Pilz PSENvip RL D P User Manual

Operating Manual PSENvip RL D P Set

Operating Manual PSENvip RL D P Set

PSENvip RL D P Set

Safe camera systems

Operating Manual — No. 1001641-EN-07

This document is a translation of the original document.

All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes.

Suggestions and comments for improving this documentation 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.

Preface

Contents

Contents

Contents Page

Chapter 1 Introduction

1.1 Validity of the documentation 1-2

1.2 Overview of documentation 1-3

1.3 Definition of symbols 1-5

Chapter 2 Overview

2.1 Scope of supply 2-3

Chapter 3 Safety

3.1 Intended use 3-1

3.1.1 Approvals 3-2

3.1.2 Safety during operation 3-2

3.1.2.1 Hazards arising from the installation of the

3-2

PSENvip

3.1.2.2 Hazards arising from a reduced protected

3-2

field

3.1.2.3 Hazards arising from incorrect handling of

3-3

the workpiece

3.1.2.4 Correct handling of the workpiece 3-3

3.1.3 Categories / SIL 3-6

3.1.4 Tool shapes 3-6

3.2 Standards 3-9

3.3 Safety guidelines 3-10

3.3.1 Use of qualified personnel 3-10

3.3.2 EMCD 3-10

3.3.3 Warranty and liability 3-11

3.3.4 Safety during commissioning, installation

3-11

and operation

3.3.5 Disposal 3-11

Chapter 4 Function description

4.1 Overview 4-1

4.2 Protected field 4-5

4.2.1 Dynamic muting 4-6

4.2.2 Standard interrupted press stroke 4-8

4.3 Overrun 4-10

4.4 Description of the units 4-11

4.4.1 Overview 4-11

4.4.2 Transmitter 4-11

4.4.2.1 Inputs 4-11

4.4.3 Receiver 4-12

4.4.3.1 Inputs 4-12

4.4.3.2 Outputs 4-14

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1

Contents

4.4.3.3 LED 4-16

4.4.3.4 Key display and function 4-17

4.4.4 Communication with the safety system 4-20

4.5 Protected field modes 4-24

4.5.1 Standard protected field mode 4-24

4.5.2 Box bending protected field mode 4-25

4.5.3 Back gauge protected field mode 4-26

4.5.4 Box bending with back gauge protected
field mode

4.6 Operating modes during commissioning 4-28

4.6.1 Press brake setup mode 4-28

4.6.2 Adjustment during initial commissioning 4-28

4.6.3 Adjustment during tool change 4-28

4.7 System cycle 4-30

4.7.1 System cycle for standard press stroke 4-31

4.7.2 System cycle for box bending press stroke 4-34

4.7.3 System cycle for back gauge press stroke 4-37

4.7.4 System cycle for box bending with back
gauge press stroke

4-27

4-37

Chapter 5 Installation

5.1 General requirements 5-1

5.2 Install transmitter and receiver 5-2

5.3 Dimensions 5-4

5.3.1 Transmitter 5-4

5.3.2 Receiver 5-5

5.3.3 Fastening kit for the transmitter 5-5

5.3.4 Fastening kit for the receiver 5-6

5.3.5 Bracket for transmitter and receiver 5-7

Chapter 6 Wiring

6.1 Notes on wiring 6-1

6.2 Connections 6-4

6.2.1 Receiver 6-4

6.2.2 Transmitter 6-6

6.2.3 Supply voltage 6-6

6.2.4 Connection between transmitter and re­ceiver

6.2.5 Connection diagram 6-7

Chapter 7 Commissioning

7.1 Commissioning guidelines 7-1

7.2 Initial commissioning 7-2

7.2.1 Align transmitter and receiver 7-2

7.2.1.1 Prepare for alignment 7-2

6-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany

2

Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Contents

7.2.1.2 Adjustment templates 7-2

7.2.1.3 Adjustment directions of transmitter and
receiver

7.2.1.4 Align transmitter 7-5

7.2.1.5 Tool shapes 7-6

7.2.1.6 Align receiver 7-8

7.2.2 Adjustment template with bracket 7-11

7.3 Adjustment during tool change 7-13

7.3.1 Prepare for adjustment during tool change 7-13

7.3.2 Tool detection 7-13

7.3.3 Make adjustment during tool change 7-16

7.4 Enter overrun 7-19

7.5 Check protective equipment 7-21

7.5.1 Function test of the safety device 7-21

7.5.1.1 Test during initial commissioning 7-22

7.5.1.2 Test after machine modification 7-22

7.5.1.3 Regular check 7-22

7.5.1.4 Prepare for function test 7-23

7.5.1.5 Function test using the test piece 7-23

7.5.2 Visual inspection 7-25

7-3

Chapter 8 Operation

8.1 Safety guidelines 8-1

8.2 Operating notes 8-2

8.2.1 Switch on PSENvip 8-2

8.2.2 Muting lamp 8-2

8.2.3 Initial press stroke 8-2

8.2.4 Acknowledge protected field modes 8-3

8.2.5 Tool change 8-4

8.2.6 Error messages 8-4

8.2.7 Cleaning the front lenses 8-5

Chapter 9 Diagnostics and Troubleshooting

9.1 Error Management 9-2

9.1.1 Minor errors 9-2

9.1.2 Major errors 9-2

9.1.3 Fatal errors 9-3

9.2 Error messages 9-4

9.3 DIAGNOSTICS menu 9-6

9.3.1 Diagnostic blocks and diagnostic data 9-6

Chapter 10 System Connections

10.1 Requirements of the user program 10-1

10.2 Communication with the safety system 10-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3

Contents

Chapter 11 Technical details

11.1 Technical details 11-1

11.2 Order reference 11-3

Chapter 12 Attachment

12.1 Check list 12-1

12.2 EC declaration of conformity 12-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany

4

Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1 Introduction

11000IntroductionIntroduction1-Einführung_PSENvip

Einf Aufbewahren

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 involved 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.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1-1

1 Introduction

1.1 Validity of the documentation

1.1Validity of the documentation1100Validity of th e documentation1-Einf Gltigkeit der Dokumentation

This documentation is valid for the product PSENvip RL D P Set. It is

Einfuehrung_Doku_ab_Vers ion_2.0_2012

valid until new documentation is published.

This documentation is valid for the PSENvip from Version 2.2/year of
construction 2013.

1-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1 Introduction

1.2 Overview of documentation

1.2Overview of documentation1200Overview of documentation1-Einführung_Übersicht

1 Introduction

The introduction is designed to familiarise you with the contents, struc­ture and specific order 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 adjustments 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.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1-3

1 Introduction

1.2 Overview of documentation

10 System Connections

This chapter describes how the PSENvip is connected to the press
brake's programmable safety system.

11 Technical Details

12 Appendix

1-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1 Introduction

1.3 Definition of symbols

1.3Definition of symbols1300Definition of symbols1-Einfhrung Zeichen

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 unit(s) could be damaged
and also provides information on preventive measures that can
be taken. It also highlights areas within the text that are of partic­ular importance.

INFORMATION

This gives advice on applications and provides information on
special features.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1-5

1 Introduction

1-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

2 Overview

22000OverviewOverview2-Uebersicht_Allgemein

Uebersicht_Merkmale_Sender

Uebersicht_Merkmale_Empfaenger

Uebersicht_Merkmale_Empfaenger_Eingaenge

The PSENvip is a camera-based protection and measuring system
(electrosensitive protective 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

Uebersicht_Merkmale_Empfaenger_Ausgaenge

Uebersicht_Merkmale_Empfaenger_Ausgaenge_Mute

Uebersicht_Merkmale_Empfaenger_Ein_Aus_Zusatz

Uebersicht_Merkmale_Empfaenger_LED

Uebersicht_Merkmale_Betriebszustaende

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, reduced 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

Uebersicht_Merkmale_Werkzeugerkennung

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

2-1

2 Overview

Upper die

Safety control

system

CNC

Receiver

Lower tool

Detection zone

Upper tool

Transmitter

Uebersicht_Gesamtsystem

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)

Fig. 2-1: Whole system

2-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

2 Overview

2.1 Scope of supply

2.1Scope of supply2100Scope of supply2-Grundlagen

PSENvip RL D P Set: complete set

Order reference Description

PSENvip RL D P PSENvip receiver, left, with display

and dynamic muting

PSENvip T PSENvip transmitter

PSENvip AT mag Adjustment templates with magnets

PSENvip AP Set of adjustment plates for transmit-

ter/receiver

PSENvip TP Test piece in accordance with

EN 12622, Annex H

DVD with operating manuals

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

2-3

2 Overview

2-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.1 Intended use

33000SafetySafety3-3.1Intended use3100Intended use3-Sicherheit_Bestimm_Allg

Sicherheit_Bestimm_Allg_dyn_Muting

The PSENvip is exclusively designed for stationary use on press brakes.
As electrosensitive 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 remaining gap of 6 mm (dynamic muting)

Sicherheit_Bestimm_Allg_NLW

Sicherheit_Bestimm_Allg_Zusaetze

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 safeguard 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 interference, e.g. wireless remote controls for cranes,
welding sparks, strobe lighting effects.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-1

3 Safety

4

4

4

3.1 Intended use

3.1.1 Approvals

Approvals3-Sicherheit_Zulassungen

3.1.2 Safety during operation

Safety during operation3-Sicherheit_Betrieb_Allg

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

Hazards arising from the installation of the PSENvip3-Sicherheit_Betrieb_Montage

When installing the PSENvip, please note the following:

 The PSENvip must be installed so that there are no crushing or shear-

ing 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

Hazards arising from a reduced protected field3-Sicherheit_Betrieb_Schutzfeld_reduziert

The full protected field is only active in standard protected field mode.
In box bending 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 protected 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.

3-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.1 Intended use

3.1.2.3 Hazards arising from incorrect handling of the workpiece

Hazards arising from incorrect handling of the workpiece3-Sicherheit_Betrieb_Handhabung_Werkstueck_falsch

The PSENvip does not protect against hazards arising from incorrect
handling of the workpiece.

When bending metal sheets on press brakes there is a risk of hand inju­ries

 From the tool's closing movement
 From the swivel movement of the parts of the metal sheet that pro-

trude 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 work-

piece is handled correctly.

 Wear protective gloves to prevent cuts from edges, corners and ridg-

es.

3.1.2.4 Correct handling of the workpiece

Correct handling of the workpiece3-Sicherheit_Warnung_Quetschen_1

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.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-3

3 Safety

3.1 Intended use

Sicherheit_Betrieb_Handhabung_Werkstueck_richtig

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. 3-1: Handling flat workpieces

3-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.1 Intended use

Correct handling with box bending

 Hold the sheet on the right and left between the thumb and index fin-

ger.

 As you hold the sheet, do not reach with your hands into the box. Dur-

ing the bending operation, fingers or hands can become crushed or
trapped between the workpiece and upper tool.

Fig. 3-2: Handling box bending

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-5

3 Safety

3.1 Intended use

3.1.3 Categories / SIL

Categories / SIL3-Sicherheit_Kategorien_P_Variante

3.1.4 Tool shapes

Tool shapes3-Sicherheit_Werkzeugformen

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 assessment. For this reason, Pilz
cannot accept liability for the correct classification into a category or
SIL.

All tool shapes are permitted in principle. They are divided into tool
classes by the PSENvip. Classification is based on EN 12622, according
to which the protected field must safeguard 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

"Commissioning".

 In the section entitled "Requirements of the user program", un-

der "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.

3-6

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.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.1 Intended use

 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.

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 system.

– Each press stroke must be acknowledged by the operator

prior to initiation.

Sicherheit_Werkzeugformen_Beispiele

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-7

3 Safety

3.1 Intended use

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. 3-3: Danger zone in unmonitored zone

Example: In unmonitored zones, the use of tools which are not fully de­tected by the protected 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!

3-8

Fig. 3-4: Crush points when the tool is wider than the protected field

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.2 Standards

3.2Standards3200St andards3-Sicherheit_Normen

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 61496-1:2004: Safety of machinery - Electrosensitive protective

equipment, Part 1

 CLC/TS 61496-2:2006: Safety of machinery - Electrosensitive protec-

tive equipment, Part 2

 EN 12622:2009: Machine tools - Hydraulic press brakes
 EN ISO 13849-1:2008: Safety of machinery – Safety-related parts of

control systems - Part 1: General principles for design

 EN ISO 13849-2:2008: Safety of machinery – Safety-related parts of

control systems - Part 2: Validation

 EN 61508:2001: Functional safety of safety-related electrical/elec-

tronic/programmable electronic systems

Please note this is not an exhaustive list of safety standards and direc­tives.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-9

3 Safety

3.3 Safety guidelines

3.3Safety guidelines3300Safety guidelines3-Sicherheit_Sicherheitsrichtlinien_Allgemein

Failure to keep to these guidelines will render all warranty and liability
claims invalid:

 All health and safety / accident prevention regulations for the particu-

lar 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 themselves responsible for agreeing the regulations with
the relevant authorities and complying with them.

3.3.1 Use of qualified personnel

Use of qualified personnel3-Sich Qualif. Personal

Sicherheit_Qualifikation_BWS

The products may only be assembled, installed, programmed, commis­sioned, operated, maintained and decommissioned by competent per­sons.

A competent person is someone who, because of their training, experi­ence and current professional activity, has the specialist knowledge re­quired to test, assess and operate the work equipment, devices,
systems, plant and machinery in accordance with the general standards
and guidelines for safety technology.

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 safety guidelines given in this descrip-

tion

 Have a good knowledge of the generic and specialist standards ap-

plicable 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.

3-10

3.3.2 EMCD

EMCD3-Sicherheit_EMVG

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.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3 Safety

3.3 Safety guidelines

3.3.3 Warranty and liability

Warranty and liability3-Sich Gewhrleistung

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 compo-

nents on the PCB boards, soldering work etc.).

3.3.4 Safety during commissioning, installation and operation

Safety during commissioning, installation and operation3-Sicherheit_Inbetriebnahme_Montage_Betrieb

Please read the guidelines stated in the chapters entitled "Commission­ing", "Installation" and "Operation".

3.3.5 Disposal

Disposal3-Si ch Entsorgung

 In safety-related applications, please comply with the mission time t

M

in the safety-related characteristic data.

 When decommissioning, please comply with local regulations regard-

ing the disposal of electronic devices (e.g. Electrical and Electronic
Equipment Act).

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

3-11

3 Safety

3-12

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

3

12

4 56

4.1 Overview

44000Function descriptionFunction description4-4.1Overview4100Overview4-Funktion_Ueberblick_P_Variante

The PSENvip is a camera-based protection system for press brakes. It
consists of a transmitter 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.

Fig. 4-1: Press brake with PSENvip

 1: Upper tool
 2: Upper die
 3: Receiver
 4: Detection zone
 5: Lower tool

Funktion_Gesamtsystem_P_Variante

 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 re-

duced protected field or setup mode, E-STOP pushbutton)

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-1

4 Function description

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

Acknowledge­ment 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

4.1 Overview

 Other safety devices (safety valves, prefill valve, contactor for E-

STOP)

The following overview shows the fundamentals of the whole system.
The signals from the PSENvip transmitter and receiver are explained in
the sections below.

Funktion_Geraete_Schutzfeldmodus

4-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 4-2: Overview of overall system

4 Function description

4.1 Overview

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.

Funktion_PSS_4000

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

Funktion_Optik

10 "System Connections").

Funktion_Schutzraum

The receiver evaluates the parallel beams generated by the transmitter.
The beam is enclosed by the illuminated target area. The lens on the re­ceiver only detects light that runs parallel to the optical axis. This guar­antees stability against diffused light.

WARNING!

The light generated by the transmitter is not hazardous to the
human eye.
However, do not use additional optical aids, e.g. lenses, to look
at the light from the transmitter. This could damage the eye.

The receiver monitors and evaluates the detection zone between the
transmitter and receiver. The protected field is the cross section of the
detection zone. It consists of several segments.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-3

4 Function description

1

2

3

4

4.1 Overview

Funktion_Schutzfeld_allgemein

Fig. 4-3: Definitions

Key:

 1: Light beam bundle
 2: Illuminated target area
 3: Protected field
 4: Detection zone

The shape and size of the protected field depend on the bending func­tion and the machine-dependent overrun. A reduced protected field is
possible for box bending and/or back gauge mode (for the size of the
protected field please see "Protected field" section and the chapter en­titled "Technical Details").

If an object encroaches into the detection zone, both output signal
switching devices (OSSD1 and OSSD2) on the PSENvip will switch to
the OFF-state. The safety system will use these signals to initiate stop­ping of the press stroke.

4-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

Bending line

Upper tool
Illuminated target area

Rear segments

Workpiece

Lower tool

Adjustment line

Front segments

Central segments

44

max. 20

min. 8

6

1

Overrun distance 2 m

Overrun distance 14 mm

4.2 Protected field

4.2Protected field4200Protected field4-Funktion_Schutzfeld

The protected field consists of several segments. The front and rear seg­ments (viewed from the operator's side) can be deactivated. This pro­vides flexibility to adapt to the bending function:

 Standard

Full protected field: all segments active

 Box bending

Reduced protected field: front segments deactivated

 Bending with back gauge

Reduced protected field: rear segments deactivated

 Box bending with back gauge

Reduced protected field: front and rear segments deactivated

Funktion_Schutzfeld_Groesse

Funktion_Schutzfeld_Info_Kastenbiegen

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 4-4: Protected field definitions

The height of the protected field depends on the overrun. For the setting
range of the overrun please see following figure and Chapter 11, "Tech­nical Details".

Fig. 4-5: Size of the detection zone

4-5

4 Function description

max. 20

0,4

4.2 Protected field

INFORMATION

Please note that the central segments are 1 mm behind the
bending line. With box bending you must ensure that the side
panels of the box do not encroach into this area.

Funktion_Schutzfeld_Hinweise

The two following sections explain the basic mode of action of the pro­tected field during a press stroke (interrupted and uninterrupted).

INFORMATION

The cycle of a press stroke with the corresponding inputs and
outputs is explained in this chapter, in the section entitled "Sys­tem cycle".

4.2.1 Dynamic muting

Funktion_vorauseilendes_Messfeld_Muting_Allgemein

Dynamic muting4-

Funktion_vorauseilendes_Messfeld_Groesse

Funktion_vorauseilendes_Messfeld_Muting_Zustaende

An advance measuring field is located below the protected field. If is in­terrupted, the dynamic muting is started. The dynamic muting ensures
that the danger zone between upper tool and plate is monitored up to a
remaining gap of 6 mm during the downward movement.

The distance of the advance measuring field to the lower edge of the
protected field is constant. The distance to the top edge of the protected
field varies according to the length of the overrun.

Fig. 4-6: Distance of advance measuring field from protected field

4-6

Procedure:

1. The press is on downward movement. The protected field moves
down with the upper tool.

2. The advance measuring field touches the workpiece. The outputs
Mute1 and Mute2 at the receiver are set = 0.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

6 mm

4.2 Protected field

3. The advance measuring field is used to hold the protected field sta­tionary at the pinch point on the workpiece. The segment division is
optimised for the dynamic muting process.

4. The respective upper segments are deactivated before the upper tool
enters the protected field.

NOTICE

The control system may only override the safety function from a
remaining gap of 6 mm.

Signal statuses of the outputs Mute1/Mute2 and OSSD1/OSSD2

full protected field active

OSSD1/ OSSD2 = 1
Mute1/Mute2 = 1

full protected field active
advance measuring field touches
plate

OSSD1/ OSSD2 = 1
Mute1/Mute2 = 1 -> 0

Remaining gap = 6mm

OSSD1/ OSSD2 = 1 -> 0
Mute1/Mute2 = 0

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-7

4 Function description

4.2 Protected field

The signal statuses of the outputs Mute1/Mute2 and OSSD1/OSSD2
when interrupting the protected field by side intervention or interruption
of the advance measuring field before reaching the plate are described
in section entitled "Standard interrupted press stroke".

4.2.2 Standard interrupted press stroke

Standard interrupted press stroke4-Funktion_Pressenhub_mit_Unterbrechung_dyn_mute

It is necessary to distinguish between

 Interruption of the advance measuring field

and

 Side intervention with full protected field and reduced protected field

during the dynamic muting

Interruption of the advance measuring field

1

Downward movement
Object interrupts advance
measuring field, starts dy­namic muting

OSSD1/OSSD2 = 1
Mute1/Mute2 = 1 -> 0

Safety system initiated the
stopping of the press,
measuring field was not in­terrupted in the expected
position (pinch point)

2

Upper tool continues mov­ing for the overrun distance.
Protected field interrupted
Object is removed Protect­ed field cleared. Press
stroke can be resumed.

4-8

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.2 Protected field

Side intervention with full protected field or reduced protected field
during the dynamic muting

1

Object interrupts the pro­tected field to the side:

OSSD1/OSSD2= 1 -> 0
Mute1/Mute2 = 1

Safety system initiates the
stopping of the press stroke

2

Upper tool continues mov­ing for the overrun distance.
Protected field interrupted
Object is removed Protect­ed field cleared. Press
stroke can be resumed.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-9

4 Function description

4.3 Overrun

4.3Overrun4300Overrun4-Funktion_Nachlaufweg_Allgemein

The max. overrun is a press brake variable that will depend on the ma­chine type. Once the closing movement has stopped, the max. overrun
must not be exceeded.

The overrun is entered during configuration via the keypad on the
PSENvip receiver.

INFORMATION

Please refer to chapter 11, "Technical Details", for more informa­tion about the input area of the overrun.
Details on how to enter the overrun are described in Chapter 7,
“Commissioning”, section entitled “Enter overrun”.

Funktion_Nachlaufweg_P_Variante

Funktion_Nachlaufweg_Warnung_3

Normally, the factory-assigned overrun is sufficient and does not have
to be configured.

WARNING!

If you require a different overrun path than the factory-set path,
then use the value indicated by the manufacturer on the name­plate of the press brake, or a higher value.
If you enter a lower value for the overrun, the protected field will
also be reduced to an unpermitted level.
Failure to comply could result in a hazardous situation, which
could lead to serious injury and death.

4-10

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

1

2

3

4

4.4 Description of the units

4.4Description of the units4400Descriptio n of the units4-

4.4.1 Overview

Overview4-Funktion_Geraete_Sender_Empfaenger

The transmitter and receiver form one unit. The receiver contains all the
inputs and outputs required for communication with the CNC controller,
programmable safety system, transmitter and press brake. The trans-

Funktion_Geraete_Sender_Empfaenger_RL_D

mitter merely contains the inputs for controlling the light source.

4.4.2 Transmitter

Transmitter4-Funktion_Geraete_Sender_Stecker

4.4.2.1 Inputs

Inputs4-Funktion_Geraete_Sender_Eingang_TRM_ON_TRM_SYNC

Fig. 4-7: Transmitter and receiver

 1: Display
 2: Receiver
 3: LED: OSSD status
 4: Transmitter

The top of the transmitter has a 4-pin M12 connector.

The receiver uses these standard inputs to control the transmitter's light
source. The user cannot influence these internal signals.

 TRM_ON

The receiver uses this signal to switch the transmitter's light source
on and off.

 TRM_SYNC

The receiver uses this signal to control the intensity of the transmit­ter's light source.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-11

4 Function description

4.4 Description of the units

4.4.3 Receiver

Receiver4-Funktion_Geraete_Empfaenger_Stecker

The top of the receiver has two 8-pin M12 connectors.

4.4.3.1 Inputs

Inputs4-Funktion_Geraete_Empfaenger_Eingaenge_1_P

Funktion_Geraete_Empfaenger_Eingaenge_2

 System-Init

Input whose signal comes from the safety system PSS 4000.
System-Init = 1: Press at top dead centre or in an upward movement
System-Init = 0: Downward movement
The PSENvip can perform internal availability tests and completely
activate the protected field when System-Init = 1. The outputs OSSD
and mute are in the OFF state (OSSD = 0, Mute = 0).

Funktion_Geraete_Empfaenger_Eingaenge_3

INFORMATION

Please note that the PSENvip independently carries out an inter­nal safety test every 2 minutes, if such a test is not requested
within this time by an external control system through System­Init = 1. The PSENvip switches the OSSDs off during the safety
tests. For this reason you should ensure that the safety tests are
requested by an external control system before these 2 minutes
have elapsed. The best time to do this is when the OSSDs are
already switched off due to the position within the press stroke,
e.g. at top dead centre.

 Power Off

Input signalling that the press brake is in setup mode.
Power Off = 1: Setup mode activated
All safety functions are deactivated in setup mode.

– The display is switched on.
–The OSSD LED on the receiver lights up red.
– The light source is switched off.

4-12

INFORMATION

The Power Off input has another function during the system sta­tus TEST. It is used for communication with the safety system.
See "Communication with a safety system" in this section.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.4 Description of the units

 Acknowledgement

Input to acknowledge that a press stroke is to be performed with a
reduced protected field (front and/or rear segments blanked). The
protected field mode selected is shown on the receiver's display.
Acknowledgement = 0/1 pulse edge via pushbutton: Run selected
protected field mode

 Protected field mode 1/protected field mode 2

Two safe inputs for setting the protected field mode. The CNC or
safety system provides the signal. It is only absolutely necessary to
connect the inputs to a safety system if communication is needed for
tool detection.

Protected
field mode

12

0 0 Standard

10Box bending

0 1 Bending with back gauge

1 1 Box bending with back gauge

INFORMATION

The inputs for protected field mode have another function during
the system status TEST. They are used for communication with
the safety system. See "Communication with a safety system" in
this section.

Bending function

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-13

4 Function description

4.4 Description of the units

4.4.3.2 Outputs

Outputs4-Funktion_Geraete_Empfaenger_Ausgang_OSSD

 OSSD1/OSSD2 in accordance with EN 61496-1, type 4

Two safe outputs that signal the status of the protected field:
OSSD = 1: Protected field clear

Funktion_Geraete_Empfaenger_Ausgang_Mute

OSSD = 0: Protected field broken

 Mute1/Mute2 in accordance with EN 61496-1, type 4

Two safe outputs that signal the dynamic muting
Mute1/Mute2 = 1: no dynamic muting
Mute1/Mute2 = 0: dynamic muting active

INFORMATION

The outputs Mute1/Mute2 have another function during the sys­tem status TEST. They are used for communication with the
safety system. See "Communication with a safety system" in
this section.

Funktion_Geraete_Empfaenger_Ausgang_Ausgangstest_Info

Funktion_Geraete_Empfaenger_Ausgang_Ausgangstest

INFORMATION

For details of the output behaviour during a press stroke please
refer also to the section entitled "System cycle", in this chapter.

INFORMATION

The outputs OSSD1/OSSD2 and Mute1/Mute2 are checked via
regular output tests.

Output test

Outputs that are switched on are checked via regular off tests.

 Test pulses for outputs that are switched on: see Technical Details
 Outputs that are switched on are switched off for the duration of the

test pulse.

 The load must not switch off because of the test.

Outputs that are switched off are checked via regular on tests.

 Test pulses for outputs that are switched off: see Technical Details
 Outputs that are switched off are switched on for the duration of the

test pulse.

4-14

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

1

t

2

t

1

t

1

t

3

t

1

t

t

2

t

1

U

0

4.4 Description of the units

 The load must not switch on because of the test.

Testing for shorts

 A test is regularly carried out to check for shorts between the outputs.

][Funktionsbeschreibung_BA_Zusatz Einschalttest

Fig. 4-8: Test pulses

Key:

 t

: Pulse length of on test (40 μs)

1

 t

: Repetition length of on test (100 μs ... 3 ms)

2

 t

: Cycle time of on test (30 μs ... 5 min)

3

WARNING!

When wiring an output with capacitance it is essential to note
the pulse duration, repetition period and scan time of the power­up test, otherwise the load may switch on unintentionally.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-15

4 Function description

1

4.4 Description of the units

4.4.3.3 LED

LED4-Funktion_Geraete_Empfaenger_LED_OSSD

 OSSD

The OSSD LED on the receiver indicates the status of the protected
field.
Green: The protected field is clear

Funktion_Geraete_Empfaenger_LED_RL_D_Abbildung

Red: Protected field is interrupted

Fig. 4-9: LED on receiver

 1: OSSD LED

4-16

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

PSENvip

12 3

46

MODE

ESC

5

MODE

ESC

4.4 Description of the units

4.4.3.4 Key display and function

Key display and function4-Funktion_Display_Allgemein

The PSENvip receiver has an integrated display. Data can be entered via

Funktion_Display_Pilz

a membrane keypad.

Funktion_Display_Legende

Funktion_Display_Tasten

Fig. 4-10: Display on the receiver

Key:

 1: Navigation keys
 2: <MODE> key
 3: Display
 4: <ESC> key
 5: Tool change
 6: <ENTER> key

Key functions

Key Description

Move in the direction of the arrows (scroll function) (up/
down)

Confirm entry - together with the <ENTER> key when con­firming the entered overrun and making adjustments during
a tool change

Call up the operating modes: tool change and adjustment
during initial commissioning. The DIAGNOSTICS menu is
also available.

Close current window, cancel entry

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-17

4 Function description

SYSTEM OK

OSSD ON

NORMAL OPERATION

À

Ã

Â

Á

4.4 Description of the units

Key Description

Funktion_Display_Abbildung

Display

Call up tool change operating mode directly

Confirm entry or menu option selection

Funktion_Display_Systemzustand

Fig. 4-11: Information on the display

The display is divided into 4 segments:

 1: System status
 2: Status of the OSSD
 3: Input and display field
 4: Operating status

4-18

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.4 Description of the units

System status

Status Description

SYSTEM OK The PSENvip is performing the specified operating mode

TEST The PSENvip is performing calibration and internal tests.

STANDBY The PSENvip is deactivated when the press is in setup

ERROR An error has occurred (HOLD, STOP, FATAL). See

Funktion_Display_OSSD

Status of the OSSD

Status Description

OSSD ON The output signal switching devices OSSD1 and OSSD2

OSSD OFF The output signal switching devices OSSD1 and OSSD2

Funktion_Display_Betriebszustand_P_Variante

without error, see table: "Operating status"

mode.

Chapter 9, "Diagnostics and Troubleshooting"

are in the ON state.
The protected field is clear.

are in the OFF state.
The protected field is interrupted. Or the PSENvip is not in
the status: SYSTEM OK or NORMAL OPERATION

Funktion_Display_Eingabe feld

Operating state

State Description

NORMAL OP­ERATION

SETUP This is the operating mode in which you enter the overrun.

TOOL CHANGE This is the operating mode in which you track the adjust-

ADJUSTMENT This is the operating mode in which you set up the trans-

DIAGNOSTICS System data and error codes are displayed in this menu.

MENU On pressing the <MODE> key, you can choose between

One of the protected field modes is activated.
See Chapter 8, "Operation"

See Chapter 7, "Commissioning"

ment line to the tip of the tool during a tool change.
See Chapter 7, "Commissioning"

mitter and receiver mechanically so that they are calibrated
with each other.
See Chapter 7, "Commissioning"

Pilz technical support can use these to locate errors.
See Chapter 9, "Diagnostics and Troubleshooting"

the following
options:

- TOOL CHANGE: Adjustment during tool change

- ADJUSTMENT: Adjustment during initial commissioning

- DIAGNOSTICS: Display error codes

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-19

4 Function description

4.4 Description of the units

The input and display field is used to

 Display the active protected field mode

See chapter 8, "Operation"

 Enter the overrun

See chapter 7, "Commissioning"

 Menu Selection
 Display the adjustment image during initial commissioning

See chapter 7, "Commissioning"

 Display the adjustment image during a tool change

See chapter 7, "Commissioning"

 Display of error messages and system data

See Chapter 9, "Diagnostics and Troubleshooting"

4.4.4 Communication with the safety system

Communication with the safety system4-Funktion_Kommunikation_Allg

Communication between the PSENvip and safety system is required if
you use tools that cannot be safeguarded in compliance with the stand­ards (see section entitled "Tool shapes", under "Safety"). This is the
case with tool classes 2 and 3. User programs that do not support com­munication with the PSENvip can be used if you only intend to safeguard
tools of tool class 1. This is the case with older versions of the PSENvip,
for example.

Communication between the PSENvip and the PLC safety system is
conducted via digital inputs and outputs. Some inputs and outputs on
the PSENvip have another function compared to normal mode.

Communication only occurs in the system status TEST. This status is
adopted

 After power-up.
 After a tool change.
 After a 0/1 pulse edge at the input System-Init.

Funktion_Kommunikation_P_Variante

 Periodically every 2 minutes.

4-20

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

X1, 1

PLC Ready

X2, 1

X1, 6

X2, 6

X2, 2

PSENvip

Tool class PLC -> PSENvip Bit 1

Acknowledge PSENvip -> PLC

Tool class PSENvip -> PLC Bit 1

X1, 3

X1, 4

Activate

Tool class PSENvip -> PLC Bit 2

Tool class PLC -> PSENvip Bit 2

PLC

I1

I4

I3

I2

O3

O2

O1

4.4 Description of the units

Terminal Input/output Normal mode Communication with safety sys-

X1, 1 Output No function Activate The PSENvip starts com-

X2, 1 Output No function Acknowledge PSENvip -> PLC The PSENvip confirms

X1, 6 Output Mute1 Tool class PSENvip -> PLC Bit 1 The PSENvip sends Bit 1

X2, 6 Output Mute2 Tool class PSENvip -> PLC Bit 2 The PSENvip sends Bit 2

X2, 2 Input Power Off PLC Ready The safety system is

X1, 3 Input Protected field

X1, 4 Input Protected field

Funktion_Kommunikation_Ablauf

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 4-12: Digital inputs and outputs for communication

Key to inputs and outputs:

tem

Tool class PLC -> PSENvip Bit 1 The safety system re-

mode 1

Tool class PLC -> PSENvip Bit 2 The safety system re-

mode 2

Notes

munication.

the validity of the tool
class registered on the
safety system.

of the detected tool class
to the safety system.

of the detected tool class
to the safety system.

ready for communication.

flects Bit 1 of the tool
class.

flects Bit 2 of the tool
class.

4-21

4 Function description

PLC Ready

1

0

1

0
1

0
1

0
1

0

Activate

Acknowledge PSENvip -> PLC

1

0

Tool class PSENvip -> PLC Bit 1

1

0

Tool class PSENvip -> PLC Bit 2

Tool class PLC -> PSENvip Bit 1

Tool class PLC -> PSENvip Bit 2

12345 6 7

max. 600 ms

max.

200 ms

max.

200 ms

max.

200 ms

4.4 Description of the units

Communication sequence:

4-22

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

 1

– The PSENvip starts communication.

Activate = 0/1 pulse edge

– Tool class PLC -> PSENvip Bit 1/2: Bits can have any status

 2

– The safety system is ready for communication.

PLC Ready = 0/1 pulse edge

– Tool class PLC -> PSENvip Bit 1/2 = 0 to step 5

 3

The PSENvip sends the detected tool class to the safety system.

Tool class PSENvip -> PLC Bit 1 0 1 1

Tool class PSENvip -> PLC Bit 2 1 0 1

 4

The PSENvip confirms the validity of the tool class registered on the
safety system in step 3.
Acknowledge PSENvip -> PLC = 0/1 pulse edge

 5

– The safety system reflects the tool class transmitted by the PSEN-

vip.

– Tool class PLC -> PSENvip Bit 1/2 = 0 or 1, depending on the tool

class

Tool class
123

4 Function description

4.4 Description of the units

Tool class PLC -> PSENvip Bit 1 0 1 1

Tool class PLC -> PSENvip Bit 2 1 0 1

 6

The PSENvip ends communication.

All outputs are set = 0:
– Activate = 0
– Acknowledge PSENvip -> PLC = 0
– Tool class PSENvip -> PLC Bit 1 = 0
– Tool class PSENvip -> PLC Bit 2 = 0

 7

– The safety system ends communication.

PLC Ready = 1/0 pulse edge

– Tool class PLC -> PSENvip Bit 1/2 = 0 or 1, depending on the orig-

inal status

Tool class
123

INFORMATION

The requirements of the user program in the safety system are
described under "System Connections".

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-23

4 Function description

4.5 Protected field modes

4.5Protected field modes4500Protected field modes4-Funktion_Schutzfeldmodus

Four protected field modes are available for adapting to different bend­ing functions:

 Full protected field: Standard press stroke
 Reduced protected field:

– Box bending press stroke
– Back gauge press stroke
– Box bending with back gauge press stroke

Funktion_Schutzfeldmodus_Werkzeugklasse

Use of the protected field modes depends on the tool class. Not all pro­tected field modes can be selected with tool class 2 and 3.

Protected field mode Tool class

Standard
Full protected field

Box bending
Front segments blanked

Back gauge
Rear segments blanked

123

Yes Yes Yes

Yes Yes No

Yes No No

4.5.1 Standard protected field mode

Standard protected field mode4-Funktion_Schutzfeldmodus_Standard

The full protected field is available with standard protected field mode.
This protected field mode is applied for flat workpieces.

Fig. 4-13: Standard protected field mode

4-24

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

1

4.5 Protected field modes

4.5.2 Box bending protected field mode

Box bending protected field mode4-Funktion_Schutzfeldmod us_Kastenbiegen

With box bending protected field mode, the front segments of the pro­tected field are blanked. This protected field mode is used for workpiec­es that need to be bent several times, e.g. a box. Interruption of the front
segments is to be expected and does not cause the press stroke to
stop.

The central segments of the protected field are behind the bending line.
The box's side panels must not encroach into the central segments.

If the central or rear segments of the protected field are interrupted, the
OSSDs switch to the OFF state.

Sicherheit_Warnung_Quetschen_Kastenbiegen

Fig. 4-14: Box bending protected field mode

 1: Front segments of protected field are blanked

The box bending protected field mode is only active for one press stroke
and must be acknowledged by the operator before it is initiated.

WARNING!
Crushing and trapping of fingers or hands!

With box bending protected field mode, the front segments of
the protected field are blanked.
Around the bending line there is an increased risk of crushing
and trapping of fingers or hands.
Make sure that the workpiece is handled correctly (see
Chapter 3, “Safety”).

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-25

4 Function description

1

4.5 Protected field modes

4.5.3 Back gauge protected field mode

Back gauge protected field mode4-Funktion_Schutzfeldmodus_Anschlag

With back gauge protected field mode, the rear segments of the protect­ed field are blanked. This protected field mode is used when the rear
back gauge extends into the vicinity of the bending line. Interruption of
the rear segments is to be expected and does not cause the press
stroke to stop.

If the front and central segments of the protected field are interrupted,
the OSSDs switch to the OFF state.

Sicherheit_Warnung_Quetschen_Anschlag

Fig. 4-15: Back gauge protected field mode

 1: Rear segments of protected field are blanked

The back gauge protected field mode is only active for one press stroke
and must be acknowledged by the operator before it is initiated.

WARNING!
Crushing and trapping of fingers or hands!

With back gauge protected field mode, the rear segments of the
protected field are blanked.
Around the bending line there is an increased risk of crushing
and trapping of fingers or hands.
Make sure that the workpiece is handled correctly (see
Chapter 3, “Safety”).

4-26

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

1

2

4.5 Protected field modes

4.5.4 Box bending with back gauge protected field mode

Box bending with back gauge protected field mode4-Funktion_Schutzfeldmodus_Kaste mbiegen_mit_Anschlag

With box bending with back gauge protected field mode, both the rear
and front segments of the protected fields are blanked. This protected
field mode is applied for workpieces that need to be bended several
times, e.g. boxes, and when the rear back gauge extends into the vicin­ity of the bending line. Interruption of the front and rear segments is to
be expected and does not cause the press stroke to stop.

The central segments of the protected field are behind the bending line.
The box's side panels must not encroach into the central segments.

If the central segments of the protected field are interrupted, the OSSDs
switch to the OFF state.

Fig. 4-16: Box bending with back gauge protected field mode

 1: Rear segments of protected field are blanked
 2: Front segments of protected field are blanked

The box bending with back gauge protected field mode is only active for
one press stroke and must be acknowledged by the operator before it is
initiated.

Sicherheit_Warnung_Quetschen_Kastenbiegen_Anschlag

WARNING!
Crushing and trapping of fingers or hands!

With box bending with back gauge protected field mode, both
the front and rear segments of the protected fields are blanked.
Around the bending line there is an increased risk of crushing
and trapping of fingers or hands.
Make sure that the workpiece is handled correctly (see
Chapter 3, “Safety”).

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-27

4 Function description

4.6 Operating modes during commissioning

4.6Operating modes during commissioning4600Operating modes during commissioning4-Funktion_Betriebsarten_Inbetriebnahme_Allg

The PSENvip has the following options for commissioning:

 Press brake setup mode
 Adjustment during initial commissioning
 Adjustment during tool change

4.6.1 Press brake setup mode

Press brake setup mode4-Funktion_Betriebsarten_Inbetriebnahme_Einrichten

Setup mode must be activated when work is to be carried out on the
press brake. The transmitter and receiver must be switched off. The dis­play is switched on. By switching off the transmitter's light source the
tool setter has visual communication that there is no safety function via
the protected field. The OSSD LED on the receiver lights up red.

The input Power Off = 1 switches off the transmitter's light source.

4.6.2 Adjustment during initial commissioning

Adjustment during initial commissioning4-Funktion_Betriebsarten_Inbetriebnahme_Justage_Erstinbetriebnehme

The transmitter and receiver are aligned to each other during initial com­missioning. The vertical and horizontal alignment is performed using
templates and is displayed on the receiver.

In this operating mode

 The protected field is inactive.
 The OSSDs are switched off.
 There is no protection via the PSENvip.

INFORMATION

Details of the adjustments made during initial commissioning are
described in Chapter 7, "Commissioning", section entitled "Ini­tial commissioning".

4-28

4.6.3 Adjustment during tool change

Adjustment during tool change4-Funktion_Betriebsarten_Inbetriebnahme_Justage_Werkzeugwechsel_1

The tool is assigned to a tool class in "Tool change" operating mode.
Once the tool data has been saved it is downloaded to the safety sys­tem.

Funktion_Betriebsarten_Inbetriebnahme_Justage_Werkzeugwechsel

The adjustment line is automatically tracked to the tip of the tool. The
tracking is shown on the display. This makes it easier to adjust to the dif­ferent tool sizes.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.6 Operating modes during commissioning

INFORMATION

Generally you should not have to mechanically realign the trans­mitter and receiver during a tool change.

In this operating mode

 The protected field is inactive.
 The OSSDs are switched off.
 There is no protection via the PSENvip.

INFORMATION

Details of the adjustments made during a tool change are
described in Chapter 7, "Commissioning", section entitled
"Adjustment during tool change".

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-29

4 Function description

TDC

6 mm

BDC

v = 0

v > 0
v < 0

v = 0

6 mm

KP

Mute 1/2

4.7 System cycle

4.7System cycle4700System cycle4-Funktion_Systemablauf_Muting

This section illustrates the interdependencies of the parameters on the
press brake, PSENvip and safety system during a press stroke. The fol­lowing parameters are illustrated:

 Status: Describes the cycle status. The upward movement of the

press is assumed as a safe movement.

 Foot switch: Start/stop press stroke
 System-Init: Press brake is at top dead centre
 OSSD: Output signal switching devices of the PSENvip
 Protected field: Free, interrupted
 Mute 1/2: signals whether dynamic muting is activated or deactivat-

ed.

Mute 1/2 are reset to "1" when the protected field is completely ac-

tivated and the advance measuring field is free.

A protected field that has already been partly deactivated can be

completely reactivated by
– side intervention
– the signal System-Init = 1

 Dynamic muting:

– reset: advance measuring field touches pinch point on the work-

piece

– End: Tool centre point reaches the 6 mm point

4-30

Fig. 4-17: Definitions

Legend:

 TDC top dead centre

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

 6 mm: 6 mm point, end of dynamic muting
 PP: Pinch point
 BDC bottom dead centre
 v = 0 mm/s closing speed at top/bottom dead centre
 v > 0 mm/s downward movement

4 Function description

v = 0

TDC

v > 0

4.7 System cycle

 v > 0 mm/s upward movement
 Mute 1/2: Segment switches outputs Mute 1 and Mute 2

4.7.1 System cycle for standard press stroke

System cycle for standard press stroke4-Funktion_Systemablauf_Pressenhub_Standard_Muting

Inputs on the PSENvip receiver:

 Protected field mode 1 = 0
 Protected field mode 2 = 0
 Power Off = 0

1

Status Press is at top dead centre
Foot switch 0
System-Init 1
OSSD 0
Protected field Free
Mute 1/2 0
Dynamic muting Inactive

2

Status Downward movement
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 1
Dynamic muting Inactive

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-31

4 Function description

v > 0

KP

v > 0

KP

8 mm

v > 0

6 mm

6 mm

4.7 System cycle

3

Status Downward movement

Advance measuring field touches

plate (pinch point)
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 1 -> 0
Dynamic muting Start

4

Status Downward movement

Tool centre point reaches the 8 mm

point
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 0
Dynamic muting Active

5

Status Downward movement

Tool centre point reaches the 6 mm

point
Foot switch 1
System-Init 0
OSSD 1 -> 0

Muting of the OSSD in steps 5 to 8 in

the safety system
Protected field Interrupted
Mute 1/2 0
Dynamic muting End

4-32

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

v > 0

6 mm

v = 0

BDC

v < 0

4.7 System cycle

6

Status Downward movement
Foot switch 1
System-Init 0
OSSD 0
Protected field Interrupted
Mute 1/2 0
Dynamic muting Inactive

7

Status Press is at bottom dead centre
Foot switch 1
System-Init 0
OSSD 0
Protected field Interrupted
Mute 1/2 0
Dynamic muting Inactive

8

Status Upward movement

Advance measuring field is cleared
Foot switch 1

Generally, the press travels up auto-

matically, the operator can release the

foot switch.
System-Init 1
OSSD 1 or 0
Protected field Free or interrupted
Mute 1/2 0 - > 1
Dynamic muting Inactive

Continue with step 1

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-33

4 Function description

TDC

v = 0

v > 0

4.7 System cycle

4.7.2 System cycle for box bending press stroke

System cycle for box bending press stroke4-Funktion_Systemablauf_Pressenhub_Kastenbiegen_Muting

Inputs on the PSENvip receiver:

 Protected field mode 1 = 0

 Protected field mode 2 = 1

 Acknowledgement of reduced protected field = Press pushbutton

and then release

1

Status Press is at top dead centre
Foot switch 0
System-Init 1
OSSD 0
Protected field Free
Mute 1/2 0
Dynamic muting Inactive

2

Status Downward movement
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 1
Dynamic muting Inactive

4-34

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

v > 0

KP

v > 0

KP

8 mm

v > 0

6 mm

6 mm

4.7 System cycle

3

Status Downward movement

Advance measuring field touches

plate (pinch point)
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 1 -> 0
Dynamic muting Start

4

Status Downward movement

Tool centre point reaches the 8

mm point
Foot switch 1
System-Init 0
OSSD 1
Protected field Free
Mute 1/2 0
Dynamic muting Active

5

Status Downward movement

Tool centre point reaches the 6

mm point
Foot switch 1
System-Init 0
OSSD 1 -> 0

Muting of the OSSD in steps 5 to

8 in the safety system
Protected field Interrupted
Mute 1/2 0
Dynamic muting End

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-35

4 Function description

v > 0

6 mm
v = 0

BDC

v < 0

4.7 System cycle

6

Status Downward movement
Foot switch 1
System-Init 0
OSSD 0
Protected field Interrupted
Mute 1/2 0
Dynamic muting Inactive

7

Status Press is at bottom dead centre
Foot switch 1
System-Init 0
OSSD 0
Protected field Interrupted
Mute 1/2 0
Dynamic muting Inactive

8

Status Upward movement

Advance measuring field is

cleared
Foot switch 1

Generally, the press travels up

automatically, the operator can

release the foot switch.
System-Init 1
OSSD 1 or 0
Protected field Free or interrupted
Mute 1/2 0 - > 1
Dynamic muting Inactive

4-36

Continue with step 1

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4 Function description

4.7 System cycle

4.7.3 System cycle for back gauge press stroke

System cycle for back gauge press stroke4-Funktion_Systemablauf_Pressenhub_mit_Anschlag

Inputs on the PSENvip receiver:

 Protected field mode 1 = 1
 Protected field mode 2 = 0
 Acknowledgement of reduced protected field = Press pushbutton

and then release

The system cycle is the same as for box bending. Please note that with
back gauge protected field mode, the rear segments of the protected
field are blanked.

4.7.4 System cycle for box bending with back gauge press stroke

System cycle for box bending with back gauge press stroke4-Funktion_Systemablauf_Pressenhub_Kastenbiegen_mit_Anschlag

Inputs on the PSENvip receiver:

 Protected field mode 1 = 1
 Protected field mode 2 = 1
 Acknowledgement of reduced protected field = Press pushbutton

and then release

The system cycle is the same as for box bending. Please note that with
box bending with back gauge protected field mode, both the front and
rear segments of the protected field are blanked.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

4-37

4 Function description

4-38

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5 Installation

5.1 General requirements

55000InstallationInstallation5-5.1General requirements5100General req uirements5-Montage_Allgemeine_Anforderungen

Please note for installation:

 The PSENvip may only be installed by qualified personnel.
 The environmental data for the PSENvip must be taken into account.

Details are available in the chapter entitled “Technical Details”.

 The transmitter and receiver should be installed with the respective

front lenses aligned in parallel to each other.

 The distance between the transmitter and receiver may not be greater

than the value stated in the "Technical Details".

CAUTION!

Ensure that the field of vision of the front lenses on the transmit­ter and receiver is not restricted. Do not attach any other optical
elements such as glass/plastic surfaces, films or lenses.

 Check the fastening of the PSENvip at regular intervals.
 Check that the fastening of the PSENvip is not accidentally

working its way loose as a result of vibration from the press
brake.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5-1

5 Installation

14

+0,3

7

+0,3

15

+0,2

8,3

+0,2

1

17

+0,5

(4x) ø15

(4x) ø8.4

(32)

5

(71.5)

115

35

35

27

A-A

B

B

5.2 Install transmitter and receiver

5.2Install transmitter and receiver5200Install transmitter and receiver5-Montage_Sender_Empfaenger_Zusatz

Montage_Sender_Empfaenger

 Fastening kits for the transmitter and receiver are available as acces-

sories (for order no. see Chapter 11, "Technical Details").

 The fastening kit consists of an adapter plate and adjustment plate

with a slot nut. The bracket on the upper die must have a correspond­ing groove in which to insert the slot nut (see Fig. 5-1).

Fig. 5-1: Dimensions of adapter plate with groove, dimensions in

mm

 Both the transmitter and receiver are installed in the same way. Only

the dimensions of the adjustment plates for the transmitter and re­ceiver are different.

To install the system, proceed as follows:

 Fasten the adjustment plate as shown in the diagram below. Ensure

that the flat washers, spring washers and nuts are attached in the
right order.

5-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5 Installation

Nut

Auxiliary adjustment plate

Adjustment plate

Flat washer

5.2 Install transmitter and receiver

Fig. 5-2: Installing the transmitter and receiver

Viewed from the operator's side, the receiver is installed on the left-hand
bracket and the transmitter on the right-hand bracket.

 Slide the nut slot on the adjustment plate into the groove on the

bracket attached to the upper die.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5-3

5 Installation

80

55

168

115.5

142.5

52

112

52

5.3 Dimensions

5.3Dimensions5300Di mensions5-

5.3.1 Transmitter

Transmitter5-Montage_Abmessungen_Sender

Fig. 5-3: Transmitter dimensions, dimensions in mm

5-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5 Installation

55

137

228

115.5

112

52

142.5

52

112

MODE

ESC

97.6

8

36.5

9

46

20

(162)

13

6

72

5.3 Dimensions

5.3.2 Receiver

Receiver5-Montage_Abmessungen_Empfaenger

Fig. 5-4: Receiver dimensions, dimensions in mm

5.3.3 Fastening kit for the transmitter

Fastening kit for the transmitter5-Montage_Befestigungssatz_Sender

Fig. 5-5: Dimensions of the fastening kit for the transmitter, dimen-

sions in mm

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5-5

5 Installation

156

36.5

9

76

20

13

6

8

(162)

72

5.3 Dimensions

5.3.4 Fastening kit for the receiver

Fastening kit for the receiver5-Montage_Befestigungssatz_Empfaenger

Fig. 5-6: Dimensions of the fastening kit for the receiver, dimensions

in mm

5-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5 Installation

1

2

3

4

5

5.3 Dimensions

5.3.5 Bracket for transmitter and receiver

Bracket for transmitter and receiver5-Montage_Haltearm

 Brackets for the transmitter and receiver are available as accessories

(for order no. see Chapter 11, "Technical Details").

 Details about installation can be found in the diagram below.

Fig. 5-7: Bracket for transmitter and receiver

Key:

 1: left bracket
 2: right bracket
 3: 2 x DIN 912 M8x20 cheese head screw
 4: adapter plate
 5: 4 x DIN 912 M8x20 cheese head screw

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

5-7

5 Installation

5-8

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6 Wiring

6.1 Notes on wiring

66000WiringWiring6-6.1Notes on wiring6100Notes on wiring6-Verdrahtung_Hinweise_Einf

Sicherheit_Achtung_unbeabsichtigter_Start

Verdrahtung_Hinweise_Netzteil

Sicherheit_Warnung_elektrischer_Schlag

Please observe the following when wiring:

CAUTION!
Unintended machine start up!

Voltage should be removed from the whole machine and
PSENvip during wiring.

Power supply

 When selecting the power supply, please refer to the requirements

stated under “Technical Details”.

 The power supply used to supply the PSENvip transmitter and receiv-

er must be able to bridge a power outage of 10 ms. This requirement
comes from EN 61496-1:2004: Safety of machinery – Electrosensitive
protective equipment. Supply interruptions on the PSENvip that can­not be bridged by the PSENvip will always lead to a safe condition
(OSSD1, OSSD2 in OFF condition).

 Overload protection must be provided. Use a circuit breaker with

characteristic C, 4 A or 6 A, depending on the inrush current. Please
refer to the recommendations of the power supply manufacturer.

Verdrahtung_Hinweise_Kabel

WARNING!
Electric shock!

Safe electrical isolation must be ensured for the external power
supply generating the 24 V supply voltage and the voltages to
the inputs on the PSENvip. Failure to do so could result in elec­tric shock. The power supplies must comply with EN 60950-1
and EN 61558-2-6.

Cable

 The transmitter and receiver should only be connected using shielded

cables (available as accessories). The cable shield is connected to the
metal coupling on the M12 connectors.

 Earth the cable shield connection within the control cabinet, e.g. on a

bus bar.

 The ready-made cables from Pilz should preferably be used for con-

necting The PSENvip (see chapter 11, "Technical Details").

 Protect the cable from mechanical damage. Lay the cable in such a

way that wire short circuits are excluded. If the cable is not protected
through the machine, it should be laid in armoured hose.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6-1

6 Wiring

Protected field mode 2

Protected field mode 1

X1

3

4

24 V DC

6.1 Notes on wiring

Verdrahtung_Hinweise_EMV

Verdrahtung_Hinweise_Eingaenge_des_Empfaengers

EMC

 Avoid interference (e.g. from motors, power lines) by laying cables in

a way that is EMC-compliant.

Inputs on the receiver

 The inputs Protected field mode 1/Protected field mode 2 are safe-

ty-related.
– The CNC or safety system provides the signal. It is only absolutely

necessary to connect the inputs to a safety system if communica­tion is needed for tool detection.

– When driven via relay contacts it is the user's responsibility to apply

an appropriate safety concept.
The inputs for protected field mode 1 and protected field mode 2 can
be switched directly via the 24 VDC supply. In this case, both inputs
should be linked. Only the following protected field modes are pos­sible:

– "Standard" protected field mode (switch open, both inputs = "0")
– "Box bending with back gauge" protected field mode (switch

closed, both inputs = "1")

Verdrahtung_Hinweise_Fu nktionspruefung

6-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 6-1: Protected field mode 1/2 directly at the 24 V DC supply

 The input to acknowledge the specified protected field mode can be

switched directly via the 24 VDC supply.

NOTICE

The acknowledgement button for the protected field mode must
be positioned outside the danger zone in such a way that the
operator can see all of the danger zone.

6 Wiring

6.1 Notes on wiring

Function test

 When the wiring is complete the protective equipment will need to un-

dergo a function test.

INFORMATION

To perform the function test, follow the procedure described in
Chapter 7, "Commissioning", section entitled "Function test of
the safety device".

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6-3

6 Wiring

X1

X2

1

2

3

4

8

5

6

7

6.2 Connections

6.2Connections62 00Connections6-

6.2.1 Receiver

Receiver6-Funktion_Geraete_Empfaenger_Stecker

Verdrahtung_Anschluss_Empfaenger

The top of the receiver has two 8-pin M12 connectors.

Fig. 6-2: M12 connector on the receiver

The receiver is connected via two 8-pin cables.

Fig. 6-3: Receiver's pin assignment

The cable ends of the Pilz ready-made cable are colour-coded. Please
refer to the tables below for the coding details.

Verdrahtung_Anschluss_Empfaenger_mit_dyn_muting

Pin assignment of M12 connector X1 on the receiver

PIn No. Designation Description Colour

1 Activate *) Output: Start communication with safety system White

2 24 VDC Input, 24 VDC supply voltage Brown

3 Protected field mode 1 Input, setting of protected field modes Green

Tool class PLC -> PSENvip Bit 1 *)Input, safety system reflects tool class Bit 1

4 Protected field mode 2 Input, setting of protected field modes Yellow

Tool class PLC -> PSENvip Bit 2 *)Input, safety system reflects tool class Bit 2

5 OSSD1 Output, OSSD1 Grey

6 Mute1 Output, dynamic muting Pink

Tool class PSENvip -> PLC Bit 1 *)Output, sends tool class Bit 1 to safety system

7 0 V Input, 0 V supply voltage Blue

6-4

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6 Wiring

OSSD2

OSSD1

OSSD2

OSSD1

6.2 Connections

PIn No. Designation Description Colour

8 TRM_ON Output, signal to switch the transmitter's light

source on and off

Shield Cable shield

*) Used in communication between PSENvip and safety system.

Pin assignment of M12 connector X2 on the receiver

PIn No. Designation Description Colour

1 Acknowledge PSENvip -> PLC *) Output, confirm validity of tool class White

2 Power Off Input, activates setup mode Brown

PLC Ready *) Input, safety system signals that it is ready for com-

munication

3 Acknowledgement Input, acknowledges initiation of a press stroke with

reduced protected field

4 System-Init Input, the press is at top dead centre Yellow

5 OSSD2 Output, OSSD2 Grey

6 Mute2 Output, dynamic muting Pink

Tool class PSENvip -> PLC Bit 2 *)Output, sends tool class Bit 2 to safety system

Red

Green

7 0 V Input, 0 V supply voltage Blue

8 TRM_SYNC Output, signal to control the intensity of the trans-

mitter's light source

Shield Cable shield

Red

*) Used in communication between PSENvip and safety system.

Verdrahtung_Anschluss_Empfänger_OSSD

The two safety outputs OSSD1 and OSSD2 must be connected sepa­rately to the machine's programmable safety system. OSSD1 and
OSSD2 must not be connected.

Fig. 6-4: Correct and incorrect connection of OSSD1 and OSSD2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6-5

6 Wiring

1

2

3

4

6.2 Connections

6.2.2 Transmitter

Transmitter6-Funktion_Geraete_Sender_Stecker

Verdrahtung_Anschluss_Sender

Fig. 6-5: Pin assignment of transmitter

The transmitter is connected via a 4-core cable. The cable ends of the
Pilz ready-made cable are colour-coded. Please refer to the table below
for the coding details.

Pin assignment of M12 connector X3 on the transmitter

Pin no. Designation Description Colour

1 24 V DC Input, 24 V DC supply voltage brown

The top of the transmitter has a 4-pin M12 connector.

2 TRM_SYNC Input, signal to control the intensity of the light

source

3 0 V Input, 0 V supply voltage blue

4 TRM_ON Input, signal to switch the light source on and off Black

Shield Cable shielding

white

6.2.3 Supply voltage

Supply voltage6-Verdrahtung_Anschluss_Versorgungsspannung

The supply voltage is fed to the receiver and transmitter via the 8-core /
4-core connection cable.

6.2.4 Connection between transmitter and receiver

Connection between transmitter and receiver6-Verdrahtung_Anschluss_Verbildung_Sender_Empfaenger

The signals TRM_ON and TRM_SYNC are routed via the control cabinet.

6-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

1

PSENvip
Receiver

X1

PSENvip

Transmitter

2

3

4

5

6

7

8

Protected field mode 1 / Tool class PLC -> PSENvip Bit 1

Protected field mode 2 / Tool class PLC -> PSENvip Bit 2 *)

OSSD 1

Mute 1 / Tool class PSENvip -> PLC Bit 1 *)

1

2

3

4

5

6

7

8

1

2

3

4

24 V DC

0 V

Power Off (Setup) / PLC Ready *)

Acknowledgement

System-Init

OSSD 2

TRM_ON

TRM_SYNC

TRM_ON

TRM_SYNC

X2

X3

Mute 2 / Tool class PSENvip -> PLC Bit 2 *)

Activate *)

Acknowledge PSENvip -> PLC *)

*) Used in communication between
PSENvip and safety system

6 Wiring

6.2 Connections

6.2.5 Connection diagram

Connection diagram6-Verdrahtung_Anschluss_Schema_dyn_mute

Fig. 6-6: Connection diagram

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

6-7

6 Wiring

6-8

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

7.1 Commissioning guidelines

77000CommissioningComm issioning7-7.1Commissioning guidelines7100Commissioning guidelines7-Inbetriebnahme_Hinweise

When commissioning for the first time, please note the following:

CAUTION!
Have the protective equipment tested and approved before
commissioning for the first time!

Any machine safeguarded by the PSENvip must be tested and
approved by qualified personnel before it is placed on the mar­ket. A test report must be generated and archived during initial
commissioning.
Please refer to the guidelines given in the chapter entitled
"Safety", under "Qualified Personnel".

Initial commissioning involves

 Aligning the transmitter and receiver
 Tracking the adjustment line to the tip of the upper tool
 Entering the overrun
 Performing the function test using the test piece

The tool change adjustment involves

 Tracking the adjustment line to the tip of the upper tool
 Performing the function test using the test piece

NOTICE

The tool change adjustment must also be made during initial
commissioning.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-1

7 Commissioning

7.2 Initial commissioning

7.2Initial commissioning7200Initial commissioning7-

7.2.1 Align transmitter and receiver

Align transmitter and receiver7-Inbetriebnahme_Erstinbetriebnahme_Ausrichten

Please note the following when aligning the transmitter and receiver:

 Once installed, the transmitter and receiver must be exactly aligned

to each other and to the tip of the upper tool. The vertical and hori­zontal alignment is performed using adjustment templates and is dis­played on the receiver.

 The transmitter and receiver must also be aligned after changing ei-

ther the PSENvip transmitter or receiver.

7.2.1.1 Prepare for alignment

Prepare for alignment7-Inbetriebnahme_Erstinbetriebnahme_Ausrichtung_vorbereiten

Please note the following when preparing for alignment:

 Transmitter and receiver must be installed correctly on the press

brake (see Chapter 5, "Installation") and electrically wired (see Chap­ter 6, "Wiring").

 An upper tool must be fitted to the right and left-hand edge of the

press brake.

 Switch on the supply to the PSENvip.

7.2.1.2 Adjustment templates

Adjustment templates7-Inbetriebnahme_Erstinbetriebnahme_Justageschablonen

Two adjustment templates and the information on the display provide
support when aligning the transmitter and receiver.

Please note the different cut-outs around the cross-hair on the two ad­justment templates. On the left-hand adjustment template in the illustra­tion below, the cross-hair is located within a square cutout. The different
forms make it easier to secure information about the direction of move­ment when aligning the transmitter and receiver.

7-2

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

Magnet

Alignment grid

Magnet

Back gauge with notch

Cross-hair

7.2 Initial commissioning

Fig. 7-1: Adjustment templates (viewed from the magnet side)

You can select either adjustment template to attach to the transmitter or
receiver side.

7.2.1.3 Adjustment directions of transmitter and receiver

Adjustment directions of transmitter and receiver7-Inbetriebnahme_Erstinbetriebnahme_Verstellrichtungen

The PSENvip transmitter and receiver can be adjusted in three direc­tions.

Fig. 7-2: Adjustment directions of transmitter and receiver

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-3

7 Commissioning

7.2 Initial commissioning

Direction What?

A Move horizontally within the groove of the adjustment plate

B Rotate on a horizontal plane within the slot holes of the ad-

C Move vertically by adjusting the nuts on the bolts

Guidelines for the mechanical alignment of transmitter and receiver:

 When making the alignment, the nuts on the bolt connecting the

PSENvip to the adjustment plate should only be hand-tightened.

 There are three notches on the adjustment plate and auxiliary adjust-

ment plate for rotating the transmitter and receiver. The transmitter or
receiver is inserted into the slot holes on the adjustment plate (adjust­ment direction B).

 Push the screwdriver blade into the middle notch of the auxiliary ad-

justment plate and adjustment plate.

 Rotate the screwdriver blade in the required direction.
 You can use the left or right-hand notch to rotate the transmitter or

receiver even further to the left or right.

justment plate

7-4

Fig. 7-3: Adjustment direction B

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

Align the
alignment grid
on the upper
tool

Centre point of
the upper tool
in the notch on
the back stop

Illuminated target area

7.2 Initial commissioning

7.2.1.4 Align transmitter

Align transmitter7-Inbetriebnahme_Erstinbetriebnahme_Sender_ausrichten

 Attach an adjustment template with magnets to the upper tool. The tip

of the upper tool must sit in the notch on the stop of the adjustment
template.

Align the alignment grid of the adjustment template to the contour of
the upper tool.

Fig. 7-4: Attach the adjustment template to the transmitter

 The illuminated target area must completely envelop the receiver. If

you hold a white sheet of paper behind the receiver you will be able
to see the contours of the receiver better.

Fig. 7-5: Receiver illuminated by transmitter

 If the illuminated target area does not enclose the receiver as shown

in the diagram, then you will need to realign the transmitter

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-5

7 Commissioning

7.2 Initial commissioning

INFORMATION

Carefully align the illuminated target area to the receiver. This will
make the adjustments in the following work stages easier.

7.2.1.5 Tool shapes

Tool shapes7-Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Werkzeuge_1

The correct adjustment of the upper tool also depends on the tool
shape. The tools are divided into tool classes in the Tool Change menu.

INFORMATION

You must comply with the tool class information provided in

 Section 7.3 "Adjustment during tool change", "Tool detection"

 Section entitled "Tool shapes", under "Safety"
 "System Connections" chapter

in this chapter.

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Werkzeuge_2

During initial commissioning, the upper tool should be positioned in a
way that corresponds to the expected tool class.

Two bending lines are available on the PSENvip display for correct align­ment of the various tool types. In the following examples, please note
that the maximum width of the respective tools for the tool class can be
achieved when the appropriate bending line is used.

7-6

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

> 15 mm

< 15 mm

< 15 mm

7.2 Initial commissioning

Examples of the correct adjustment of various tool types:

Tool class 1: Pointed tools
For these tools we recommend alignment to
the left-hand bending line. The distance from
the bending line to the front segments of the
protected field is >15 mm.

Tool class 2: Semi-circular tools
For these tools we recommend alignment to
the left-hand bending line. The distance from
the front bending line of the tool to the front
segments of the protected field is <15 mm.
The rear bending line of the tool is detected
by the protected field. The position of the
front bending line must be considered in the
hazard analysis.

Tool class 2: Stamp
For these tools we recommend alignment to
the central bending line. The distance from
the front bending line of the tool to the front
segments of the protected field is <15 mm.
The rear bending line of the tool is detected
by the protected field. The position of the
front bending lines must be considered in the
hazard analysis.

Tool class 3: Stamp
The front and rear bending lines of the tool
are outside the protected field. The position
of the bending lines must be considered in
the hazard analysis.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-7

7 Commissioning

Align the
alignment grid
on the upper
tool

Centre point of
the upper tool
in the notch on
the back stop

7.2 Initial commissioning

7.2.1.6 Align receiver

Align receiver7-Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_1

 Attach an adjustment template with magnets to the upper tool. The tip

of the upper tool must sit in the notch on the stop of the adjustment
template.

Align the alignment grid of the adjustment template to the contour of
the upper tool.

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Justagebild_1

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Justagebild_nicht_mittig_1

Fig. 7-6: Attach the adjustment template to the receiver

 Press the <MODE> key.

 Using the keys , select the Adjustment option.
 Press the <ENTER> key to open the Adjustment option.

The adjustment image shown in the illustration below will appear on the
receiver display.

Please note that the bending line is approximately 7 mm to the left of the
centre of the display.

7-8

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

7.2 Initial commissioning

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Justagebild_2

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_Justagebild_nicht_mittig_2

Fig. 7-7: Adjustment image

The receiver is correctly aligned with the transmitter when:

 The cross-hairs of both adjustment templates overlap
 The quadrants form a full circle and
 The centre point of the upper tool is on the bending line.

The correct adjustment image on the display will look like the image
shown in the illustration below.

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_2

Fig. 7-8: Correct adjustment image

INFORMATION

The adjustment templates have different cut-outs around the
cross-hair (see section entitled "Adjustment templates"). This
makes it easier to evaluate the adjustment direction required by
the transmitter and receiver.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-9

7 Commissioning

7.2 Initial commissioning

 Adjust the direction of the receiver as described in the section entitled

"Adjustment directions of transmitter and receiver".

 Remove the adjustment templates.

The correct adjustment image on the display will look like the image
shown in the illustration below:

 The bending line should be on the vertical guide.
 The tool centre point should be aligned with the horizontal guide (the

horizontal guide is firmly in the middle of the range bar (see section

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_3_nicht_mittig

entitled "Make adjustment during tool change").

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_4

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_5_nicht_mittig

Fig. 7-9: Correct adjustment image

 Select <ENTER>.

A guide frame appears on the display. Apart from the areas around the
tool centre point, the guide frame should be clear of objects. The follow­ing diagram illustrates a valid and an an invalid adjustment image.

In the case of an invalid adjustment (right-hand diagram), the Out of ran-
ge message will also appear.

7-10

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7 Commissioning

Out of range

7.2 Initial commissioning

Fig. 7-10: Checking the adjustment image with superimposed guide

Inbetriebnahme_Erstinbetriebnahme_Empfaenger_ausrichten_6

 You can switch to the adjustment image without guide frame by

pressing <ENTER> again.

 Exit the adjustment using the <ESC> key.

frame

The transmitter and receiver are now mechanically aligned.

NOTICE

After you have aligned the transmitter and receiver you will still
need to carry out the step for "Adjustment during tool change"
(see section entitled "Adjustment during tool change").

7.2.2 Adjustment template with bracket

Adjustment template with bracket7-Inbetriebnahme_Erstinbetriebnahme_Justageschablone_mit_Traeger

An adjustment template screwed to a suitable bracket is also available
as an accessory. This bracket is not supplied with the system.

 Fasten the template to the bracket using half length taper-grooved

dowel pins and cylinder head bolts (see illustration).

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-11

7 Commissioning

10

45

65

Ø 3

+0,1

Ø 3,4

Ø 3,4

Ø 3

+0,1

1

3

2

1

7.2 Initial commissioning

Fig. 7-11: Adjustment template to attach to bracket

 1: Ø 3 mm DIN 1472 half length taper-grooved dowel pin
 2: M3 x 10 cylinder head bolts
 3: Ø 3 mm DIN 1472 half length taper-grooved dowel pin
 Attach the bracket to the upper tool clamp.

7-12

Fig. 7-12: Adjustment template with bracket

 1: Bracket

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

INFORMATION

To align the transmitter and receiver, follow the same procedure
as outlined in the section entitled "Align transmitter and
receiver".

7 Commissioning

7.3 Adjustment during tool change

7.3Adjustment during tool change7300Adjustm ent during tool change7-Inbetriebnahme_Justage_bei_Werkzeugwechsel

The adjustment line is automatically tracked to the tip of the tool. The
tracking of the adjustment line is shown on the display.

INFORMATION

Generally you should not have to mechanically realign the trans­mitter and receiver during a tool change.

CAUTION!

The manufacturer or operator of the press must ensure safe
selection of the "Adjustment during tool change" operating
mode with appropriate measures.

CAUTION!
The protective equipment must be tested following a tool
change adjustment!

Use the standardised test piece to perform a function test, see
section entitled "Function test of the safety device".

7.3.1 Prepare for adjustment during tool change

Prepare for adjustment during tool change7-Inbetriebnahme_Justage_bei_Werkzeugwechsel_vorbereiten

 Transmitter and receiver must be exactly aligned to each other and to

the centre point of the upper tool, as described in the section entitled
"Initial commissioning".

 The supply voltage must be present.

7.3.2 Tool detection

Tool detection7-Inbetriebnahme_Justage_bei_Werkzeugwechsel_Werkzeugerkennung

All tool shapes are permitted in principle (but please refer to the warn­ings in the section entitled "Tool shapes", under "Safety").

In TOOL CHANGE operating mode, the PSENvip detects the contour of
the tool and assigns it to a tool class.

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

7-13

7 Commissioning

>15 mm

1

2

3

<15 mm

H3 V2H2 V3V1H1 B1

max. 32 mm

max. 25 mm

> 15 mm

> 15 mm

HHVV

7.3 Adjustment during tool change

Assignment to a tool class depends on

 Compliance with the requirement from EN 12622, whereby the pro-

tected field must safeguard areas lying 15 mm before the front bend­ing line.

 Full or partial detection of the upper tool via the protected field.

Fig. 7-13: Classification of tools into tool classes

Tool class 1

 The contour of these tools is fully detected by the PSENvip.
 The front (V1 or B1) and rear (H1 or B1) bending lines are within the

protected field.

 The front segments of the protected field are at least 15 mm away

from the front bending line.

 These tools are safeguarded in compliance with the standards.
 Example:

7-14

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 7-14: Example for tool class 1

7 Commissioning

> 25 mm

<15 mm

HV

HV

7.3 Adjustment during tool change

Tool class 2

 The contour of these tools is fully detected by the PSENvip.
 The front (V2) and rear (H2) bending lines are within the protected

field.

 The front segments of the protected field are less than 15 mm away

from the front bending line.

 These tools are not safeguarded in compliance with the standards.
 Example:

Fig. 7-15: Example for tool class 2

Tool class 3

 The contour of these tools is not fully detected by the PSENvip.
 The front (V3) and/or rear (H3) bending lines are within the protected

field.

 These tools are not safeguarded in compliance with the standards.
 Example:

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Fig. 7-16: Example for tool class 3

7-15

7 Commissioning

SYSTEM OK

OSSD OFF

TOOL CHANGE

SYSTEM OK

OSSD OFF

TOOL CHANGE

SYSTEM OK

OSSD OFF

TOOL CHANGE

Tool class 1

Tool class 2

Tool class 3

7.3 Adjustment during tool change

The tools are displayed as follows on the PSENvip display:

7.3.3 Make adjustment during tool change

Make adjustment during tool change7-Inbetriebnahme_Justage_bei_Werkzeugwechsel_durchführen_1

Fig. 7-17: Tool detection on the PSENvip display

To achieve optimum results, the tool should be aligned to an appropriate
bending line during initial commissioning (see section entitled "Initial
commissioning").

There are two ways of starting the function "Adjustment during tool
change":

Option 1:

 Press the <MODE> key.

 Using the keys , select the Tool Change option.
 Press the <ENTER> key to start the Tool Change.

7-16

Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany

7 Commissioning

SYSTEM OK

OSSD OFF

TOOL CHANGE

À

Â

Á

Ä

Å

Tool class 1

Æ

Ã

7.3 Adjustment during tool change

Option 2:

 Press the ( ) key to start the Tool Change.

Inbetriebnahme_Justage_bei_Werkzeugwechsel_durchführen_2

Fig. 7-18: Tool change menu

 1: Tool centre point
 2: Range bar
 3: Adjustment line
 4: Central and rear bending line

 5: No tool identified or vertical position of tool centre point out-

side of the range bar

 6: Receiver insufficiently lit by transmitter
 7: Detected tool class

The adjustment line is automatically tracked to the tool centre point.

The vertical position of the tool centre point must be within the range
bar. Once the adjustment line is at the top or bottom of the range bar,

the following symbol appears: .

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]

If the symbol appears on the display, there is a problem with the
lighting of the receiver by the transmitter:

 Check that the transmitter and receiver are aligned correctly. The illu-

minated target area must completely envelop the receiver. If neces­sary, realign the transmitter (see section entitled "Align transmitter").

 Remove any potential contamination on the lens of the transmitter or

receiver.

7-17

7 Commissioning

7.3 Adjustment during tool change

The adjustment has been carried out correctly when none of the sym­bols appear:

 Finish the adjustment using the <ENTER> key.

The PSENvip prompts you to confirm that you accept the new tool
data:

 Within 3 seconds, press the key .
 You can exit the menu at any time without confirming by pressing

<ESC>. In this case, the previous tool data will be retained.

7-18

Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [e-mail]