Pilz PSENvip RL D P Set User manual

PSENvip RL D P Set
Operating Manual-1001641-EN-09
}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.
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 Overview of documentation ...................................................................................................... 6
1.3 Definition of symbols................................................................................................................. 7
2 Overview ................................................................................................................................. 8
2.1 Scope of supply ........................................................................................................................ 9
3 Safety ...................................................................................................................................... 10
3.1 Intended use ............................................................................................................................. 10
3.1.1 Approvals.................................................................................................................................. 11
3.1.2 Safety during operation............................................................................................................. 11
3.1.2.1 Hazards arising from the installation of the PSENvip ............................................................... 11
3.1.2.2 Hazards arising from a reduced protected field ........................................................................ 11
3.1.2.3 Hazards arising from incorrect handling of the workpiece ........................................................ 11
3.1.2.4 Correct handling of the workpiece ............................................................................................ 12
3.1.3 Categories / SIL ........................................................................................................................ 13
3.1.4 Tool shapes .............................................................................................................................. 14
3.2 Standards ................................................................................................................................. 16
3.3 Safety guidelines ...................................................................................................................... 16
3.3.1 Use of qualified personnel ........................................................................................................ 17
3.3.2 EMCD ....................................................................................................................................... 17
3.3.3 Warranty and liability ................................................................................................................ 17
3.3.4 Safety during commissioning, installation and operation.......................................................... 17
3.3.5 Disposal .................................................................................................................................... 17
4 Function description ............................................................................................................. 18
4.1 Overview................................................................................................................................... 18
4.2 Protected field........................................................................................................................... 21
4.2.1 Dynamic muting ........................................................................................................................ 22
4.2.2 Standard interrupted press stroke ............................................................................................ 24
4.3 Overrun..................................................................................................................................... 25
4.4 Description of the units ............................................................................................................. 26
4.4.1 Overview................................................................................................................................... 26
4.4.2 Transmitter................................................................................................................................ 26
4.4.2.1 Inputs ........................................................................................................................................ 26
4.4.3 Receiver.................................................................................................................................... 27
4.4.3.1 Inputs ........................................................................................................................................ 27
4.4.3.2 Outputs ..................................................................................................................................... 28
4.4.3.3 LED........................................................................................................................................... 30
4.4.3.4 Key display and function........................................................................................................... 30
4.4.4 Communication with the safety system .................................................................................... 33
4.5 Protected field modes ............................................................................................................... 36
4.5.1 Standard protected field mode.................................................................................................. 37
4.5.2 Box bending protected field mode ............................................................................................ 38
4.5.3 Back gauge protected field mode ............................................................................................. 39
4.5.4 Box bending with back gauge protected field mode ................................................................. 40
4.6 Operating modes during commissioning .................................................................................. 41

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4.6.1 Press brake setup mode........................................................................................................... 41
4.6.2 Adjustment during initial commissioning................................................................................... 41
4.6.3 Adjustment during tool change ................................................................................................. 41
4.7 System cycle............................................................................................................................. 42
4.7.1 System cycle for standard press stroke.................................................................................... 43
4.7.2 System cycle for box bending press stroke .............................................................................. 46
4.7.3 System cycle for back gauge press stroke ............................................................................... 48
4.7.4 System cycle for box bending with back gauge press stroke ................................................... 49
5 Installation .............................................................................................................................. 50
5.1 General requirements ............................................................................................................... 50
5.2 Install transmitter and receiver.................................................................................................. 51
5.3 Dimensions ............................................................................................................................... 53
5.3.1 Transmitter................................................................................................................................ 53
5.3.2 Receiver.................................................................................................................................... 54
5.3.3 Fastening kit for the transmitter ................................................................................................ 54
5.3.4 Fastening kit for the receiver .................................................................................................... 55
5.3.5 Bracket for transmitter and receiver.......................................................................................... 56
6 Wiring ...................................................................................................................................... 57
6.1 Notes on wiring ......................................................................................................................... 57
6.2 Connections.............................................................................................................................. 59
6.2.1 Receiver.................................................................................................................................... 59
6.2.2 Transmitter................................................................................................................................ 61
6.2.3 Supply voltage .......................................................................................................................... 61
6.2.4 Connection between transmitter and receiver .......................................................................... 61
6.2.5 Connection diagram.................................................................................................................. 62
7 Commissioning ...................................................................................................................... 63
7.1 Commissioning guidelines ........................................................................................................ 63
7.2 Initial commissioning................................................................................................................. 63
7.2.1 Align transmitter and receiver ................................................................................................... 63
7.2.1.1 Prepare for alignment ............................................................................................................... 64
7.2.1.2 Adjustment templates ............................................................................................................... 64
7.2.1.3 Adjustment directions of transmitter and receiver..................................................................... 65
7.2.1.4 Align transmitter........................................................................................................................ 66
7.2.1.5 Tool shapes .............................................................................................................................. 67
7.2.1.6 Align receiver ............................................................................................................................ 69
7.2.2 Adjustment template with bracket............................................................................................. 73
7.3 Adjustment during tool change ................................................................................................. 74
7.3.1 Prepare for adjustment during tool change............................................................................... 74
7.3.2 Tool detection ........................................................................................................................... 75
7.3.3 Make adjustment during tool change........................................................................................ 78
7.4 Enter overrun ............................................................................................................................ 80
7.5 Check protective equipment ..................................................................................................... 81
7.5.1 Function test of the safety device ............................................................................................. 82
7.5.1.1 Test during initial commissioning.............................................................................................. 82
7.5.1.2 Test after machine modification................................................................................................ 82
7.5.1.3 Regular check........................................................................................................................... 83

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7.5.1.4 Prepare for function test ........................................................................................................... 83
7.5.1.5 Function test using the test piece ............................................................................................. 84
7.5.2 Visual inspection....................................................................................................................... 85
8 Operation ................................................................................................................................ 86
8.1 Safety guidelines ...................................................................................................................... 86
8.2 Operating notes ........................................................................................................................ 86
8.2.1 Switch on PSENvip................................................................................................................... 86
8.2.2 Muting lamp .............................................................................................................................. 86
8.2.3 Initial press stroke..................................................................................................................... 87
8.2.4 Acknowledge protected field modes ......................................................................................... 87
8.2.5 Tool change .............................................................................................................................. 88
8.2.6 Error messages ........................................................................................................................ 88
8.2.7 Cleaning the front lenses .......................................................................................................... 88
9 Diagnostics and Troubleshooting ........................................................................................ 90
9.1 Error Management.................................................................................................................... 90
9.1.1 Minor errors .............................................................................................................................. 90
9.1.2 Major errors .............................................................................................................................. 91
9.1.3 Fatal errors ............................................................................................................................... 91
9.2 Error messages ........................................................................................................................ 92
9.3 DIAGNOSTICS menu ............................................................................................................... 94
9.3.1 Diagnostic blocks and diagnostic data...................................................................................... 94
10 System Connections ............................................................................................................. 96
10.1 Requirements of the user program ........................................................................................... 96
10.2 Communication with the safety system .................................................................................... 96
11 Technical details .................................................................................................................... 102
11.1 Technical details ....................................................................................................................... 102
11.2 Order reference ........................................................................................................................ 105
12 Attachment ............................................................................................................................. 107
12.1 Check list .................................................................................................................................. 107
12.2 EC declaration of conformity..................................................................................................... 109

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 system for press brakes.
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.
This documentation is intended for instruction and should be retained for future reference.
1.1 Validity of the documentation
This documentation is valid for the product PSENvip RL D P Set. It is valid until new docu-
mentation is published.
This documentation is valid for the PSENvip from Version 1.0/year of construction 2014.
1.2 Overview of documentation
1 Introduction
The introduction is designed to familiarise you with the contents, structure and specific or-
der 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.
4 Function Description
This chapter provides an overview of the PSENvip's mode of operation. It describes the
units and the system procedures.
5 Installation
This chapter explains how to install the PSENvip.
6 Wiring
This chapter explains how to wire the inputs and outputs on the PSENvip.
7 Commissioning
This chapter explains how to commission the PSENvip. It contains information on adjust-
ments and on the tests performed on the safety device.
8 Operation
This chapter contains all the information required by the operator.
9 Diagnostics and Troubleshooting
This chapter describes the output of diagnostics on the display and explains how to handle
errors.

Introduction
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10 System Connections
This chapter describes how the PSENvip is connected to the press brake's programmable
safety system.
11 Technical Details
12 Appendix
1.3 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
The PSENvip is a camera-based protection and measuring system (electrosensitive pro-
tective 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.
Transmitter
}Generates parallel beam
}2 inputs for controlling the light source
Receiver
}Evaluates the light generated by the transmitter
}Display for the operating statuses and inputs
}Membrane keypad for operating the menus and for inputs
}Max. distance between transmitter and receiver: 10 m
Inputs
}1 input for setup mode
}1 input for signalling when the press brake is at top dead centre
}2 inputs for controlling the protected field mode:
Protected field can be adapted to a range of bending functions: full protected field, re-
duced protected field for box bending and lower tools with back gauge
}1 input for acknowledging the protected field mode
Outputs
}2 output signal switching devices (OSSD) for signalling the status of the protected field
(clear or interrupted)
}2 outputs for signalling that PSENvip is in dynamic muting
Some inputs and outputs are used for communication with the safety system during the
system status TEST:
}Register tool class on safety system
}Approve tool class for PSENvip
LED indicators for
}Status of OSSDs
Operating statuses
}Adjustment for initial commissioning
}Tool change
}Diagnostics

Overview
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Tool detection
}Automatic detection of tool contour during tool change
}Assignment of tool to a tool class
The whole system consists of:
}Press brake
}Numerical controller (CNC)
}Programmable safety system
}PSENvip (transmitter and receiver)
Upper die
Safety control
system
CNC
Receiver Lower tool Detection zone
Upper tool
Transmitter
Fig.: Whole system
2.1 Scope of supply
PSENvip RL D P Set: complete set
Order reference Description
PSENvip RL D P PSENvip receiver, left, with display and dy-
namic muting
PSENvip T PSENvip transmitter
PSENvip AT mag Adjustment templates with magnets
PSENvip AP Set of adjustment plates for transmitter/re-
ceiver
PSENvip TP Test piece in accordance with EN 12622,
Annex H
DVD with operating manuals

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), 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. 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.
The protected field monitors the danger zone between upper tool and plate up to a remain-
ing gap of 6 mm (dynamic muting)
The upward movement of the press is assumed as a safe movement.
Use of the PSENvip RL D P Set is only permitted with the automation system PSS4000
from Pilz. In the PSS 4000 user program, safety functions must be implemented to safe-
guard the dynamic muting of PSENvip:
}Monitoring of the pinch point
}Monitoring of the press braking ramp
}Definition of a safe position and safe speed for the upper tool
}Activation of the entire protected field via System-Init = 1, when the press stops during
dynamic muting and then the upward movement is initiated.
For this safety function Pilz provides a certified evaluation program for the PSS 4000.
The press brake must observe a max. overrun of 14 mm.
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 chapter entitled
"Technical Details")
Intended use includes making the wiring EMC-compliant. Please refer to the guidelines
stated in this manual, in the section entitled "Wiring".
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.

Safety
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3.1.1 Approvals
4
4
4
3.1.2 Safety during operation
Intended use also includes awareness of the hazards that arise during operation, against
which the PSENvip does not provide protection.
3.1.2.1 Hazards arising from the installation of the PSENvip
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.
3.1.2.2 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.
3.1.2.3 Hazards arising from incorrect handling of the workpiece
The PSENvip does not protect against hazards arising from incorrect handling of the work-
piece.
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.

Safety
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3.1.2.4 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.
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
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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
3.1.3 Categories / SIL
The PSENvip may only be used with an automation system PSS4000 from Pilz with SIL3
of EN 61508 and PLe 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 as-
sessment. For this reason, Pilz cannot accept liability for the correct classification into a cat-
egory or SIL.

Safety
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3.1.4 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.
INFORMATION
Please refer to the information on tool classes
– In the section entitled "Adjustment during tool change", under "Com-
missioning".
– In the section entitled "Requirements of the user program", under
"System Connections".
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 more than 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.
}Upper tools with a width of max. 43 mm or radius of max. 50 mm.
}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.
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.
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.
}The following safety guideline applies for press brakes with tools in this tool class.

Safety
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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.
Secure these zones with appropriate additional measures!
– Carry out a hazard analysis!
– Raise the switchover point, which initiates braking at low speed. It
must be placed even higher than the position used for tools of tool
class 2. The switchover point must be monitored by the safety sys-
tem.
– 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.
Example: Upper tool with a danger zone outside the zone monitored by the PSENvip
Fig.: Danger zone in unmonitored zone

Safety
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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
3.2 Standards
To use the PSENvip correctly you will need to have a good knowledge of the relevant
standards and directives. The following gives an overview of the most important standards:
}EN 61496-1: Safety of machinery - Electrosensitive protective equipment, Part 1
}CLC/TS 61496-2: Safety of machinery - Electrosensitive protective equipment, Part 2
}EN 12622: Machine tools - Hydraulic press brakes
}EN ISO 13849-1: Safety of machinery – Safety-related parts of control systems - Part 1:
General principles for design
}EN ISO 13849-2: Safety of machinery – Safety-related parts of control systems - Part 2:
Validation
}EN 61508: Functional safety of safety-related electrical/electronic/programmable elec-
tronic systems
Please note this is not an exhaustive list of safety standards and directives.
3.3 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.

Safety
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3.3.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
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.
Approved personnel must be familiar with how to use and test ESPE and be authorised by
the ESPE operator to do this.
3.3.2 EMCD
The PSENvip is designed for use in an industrial environment. It is not suitable for use in a
domestic environment, as this can lead to interference.
3.3.3 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.).
3.3.4 Safety during commissioning, installation and operation
Please read the guidelines stated in the chapters entitled "Commissioning", "Installation"
and "Operation".
3.3.5 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
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4 Function description
4.1 Overview
The PSENvip is a camera-based protection system for press brakes. It consists of a trans-
mitter 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. If an object encroaches into the detection zone, both output signal switching devices
(OSSD1, OSSD2) on the PSENvip will switch to the OFF-state. The safety system will use
these signals to initiate stopping of the press stroke.
3
1 2
4 5 6
Fig.: Press brake with PSENvip
}1: Upper tool
}2: Upper die
}3: Receiver
}4: Detection zone
}5: Lower tool
}6: Transmitter
The PSENvip is part of an overall system comprising
}PSENvip transmitter and receiver
}Programmable safety system PSS 4000
}CNC controller
}Signals from incremental encoders for defining the position and speed
}External operator elements or signals (foot switch, reset button for reduced protected field
or setup mode, E-STOP pushbutton)
}Other safety devices (safety valves, prefill valve, contactor for E-STOP)

Function description
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The following overview shows the fundamentals of the whole system. The signals from the
PSENvip transmitter and receiver are explained in the sections below.
OSSD 1
OSSD 2
Mute 1 TRM_ON
TRM_SYNC
TRM_ON
TRM_SYNC
Programmable safety
system
PSS 4000
Incremental encoder
Mute 2
Pinch point
Up/
Down
Power Off
System-Init
Protected field mode
Acknowledge-
ment of reduced
protected field
Inputs
Outputs
PSENvip receiver
PSENvip transmitter
CNC controller
Protected field mode
Setup
Foot switch
E-STOP
E-STOP contactor
User program
Safety valve
Prefill valve
Fig.: Overview of overall system
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.

Function description
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The motion sequence of the press is monitored by the automation system PSS 4000. In the
PSS 4000 user program safety functions must be implemented to safeguard the dynamic
muting of PSENvip. (see chapter 10 "System Connections").
The receiver receives the parallel light beam bundle generated by the transmitter. The light
beam bundle is enclosed by the illuminated target area. The lens on the receiver only de-
tects light that runs parallel to the optical axis. This guarantees stability against diffused
light.
NOTICE
Do not use optical aids (e.g. lenses) to look at the light from the trans-
mitter.
This could damage the eye. If you do not use optical aids, there is no
danger to the eye.
The receiver monitors and evaluates the detection zone between the transmitter and re-
ceiver. The protected field is the cross section of the detection zone. It consists of several
segments.
1
2
3
4
Fig.: Definitions
Key:
}1: Light beam bundle
}2: Illuminated target area
}3: Protected field
}4: Detection zone