SICK V4000 User manual

OPERATING INSTRUCTIONS
GB
V4000 Press Brake sensor system
for protecting the press brake

Operating instructions
V4000 PB
2© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
This document is protected by copyright. The SICK AG company retains this right. Reproducing this document in
whole or part is only permissible within the limits of the statutory regulations of copyright law. Modifying or
abridging the document is impermissible without the express written permission of from the SICK AG company.

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V4000 PB
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Update
a
WARNING
Please take note of the following updates to this document!
Based on Machinery Directive 2006/42/EC, we have added the following supplementary
data or change notices on our product to the following document.
Scope
This document is an original document.
Cited standards and directives
The standards and directives cited in these operating instructions might have changed.
The following list indicates the standards and directives that might have been cited and
their successive versions.
Kindly replace the standards and directives cited in these operating instructions with the
successive versions listed in the table.
Previous standard or directive Successive standard and directive
Machinery Directive 98/37/EC Machinery Directive 2006/42/EC
Directive 93/68/EEC Directive 93/68/EC
EMC directive 89/336/EEC EMC directive 2004/108/EC
Low Voltage Directive 73/23/EC Low Voltage Directive 2006/95/EC
DIN 40050 EN 60529
IEC 536:1976 EN 61140
DIN EN 50178:1998-04/
VDE 0160:1998-04
EN 50178
EN 775 EN ISO 10218-1
EN 292-1 EN ISO 12100-1
EN 292-2 EN ISO 12100-2
EN 954-1 EN ISO 13849-1
EN 418 EN ISO 13850
EN 999 EN 999+A11)
EN 294 EN ISO 13857
EN 811 EN ISO 13857
EN 1050 EN ISO 14121-1
IEC 68, part 2-27 or IEC 68 EN 60068-2-27
IEC 68, part 2-29 EN 60068-2-27
IEC 68, part 2-6 EN 60068-2-6
prEN 501001 EN 61496-1
ANSI B11.19-1990 ANSI B11.19:200304, Annex D
1) EN 999 will be replaced by EN ISO 13855.
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved

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Electrical installation
Prevent the formation of a potential difference between the load and the protective
device!
a
WARNING  If you connect loads that are not reverse-polarity protected to the OSSDs or the safety
outputs, you must connect the 0 V connections of these loads and those of the
corresponding protective device individually and directly to the same 0 V terminal strip.
This is the only way to ensure that, in the event of a defect, there can be no potential
difference between the 0 V connections of the loads and those of the corresponding
protective device.
OSSD1 Safety output 1 OSSD2 Safety output 2 OSSD1 Safety output 1 OSSD2 Safety output 2
Technical specifications
Safety-related parameters according to EN ISO 13849, EN 62061, IEC 61508:
V4000 PB: General system data
Type Type 4 (IEC 61496)
Safety Integrity Level2) SIL3 (IEC 61508),
SILCL3 (EN 62061)
Category Category 4 (EN ISO 13849)
Category 4 (EN 9543))
Performance Level2) PL e (EN ISO 13849)
PFHd (mean probability of a dangerous failure
per hour)
1.52×10–8
TM(mission time) 16.6 years (EN ISO 13849)
EC declaration of conformity
You can obtain the EC declaration of conformity with the standards used at: www.sick.com
Note
2) For detailed information on the exact design of your machine/system, please contact your local SICK
representative.
3) Only valid for the assumption of conformity until 28.12.2009. From then on it will only be permissible to use
the successor EN ISO 13849.
© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27

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V4000 PB
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Checklist for the manufacturer
L
Checklist for the manufacturer/installer for the installation of electro-
sensitive protective equipment (ESPE)
Details about the points listed below must be present at least during initial commissioning — they are, however,
dependent on the respective application, the specifications of which are to be controlled by the manufacturer/installer.
This checklist should be retained and kept with the machine documentation to serve as reference during recurring
tests.
1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to
the machine?
Yes No 
2. Are the applied directives and standards listed in the declaration of conformity? Yes No 
3. Does the protective device fulfil the required PL/SILCL and PFHd according to EN ISO 138491/EN 62061 and
the type according to EN 614961?
Yes No 
4. Is the access to the hazardous area/hazardous point only possible through the protective field of the ESPE? Yes No 
5. Have appropriate measures been taken to prevent (mechanical protection) or monitor unprotected presence in
the hazardous area when protecting a hazardous area/hazardous point and have these been secured against
removal?
Yes No 
6. Are additional mechanical protective measures fitted and secured against manipulation which prevent reaching
under, over or around the ESPE?
Yes No 
7. Has the maximum stopping and/or stopping/run-down time of the machine been measured, specified and
documented (at the machine and/or in the machine documentation)?
Yes No 
8. Has the ESPE been mounted such that the required safety distance from the nearest hazardous point has been
achieved?
Yes No 
9. Are the ESPE devices correctly mounted and secured against manipulation after adjustment? Yes No 
10. Are the required protective measures against electric shock in effect (protection class)? Yes No 
11. Is the control switch for resetting the protective device (ESPE) or restarting the machine present and correctly
installed?
Yes No 
12. Are the outputs of the ESPE (OSSDs, ASInterface Safety at Work) integrated in compliance with the required
PL/SILCL according to EN ISO 13849/EN 62061 and does the integration comply with the circuit diagrams?
Yes No 
13. Has the protective function been checked in compliance with the test notes of this documentation? Yes No 
14. Are the given protective functions effective at every setting of the operating mode selector switch? Yes No 
15. Are the switching elements activated by the ESPE, e.g. contactors, valves, monitored? Yes No 
16. Is the ESPE effective over the entire period of the dangerous state? Yes No 
17. Once initiated, will a dangerous state be stopped when switching the ESPE on or off and when changing the
operating mode, or when switching to another protective device?
Yes No 
18. Has an information label for the daily check been attached so that it is easily visible for the operator? Yes No 
19. Have you made sure that the protective device itself when mounted is not a source of danger during machine
operation (for example, catching between the device and parts of the machine)?
Yes No 
This checklist does not replace the initial commissioning, nor the regular inspection by qualified safety personnel.
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved

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© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27

Operating instructions
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 3
Contents
Contents
1 About this document ......................................................................................................6
1.1 Function of this document....................................................................................6
1.2 Target groups ........................................................................................................6
1.3 Scope .....................................................................................................................6
1.4 Depth of information.............................................................................................6
1.5 Abbreviations.........................................................................................................7
1.6 Symbols used ........................................................................................................8
2 On safety..........................................................................................................................9
2.1 Specialist personnel..............................................................................................9
2.2 Applications of the system ...................................................................................9
2.3 Correct use of the system.................................................................................. 10
2.4 General protective notes and protective measures......................................... 10
2.5 Safety in operation............................................................................................. 11
2.6 Environmental protection .................................................................................. 16
2.6.1 Disposal ............................................................................................ 16
3 Product description ..................................................................................................... 17
3.1 Special features ................................................................................................. 17
3.2 Safety concept.................................................................................................... 18
3.2.1 Protection principle of the V4000 PB ............................................. 18
3.2.2 Protective volume during the operating cycle ................................ 20
3.2.3 Intrusion of the protective volume during the operating cycle...... 21
3.3 Range of use ...................................................................................................... 22
3.4 Structure of the device ...................................................................................... 23
3.4.1 Sender and receiver......................................................................... 23
3.4.2 Displays at the sender and receiver ............................................... 24
3.4.3 Interfaces at the receiver................................................................. 26
3.4.4 PBI (press brake interface).............................................................. 28
3.4.5 CDS (Configuration & Diagnostics Software).................................. 29
3.4.6 External operating elements ........................................................... 31
3.5 Possible system configurations......................................................................... 31
3.5.1 Source of the operator signals ........................................................ 33
3.5.2 Baud rate communication interface ............................................... 33
3.5.3 Application name ............................................................................. 33
3.5.4 Repetition interval of power-up cycle.............................................. 33
3.5.5 Mounting of receiver ........................................................................ 34
3.5.6 Speed-dependent muting ................................................................ 34
3.5.7 Position-sensing system .................................................................. 34
3.5.8 External device monitoring (EDM)................................................... 35
3.5.9 Default value for braking distance.................................................. 35
3.5.10 Travel for determining the braking distance .................................. 36
3.5.11 Braking offset ................................................................................... 36
3.5.12 Target speed vslow for determining the braking distance ............... 36
3.5.13 Monitoring of the slow closing speed vcrawl from the pinch
point.................................................................................................. 37
3.5.14 Maximum closing speed and maximum overall machine
overrun.............................................................................................. 37
3.5.15 Travel for determining the overall machine overrun...................... 38
3.5.16 Standstill time for determining the top dead centre...................... 38
3.5.17 Start delay for closing movement .................................................. 39

Operating instructions
V4000 PB
4© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
Contents
3.5.18 Time for standstill detection ............................................................ 39
3.5.19 Settling times for inputs ................................................................... 39
3.5.20 Discrepancy times for inputs ........................................................... 40
3.5.21 Start signal at reduced protective volume ...................................... 40
3.5.22 Minimum state time for standard outputs ...................................... 41
3.5.23 Minimum switch-off time for safety-relevant outputs..................... 41
3.5.24 Bypass ............................................................................................... 41
3.6 Protective operation ........................................................................................... 42
3.6.1 Power-up cycle .................................................................................. 42
3.6.2 Teach-in............................................................................................. 43
3.6.3 Protective volume modes in protective operation .......................... 43
3.7 System sequences in protective operation....................................................... 46
3.7.1 Power-up cycle in standard mode.................................................... 47
3.7.2 Teach-in............................................................................................. 51
3.7.3 Operating cycle in standard mode................................................... 53
3.7.4 Operating cycle in box mode............................................................ 55
3.7.5 Operating cycle in back-stop mode ................................................. 57
3.8 Alignment mode.................................................................................................. 59
4 Mounting....................................................................................................................... 60
4.1 Steps for mounting ............................................................................................. 60
4.1.1 Mounting the sender or receiver using SICK mounting kit 1 ......... 60
4.1.2 Mounting the sender or receiver using SICK mounting kit 2 ......... 61
4.1.3 Sticker: Information for daily inspection ......................................... 62
5 Electrical installation................................................................................................... 63
5.1 Connecting the receiver .................................................................................... 63
5.2 Connecting the sender ....................................................................................... 66
5.3 Making up the connections for receiver and sender....................................... 67
5.4 Connecting the PBI ............................................................................................ 67
5.5 External device monitoring (EDM) ..................................................................... 69
5.6 Bypass ................................................................................................................. 70
5.7 Configuration connection (serial interface)....................................................... 71
6 Configuration................................................................................................................ 72
6.1 Delivery state ...................................................................................................... 72
6.2 Configuration preparations ................................................................................ 73
7 Commissioning ............................................................................................................. 74
7.1 Test notes ........................................................................................................... 74
7.2 Aligning sender and receiver ............................................................................. 74
7.2.1 Initial alignment ................................................................................ 74
7.2.2 Alignment following a tooling change.............................................. 81
7.3 Function check ................................................................................................... 83
7.4 Regular checks of the protective device by specialist personnel ................... 86
7.5 Daily checks of the protective device by authorised commissioned
persons ............................................................................................................... 86
8 Operation ...................................................................................................................... 88
8.1 Switching the machine on.................................................................................. 88
8.2 Selecting protective volume mode .................................................................... 89
8.3 Resetting ............................................................................................................. 89
8.4 Carrying out a power-up cycle ............................................................................ 89
8.5 Carrying out teach-in .......................................................................................... 91
8.6 Bending in standard mode................................................................................. 92

Operating instructions
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 5
Contents
8.7 Bending in box mode ........................................................................................ 92
8.8 Bending in back-stop mode.............................................................................. 92
8.9 Changing the sheet thickness ........................................................................... 92
8.10 Tool changing ..................................................................................................... 93
8.11 Care and maintenance ...................................................................................... 93
9 Diagnostics...................................................................................................................94
9.1 Response to errors and malfunctions............................................................... 94
9.2 Error displays of the LEDs.................................................................................. 94
9.3 Error displays of the 7-segment display............................................................ 95
9.4 Extended diagnostics via CDS........................................................................... 97
9.5 SICK support....................................................................................................... 98
10 Technical data.............................................................................................................. 99
10.1 Device data sheet .............................................................................................. 99
10.1.1 V4000 PB technical data................................................................. 99
10.1.2 Technical data for PBI (press brake interface)............................. 105
10.1.3 Incremental encoder technical data ............................................. 106
10.2 Dimensional drawings ..................................................................................... 107
10.2.1 Sender and receiver....................................................................... 107
10.2.2 SICK mounting kit 1 ....................................................................... 108
11 Ordering information ................................................................................................. 109
11.1 Scope of delivery.............................................................................................. 109
11.2 Available systems............................................................................................. 109
11.3 Accessories....................................................................................................... 109
12 Glossary ...................................................................................................................... 111
13 Annex .......................................................................................................................114
13.1 Detailed system sequences in protective operation...................................... 114
13.1.1 Power-up cycle................................................................................ 114
13.1.2 Teach-in .......................................................................................... 116
13.1.3 Standard mode .............................................................................. 118
13.1.4 Box or back-stop mode with interruption of the protective
volume ............................................................................................ 120
13.2 Declaration of Conformity................................................................................ 122
13.3 Manufacturer’s checklist ................................................................................. 124
13.4 List of tables..................................................................................................... 125
13.5 List of illustrations............................................................................................ 126
13.6 Index ................................................................................................................. 128

Chapter 1Operating instructions
V4000 PB
6© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
About this document
1 About this document
Read this chapter carefully before working with the operating instructions and the
V4000 Press Brake system.
For "V4000 Press Brake system" we shall use the abbreviation "V4000 PB" from now on.
1.1 Function of this document
These operating instructions are intended for the technical personnel of the machine
manufacturer or the machine operator in regards to safe mounting, electrical installation,
configuration, commissioning, operation and diagnostics of the V4000 PB sensor.
These operating instructions do not provide instructions for operating machines on which
the V4000 PB is, or will be, integrated. Information of this kind will be found in the
operating instructions for the machine.
1.2 Target groups
These operating instructions are intended for manufacturers, operators and the users of
press brakes which are to be protected by a V4000 PB. It also addresses people who
integrate the V4000 PB into a machine, initialise its use, or who check the unit.
1.3 Scope
These operating instructions apply for the V4000 PB with the following type label entry in
the Operating Instructions field: 8 010 501. This document is part of SICK part number 8
010 501 (V4000 Press Brake sensor system in all available languages).
You will require a CDS (Configuration & Diagnostic Software) version 3.0 or greater for the
configuration and diagnostics of this system. To determine the software version, select the
Module info item from the ?menu in the menu bar.
1.4 Depth of information
These operating instructions contain information on the V4000 PB regarding the following
subjects:
 Mounting
 Electrical installation
 Configuration and commissioning
 Operation, care and maintenance
 Error diagnostics and remedying
 Technical data and order numbers
 Conformity and approval
Planning and using protective devices such as the V4000 PB sensor also require specific
technical skills which are not detailed in these operating instructions.
When operating the V4000 PB sensor, the national, local and statutory rules and
regulations must be observed.
General information on health and safety using opto-electronic protective devices is
contained in the brochure "Safe Machines with Opto-Electronic Protective Devices".
Note

Operating instructions Chapter 1
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 7
About this document
We also refer you to the SICK homepage on the Internet at
http://www.sick.com
Here you will find:
 These operating instructions in different languages for viewing and printing
 The EC Declaration of Conformity
1.5 Abbreviations
American National Standards Institute
Electro-sensitive protective equipment (ESPE) (e. g. V4000 PB)
SICK Configuration & Diagnostic Software = software for configuring and diagnosing the
V4000 PB system
External device monitoring
Electro-sensitive protective equipment
Human machine interface
Laser diode
Light-emitting diode
Mute point
Numerical control
Overall machine overrun
Overall response time
Output signal switching device = signal output of the protective device to the controller
used for switching off the movement which is the source of danger
Programmed bottom dead centre
Press brake interface
Programmed top dead centre
Pinch point
Switch-over point (from vpto vslow)
Safety programmable logic control
V4000 Press Brake (sensor system)
Note
ANSI
BWS
CDS
EDM
ESPE
HMI
LD
LDLED
MP
NC
OMO
ORT
OSSD
PBDC
PBI
PTDC
PP
SP
SPLC
V4000 PB

Chapter 1Operating instructions
V4000 PB
8© SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
About this document
1.6 Symbols used
Recommendations are designed to provide some assistance for your decision-making
process regarding application of a certain function or technical measure.
Notes provide special information about the device.
Display indicators show the status of the 7-segment display of the receiver:
7Constant display of the letter F
Flashing display of the letter F
7O) Alternating display of F and 2
LED symbols describe the state of an LED:
OThe LED is illuminated constantly.
ÖThe LED is flashing.
o The LED is off.
ON or OFF state:
 ON
 OFF
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
Warning!
A warning indicates concrete or potential dangers. They save you from harm.
Read warnings carefully and abide by them!
Software notes show the location in the CDS (Configuration & Diagnostic Software) where
you can make the appropriate settings and adjustments. Go to the View menu, Dialogue
windows of the CDS and activate the item tabs to view the named dialogue boxes as
required. Otherwise use the software wizard to make the desired settings.
Sender and receiver
In drawings and diagrams, the ssymbol denotes the sender and the symbol rthe
receiver.
The term "dangerous state"
In the drawings in these operating instructions, the dangerous state (standard term) of the
machine is always represented as a movement of a machine part. In practical operation
there may be a number of different dangerous states:
 Machine movements
 Electrical conductors
 Visible or invisible radiation
 A combination of several risks and hazards
Representation of the signals for teach-in, alignment mode and selection of protective
volume mode
These operating instructions also describe the V4000 PB input and output signals. As a
way of uniquely representing the signals for teach-in, alignment mode and selection of
protective volume mode (input signals), tactile switching amplifiers (buttons, switches) are
used. The signals can be generated at the inputs of the V4000 PB by, for example, foot
switches, alignment buttons, teach-in buttons, selector switches and key-operated
switches or by the corresponding switching elements on the HMI of the press controller.
Recommendation
Note
;, , ;O(
OYellow, ÖYellow,
oYellow
, 
>Action …
a
WARNING
n
sr

Operating instructions Chapter 2
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 9
On safety
2 On safety
This chapter deals with your own safety and the safety of the operators.
> Read this chapter carefully before working with the V4000 PB or with the machine
protected by the V4000 PB.
2.1 Specialist personnel
The V4000 PB must be mounted, connected, commissioned and serviced only by
specialist personnel. Specialist personnel are defined as persons who
 due to their technical training and experience possess sufficient knowledge in the field
of safety equipment for making press brakes safe
and
 who have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
 have sufficient familiarity with the relevant national industrial safety regulations, work
safety regulations, directives and the generally recognised code of practice of the
industry (for example, DIN standards, VDE specifications, technical codes of other EC
member states) that they can judge whether the press brake is safe from the
occupational safety point of view
and
 have access to and have read these operating instructions.
As a rule these will be specialist personnel, the manufacturer of the ESPE or even such
persons who have been given the corresponding training by the ESPE manufacturer, who
are mainly concerned with inspecting and testing ESPEs and have been commissioned by
the ESPE operator in this regard.
2.2 Applications of the system
The V4000 PB is an ESPE (electro-sensitive protective equipment) device designed to
protect the area beneath the die of press brakes at high closing speeds. As soon as an
object enters the protective volume beneath the die, the ESPE issues the signal to the
press controller to stop the fast closing movement and this system must then stop the
closing movement.
The V4000 PB system consists of a sender and a receiver which are mounted on the press
crosshead. The protective volume between the sender and the receiver moves with the
press crosshead and thus ensures that the safeguarded area stays beneath the die.
The system is a Type 4 ESPE as defined by to IEC 61 496-1 and 2 and is therefore allowed
for use with controls of safety category 4 in compliance with EN 954-1. It may be used in
safety applications up to SIL 3 in accordance with IEC 61 508.

Chapter 2Operating instructions
V4000 PB
10 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
On safety
Use of the V4000 PB in the open air or explosion hazard areas is not permitted. The
V4000 PB can only be used in normal industrial environments.
Do not use the V4000 PB as a separating protective measure!
An opto-electronic protective device provides indirect protection, e.g., by switching off the
power at the source of the hazard. It cannot provide protection neither from parts thrown
out, nor from emitted radiation. Transparent objects are not detected.
Depending on its applications, mechanical protective devices may be needed in addition to
the V4000 PB.
2.3 Correct use of the system
The V4000 PB system is intended to be used solely at a fixed location on press brakes and
may only be used as defined by Section 2.2 "Applications of the system". It must be used
only by specialist personnel and only on the machine where it has been mounted and
initially commissioned by specialist personnel in accordance with these operating
instructions.
SICK AG accepts no claims for liability if the equipment is used in any other way or if
modifications are made to the device, even in the context of mounting and installation.
2.4 General protective notes and protective measures
Protective notes
Please observe the following protective notes in order to ensure the correct and safe use
of the V4000 PB.
 Warnings on the V4000 PB must be observed without fail.
 The V4000 PB meets the requirements of laser protection class 1 M. Do not look into
the laser beam neither with the naked eye nor using optical equipment (such as
binoculars).
LASER RADIATION
DO NOT STARE INTO THE BEAM OR VIEW
DIRECTLY WITH OPTICAL INSTRUMENTS
CLASS 1M LASER PRODUCT
ACCORDING TO IEC 60825-1:2001
Max. output: < 5mW
Puls duration: < 2ms
Wavelength: 620 TO 650 nm
Complies with 21 CFR 1040.10 and 1040.11 except
for deviations pursuant to laser notice No. 50, July 2001
 This device meets the norms: CDRH 21 CFR 1040.10, 1040.11 as well as DIN EN 60
825:2001. There the following note is required:”Caution – use of controls or
adjustments or performance of procedures other than those specified herein may result
in hazardous radiation exposure!”
 The V4000 PB components must not be opened for maintenance work. Defective
devices have to be sent back to the manufactorer.
a
WARNING
a
WARNING
Fig. 1: Warning regarding
laser class 1M

Operating instructions Chapter 2
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 11
On safety
 The national/international rules and regulations apply to the installation, commissioning
and periodic technical inspections of the V4000 PB, in particular:
– Machinery Directive 98/37/EC
– Provision and use of Work Equipment Directive 89/655/EEC
– The work safety regulations/safety rules
– Relevant national health and safety regulations
Manufacturers and operators of the machine on which the V4000 PB is used are
responsible for obtaining and observing all applicable safety regulations and rules.
 The notices, in particular the test regulations (see Chapter 7 "Commissioning") of these
operating instructions (e.g. on use, mounting, installation or integration into the existing
machine controller) must be observed.
 The tests must be carried out by specialist personnel or specially qualified and
authorised personnel and must be recorded and documented to ensure that the tests
can be reconstructed and retraced at any time.
 The operating instructions must be made available to the operator of the machine where
the V4000 PB is fitted. The machine operator is to be instructed in the use of the device
by specialist personnel and must be instructed to read the operating instructions of the
V4000 PB and of the machine.
2.5 Safety in operation
Dangers which the V4000 PB does not protect against!
The different ways in which the press brake can be used in manufacturing means that
indirect dangers may arise.
Please observe and comply with the following points in order to protect yourself against
dangers during machine operation.
The V4000 PB safeguards the hazardous point beneath the die at high closing speeds
(over 10 mm/s) or irrespective of the speed up to a gap of 6 mm. The maximum height of
the protective volume up to the lower edge of the die is 26 mm.
Maximum protection is provided in standard protective volume mode.
In the case of box-bending or back-stop operation, use of a restricted protective volume is
possible. With this kind of work, the reduced dimensions of the protective volume means
that only limited protection against getting caught or crushed is possible.
If parts of the body are brought into the hazardous point within a box, they will only be
detected behind the tolerance zone around the pressure axis. There is a danger of injury
by being caught or crushed.
For a time interval of 100–150 ms (just before the gap height of 6 mm is reached) there is
the possibility of an object which is moving into the space between the die and the
workpiece being crushed.
Correct handling of the workpiece
By handling the sheet properly you can avoid your hands or fingers being caught or
crushed.
a
WARNING

Chapter 2Operating instructions
V4000 PB
12 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
On safety
> Use gloves to prevent:
– Injuries caused by edges, corners and burr
– Residues and rust caused by sweat from the hands getting on dies and workpieces
– Deposits on the hands
– Slipping of smooth workpieces
> Hold the sheet by the left and right corners of the end facing you.
> Use both hands to hold the sheet firmly from below (thumb on top of the sheet, rest of
hand underneath)
> When holding the sheet, be sure not to spread your fingers.
Spread fingers will interrupt the protective volume of the V4000 PB. The protective
function of the V4000 PB will be triggered and the V4000 PB initiates a stop.
If the protective volume is limited (box-bending and back-stop operation) there will be an
additional risk of getting your hand caught.
Fig. 2: Handling of the
workpiece 1
Fig.
3: Handling of the
workpiece 2
Note

Operating instructions Chapter 2
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 13
On safety
Correct handling of pre-flanged sheets
If pre-flanged sheets are not handled correctly, your hands could get caught between the
sheet and the die or press crosshead.
> Hold the pre-flanged sheet by the left and right edges between the thumbs and index
fingers.
> Use both hands to hold the sheet firmly.
Fig. 4: Handling o
f
pre-flanged sheets
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Chapter 2Operating instructions
V4000 PB
14 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
On safety
Correct handling with box-bending
In box-bending and back-stop modes the protective volume is limited and a tolerance zone
around the pressure axis is hidden. If box-like workpieces are not handled correctly, your
hands could get caught between the workpiece and the die or press crosshead.
> Do not hold the upper box walls by the edges or corners on the pressure axis.
> Hold box-shaped workpieces by their back part (closest to you) outside the hazardous
point.
The V4000 PB cannot protect you against these dangers:
 Crushing your hands or fingers between the workpiece and the press crosshead as a
result of handling the workpiece incorrectly during bending
 Crushing your fingers between the die and the workpiece as a result of handling the
workpiece incorrectly
 The risk of injury from workpieces falling when the press brake is opened
 The risk of injury from large workpieces swinging upwards during bending
 When bending aids are used:
Risk of injury due to the workpiece swinging up or down, or to the movement of the
bending aids
Fig. 5: Handling o
f
box-shaped workpieces
Note

Operating instructions Chapter 2
V4000 PB
8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 15
On safety
 When automatically traversing rear stops are used:
– Crushing your hands or fingers between the rear stops and the female die during
traversing movements towards the operator
– The operator being crushed by large workpieces being pushed at him by the rear stops
 Risk of injury in the rear space arising from automatically traversing stops, moving tools,
workpieces or bending aids.
Access to the rear space or standing in the rear space must be prevented by means of the
appropriate safety devices, such as a light grid.
Dangers arising from mounting of the V4000 PB
> When mounting the V4000 PB make sure that there will be no crushing or shearing
points between the moving sender and receiver and other stationary machine parts or
devices in the vicinity of the machine.
> If hazardous points cannot be avoided, they must be made safe by other protective
measures or remedied by design changes.
Note

Chapter 2Operating instructions
V4000 PB
16 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27
On safety
2.6 Environmental protection
The V4000 PB has been designed to minimise environmental impact. It uses only a
minimum of power and natural resources.
> At work, always act in an environmentally responsible manner.
2.6.1 Disposal
Disposal of unusable or irreparable devices should always occur in accordance with the
applicable country-specific waste-disposal regulations
(e.g. European Waste Code 16 02 14).
Before you can turn over the devices for environmentally-friendly recycling, you must
separate the different materials of the V4000 PB from one another.
> Separate the housing from the remaining components (especially the PCB).
> Press the front lens out of the lens holder.
> Send the separated components to the corresponding recycling centres (see Tab. 1).
Component Disposal
Product
Housing Metal recycling (aluminium)
Front lens Glass recycling (used glass)
PCBs, cables, plugs and
electrical connection pieces
Electronics recycling
Packaging
Cardboard, paper Paper/cardboard recycling
Polyethylene packaging Plastic recycling
We would be pleased to be of assistance on the disposal of the V4000 PB. Contact your
local SICK representative.
Material separation may only be performed by specialist personnel!
Exercise care when disassembling the devices. The danger of injury is present.
Tab. 1: Overview of disposal
by component
Note
a
WARNING