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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 3
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 4
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 5
11 Technical details ....................................................................................................................113
11.1 Safety characteristic data ......................................................................................................... 115
12 Order reference ......................................................................................................................116
12.1 Device....................................................................................................................................... 116
12.2 Accessories .............................................................................................................................. 116
13 Attachment ............................................................................................................................. 118
13.1 Check list .................................................................................................................................. 118

Introduction
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 6
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 7
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 8
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 9
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
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 10
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.

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 11
}The special module PSSuKFFAUP must be used for signal evaluation. If the muting
end point is to be configurable, the special module PSSuKFFAUP from Hardware ver-
sion 2.0 and Software version 1.1 must be used for signal evaluation.
}In the PSS 4000 user program, safety functions must be implemented to safeguard the
dynamic muting of the PSENvip:
– Monitoring of the pinch point
– Definition of a safe position and safe speed for the upper tool
– Activation of the entire protected field by a signal from the CNC (System-Init = 1), if
the press stops during dynamic muting and the upward movement is then initiated.
}Monitoring of the press ramp is absolutely essential. Two procedures can be selected:
– Brake ramp monitoring by the PAS4000 user program
or
– Brake ramp monitoring by PSEnvip
From Hardware version 2 and Firmware version 2.0 the receiver PSENvip R/PSENvip
R LR is supported by a procedure for braking ramp monitoring. For braking ramp
monitoring by PSENvip, a special module PSSu K F FAU P from Hardware version 3
and Firmware version 2.0. is required.
}Certified blocks are available for the safety functions in the PAS4000 Library. The blocks
are exclusively intended for use with a fixed muting end point of 4 mm.
Intended use also includes
}EMC-compliant wiring
Please refer to the guidelines stated in this manual, in the section entitled "Wiring".
}Use of the module PSSuKFFAUB or PSSuKFFAUP
Please refer to the operating manual PSSuKFFAUB, PSSuKFFAUP
The protective function of the PSENvip must not be adversely affected by sources of inter-
ference, e.g. wireless remote controls for cranes, welding sparks, strobe lighting effects.
The following is deemed improper use
}Any structural, technical or electrical modification to the PSENvip
}Use of the PSENvip outside the zones described in this manual
}Use of the PSENvip contrary to the documented technical details (see "Technical De-
tails").

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 12
3.1.1 Safety during operation
Intended use also includes awareness of the hazards that arise during operation, against
which the PSENvip does not provide protection.
3.1.1.1 Hazards arising from installation
When installing the PSENvip, please note the following:
}The PSENvip must be installed so that there are no crushing or shearing hazards
between the moving transmitter/receiver and the fixed machine parts or any other parts
around the machine.
}If hazard areas cannot be avoided, other safeguards must be put in place.
3.1.1.2 Hazards arising from a reduced protected field
The full protected field is only active in standard protected field mode. In box bending, back
gauge or box bending 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 zone behind the bending line. Any parts of the body within
the danger zone will only be detected behind the bending line. There is a risk of injury from
trapping or crushing.
3.1.1.3 Hazards arising from incorrect handling of the workpiece
PSENvip does not protect against hazards arising from incorrect handling of the workpiece.
When bending metal sheets on press brakes there is a risk of hand injuries
}From the tool's closing movement
}From the swivel movement of the parts of the metal sheet that protrude from the tool and
}From the dropping of the metal sheet when the tool is opened.
So please note the following:
}You can avoid crushing and trapping of fingers or hands if the workpiece is handled cor-
rectly.
}Wear protective gloves to prevent cuts from edges, corners and ridges.
3.1.1.4 Correct handling of the workpiece
WARNING!
Crushing and trapping of fingers or hands!
With box 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.

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 13
Correct handling with flat workpieces
}Grip the metal sheet by the front corners. Thumbs should be on top of the sheet, palms
should hold the sheet from below.
Fig.: Handling flat workpieces

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 14
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 op-
eration, fingers or hands can become crushed or trapped between the workpiece and up-
per tool.
Fig.: Handling box bending

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 15
3.1.2 Tool shapes
All tool shapes are permitted in principle. They are divided into tool classes by the PSEN-
vip. Classification is based on EN12622, according to which the protected field must safe-
guard areas lying 15 mm in front of the bending line.
Please note the following when using tools:
Tool class 1
}These tools can be safeguarded in compliance with the standards: The front and rear
bending lines are detected by the protected field on the PSENvip. The front segments of
the protected field are at least 15mm away from the front bending line.
}Upper tools with a width of max. 32mm or radius of max. 25mm.
}Press brakes can travel up to the regular switchover 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. The front segments of
the protected field are less than 15 mm away from the front bending line.
}Under the following conditions, this tool class must be evaluated in the PAS4000 user
program:
– after the PSENvip is switched on
– after a tool change
– after the control system is restarted
Please refer to the information in the operating manual for the PSSuKFFAUP (see un-
der "Communication with the safety system").
}Upper tools with a width of max. 43 mm or radius of max. 50 mm.
WARNING!
Hazard areas that are not monitored by the PSENvip!
Additional hazard areas in zones that are not monitored by the PSENvip
can lead to serious injuries (fingers or hands being crushed or trapped).
Secure these zones with appropriate additional measures:
– Carry out a hazard analysis.
– Raise the regular switchover point, which initiates braking at low
speed. The switchover point must be monitored by the safety system.

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 16
Tool class 3
}These tools cannot be safeguarded in compliance with the standards: The front and rear
bending lines are not detected by the protected field on the PSENvip.
}Under the following conditions, this tool class must be evaluated in the PAS4000 user
program:
– after the PSENvip is switched on
– after a tool change
– after the control system is restarted
Please refer to the information in the operating manual for the PSSuKFFAUP (see un-
der "Communication with the safety system").
}The following safety guideline applies for press brakes with tools in this tool class.
WARNING!
Hazard areas that are not monitored by the PSENvip!
Additional hazard areas in zones that are not monitored by the PSENvip
can lead to serious injuries (fingers or hands being crushed or trapped).
Secure these zones with appropriate additional measures:
– Carry out a hazard analysis.
– Raise the regular switchover point, which initiates braking at low
speed. The switchover point must be monitored by the safety system.
– Each press stroke must be acknowledged by the operator prior to ini-
tiation.
Please also note the following guidelines in danger zones in areas that cannot be detected
and monitored by the safeguard.

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 17
Example: Upper tool with a danger zone outside the zone monitored by the PSENvip
Fig.: Danger zone in unmonitored zone
Example: In unmonitored zones, the use of tools which are not fully detected by the protec-
ted field on the PSENvip (e.g. tools with a radius greater than 25mm) will lead to the risk of
fingers or hands being crushed or trapped!
Fig.: Crush points when the tool is wider than the protected field

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 18
3.2 Safety guidelines
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.
}Please note that manufacturers and company operators who use the PSENvip are them-
selves responsible for agreeing the regulations with the relevant authorities and comply-
ing with them.
3.2.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident prevention,
}Have read and understood the information provided in the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the specific
application.
Competent personnel must also be familiar with how to use and test ESPE and be author-
ised to do this by the ESPE operator.
3.2.2 EMCD
The PSENvip is designed for use in an industrial environment. It is not suitable for use in a
domestic environment, as this can lead to interference.
3.2.3 Warranty 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.).
3.2.4 Safety during commissioning, installation and operation
Please read the guidelines stated in the chapters entitled "Commissioning", "Installation"
and "Operation".

Safety
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 19
3.2.5 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Function description
Operating Manual PSENvip R, PSENvip R LR,PSENvip E
1003449-EN-06 | 20
4 Function description
4.1 Overview
The detection zone between the transmitter and receiver monitors the immediate danger
zone below the moving upper tool of a press brake. The detection zone moves with the up-
per die, providing mobile safeguarding of the danger zone. The receiver transfers the image
data from the detection zone to the special module PSSu K F FAU. If an object encroaches
into the detection zone, the two outputs on the PSSu K F FAU shut down and the LED on
the receiver goes out. A stop of the press stroke is initiated.
On the productive version, safety functions must be implemented in the PAS4000 user pro-
gram in order to safeguard dynamic muting. Certified Pilz blocks are available for this the
PAS4000 Library.
CNC controller
PSSu system with
PSSu K F FAU
Function blocks
(user program)
Incremental encoder
OSSD status
Image fdata
Receiver
Transmitter PSENvip E
Safety valve
Prefill valve
Foot switch
Emergency switching off
E-STOP contactor
PSENvip R/PSENvip R LR
Fig.: Overview of overall system