Pilz PSENvip R User manual

PSENvip R, PSENvip R LR
PSENvip E
Operating Manual-1003449-EN-06
}Safe camera systems

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
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 Secure Digital

Contents
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1 Introduction ............................................................................................................................6
1.1 Validity of the documentation.................................................................................................... 6
1.2 Retaining the documentation .................................................................................................... 6
1.3 Definition of symbols................................................................................................................. 7
2 Overview .................................................................................................................................8
3 Safety ...................................................................................................................................... 10
3.1 Intended use ............................................................................................................................. 10
3.1.1 Safety during operation............................................................................................................. 12
3.1.1.1 Hazards arising from installation .............................................................................................. 12
3.1.1.2 Hazards arising from a reduced protected field ........................................................................ 12
3.1.1.3 Hazards arising from incorrect handling of the workpiece ........................................................ 12
3.1.1.4 Correct handling of the workpiece ............................................................................................ 12
3.1.2 Tool shapes .............................................................................................................................. 15
3.2 Safety guidelines ...................................................................................................................... 18
3.2.1 Use of qualified personnel ........................................................................................................ 18
3.2.2 EMCD ....................................................................................................................................... 18
3.2.3 Warranty and liability ................................................................................................................ 18
3.2.4 Safety during commissioning, installation and operation.......................................................... 18
3.2.5 Disposal .................................................................................................................................... 19
4 Function description ............................................................................................................. 20
4.1 Overview................................................................................................................................... 20
4.2 Protected field........................................................................................................................... 22
4.2.1 Protected field modes ............................................................................................................... 23
4.2.1.1 Standard protected 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 base version ....................................................................................................... 38
4.8.1 System cycle for standard press stroke.................................................................................... 39
4.8.2 System procedure in box bending press stroke........................................................................ 42
4.8.2.1 Acknowledgement when starting at top dead centre ................................................................ 42
4.8.2.2 Acknowledgement after protected field meets the workpiece................................................... 45
4.8.3 System cycle for back gauge press stroke ............................................................................... 48
4.8.4 System cycle in for box bending with back gauge press stroke ............................................... 48
4.8.5 System cycle for overrun measurement ................................................................................... 49
4.9 System cycle productive version ............................................................................................. 51
4.9.1 System cycle for standard press stroke.................................................................................... 53
4.9.2 System cycle for box bending press stroke .............................................................................. 57
4.9.2.1 Acknowledgement when starting at top dead centre ................................................................ 57

Contents
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4.9.2.2 Acknowledgement after protected field meets the workpiece................................................... 62
4.9.3 System cycle for back gauge press stroke ............................................................................... 68
4.9.4 System cycle for box bending with back gauge press stroke ................................................... 69
4.10 Web interface............................................................................................................................ 70
5 Installation ..............................................................................................................................71
5.1 General requirements ............................................................................................................... 71
5.2 Install transmitter and receiver.................................................................................................. 72
5.3 Dimensions ............................................................................................................................... 74
5.3.1 Transmitter................................................................................................................................ 74
5.3.2 Receiver.................................................................................................................................... 75
5.3.3 Fastening kit for the transmitter ................................................................................................ 75
5.3.4 Fastening kit for the receiver .................................................................................................... 76
6 Wiring ...................................................................................................................................... 77
6.1 Notes on wiring ......................................................................................................................... 77
6.2 Receiver.................................................................................................................................... 78
6.3 Transmitter................................................................................................................................ 79
6.4 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 safeguard ............................................................................................ 98
8 Operation ................................................................................................................................101
8.1 Procedure after power up ......................................................................................................... 101
8.2 Tool change and adjustment after tool change......................................................................... 104
8.3 Set-up mode ............................................................................................................................. 105
9 Diagnostics and Troubleshooting ........................................................................................ 106
9.1 Error Management.................................................................................................................... 106
9.1.1 Transmitter/receiver error ......................................................................................................... 106
9.1.2 Major errors .............................................................................................................................. 107
10 Change, maintenance ............................................................................................................ 108
10.1 Regular checks and maintenance ............................................................................................ 109
10.2 Check after modification ........................................................................................................... 111
10.3 Cleaning the lens ...................................................................................................................... 112

Contents
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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

Introduction
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1 Introduction
This operating manual contains information about the intended operation of the PSENvip.
The PSENvip is a camera-based protection and measuring system for press brakes. It con-
sists of 3 components and is available in 2 versions:
}Base version, consisting of
– Transmitter PSENvip E
– Receiver PSENvipR or PSENvipRLR
– Special module PSSu K F FAU B
}Productive version, consisting of
– Transmitter PSENvip E
– Receiver PSENvipR or PSENvipRLR
– Special module PSSu K F FAU P
The term PSENvip is used to describe both versions in this document. If a description
refers exclusively to one of the two versions, the term base version or productive version
will be used.
In the same way, PSSuKFFAU will be used to describe both versions 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 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. Please refer to the press brake operating manual for this information.
1.1 Validity of the documentation
This documentation is valid for PSENvip E from version 1.0/year of build 2014 and PSEN-
vip R/PSENvip R LR from Hardware version 2 and Firmware version 2.0/year of build 2016.
It is valid until new documentation is published.
1.2 Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.

Introduction
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1.3 Definition of 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.
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 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 on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
PSENvip is a camera-based protection and measuring system (electrosensitive protective
equipment) for press brakes. It consists of a transmitter, receiver and a PSSu module to
evaluate recordings. It monitors the detection zone between the transmitter and receiver
below the moving upper tool. Operation, visualisation and configuration is via a web inter-
face on the 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 the data provided by the receiver
}Evaluation of protected field and fast shutdown of the press if the protected field is viol-
ated
}2 outputs to control the transmitter
}Communication via Ethernet interface with the CNC
}Troubleshooting and diagnostics

Overview
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PSENvip is part of an overall system comprising:
}Press brake
}Numerical controller (CNC) with web interface for visualisation and operation
}PSENvip transmitter and PSENvip receiver
}Control system PSSuniversal PLC from the automation system PSS4000 with special
module PSSuKFFAU
}PAS4000 user program
Monitor
PSSu K F FAU
Control cabinet
Press brake
Web Interface
Control system
PSSuniversal
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 monitors a fixed, configured protected field.
}The productive version monitors a dynamic protected field.
PSENvip automatically detects a tool contour. The adjustment during initial commissioning
or during a tool change is made using the web interface on the CNC.

Safety
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3 Safety
3.1 Intended use
The PSENvip is exclusively designed for stationary use on press brakes. As electrosensit-
ive protective equipment (ESPE), PSENvip meets the requirements of a type 4 ESPE in ac-
cordance with EN 61496-1.
PSENvip safeguards the danger zone below the moving upper tool.
Danger zones outside of the protected field are not protected. Hazards in the area of the
lower tool and above the protected field must be protected by the press manufacturer with
appropriate measures. Please refer to the guidelines given in the "Tool shapes" section in
this chapter.
Base version
}A control system PSSuPLC from the automation system PSS4000 from Pilz must be
used for safety-related evaluation of the PSENvip signals. The control system must have
the FS resource system section. The special module PSSuKFFAUB must be used for
signal evaluation.
}The control system PSSuPLC may mute the protective function of the PSENvip if there is
a slow closing speed v ≤ 10mm/s (creep speed mode).
}The upward movement of the press is assumed as a safe movement.
}The press brake must observe a max. overrun 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 function of the PSENvip from
the muting end point of 4 mm (4 mm point) (muting).
Please note: The protective function of the PSENvip may be muted from a remaining
gap of 6 mm, depending on the requirements of the country in which the PSENvip is
operated and the requirements of the appropriate regulatory body.
or
– Using a configured muting end point
The protected field monitors the danger zone between the upper tool and workpiece
up to a configured remaining gap. A value between 4 mm and 1.6 mm must be con-
figured for the muting end point. The control system PSSuPLC may mute the protect-
ive function of the PSENvip from the configured muting end point (muting).
}The upward movement of the press is assumed as a safe movement.
}The press brake must observe a max. overrun of 14 mm.
}A control system PSSuPLC from the automation system PSS4000 from Pilz must be
used for safety-related evaluation of the PSENvip signals.
The control system must have the FS resource system section.