the dynamic muting 1 Object interrupts the protected field to the side: OSSD1/OSSD2= 1 -> 0 Mute1/Mute2 = 1 Safety system initiates the stopping of the press stroke 2 Upper tool continues moving for the overrun distance. Protected field interrupted Object is removed Protected field cleared. Press stroke can be resumed. Pilz GmbH & Co.
4 Function description 4.3 Overrun Funktion_Nachlaufweg_Allgemein 44300 Overrun 4.3 The max. overrun is a press brake variable that will depend on the machine type. Once the closing movement has stopped, the max. overrun must not be exceeded. The overrun is entered during configuration via the keypad on the PSENvip receiver. INFORMATION Please refer to chapter 11, "Technical Details", for more information about the input area of the overrun.
4 Function description 4.4 Description of the units 4.4.1 Overview 4.4 Description 4400 4of the units Funktion_Geraete_Sender_Empfaenger 4Overview The transmitter and receiver form one unit. The receiver contains all the inputs and outputs required for communication with the CNC controller, programmable safety system, transmitter and press brake. The transmitter merely contains the inputs for controlling the light source. Funktion_Geraete_Sender_Empfaenger_RL_D 1 2 4 3 Fig.
4 Function description 4.4 Description of the units 4.4.3 Receiver Funktion_Geraete_Empfaenger_Stecker 4Receiver The top of the receiver has two 8-pin M12 connectors. 4.4.3.1 Funktion_Geraete_Empfaenger_Eingaenge_1_P 4Inputs Inputs System-Init Input whose signal comes from the safety system PSS 4000.
4 Function description 4.4 Description of the units Acknowledgement Input to acknowledge that a press stroke is to be performed with a reduced protected field (front and/or rear segments blanked). The protected field mode selected is shown on the receiver's display. Acknowledgement = 0/1 pulse edge via pushbutton: Run selected protected field mode Protected field mode 1/protected field mode 2 Two safe inputs for setting the protected field mode. The CNC or safety system provides the signal.
4 Function description 4.4 Description of the units 4.4.3.
4 Function description 4.4 Description of the units The load must not switch on because of the test. Testing for shorts A test is regularly carried out to check for shorts between the outputs. U 1 0 t t1 t2 t1 t3 Fig. 4-8: t1 t2 t1 Test pulses Key: t1: Pulse length of on test (40 μs) t2: Repetition length of on test (100 μs ... 3 ms) t3: Cycle time of on test (30 μs ...
4 Function description 4.4 Description of the units 4.4.3.3 LED LED Funktion_Geraete_Empfaenger_LED_OSSD 4- OSSD The OSSD LED on the receiver indicates the status of the protected field. Green: The protected field is clear Red: Protected field is interrupted Funktion_Geraete_Empfaenger_LED_RL_D_Abbildung 1 Fig. 4-9: LED on receiver 1: OSSD LED 4-16 Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.
4 Function description 4.4 Description of the units 4.4.3.4 Key display and function Key display and function Funktion_Display_Allgemein 4- The PSENvip receiver has an integrated display. Data can be entered via a membrane keypad. Funktion_Display_Pilz 1 2 3 PSENvip MODE ESC 4 5 Fig.
4 Function description 4.4 Description of the units Key Description Call up tool change operating mode directly Confirm entry or menu option selection Funktion_Display_Abbildung Display À Á SYSTEM OK OSSD ON Â NORMAL OPERATION Ã Fig. 4-11: Information on the display The display is divided into 4 segments: 1: System status 2: Status of the OSSD 3: Input and display field 4: Operating status Funktion_Display_Systemzustand 4-18 Pilz GmbH & Co.
4 Function description 4.4 Description of the units System status Status Description SYSTEM OK The PSENvip is performing the specified operating mode without error, see table: "Operating status" TEST The PSENvip is performing calibration and internal tests. STANDBY The PSENvip is deactivated when the press is in setup mode. ERROR An error has occurred (HOLD, STOP, FATAL).
4 Function description 4.4 Description of the units The input and display field is used to Display the active protected field mode See chapter 8, "Operation" Enter the overrun See chapter 7, "Commissioning" Menu Selection Display the adjustment image during initial commissioning See chapter 7, "Commissioning" Display the adjustment image during a tool change See chapter 7, "Commissioning" Display of error messages and system data See Chapter 9, "Diagnostics and Troubleshooting" 4.4.
4 Function description 4.4 Description of the units PLC PSENvip Activate Acknowledge PSENvip -> PLC Tool class PSENvip -> PLC Bit 1 Tool class PSENvip -> PLC Bit 2 PLC Ready Tool class PLC -> PSENvip Bit 1 Tool class PLC -> PSENvip Bit 2 Fig.
4 Function description 4.4 Description of the units Communication sequence: 1 Activate 0 1 PLC Ready 0 1 Tool class PSENvip -> PLC Bit 1 0 1 Tool class PSENvip -> PLC Bit 2 0 1 Acknowledge PSENvip -> PLC 0 1 Tool class PLC -> PSENvip Bit 1 0 1 Tool class PLC -> PSENvip Bit 2 0 1 2 max. 200 ms 3 4 5 max. 600 ms max. 200 ms 6 7 max. 200 ms 1 – The PSENvip starts communication.
4 Function description 4.4 Description of the units Tool class 1 2 3 Tool class PLC -> PSENvip Bit 1 0 1 1 Tool class PLC -> PSENvip Bit 2 1 0 1 6 The PSENvip ends communication. All outputs are set = 0: – Activate = 0 – Acknowledge PSENvip -> PLC = 0 – Tool class PSENvip -> PLC Bit 1 = 0 – Tool class PSENvip -> PLC Bit 2 = 0 7 – The safety system ends communication.
4 Function description 4.5 Protected field modes 4.5 Protected 4500 Funktion_Schutzfeldmodus 4field modes Four protected field modes are available for adapting to different bending functions: Full protected field: Standard press stroke Reduced protected field: – Box bending press stroke – Back gauge press stroke – Box bending with back gauge press stroke Funktion_Schutzfeldmodus_Werkzeugklasse Use of the protected field modes depends on the tool class.
4 Function description 4.5 Protected field modes 4.5.2 Box bending protected field mode Box bending protected field mode Funktion_Schutzfeldmodus_Kastenbiegen 4- With box bending protected field mode, the front segments of the protected field are blanked. This protected field mode is used for workpieces that need to be bent several times, e.g. a box. Interruption of the front segments is to be expected and does not cause the press stroke to stop.
4 Function description 4.5 Protected field modes 4.5.3 Back gauge protected field mode Back gauge protected field mode Funktion_Schutzfeldmodus_Anschlag 4- With back gauge protected field mode, the rear segments of the protected field are blanked. This protected field mode is used when the rear back gauge extends into the vicinity of the bending line. Interruption of the rear segments is to be expected and does not cause the press stroke to stop.
4 Function description 4.5 Protected field modes 4.5.4 Box bending with back gauge protected field mode Box bending with back gauge protected field mode Funktion_Schutzfeldmodus_Kastembiegen_mit_Anschlag 4- With box bending with back gauge protected field mode, both the rear and front segments of the protected fields are blanked. This protected field mode is applied for workpieces that need to be bended several times, e.g.
4 Function description 4.6 Operating modes during commissioning 4.6 Operating 4600 Funktion_Betriebsarten_Inbetriebnahme_Allg 4modes during commissioning The PSENvip has the following options for commissioning: Press brake setup mode Adjustment during initial commissioning Adjustment during tool change 4.6.1 Press brake setup mode Press brake setup mode Funktion_Betriebsarten_Inbetriebnahme_Einrichten 4- Setup mode must be activated when work is to be carried out on the press brake.
4 Function description 4.6 Operating modes during commissioning INFORMATION Generally you should not have to mechanically realign the transmitter and receiver during a tool change. In this operating mode The protected field is inactive. The OSSDs are switched off. There is no protection via the PSENvip. INFORMATION Details of the adjustments made during a tool change are described in Chapter 7, "Commissioning", section entitled "Adjustment during tool change". Pilz GmbH & Co.
4 Function description 4.7 System cycle 4.7 System 4700 Funktion_Systemablauf_Muting 4cycle This section illustrates the interdependencies of the parameters on the press brake, PSENvip and safety system during a press stroke. The following parameters are illustrated: Status: Describes the cycle status. The upward movement of the press is assumed as a safe movement.
4 Function description 4.7 System cycle v > 0 mm/s upward movement Mute 1/2: Segment switches outputs Mute 1 and Mute 2 4.7.
4 Function description 4.
4 Function description 4.
4 Function description 4.7 System cycle 4.7.
4 Function description 4.
4 Function description 4.
4 Function description 4.7 System cycle 4.7.3 System cycle for back gauge press stroke System cycle for back gauge press stroke Funktion_Systemablauf_Pressenhub_mit_Anschlag 4- Inputs on the PSENvip receiver: Protected field mode 1 = 1 Protected field mode 2 = 0 Acknowledgement of reduced protected field = Press pushbutton and then release The system cycle is the same as for box bending. Please note that with back gauge protected field mode, the rear segments of the protected field are blanked.
4 4-38 Function description Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
5 Installation 5.1 General requirements 5.1 5000 Installation General 5100 Montage_Allgemeine_Anforderungen 5requirements Please note for installation: The PSENvip may only be installed by qualified personnel. The environmental data for the PSENvip must be taken into account. Details are available in the chapter entitled “Technical Details”. The transmitter and receiver should be installed with the respective front lenses aligned in parallel to each other.
5 Installation 5.2 Install transmitter and receiver Fastening kits for the transmitter and receiver are available as acces- 5.2 Install 5200 Montage_Sender_Empfaenger_Zusatz 5transmitter and receiver sories (for order no. see Chapter 11, "Technical Details"). The fastening kit consists of an adapter plate and adjustment plate with a slot nut. The bracket on the upper die must have a corresponding groove in which to insert the slot nut (see Fig. 5-1).
5 Installation 5.2 Install transmitter and receiver Nut Auxiliary adjustment plate Adjustment plate Flat washer Fig. 5-2: 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. Slide the nut slot on the adjustment plate into the groove on the bracket attached to the upper die. Pilz GmbH & Co.
5 Installation 5.3 Dimensions 5.3.1 Transmitter 55300 Dimensions 5.3 Montage_Abmessungen_Sender 5Transmitter 80 52 142.5 115.5 55 112 52 168 Fig. 5-3: 5-4 Transmitter dimensions, dimensions in mm Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
5 Installation 5.3 Dimensions 5.3.2 Receiver Montage_Abmessungen_Empfaenger 5Receiver 55 52 115.5 MODE 142.5 137 ESC 112 112 52 228 Fig. 5-4: 5.3.3 Receiver dimensions, dimensions in mm Fastening kit for the transmitter Fastening kit for the transmitter Montage_Befestigungssatz_Sender 5- 97.6 9 20 46 13 72 (162) 8 36.5 6 Fig. 5-5: Dimensions of the fastening kit for the transmitter, dimensions in mm Pilz GmbH & Co.
5 Installation 5.3 Dimensions 5.3.4 Fastening kit for the receiver Fastening kit for the receiver Montage_Befestigungssatz_Empfaenger 5- 156 9 20 76 13 72 8 (162) 36.5 6 Fig. 5-6: 5-6 Dimensions of the fastening kit for the receiver, dimensions in mm Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
5 Installation 5.3 Dimensions 5.3.5 Bracket for transmitter and receiver Bracket for transmitter and receiver Montage_Haltearm 5- Brackets for the transmitter 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.
5 5-8 Installation Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
6 Wiring 6.1 Notes on wiring 6.1 6000 on wiring Wiring Notes 6100 Verdrahtung_Hinweise_Einf 6- Please observe the following when wiring: Sicherheit_Achtung_unbeabsichtigter_Start CAUTION! Unintended machine start up! Voltage should be removed from the whole machine and PSENvip during wiring. Verdrahtung_Hinweise_Netzteil Power supply When selecting the power supply, please refer to the requirements stated under “Technical Details”.
6 Wiring 6.1 Notes on wiring Verdrahtung_Hinweise_EMV EMC Avoid interference (e.g. from motors, power lines) by laying cables in a way that is EMC-compliant. Verdrahtung_Hinweise_Eingaenge_des_Empfaengers Inputs on the receiver The inputs Protected field mode 1/Protected field mode 2 are safety-related. – The CNC or safety system provides the signal. It is only absolutely necessary to connect the inputs to a safety system if communication is needed for tool detection.
6 Wiring 6.1 Notes on wiring Function test When the wiring is complete the protective equipment will need to undergo a function test. INFORMATION To perform the function test, follow the procedure described in Chapter 7, "Commissioning", section entitled "Function test of the safety device". Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
6 Wiring 6.2 Connections 6.2.1 Receiver 66200 Connections 6.2 Funktion_Geraete_Empfaenger_Stecker 6Receiver The top of the receiver has two 8-pin M12 connectors. Verdrahtung_Anschluss_Empfaenger X2 X1 Fig. 6-2: M12 connector on the receiver The receiver is connected via two 8-pin cables. 8 5 6 4 7 3 1 Fig. 6-3: 2 Receiver's pin assignment The cable ends of the Pilz ready-made cable are colour-coded. Please refer to the tables below for the coding details.
6 Wiring 6.2 Connections PIn No. Designation Description Colour 8 TRM_ON Output, signal to switch the transmitter's light source on and off Red Shield Cable shield *) Used in communication between PSENvip and safety system. Pin assignment of M12 connector X2 on the receiver PIn No.
6 Wiring 6.2 Connections 6.2.2 Transmitter Funktion_Geraete_Sender_Stecker 6Transmitter The top of the transmitter has a 4-pin M12 connector. Verdrahtung_Anschluss_Sender Fig. 6-5: 4 3 1 2 Pin assignment of transmitter The transmitter is connected via a 4-core cable. The cable ends of the Pilz ready-made cable are colour-coded. Please refer to the table below for the coding details. Pin assignment of M12 connector X3 on the transmitter Pin no.
6 Wiring 6.2 Connections 6.2.
6 6-8 Wiring Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
7 Commissioning 7.1 Commissioning guidelines 7.1 7000 Commissioning 7100 Inbetriebnahme_Hinweise 7guidelines When commissioning for the first time, please note the following: CAUTION! Have the protective equipment tested and approved before commissioning for the first time! Any machine safeguarded by the PSENvip must be tested and approved by qualified personnel before it is placed on the market. A test report must be generated and archived during initial commissioning.
7 Commissioning 7.2 Initial commissioning 7.2.1 Align transmitter and receiver 7.2 commissioning Initial 7200 7- Align transmitter and receiver Inbetriebnahme_Erstinbetriebnahme_Ausrichten 7- Please note the following when aligning the transmitter and receiver: Once installed, the transmitter and receiver must be exactly aligned to each other and to the tip of the upper tool. The vertical and horizontal alignment is performed using adjustment templates and is displayed on the receiver.
7 Commissioning 7.2 Initial commissioning Magnet Alignment grid Magnet Back gauge with notch Cross-hair Fig. 7-1: Adjustment templates (viewed from the magnet side) You can select either adjustment template to attach to the transmitter or receiver side. 7.2.1.3 Adjustment directions of transmitter and receiver Adjustment directions of transmitter and receiver Inbetriebnahme_Erstinbetriebnahme_Verstellrichtungen 7- The PSENvip transmitter and receiver can be adjusted in three directions. Fig.
7 Commissioning 7.2 Initial commissioning 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 adjustment plate should only be hand-tightened.
7 Commissioning 7.2 Initial commissioning 7.2.1.4 Align transmitter Align transmitter Inbetriebnahme_Erstinbetriebnahme_Sender_ausrichten 7- 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 the back stop Fig.
7 Commissioning 7.2 Initial commissioning INFORMATION Carefully align the illuminated target area to the receiver. This will make the adjustments in the following work stages easier. 7.2.1.5 Tool shapes Tool shapes Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Werkzeuge_1 7- The correct adjustment of the upper tool also depends on the tool shape. The tools are divided into tool classes in the Tool Change menu.
7 Commissioning 7.2 Initial commissioning Examples of the correct adjustment of various tool types: Tool class 1: Pointed tools For these tools we recommend alignment to the left-hand bending line. 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.
7 Commissioning 7.2 Initial commissioning 7.2.1.6 Align receiver Align receiver Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_1 7- 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 the back stop Fig.
7 Commissioning 7.2 Initial commissioning Fig. 7-7: Adjustment image Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Justagebild_2 The receiver is correctly aligned with the transmitter when: The cross-hairs of both adjustment templates overlap The quadrants form a full circle and The centre point of the upper tool is on the bending line. The correct adjustment image on the display will look like the image shown in the illustration below.
7 Commissioning 7.2 Initial commissioning Adjust the direction of the receiver as described in the section entitled "Adjustment directions of transmitter and receiver". Remove the adjustment templates. The correct adjustment image on the display will look like the image shown in the illustration below: The bending line should be on the vertical guide.
7 Commissioning 7.2 Initial commissioning Out of range Fig. 7-10: Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_6 Checking the adjustment image with superimposed guide frame You can switch to the adjustment image without guide frame by pressing again. Exit the adjustment using the key. The transmitter and receiver are now mechanically aligned.
7 Commissioning 7.2 Initial commissioning +0,1 Ø3 Ø 3,4 65 45 1 2 10 Ø 3,4 +0,1 Ø3 3 Fig. 7-11: 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.
7 Commissioning 7.3 Adjustment during tool change 7.3 Adjustment 7300 Inbetriebnahme_Justage_bei_Werkzeugwechsel 7during tool change The adjustment line is automatically tracked to the tip of the tool. The tracking of the adjustment line is shown on the display. INFORMATION Generally you should not have to mechanically realign the transmitter and receiver during a tool change.
7 Commissioning 7.3 Adjustment during tool change Assignment to a tool class depends on Compliance with the requirement from EN 12622, whereby the protected field must safeguard areas lying 15 mm before the front bending line. Full or partial detection of the upper tool via the protected field. 3 2 1 H3 H2 H1 B1 V1 V2 V3 <15 mm >15 mm Fig. 7-13: Classification of tools into tool classes Tool class 1 The contour of these tools is fully detected by the PSENvip.
7 Commissioning 7.3 Adjustment during tool change Tool class 2 The contour of these tools 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 bending line. These tools are not safeguarded in compliance with the standards. Example: m 5m >2 <15 mm H Fig.
7 Commissioning 7.3 Adjustment during tool change The tools are displayed as follows on the PSENvip display: SYSTEM OK OSSD OFF SYSTEM OK OSSD OFF Tool class 1 Tool class 2 TOOL CHANGE TOOL CHANGE SYSTEM OK OSSD OFF Tool class 3 TOOL CHANGE Fig. 7-17: 7.3.
7 Commissioning 7.3 Adjustment during tool change Option 2: Press the ( ) key to start the Tool Change. SYSTEM OK OSSD OFF À Á Tool class 1 TOOL CHANGE Fig.
7 Commissioning 7.3 Adjustment during tool change The adjustment has been carried out correctly when none of the symbols appear: Finish the adjustment using the key. The PSENvip prompts you to confirm that you accept the new tool data: Within 3 seconds, press the key . You can exit the menu at any time without confirming by pressing . In this case, the previous tool data will be retained. 7-18 Pilz GmbH & Co.
7 Commissioning 7.4 Enter overrun 7.4 overrun Enter 7400 Inbetriebnahme_Nachlaufweg_eingeben_P_Variante_1 7- The max. overrun is a press brake variable that will depend on the machine type. Once the closing movement has stopped, the max. overrun must not be exceeded. The overrun is entered during configuration via the keypad on the PSENvip receiver. NOTICE The overrun may only be entered by the press brake manufacturer or suitably authorised persons.
7 Commissioning 7.4 Enter overrun INFORMATION The PSENvip will need to be restarted if the entry - Was invalid - Took longer than 10 s. SYSTEM OK OSSD OFF Overrun: 10 mm SETUP Fig. 7-19: Enter overrun Using the keys , select the overrun that is specified on the type label of the press brake. The permitted value range is 2 ... 14 mm, in 2 mm steps. Finish the entry using the key. The PSENvip prompts you to confirm that you accept the new overrun: Within 3 seconds, press the key .
7 Commissioning 7.5 Check protective equipment 7.5 Check 7500 Inbetriebnahme_Schutzeinrichtung_pruefen 7protective equipment 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.
7 Commissioning 7.5 Check protective equipment 7.5.1.1 Test during initial commissioning Test during initial commissioning Inbetriebnahme_Schutzeinrichtung_pruefen_Funjktionspruefung_Erstinbetriebnahme 7- 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 configured with the upper tool (maximum weight). The test should be performed at maximum closing speed.
7 Commissioning 7.5 Check protective equipment INFORMATION Trained operators must be used for the daily check. Depending on the level of use, safety devices and safety measures 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 book or in the machine file. Any serious non-conformances must be rectified before the press brake is returned to operation.
7 Commissioning 7.5 Check protective equipment Fig. 7-21: Function test using test rod The test rod must 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.
7 Commissioning 7.5 Check protective equipment The test piece interrupts the advance measuring field. The press stroke is stopped. The upper tool should not touch the test piece. Once the press stroke has stopped, push the 15 mm high section of the test piece beneath the upper tool. The upper tool should not touch the test 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.
7 7-26 Commissioning Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
8 Operation 8.1 Safety guidelines Operation 8.1 Betrieb_Sicherheitshinweise_Einl 8000 guidelines Safety 8100 8- Please note the following safety safety guidelines during operation: Betrieb_Sicherheitshinweise_Pruefungen Prior to operation: Carry out the daily checks on the protective equipment prior to operation (see Chapter 7, "Commissioning", section entitled “Function test of the safety device"). Pilz GmbH & Co.
8 Operation 8.2 Operating notes 8.2.1 Switch on PSENvip 8.2 Operating 8200 8notes Switch on PSENvip Betrieb_PSENvip_einschalten 8- The PSENvip is ready for operation once supply voltage has been applied and 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.
8 Operation 8.2 Operating notes Operate the foot switch to initiate the press stroke. Use the test piece to carry out the function test (see Chapter 7, "Func- tion test of the safety device"). 8.2.
8 Operation 8.2 Operating notes Betrieb_Schutzfeldmodi_quittieren_Ausfuehrung An acknowledgement button must be operated to initiate a press stroke with a reduced protected field. When initiating a press stroke while the protected field is reduced (box bending with or without back gauge), please note the following: Until the acknowledgement button is pressed, the display of the protected field to be blanked changes. Insert the workpiece. Press the acknowledgement button and release it again.
8 Operation 8.2 Operating notes 8.2.7 Cleaning the front lenses Cleaning the front lenses Betrieb_Reinigung_der_Frontlinsen 8- The front lenses on the transmitter and receiver should be cleaned at regular intervals, using an alcohol glass cleaner. NOTICE Never use aggressive solvents or abrasive cleaning agents! 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.
8 8-6 Operation Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
9 Diagnostics and Troubleshooting 9000 Diagnostics Diagnose_Sicherheitshinweis_Einl 9and Troubleshooting Please note the following safety guidelines when errors occur: Sicherheit_Warnung_Abkantpresse_stilllegen 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 qualified staff. Pilz GmbH & Co.
9 Diagnostics and Troubleshooting 9.1 Error Management 9.1 Management Error 9100 Diagnose_Fehlerbehandlung_Allg 9- The PSENvip continuously carries out self-tests and output tests during operation.
9 Diagnostics and Troubleshooting 9.1 Error Management Remedy Note the error message (see section entitled "Error messages"). Rectify the error. Restart the PSENvip: Switch supply voltage off and then on again. 9.1.3 Fatal errors Fatal errors Diagnose_Fehlerbehandlung_fatale_Fehler 9- 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 condition.
9 Diagnostics and Troubleshooting 9.2 Error messages 9.2 messages Error 9200 Diagnose_Fehlermeldungen 9- Error messages appear on the display as soon as an error occurs. ERROR OSSD OFF Error in the optical system NORMAL OPERATION Fig. 9-1: Error messages on the display Error message on the display Error message Remedy Not relevant to the user Not relevant to the user Press ESC to continue 1.) Acknowledge the error by pressing ESC Internal error STOP 1.
9 Diagnostics and Troubleshooting 9.2 Error messages Error message on the display Error message Remedy Error in the optical system 1.) Acknowledge the error by pressing ESC 2.) Restart the PSENvip: Switch supply voltage off and then on again 3.) Clean the front lenses on the transmitter and receiver 4.) If necessary, eliminate the external light source 5.) Mechanically realign the transmitter and receiver (as described under "Initial commissioning") 6.
9 Diagnostics and Troubleshooting 9.3 DIAGNOSTICS menu 9.3 DIAGNOSTICS 9300 Diagnose_Menue_DIAGNOSTICS 9menu The DIAGNOSTICS menu provides Pilz service staff with further information to help them identify faults. Press the key. Using the keys , select the DIAGNOSTICS menu. Press the key to open the DIAGNOSTICS menu. Diagnose_Menue_DIAGNOSTICS_RL_D_P SYSTEM OK OSSD OFF À System Data: Á Variant: Â 0058 3601 A000 DIAGNOSTICS Fig.
9 Diagnostics and Troubleshooting 9.3 DIAGNOSTICS menu The Error Data diagnostic block contains the following diagnostic data: Error stack with the last 10 entries The Log Data diagnostic block contains the following diagnostic data: Log data: Log book data. Press the button to access the next diagnostic block. Press the keys to access the diagnostic data within a diagnostic block. Exit the DIAGNOSTICS menu using the key. Pilz GmbH & Co.
9 9-8 Diagnostics and Troubleshooting Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
10 System Connections 10.1 Requirements of the user program 10.1 10000 Connections 10 System Requirements 10100 Systemanbindung_PSS4000 10of the user program The automation system PSS 4000 from Pilz is required to run PSENvip.
10 System Connections 10.2 Communication with the safety system 10.
10 System Connections 10.2 Communication with the safety system Tool class 2 The user program confirms tool class 2. The PSENvip switches to a RUN state. The PSENvip switches to a HOLD state if – No communication is established (within 30 s on power-up, otherwise within 200 ms). – The tool class sent by the PSENvip and reflected by the user program do not match. – Errors occur in the communications protocol. – Overall communication takes longer than 600 ms.
10 System Connections 10.
10 System Connections 10.
10 System Connections 10.
10 System Connections 10.2 Communication with the safety system LD bComEnd JMPC END RESTORE: LD FALSE ST bAcknowledgeToolChangeA0 ST bAcknowledgeToolTypeA1 ST bAcknowledgeToolTypeA2 LD TRUE R bStartCom R bToolValid END: END_FUNCTION_BLOCK Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
10 10-8 System Connections Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
11 Technical details 11.1 Technical details 11.
11 Technical details 11.1 Technical details Outputs on the receiver OSSD/Mute in accordance with EN 61496-1, type 4 Signal level at "0" Signal level at "1" Residual current at "0" signal Duration of on and off time during self test Max. cable resistance for detection of shorts between contacts Max. capacitive load Max. inductive load Transmitter synchronisation Max.
11 Technical details 11.2 Order reference 11.2 reference Order 11200 Bestelldaten 11PSENvip RL D P Order reference: PSENvip RL D P Set Designation PSENvip RL D P Set Complete PSENvip set Order no.
11 11-4 Technical details Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
12 Attachment 12.1 Check list 12.1 Attachment 12000 12 Check 12100 Anhang_Checkliste 12list The following check list is intended as a guide to provide support when commissioning and recommissioning the PSENvip and when carrying out the regular inspection as required. Please note that the check list is not intended to replace the plant-specific safety analysis required for commissioning/recommissioning, nor the resulting inspections and actions.
12 Attachment 12.1 Check list No. Action 4 Visual inspection OK Not OK Remarks Make sure that there are no objects in the protected space between the transmitter and receiver. Make sure that there are no transparent materials between the transmitter and receiver (e.g. glass panel).
12 Attachment 12.2 EC declaration of conformity 12.2declaration of conformity EC 12200 Konformitaet_Pilz 12- Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
12 12-4 Attachment Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.
Technical support +49 711 3409-444 support@pilz.com Please refer to our homepage for further details or contact our headquarters. Pilz GmbH & Co. KG Felix-Wankel-Straße 2 73760 Ostfildern, Germany Telephone: +49 711 3409-0 Telefax: +49 711 3409-133 E-Mail: pilz.gmbh@pilz.de Internet: www.pilz.com InduraNET p®, Pilz®, PIT®, PMCprotego®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks of Pilz GmbH & Co.
