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

Contents
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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.