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whole or part is only permissible within the limits of the statutory regulations of copyright law. Modifying or
abridging the document is impermissible without the express written permission of from the SICK AG company.
Please take note of the following updates to this document!
a
WARNING
Based on Machinery Directive 2006/42/EC, we have added the following supplementary
data or change notices on our product to the following document.
Scope
This document is an original document.
Cited standards and directives
The standards and directives cited in these operating instructions might have changed.
The following list indicates the standards and directives that might have been cited and
their successive versions.
Kindly replace the standards and directives cited in these operating instructions with the
successive versions listed in the table.
Previous standard or directive Successive standard and directive
Prevent the formation of a potential difference between the load and the protective
a
WARNING
device!
If you connect loads that are not reverse-polarity protected to the OSSDs or the safety
outputs, you must connect the 0 V connections of these loads and those of the
corresponding protective device individually and directly to the same 0 V terminal strip.
This is the only way to ensure that, in the event of a defect, there can be no potential
difference between the 0 V connections of the loads and those of the corresponding
protective device.
OSSD1
Safety output 1
OSSD2
Safety output 2
OSSD1
Safety output 1
OSSD2
Safety output 2
Note
Technical specifications
Safety-related parameters according to EN ISO 13849, EN 62061, IEC 61508:
V4000 PB: General system data
Type Type 4 (IEC 61496)
Safety Integrity Level2) SIL3 (IEC 61508),
SILCL3 (EN 62061)
Category Category 4 (EN ISO 13849)
Category 4 (EN 954
3)
)
Performance Level2) PL e (EN ISO 13849)
PFHd (mean probability of a dangerous failure
1.52×10–8
per hour)
TM (mission time) 16.6 years (EN ISO 13849)
EC declaration of conformity
You can obtain the EC declaration of conformity with the standards used at: www.sick.com
2) For detailed information on the exact design of your machine/system, please contact your local SICK
representative.
3) Only valid for the assumption of conformity until 28.12.2009. From then on it will only be permissible to use
the successor EN ISO 13849.
Checklist for the manufacturer/installer for the installation of electro-
sensitive protective equipment (ESPE)
Details about the points listed below must be present at least during initial commissioning — they are, however,
dependent on the respective application, the specifications of which are to be controlled by the manufacturer/installer.
This checklist should be retained and kept with the machine documentation to serve as reference during recurring
tests.
1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to
the machine?
2. Are the applied directives and standards listed in the declaration of conformity? Yes
3. Does the protective device fulfil the required PL/SILCL and PFHd according to EN ISO 138491/EN 62061 and
the type according to EN 614961?
4. Is the access to the hazardous area/hazardous point only possible through the protective field of the ESPE? Yes
5. Have appropriate measures been taken to prevent (mechanical protection) or monitor unprotected presence in
the hazardous area when protecting a hazardous area/hazardous point and have these been secured against
removal?
6. Are additional mechanical protective measures fitted and secured against manipulation which prevent reaching
under, over or around the ESPE?
7. Has the maximum stopping and/or stopping/run-down time of the machine been measured, specified and
documented (at the machine and/or in the machine documentation)?
8. Has the ESPE been mounted such that the required safety distance from the nearest hazardous point has been
achieved?
9. Are the ESPE devices correctly mounted and secured against manipulation after adjustment? Yes
10. Are the required protective measures against electric shock in effect (protection class)? Yes
11. Is the control switch for resetting the protective device (ESPE) or restarting the machine present and correctly
installed?
12. Are the outputs of the ESPE (OSSDs, ASInterface Safety at Work) integrated in compliance with the required
PL/SILCL according to EN ISO 13849/EN 62061 and does the integration comply with the circuit diagrams?
13. Has the protective function been checked in compliance with the test notes of this documentation? Yes
14. Are the given protective functions effective at every setting of the operating mode selector switch? Yes
15. Are the switching elements activated by the ESPE, e.g. contactors, valves, monitored? Yes
16. Is the ESPE effective over the entire period of the dangerous state? Yes
17. Once initiated, will a dangerous state be stopped when switching the ESPE on or off and when changing the
operating mode, or when switching to another protective device?
18. Has an information label for the daily check been attached so that it is easily visible for the operator? Yes
19. Have you made sure that the protective device itself when mounted is not a source of danger during machine
operation (for example, catching between the device and parts of the machine)?
This checklist does not replace the initial commissioning, nor the regular inspection by qualified safety personnel.
Read this chapter carefully before working with the operating instructions and the
V4000 Press Brake system.
For "V4000 Press Brake system" we shall use the abbreviation "V4000 PB" from now on.
1.1 Function of this document
These operating instructions are intended for the technical personnel of the machine
manufacturer or the machine operator in regards to safe mounting, electrical installation,
configuration, commissioning, operation and diagnostics of the V4000 PB sensor.
These operating instructions do not provide instructions for operating machines on which
the V4000 PB is, or will be, integrated. Information of this kind will be found in the
operating instructions for the machine.
1.2 Target groups
These operating instructions are intended for manufacturers, operators and the users of
press brakes which are to be protected by a V4000 PB. It also addresses people who
integrate the V4000 PB into a machine, initialise its use, or who check the unit.
Note
1.3 Scope
These operating instructions apply for the V4000 PB with the following type label entry in
the Operating Instructions field: 8 010 501. This document is part of SICK part number 8
010 501 (V4000 Press Brake sensor system in all available languages).
You will require a CDS (Configuration & Diagnostic Software) version 3.0 or greater for the
configuration and diagnostics of this system. To determine the software version, select the
Module info item from the ? menu in the menu bar.
1.4 Depth of information
These operating instructions contain information on the V4000 PB regarding the following
subjects:
Mounting
Electrical installation
Configuration and commissioning
Operation, care and maintenance
Planning and using protective devices such as the V4000 PB sensor also require specific
technical skills which are not detailed in these operating instructions.
When operating the V4000 PB sensor, the national, local and statutory rules and
regulations must be observed.
General information on health and safety using opto-electronic protective devices is
contained in the brochure "Safe Machines with Opto-Electronic Protective Devices".
We also refer you to the SICK homepage on the Internet at
http://www.sick.com
Here you will find:
These operating instructions in different languages for viewing and printing
The EC Declaration of Conformity
1.5 Abbreviations
American National Standards Institute
Electro-sensitive protective equipment (ESPE) (e. g. V4000 PB)
SICK Configuration & Diagnostic Software = software for configuring and diagnosing the
V4000 PB system
External device monitoring
Electro-sensitive protective equipment
Human machine interface
Laser diode
Light-emitting diode
Mute point
Numerical control
Overall machine overrun
Overall response time
Output signal switching device = signal output of the protective device to the controller
used for switching off the movement which is the source of danger
Recommendations are designed to provide some assistance for your decision-making
process regarding application of a certain function or technical measure.
Notes provide special information about the device.
Display indicators show the status of the 7-segment display of the receiver:
7 Constant display of the letter F
Flashing display of the letter F
7O) Alternating display of F and 2
LED symbols describe the state of an LED:
O The LED is illuminated constantly.
Ö The LED is flashing.
o The LED is off.
ON or OFF state:
ON
OFF
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
Warning!
A warning indicates concrete or potential dangers. They save you from harm.
Read warnings carefully and abide by them!
n
s r
Software notes show the location in the CDS (Configuration & Diagnostic Software) where
you can make the appropriate settings and adjustments. Go to the View menu, Dialogue windows of the CDS and activate the item tabs to view the named dialogue boxes as
required. Otherwise use the software wizard to make the desired settings.
Sender and receiver
In drawings and diagrams, the s symbol denotes the sender and the symbol r the
receiver.
The term "dangerous state"
In the drawings in these operating instructions, the dangerous state (standard term) of the
machine is always represented as a movement of a machine part. In practical operation
there may be a number of different dangerous states:
Machine movements
Electrical conductors
Visible or invisible radiation
A combination of several risks and hazards
Representation of the signals for teach-in, alignment mode and selection of protective
volume mode
These operating instructions also describe the V4000 PB input and output signals. As a
way of uniquely representing the signals for teach-in, alignment mode and selection of
protective volume mode (input signals), tactile switching amplifiers (buttons, switches) are
used. The signals can be generated at the inputs of the V4000 PB by, for example, foot
switches, alignment buttons, teach-in buttons, selector switches and key-operated
switches or by the corresponding switching elements on the HMI of the press controller.
This chapter deals with your own safety and the safety of the operators.
> Read this chapter carefully before working with the V4000 PB or with the machine
protected by the V4000 PB.
2.1 Specialist personnel
The V4000 PB must be mounted, connected, commissioned and serviced only by
specialist personnel. Specialist personnel are defined as persons who
due to their technical training and experience possess sufficient knowledge in the field
of safety equipment for making press brakes safe
and
who have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
have sufficient familiarity with the relevant national industrial safety regulations, work
safety regulations, directives and the generally recognised code of practice of the
industry (for example, DIN standards, VDE specifications, technical codes of other EC
member states) that they can judge whether the press brake is safe from the
occupational safety point of view
and
have access to and have read these operating instructions.
As a rule these will be specialist personnel, the manufacturer of the ESPE or even such
persons who have been given the corresponding training by the ESPE manufacturer, who
are mainly concerned with inspecting and testing ESPEs and have been commissioned by
the ESPE operator in this regard.
2.2 Applications of the system
The V4000 PB is an ESPE (electro-sensitive protective equipment) device designed to
protect the area beneath the die of press brakes at high closing speeds. As soon as an
object enters the protective volume beneath the die, the ESPE issues the signal to the
press controller to stop the fast closing movement and this system must then stop the
closing movement.
The V4000 PB system consists of a sender and a receiver which are mounted on the press
crosshead. The protective volume between the sender and the receiver moves with the
press crosshead and thus ensures that the safeguarded area stays beneath the die.
The system is a Type 4 ESPE as defined by to IEC 61 496-1 and 2 and is therefore allowed
for use with controls of safety category 4 in compliance with EN 954-1. It may be used in
safety applications up to SIL 3 in accordance with IEC 61 508.
Use of the V4000 PB in the open air or explosion hazard areas is not permitted. The
V4000 PB can only be used in normal industrial environments.
Do not use the V4000 PB as a separating protective measure!
a
WARNING
An opto-electronic protective device provides indirect protection, e.g., by switching off the
power at the source of the hazard. It cannot provide protection neither from parts thrown
out, nor from emitted radiation. Transparent objects are not detected.
Depending on its applications, mechanical protective devices may be needed in addition to
the V4000 PB.
2.3 Correct use of the system
The V4000 PB system is intended to be used solely at a fixed location on press brakes and
may only be used as defined by Section
only by specialist personnel and only on the machine where it has been mounted and
initially commissioned by specialist personnel in accordance with these operating
instructions.
SICK AG accepts no claims for liability if the equipment is used in any other way or if
modifications are made to the device, even in the context of mounting and installation.
2.2 "Applications of the system". It must be used
a
WARNING
Fig. 1: Warning regarding
laser class 1M
2.4 General protective notes and protective measures
Protective notes
Please observe the following protective notes in order to ensure the correct and safe use
of the V4000 PB.
Warnings on the V4000 PB must be observed without fail.
The V4000 PB meets the requirements of laser protection class 1 M. Do not look into
the laser beam neither with the naked eye nor using optical equipment (such as
binoculars).
LASER RADIATION
DO NOT STARE INTO THE BEAM OR VIEW
DIRECTLY WITH OPTICAL INSTRUMENTS
CLASS 1M LASER PRODUCT
ACCORDING TO IEC 60825-1:2001
Max. output: < 5mW
Puls duration: < 2ms
Wavelength: 620 TO 650 nm
Complies with 21 CFR 1040.10 and 1040.11 except
for deviations pursuant to laser notice No. 50, July 2001
This device meets the norms: CDRH 21 CFR 1040.10, 1040.11 as well as DIN EN 60
825:2001. There the following note is required:”Caution – use of controls or
adjustments or performance of procedures other than those specified herein may result
in hazardous radiation exposure!”
The V4000 PB components must not be opened for maintenance work. Defective
The national/international rules and regulations apply to the installation, commissioning
and periodic technical inspections of the V4000 PB, in particular:
– Machinery Directive 98/37/EC
– Provision and use of Work Equipment Directive 89/655/EEC
– The work safety regulations/safety rules
– Relevant national health and safety regulations
Manufacturers and operators of the machine on which the V4000 PB is used are
responsible for obtaining and observing all applicable safety regulations and rules.
The notices, in particular the test regulations (see Chapter
operating instructions (e.g. on use, mounting, installation or integration into the existing
machine controller) must be observed.
The tests must be carried out by specialist personnel or specially qualified and
authorised personnel and must be recorded and documented to ensure that the tests
can be reconstructed and retraced at any time.
The operating instructions must be made available to the operator of the machine where
the V4000 PB is fitted. The machine operator is to be instructed in the use of the device
by specialist personnel and must be instructed to read the operating instructions of the
V4000 PB and of the machine.
7 "Commissioning") of these
a
WARNING
2.5 Safety in operation
Dangers which the V4000 PB does not protect against!
The different ways in which the press brake can be used in manufacturing means that
indirect dangers may arise.
Please observe and comply with the following points in order to protect yourself against
dangers during machine operation.
The V4000 PB safeguards the hazardous point beneath the die at high closing speeds
(over 10 mm/s) or irrespective of the speed up to a gap of 6 mm. The maximum height of
the protective volume up to the lower edge of the die is 26 mm.
Maximum protection is provided in standard protective volume mode.
In the case of box-bending or back-stop operation, use of a restricted protective volume is
possible. With this kind of work, the reduced dimensions of the protective volume means
that only limited protection against getting caught or crushed is possible.
If parts of the body are brought into the hazardous point within a box, they will only be
detected behind the tolerance zone around the pressure axis. There is a danger of injury
by being caught or crushed.
For a time interval of 100–150 ms (just before the gap height of 6 mm is reached) there is
the possibility of an object which is moving into the space between the die and the
workpiece being crushed.
Correct handling of the workpiece
By handling the sheet properly you can avoid your hands or fingers being caught or
crushed.
– Residues and rust caused by sweat from the hands getting on dies and workpieces
– Deposits on the hands
– Slipping of smooth workpieces
Fig. 2: Handling of the
workpiece 1
Fig.
3: Handling of the
workpiece 2
Note
> Hold the sheet by the left and right corners of the end facing you.
> Use both hands to hold the sheet firmly from below (thumb on top of the sheet, rest of
hand underneath)
> When holding the sheet, be sure not to spread your fingers.
Spread fingers will interrupt the protective volume of the V4000 PB. The protective
function of the V4000 PB will be triggered and the V4000 PB initiates a stop.
If the protective volume is limited (box-bending and back-stop operation) there will be an
additional risk of getting your hand caught.
In box-bending and back-stop modes the protective volume is limited and a tolerance zone
around the pressure axis is hidden. If box-like workpieces are not handled correctly, your
hands could get caught between the workpiece and the die or press crosshead.
> Do not hold the upper box walls by the edges or corners on the pressure axis.
> Hold box-shaped workpieces by their back part (closest to you) outside the hazardous
point.
The V4000 PB cannot protect you against these dangers:
Crushing your hands or fingers between the workpiece and the press crosshead as a
result of handling the workpiece incorrectly during bending
Crushing your fingers between the die and the workpiece as a result of handling the
workpiece incorrectly
The risk of injury from workpieces falling when the press brake is opened
The risk of injury from large workpieces swinging upwards during bending
When bending aids are used:
Risk of injury due to the workpiece swinging up or down, or to the movement of the
bending aids
The V4000 PB has been designed to minimise environmental impact. It uses only a
minimum of power and natural resources.
> At work, always act in an environmentally responsible manner.
2.6.1 Disposal
Disposal of unusable or irreparable devices should always occur in accordance with the
applicable country-specific waste-disposal regulations
(e.g. European Waste Code 16 02 14).
Before you can turn over the devices for environmentally-friendly recycling, you must
separate the different materials of the V4000 PB from one another.
> Separate the housing from the remaining components (especially the PCB).
> Press the front lens out of the lens holder.
Tab. 1: Overview of disposal
by component
> Send the separated components to the corresponding recycling centres (see
Component Disposal
Product
Housing
Front lens
PCBs, cables, plugs and
electrical connection pieces
Metal recycling (aluminium)
Glass recycling (used glass)
Electronics recycling
Tab. 1).
Note
a
WARNING
Packaging
Cardboard, paper
Polyethylene packaging
We would be pleased to be of assistance on the disposal of the V4000 PB. Contact your
local SICK representative.
Material separation may only be performed by specialist personnel!
Exercise care when disassembling the devices. The danger of injury is present.
This chapter provides information on the special features and properties of the V4000 PB.
It describes the safety concept, the range of use, the structure and operating principle of
the device, configuration options and the various operating modes.
> Read this chapter before you mount, install and commission the V4000 PB.
3.1 Special features
Sender/receiver system
Response time 10 ms
Unambiguous status information via LED and 7-segment display shown directly on the
V4000 PB receiver
All inputs and outputs of the system integrated in the receiver
Simple combination of the V4000 PB system with alternative protective measures by
means of bypass inputs and outputs
No additional evaluation unit required in the control cabinet
V4000 PB system uses the existing measurement guides of the press brake for
determining speed, position and direction
Optional operation via hardware input devices or via the outputs of the press brake
controller (e.g. NC).
The SICK CDS user interface provides ease of configuration and comprehensive
expanded diagnostics of the V4000 PB system
Reliable pinch-point monitoring even when workpiece surface has irregularities or
unevenness
Automatic functions
Determination and monitoring of the pinch point
Monitoring of the relevant overall machine overrun of the press brake as a function of
speed
Monitoring of the slow closing speed (≤ 10 mm/s) from pinch point V4000 PB (can be
configured)
Dynamic adaptation of the switch-over point
Position-dependent muting (6 mm above the pinch point)
Speed-dependent muting (configurable)
Checking of the die position to detect coarse maladjustment
Detection of box wall in front and rear spaces
Protective operation
3 protective volume modes with adapted protective volume shape corresponding to
bending task
Loading of press hydraulics minimised by box and back-stop modes without emergency
The V4000 PB consists of a sender and a receiver mounted on the press crosshead.
A light beam of light (illumination field) between sender and receiver forms a threedimensional protective field (protective volume) beneath the die tip measuring 40 mm
wide and 26 mm high. The protective volume follows the movement of the press
crosshead and in this way provides a travelling safety zone beneath the die tip.
The V4000 PB has three different kinds of protective volume (standard, box and backstop). These protective volumes differ in their dimensions and in their functions.
Should there be a partial or complete interruption of the protective volume by an object,
the output signal switching devices (OSSDs) of the ESPE which are integrated in the
receiver change over to the OFF state and generate a two-channel monitored switch-off
signal to the press controller which then must stop the closing movement of the press
crosshead with the die.
The evaluation and run concepts of the V4000 PB have been designed so that the ESPE
constantly checks its internal expected position (which depends on the operating mode,
the press crosshead position and the speed) against the actual external situation. Only
when the expected position is identical to the actual circumstances will the OSSDs remain
in the ON state. Any other result will put the OSSDs into the OFF state.
The V4000 PB safeguards the hazardous point beneath the die at high closing speeds
(> 10 mm/s) and a pass-through gap height of more than 6 mm. If the gap height between
the top of the workpiece and the die tip is 6 mm or less, the ESPE switches automatically
into muting mode.
If the muting option is activated at a low closing speed (≤ 10 mm/s), the system will
automatically go into muting mode even when the slow closing speed is reached. The
speed is monitored continuously.
In the muting state, the protective volume is inactive and the OSSDs stay in the ON state.
Note
Whether muting is permitted at the slow closing speed varies from country to country. This
option is by default disabled in the configuration.
In the event of system errors (such as an error being detected when the hardware is
tested) the V4000 PB switches into lock-out state.
3.2.2 Protective volume during the operating cycle
This sequence shows the protective volume during one operating cycle.
Step
Protective volume
1 The die is at the
programmed top dead
centre.
The operator gives the
signal to start the
closing movement (foot
switch).
2 The die descends at
high speed
(> 10 mm/s).
The entire protective
volume is active.
3 At the switch-over point
the target speed is
requested by the
V4000 PB.
The press controller
initiates the braking
procedure.
The protective volume
stays active in the gap
opening.
Step
Protective volume
4 The calculation of the
switch-over point
includes an additional
6 mm safety gap
required to reach the
target speed (v
The protective volume
becomes inactive.
6 mm
slow
5 The die contacts the
workpiece (pinch point).
).
6 The die shapes the
workpiece. The
operating cycle ends at
the programmed bottom
dead centre. The die
goes back up.
3.2.3 Intrusion of the protective volume during the operating cycle
This sequence shows how the V4000 PB responds when there is an interruption to the
protective volume.
Step
Protective volume
1 The die is at the
programmed top dead
centre.
There is a foreign object
on the workpiece or
female die.
The operator gives the
signal to start the
closing movement (foot
switch).
2 The die descends at
high speed
(> 10 mm/s).
The entire protective
volume is active.
3 Part of the protective
volume is interrupted by
the object.
The OSSDs go into the
OFF state and generate
a safe stop signal.
The press controller
must ensure the stop
procedure is
implemented.
Step
Protective volume
4 The die continues to
move in accordance
with the overall machine
overrun and stops at
least 5 mm above the
object.
5 The object is now
removed.
The protective volume is
clear again.
6 The operator gives the
signal once more to
start the closing
movement (foot switch).
The closing movement
starts and the operating
cycle resumes.
The V4000 PB is an ESPE (electro-sensitive protective equipment) device designed to
protect the area beneath the die of press brakes at high closing speeds, it provides hand
and fingers protection.
The V4000 PB is suitable for stationary use in press brakes with a maximum distance of
7.5 m between the sender and the receiver.
The press brake must be designed to comply with the maximum stopping distance of
11 m.
This corresponds, for example, to a maximum overall machine overrun of 8.5 mm at a
maximum closing speed of 300 mm/s (see also Section
closing speed vcrawl from the pinch point").
Requirements for use of the V4000 PB
Before the V4000 PB can carry out its protective functions the following conditions must
be met:
It must be possible to influence the control of the press brake by electrical means.
The OSSDs of the V4000 PB must be incorporated into the press controller in such a way
that when the OSSDs give the switch-off signal:
– the dangerous state (high closing speed of > 10 mm/s) is stopped.
or
– the press, should the lock-out state occur, does not start up again.
The V4000 PB must be mounted and configured in such a way that it can detect objects
CDS (software for configuration and diagnostics of the V4000 PB sensor)
In addition the V4000 PB needs control signals from external operating elements.
The sections which follow describe the individual components of the device.
Fig. 8: Components
N
PBI
SPLC
Fig.
9: Sender and receiver
Incremental
encoders
3.4.1 Sender and receiver
Incremental
encoders
Operating
elements
HMI
CDS
Star
Receive
LEDs
-segment displa
Sende
LED
Sender and receiver are mounted on the press crosshead and follow the movements of
the crosshead. At start-up and every time there is a change of tooling, they need to be
precisely aligned to the length of the die used and to each other.
The laser diode in the sender emits light which is collected at the transmitting lens and
given parallel alignment. The beam of light, which has a constant diameter of 58 mm
(illumination field), travels along the lower side of the die to the receiver. In the receiver
the light beam is mapped at the image detector.
The evaluation electronics with all relevant inputs and outputs is built into the receiver.
Two output switching elements (OSSDs), which go into the OFF state when the sensor
function is triggered, pass on the signal for stopping the closing movement (high closing
speed > 10 mm/s).
The digital interface receives signals from the press controller or from external operating
elements and passes them on to the receiver; it also passes signals from the receiver on
to the press controller.
Tab. 5: Inputs and outputs at
the digital interface
Number
2 Actively tested semiconductor
Inputs and outputs
with safety relevance
switching outputs (OSSDs)
Function
For the switch-off signal to the press controller
which must stop the closing movement of the
press crosshead with the die
2 Inputs For the gated signal for starting the closing
movement
Number
Standard inputs and outputs Function
2 Pulsed outputs For the bypass signal
2 Inputs For the bypass signal
1 Input For external device monitoring (EDM)
1 Output For the target speed request to the press
controller
1 Input For activating alignment mode
1 Input For activating teach-in mode
3 Inputs For selecting the protective volume mode
(standard, box, back-stop) within protective
operation
1 Output For the signal to the press controller that
teach-in is being requested
Serial interface for configuration and diagnosis
The PC is connected to the receiver via the serial RS-232 interface for configuration of the
V4000 PB and for extended diagnostics with the SICK CDS Software in the event of
servicing. For a permanent connection of the PC (CDS) to the receiver an RS-422 interface
is available for extended diagnostics. A switch allows you to switch between the two
interfaces (see Section
6.1 "Delivery state").
Interface for connecting the sender
To allow control of the sender function by the receiver, the sender and the receiver are
electronically connected to the receiver via a signal line.
Interfaces for connecting the PBI
The receiver is provided with an interface for data transmission (incremental pulses of the
measurement guide) from the PBI.
The incremental measurement guides of the press controller register the movement of the
press crosshead. The speed and direction of movement of the press crosshead and the
overall machine overrun are calculated by the V4000 PB from the signals of one
measurement guide and from other measured data (such as time).
The measurement guide is connected to the V4000 PB via the PBI in the control cabinet.
At the interface with the press controller the PBI taps onto the signals of the measurement
guide, decouples them and passes them on to the receiver.
Position detection must be checked to ensure it is working properly. The V4000 PB
monitors whether the signals (increments) from the measurement guide have a logical
order – in other words, whether they can be interpreted unambiguously as upward or
downward movement or standstill.
Example
If a start signal for the closing movement is detected by the safety-relevant inputs, it will be
assumed that the press brake is moving after a period of delay (start-up delay). If there is
no movement – in other words, the signals from the PBI cannot be unambiguously
interpreted as movement – the V4000 PB assumes that there is a fault in position
detection, switches the OSSDs into the OFF state, and goes into lock-out state.
The system will not change into the muting state unless the measurement system is
delivering correct information which agrees with the expected values.
The PBI of the V4000 PB has been designed for two-channel, incremental, linear
measurement guides with an RS- 422 interface. All signals of the measurement guide are
looped through.
3.4.5 CDS (Configuration & Diagnostics Software)
The V4000 PB is configured and diagnosed with the CDS software (Configuration &
Diagnostics Software) running on Windows 98 and later operating systems.
In the case of press brakes with PC control and a Windows user interface, the CDS for
configuration or diagnostics of the V4000 PB can be integrated into the control system.
Note
Fig. 14: System configuration
with PC control
Permanent – on-line - diagnostics and operation must be implemented solely via the
RS-422 interface.
N
PBI
SPLC
Fig.
15: System configuration
without PC control
Incremental
encoders
Incremental
encoders
Operating
elements
HMI
CDS
Star
System configuration: version B
In the case of press brakes without PC control or a Windows user interface, the CDS for
configuring the V4000 PB must be connected to the receiver. A permanent connection
with the CDS is not necessary.
For controlling the V4000 PB external signals are required. The V4000 PB has the
corresponding signal inputs for:
Starting the closing or opening movements of the press brake
Requesting alignment mode
Requesting or confirming teach-in
Selecting the protective volume mode (standard, box, back-stop)
Requesting bypass mode
The signals are generated either by operating elements such as buttons or selector
switches or by the outputs of the press controller (e.g. NC).
How these various possibilities are actually implemented (for example, foot switch,
alignment button, teach-in button, selector switch and key-operated switch, or
corresponding switching elements on the MMI of the press controller) falls within the area
of responsibility of the user.
All switching elements should be large and sturdy. It must be possible to operate them
reliably and simply while wearing gloves.
a
WARNING
n
3.5 Possible system configurations
This section describes the parameters and functions of the V4000 PB which can be
configured via CDS.
Check the V4000 PB after making changes!
After making any change to the configuration you must check the effectiveness of the
V4000 PB (function and configuration data).
When starting to configure the V4000 PB, you may save the configuration using an
application name with a maximum of 22 characters. You should use unique designations
with an evident relation to the concrete application name – such as "Machine name XYZ".
With the CDS the V4000 PB can be configured to accept operator signals (alignment,
teach-in, reset, and selection of the protective mode) either from the CDS software or from
external touch elements such as buttons or selector switches. Use of CDS to provide these
operator signals requires a dedicated permanent (on-line) communication interface
between the V4000 PB and CDS via a RS-232 port.
Another method for providing operator signals to the V4000 PB is via the HMI of the
numerical control. These signals could be collected via touch buttons connected to the NC
interface or via software buttons on the HMI console.
Signals of the operating elements of the CDS overwrite signals of the external operating
elements. There could be inconsistencies between the system state and the state of the
V4000 PB.
By means of the CDS the baud rate (transmission rate) can be set at the serial interface
for configuration (between V4000 PB and connected PC). The setting will depend on how
powerful the PC is.
The V4000 PB has an internal time monitor for certain functions. The time monitor should
ensure a regular check is made in the case of uninterrupted operation. The start times are
saved and compared with the current state. If the time for a particular function has
elapsed, a corresponding operator action will be requested.
Following an interruption to the supply voltage all times will be reset to zero.
The V4000 PB monitors the time since the last power-up cycle and requests a new powerup cycle if the configured value (≤ 24 h) is exceeded.
In back-stop mode, the active protective volume segment as seen from the operator side is
behind the pressure axis.
In order to place the active protective volume correctly, it is necessary to specify during
configuration on which side of the press brake (as seen from the operator side) the
receiver is mounted.
Any one of the following conditions will result in automatic muting of the V4000 PB
(inactivation of the protective volume):
Gap size ≤ 6 mm above the taught-in pinch point
Upward movement
Note
In addition a closing movement at a low closing speed v
the system to go automatically into muting mode provided this option has been enabled
during configuration.
The closing speed is continually monitored. If the slow closing speed v
the muting state, muting will be deactivated and the protective volume activated.
With automatic muting at the slow closing speed v
close at slow closing speed despite an interruption of the protective volume.
If slow closing speed v
interrupted, the press will be stopped. After this the press brake can be closed at slow
closing speed via the press controller and a new start signal.
If slow closing speed has already been reached when the protective volume is interrupted,
a new start signal will not be needed.
If a slow closing speed (≤ 10 mm/s) is permitted by the applicable regulations as the sole
protective measure, the option may be activated by the machine setter. In ANSI standard
B11.3 "Safety Requirements for Power Press Brakes" the slow closing speed
(≤ 10 mm/s) is not specified as the sole protective measure!
has not yet been reached when the protective volume is
crawl
crawl
(≤ 10 mm/s) will also cause
crawl
is exceeded in
crawl
it is possible for the press brake to
n
3.5.7 Position-sensing system
The measurement guides (incremental encoders) of the press controller register the
position of the press crosshead.
Increments per mm stroke
The V4000 PB requires the resolution of the incremental encoder [INC/mm] in order to
calculate the speed and direction of movement of the press crosshead and the overall
machine overrun from the signals of one measurement guide and from other measured
data (such as time).
The incremental encoder must support two channels with at least 45 INC/mm and a
maximum of 300 INC/mm at a closing speed of 300 mm/s. The recommendation is
50 INC/mm.
The specifications of the encoder manufacturer can differ from those for the V4000 PB. If,
for example, pulses/mm or a resolution of 10 μm is specified, these have to be converted
into increments/mm.
The 0° and the 90° signal of the incremental encoder are phase-shifted. During a closing
movement (positive sign) the V4000 PB expects the 0° signal to be leading.
Fig. 16: Incremental encoder
signals
0° signal
OF
Note
n
n
90° signal
ON
When connecting the incremental encoder channels, make sure that they do not swapped
or interchanged as this would lead to the direction of movement being misinterpreted. If a
measurement guide is replaced, you will need to check the configuration and input the
resolution of the new measurement guide into the configuration.
The EDM checks if the contacts actually de-energise when the protective device responds.
If an external device monitor is present, external device monitoring must be activated in
the CDS. The V4000 PB will then check the contacts every time the protective volume is
interrupted and before the press brake restarts.
The external device monitor can tell whether a contact is welded or whether a contact/
relay has not de-energised due to a different mechanical fault. If, due to the failure of a
contactor, the system cannot go into a safe operating state the OSSDs will go into the OFF
state, the V4000 PB changes to lock-out state and a reset becomes necessary.
The Braking distance tab only has to be configured if the press brake supports two speeds
(v
and v
p
slow
) and V
is connected.
slow
During the power-up cycle, the braking distance (transition from the high closing speed to
the target speed v
) is also determined.
slow
From the braking distance and the pinch point (which was determined during teach-in) the
positions for the switch-over and muting points are calculated.
The CDS includes a default value of 30 mm for the braking distance which may not, under
any circumstances, be exceeded by the measured braking distance.
3.5.14 Maximum closing speed and maximum overall machine overrun
Maximum closing speed
The following values are defined for the closing speed:
= maximum closing speed (depends on machine design), held in the configuration
v
max
= high closing speed which is reached in the current operating cycle and is
v
P
measured by the V4000 PB
During configuration the maximum closing speed of the press is input as the maximum
closing speed v
. This speed must not be exceeded in any operating cycle.
max
The press crosshead travels at high closing speed (>10 mm/s) up to the switch-over point.
The high closing speed v
is continually monitored.
p
Should the press brake exceed the high closing speed of the last power-up cycle a new
power-up cycle will be needed. During the power-up cycle, the high closing speed v
and
p
the overall machine overrun D (as a function of the high closing speed) are determined.
The high closing speed must be less than or equal to the configured maximum closing
speed.
The configured maximum closing speed in combination with the configured maximum
overall machine overrun must not exceed the stopping distance of the V4000 PB and will
therefore need to be checked during configuration.
The following values are defined for the overall machine overrun:
D
= maximum overall machine overrun (depends on machine design), held in the
max
configuration
D = overall machine overrun which is reached with the current emergency stop and
is measured by the V4000 PB
During configuration the maximum overall machine overrun of the press is input as the
maximum overall machine overrun D
. This overall machine overrun must not be
max
exceeded in any emergency stop.
During the closing movement of the press, and after an emergency stop, the press brake
will continue to run for a distance (overall machine overrun D) which is less than the
maximum machine overrun D
If the distance exceed the maximum machine overrun, D
max
.
, the V4000 PB will require a
max
new power-up cycle.
During the power-up cycle, the high closing speed v
and the overall machine overrun D (as
p
a function of the high closing speed) are determined.
At every emergency stop the overall machine overrun is measured. Should the overall
machine overrun measured exceed the value of the overall machine overrun of the last
power-up cycle the V4000 PB will switch into its lock-out state.
To cancel the lock-out state, a reset and a new power-up cycle are necessary. The overall
machine overrun is determined and at the next emergency stop is available as a wellfounded value for the overall machine overrun.
The configured maximum overall machine overrun in combination with the configured
maximum closing speed must not exceed the stopping distance of the V4000 PB and will
therefore need to be checked during configuration.
The stopping distance is a system parameter from the V4000 PB and the press brake
which is defined in the design of the V4000 PB.
The stopping distance S describes the maximum path distance that the press brake covers
in the time between the sensor function activation and the press being at a standstill.
The following condition applies: S = T
The response time T
machine overrun D
to the stopping distance.
A press brake with a large overall machine overrun can be equipped with the V4000 PB if
its maximum closing speed is limited by making modifications to the hydraulics system
(such as orifice plates). A very high closing speed is only possible when combined with a
short overall machine overrun.
The maximum overall machine overrun and the maximum closing speed must be
configured during installation so that they satisfy the condition of the stopping distance.
of the V4000 PB is constant. The parameters maximum overall
1
and maximum high closing speed v
max
* v
1
max
S ≤ 11 mm
+ D
max
can be adjusted with regard
max
n
Note
n
3.5.15 Travel for determining the overall machine overrun
During the power-up cycle, the overall machine overrun following an emergency stop
(transition from the high closing speed to standstill) is also determined. The travel for
determining the overall machine overrun is the distance the press requires to accelerate to
the high closing speed.
The CDS includes a default value of 30 mm for the maximum travel for determining the
overall machine overrun.
3.5.16 Standstill time for determining the top dead centre
The V4000 PB recognises when the opening movement of the press has ended in the
operating cycle – in other words, when the top dead centre has been reached.
Should the press crosshead make no further upward movement for a specific, configured
period of time (standstill time), the V4000 PB will assume that the top dead centre has
been reached.
Detection of the top dead centres is only necessary during the power-up cycle. The top
dead centre is not monitored and not reaching it is permitted during production operation.
If a start signal for the closing movement is detected by the safety-relevant inputs, it will be
assumed that the press brake is moving after a period of delay. If there is no movement –
in other words, the signals from the PBI cannot be unambiguously interpreted as
movement – the V4000 PB assumes that there is a fault in position detection.
The time delay between the start signal to the V4000 PB for the closing movement and the
actual movement of the press brake depends on the switching times of the individual
components of the press.
The V4000 PB detects when the press is at a standstill.
Should the press crosshead make no further change in position for a specific, configured
period of time (standstill time), the V4000 PB will assume that the press is at a standstill.
When a switch is switched on or off, there will be an undefined state for a brief period. The
signal goes back and forth between the ON and OFF states until a defined state is
reached.
ON
Signal
t
An undefined state will result in an error following logic checking by the V4000 PB and will
thus initiate the lock-out state.
To prevent this from happening, a time period (the settling time) is configured via the CDS
for which the V4000 PB will ignore the undefined state.
Settling times can be configured for the following inputs and outputs:
Two-channel inputs supply two complementary signals. Here the switching-off operation
has ended somewhat earlier than the switching-on operation. This results for a brief period
in an undefined state.
Fig. 18: Discrepancy times
ON
Channel 1
Signal
Channel 2
tt
An undefined state will result in an error following logic checking by the V4000 PB and will
thus initiate the lock-out state.
To prevent this from happening, a time period (the discrepancy time) is configured via the
CDS for which the V4000 PB will ignore the undefined state.
Discrepancy times can be configured for the following inputs and outputs:
Safety-relevant inputs
Inputs for selecting the protective volume mode
Bypass input
V4000 PB device symbol, context menu Configuration draft, Edit, Inputs or Bypass tab
n
Fig. 19: Start signal
(double-click)
3.5.21 Start signal at reduced protective volume
Two different settings can be selected here:
Double-click (default setting)
Deselect double-click
Double-click (default setting)
In the case of the box and back-stop protective volume modes, the start signal for the
closing movement must be given twice. This is intended to draw the operator's attention to
the fact that he is working in a special mode in which only limited protection is provided by
the reduced protective volume.
Via the CDS you can configure the maximum duration of the first start signal (how long
the operator must operate the corresponding operating element) and the pause between the first and second start signal.
At this setting the operator only has to trigger the start signal once (for example by
operating the foot switch once).
If you deselect the double-click, ensure that the operator has to select the Standard
protective field volume mode once briefly after a work interruption of more than 10
minutes, before continuing in the desired protective field volume mode.
The time after which a digital output signal changes from the OFF to the ON state, or vice
versa, can be configured via the CDS so that the signal can be registered by the systems
connected to the V4000 PB. The minimum configurable state time is 0 ms while the
maximum configurable state time is 1000 ms.
3.5.23 Minimum switch-off time for safety-relevant outputs
The time for which the signal of the OSSD outputs remains at minimum in the OFF state
(after an interruption of the protective volume, for example), can be configured via the CDS
so that the signal can be registered by the systems connected to the V4000 PB.
The minimum configurable switch-off time is 100 ms while the maximum configurable
switch-off time is 1000 ms.
In bypass mode the press brake can be operated without the V4000 PB protective device
being activated.
To activate bypass mode, the bypass function is enabled in the configuration and the
outputs of the bypass function at the receiver connected with its inputs.
In bypass mode the OSSDs are in the ON state and all displays on the receiver are
switched off. The V4000 PB does not generate any output signals (request for target
speed, request for teach-in).
The bypass is deactivated by breaking the electrical connection between output and input.
After the bypass mode is deactivated, the V4000 PB changes to the restart interlock and
requests a new power-up cycle.
The operator is responsible for the use and perfect functioning of additional safety devices
which ensure the safe operation of the press brake (for example, the use of robots for
handling materials).
In protective operation the V4000 PB safeguards the hazardous point beneath the die
during the operating cycle at high closing speed (>10 mm/s).
Operating states within protective operation
The following operating states are available within protective operation:
Power-up cycle
Teach-in
Production operation
The following is true for all operating states:
The protective volume is active and is monitored for interruption.
The position, direction of movement, speed and overall machine overrun are monitored
and evaluated.
Protective volume modes in protective operation
Within protective operation there are also three protective volume modes available which
make it possible to adjust the protective volume to best suit the current bending job:
Standard mode
Box mode
Back-stop mode
3.6.1 Power-up cycle
In the power-up cycle the overall machine overrun at high closing speed and, if possible,
the braking distance (the transition from high closing speed to target speed) are
determined for monitoring during press operation. Following this the teach-in procedure is
carried out.
During the power-up cycle the protective volume is active.
The power-up cycle is requested by the V4000 PB after every switch-on or reset of the
V4000 PB.
At least once every 24 hours (in the case of continuous press operation) the V4000 PB
system automatically requests the power-up cycle.
The operator confirms the power-up cycle by giving the teach-in signal via the press
During teach-in the pinch point (which depends on the thickness of the material or the
relative position of the top surface of the workpiece) is determined. The die contacts the
workpiece at the pinch point. From the pinch point the positions for the switch-over and
muting points are calculated.
During teach-in the protective volume is active.
The operator or the V4000 PB system can request teach-in.
The pinch point is monitored during each stroke of the press. The V4000 PB detects
when the position of the pinch point does not correspond to the value last determined.
The system then requests teach-in which the operator must confirm via the controller or
an external operating element.
Note
V4000 PB calculates from the pinch point all safety-relevant parameters (switch-over and
muting points). For this reason, following a change of material the safety-relevant
parameters will no longer apply.
This means that you will need to carry out the teach-in procedure every time the workpiece
material changes.
3.6.3 Protective volume modes in protective operation
Fig. 20: Protective volume in
standard mode
Standard mode
Standard mode is used when flat workpieces are to be bent and it is not expected that at
high closing speed the protective volume will be interrupted by the shape of the workpiece.
In standard mode the entire protective volume is monitored for interruption.
Catching or crushing of fingers or hands is possible due to the protective volume being
partially blanked and also in the tolerance zone at the pressure axis!
The partial blanking of the protective volume means that objects within the tolerance zone
will not be detected.
> Make sure that the workpiece is handled correctly (see Section
operation").
Box mode is used when the workpiece needs to be bent several times (as when boxes or
trays are being made, for example) and it is expected that at high closing speed the
protective volume will be interrupted by the shape of the workpiece.
Box location in front space
Box location in rear space
2.5 "Safety in
Note
blanked
Box mode may be used in either of two variants:
Variant A
Up until the time when the protective volume is interrupted by the top of the box the entire
protective volume is checked for interruption (as in standard mode).
In the case of the protective volume being interrupted from one side, either in front of or
behind the pressure axis, this interruption will automatically be interpreted as the box wall.
In box mode the corresponding segment of the protective volume and a tolerance zone
(positioned centrally on the pressure axis) will be blanked automatically and the closing
movement will not be stopped.
If the protective volume is interrupted in both segments (in front of and behind the
pressure axis), this will initiate a stop signal which must stop the movement of the press
crosshead.
Since in box-bending the side walls of the box can project behind the pressure axis, the
tolerance zone at the pressure axis is blanked.
The press brake is closed at high closing speed leaving but a gap. As in standard mode the
entire protective volume is monitored. The operator stops the movement of the press
crosshead.
The box is then slid into the gap. The corresponding segment of the protective volume is
blanked automatically.
A new starting pulse finishes the operating cycle.
If possible use Variant B of box mode for bending boxes since the operating cycle is mostly
carried out in standard mode.
If the press brake is closed leaving a gap of [ 6 mm before the box is inserted into the gap,
work can be carried out in standard mode.
Back-stop mode
Catching or crushing of fingers or hands due to the protective volume being partially
blanked and also in the tolerance zone at the pressure axis!
The partial blanking of the protective volume means that objects within the tolerance zone
will not be detected.
> Make sure that the workpiece is handled correctly (see Section
operation").
2.5 "Safety in
Fig. 22: Reduced protective
volume in back-stop mode
Back-stop mode is used during bending of very short legs or flanges when the rear stops
have to be moved up very close to or even onto the female die with the result that the
protective volume is interrupted by the rear stop at high closing speed.
Boxes can also be bent in back-stop mode.
In back-stop mode, the protective volume segment on the operator side is blanked
completely and the part behind the pressure axis blanked partially.
The side on which the receiver is mounted is defined via the CDS and this ensures that the
correct protective volume segment is blanked.
PTDC Programmed top dead centre of the press
SP Switch point =
MP Mute point – protective volume inactive
PP Pinch point
PBDC Programmed bottom dead centre of the press
Slow closing speed
Braking from v
V4000 PB switch-over point – request for target speed v
≤
10 mm/s (after the pinch point)
to v
slow
P
slow
From the system sequences you can see how the protective volume adapts itself during
the operating cycle and how it reacts if necessary. The machine movement, closing speed,
and the states and signals are shown in parallel. The protective volume is located below
the tip of the die.
A requirement for the following sequences is that v
is supported by the press controller.
slow
The time context and the behaviour of the input and output signals are dealt with in
Section
13.1 "Detailed system sequences in protective operation").
Start condition: the system starts, carries out the self-test and waits for acknowledgement
from the operator for the request signal for teach-in.
Step
Protective volume
Speed; machine movement
1 The die is at any point in
the operating cycle.
The operator gives the
signal for teach-in
(teach-in button).
PTDC
=0
2 The operator gives the
signal to start the
closing movement (foot
switch). The die
descends at maximum
closing speed.
is measured.
v
p
PTDC
p
3 After about 20 mm the
OSSDs go into the OFF
state and generate a
safe stop signal.
The high closing speed
must be stopped.
The V4000 PB
determines the overall
machine overrun.
interrupts the protective
volume. The OSSDs go
into the OFF state and
generate a safe stop
signal.
From this the pinch
point PP (workpiece
surface) is obtained.
top
9 The die must stop at
least 5 mm above the
workpiece.
The positions for the
switch-over and muting
points are calculated.
The operator cancels
the start signal (foot
switch).
signal once more to
start the closing
movement (foot switch).
The operating cycle
resumes on the basis of
this position.
The protective volume is
muted as soon as the
gap is ≤ 6 mm and the
V4000 PB has reached
the muting point MP.
The V4000 PB has
updated the parameters
and the first bending
without discarding of
material can be made
after giving a new start
signal.
the operating cycle.
The operator gives the
signal for teach-in
(teach-in button).
The protective volume is
active.
=O
PTDC
2 The operator gives the
signal to start the
closing movement (foot
switch). The die
descends at high
closing speed v
The entire protective
volume is active.
.
P
PTDC
3 The workpiece
interrupts the protective
volume.
The OSSDs go into the
OFF state and generate
a safe stop signal.
From this the pinch
point PP (workpiece
surface) is obtained.
least 5 mm above the
workpiece surface.
The positions for the
switch-over and muting
points are calculated.
PTDC
5 The operator gives the
signal once more to
start the closing
movement (foot switch).
The operating cycle
resumes on the basis of
this position.
The protective volume is
muted as soon as the
gap is ≤ 6 mm and the
V4000 PB has reached
the muting point MP.
The first bending
without discarding of
material can be
completed.
programmed top dead
centre PTDC.
The operator gives the
signal to start the
closing movement (foot
switch).
PTDC
2 The die descends at
high closing speed
).
(≤v
P
The entire protective
volume is active.
3 At the switch-over point
SP the target speed is
requested by the
V4000 PB.
The press controller
starts the braking
procedure.
The protective volume
stays active in the gap
opening.
programmed top dead
centre PTDC.
The operator gives the
signal to start the
closing movement (e.g.
double-click with the
foot switch).
2 The die descends at
high closing speed
).
(≤v
P
The entire protective
volume is active.
3 If the box projects into
the protective volume in
front of the pressure
axis, the protective
volume in front of the
pressure axis will be
automatically blanked.
The die continues to
descend at maximum
speed v
The part of the
protective volume
behind the pressure
axis remains active.
programmed top dead
centre PTDC.
The operator gives the
signal to start the
closing movement (e.g.
double-click with the
foot switch).
PTDC
2 The die descends at
high closing speed
).
(≤v
P
A reduced protective
volume segment behind
the pressure axis is
active.
3 At the switch-over
point SP the target
speed is requested by
the V4000 PB.
The press controller
starts the braking
procedure.
The protective volume
segment stays active in
the gap opening.
The alignment operating mode helps the operator in aligning the sender and the receiver.
When commissioning and every time there is a change of tooling, the sender and receiver
need to be mechanically aligned with respect to each other beneath the die and with
respect to the die tip.
The operator uses the alignment masks and the 7-segment display to align the sender and
receiver exactly to each other and determines the optimum alignment of the protective
Note
volume to the die (see also Section
The following applies to alignment mode:
The protective volume is not active.
The OSSDs are in the OFF state.
The operator has no protection from the V4000 PB.
In alignment mode the laser is visible. The V4000 PB meets the requirements of laser
protection class 1 M. There is no hazard for the operator.
> Do not look into the laser beam using optical equipment (such as binoculars).
This chapter describes the preparation and completion of the mounting of the V4000 PB.
The following steps are necessary after mounting:
5)
6)
7.2)
a
WARNING
Electrical installation (Chapter
Configuration of the V4000 PB (Chapter
Aligning sender and receiver (Section
4.1 Steps for mounting
Pay particular attention to the following points during mounting:
> Mount the V4000 PB so that it is protected against moisture, contamination and
damage.
> Ensure that the viewing field of the front lenses is not restricted.
> In the case of machines with high vibration levels, use a screw-locking compound to
ensure mounting screws do not work themselves loose.
> Check the mounting screws regularly to ensure they are still tight.
Note
Fig. 24: Groove for
accommodating the sliding
nut
The sender and the receiver are mounted on the press crosshead in the same way.
4.1.1 Mounting the sender or receiver using SICK mounting kit 1
Preparation of the bracket on the press crosshead:
The SICK mounting kit 1 consists of an alignment plate with a sliding nut.
Your bracket on the press crosshead must have a corresponding groove (for dimensions,
see Fig. 24). The groove must be at least 100 mm long. In addition a free space must be
left for the front mounting bolt of the sender or receiver.
Mounting your V4000 PB with the SICK mounting kit 1:
Spring washer
uxiliary alignment plate
lignment plate
Washer
Note
Note
When installing mounting kit 1 make sure the supplied spring washers, plain washers,
nuts and auxiliary alignment plate are positioned correctly.
> Fasten the alignment plate to the sender or receiver.
> Slide the alignment plate with the sender or receiver into the groove prepared for it in
your bracket.
In back-stop mode, the active protective volume segment as seen from the operator side is
behind the pressure axis. This is why you will need to specify via the CDS in the
configuration on which side of the press brake the receiver is mounted.
4.1.2 Mounting the sender or receiver using SICK mounting kit 2
SICK mounting kit 2 consists of a device adapter with a groove for mounting the sliding nut
(SICK mounting kit 1) and a retaining arm which is mounted on the press crosshead. The
retaining arm has a rapid adjustment device for the vertical axis and an adjustment lever
in the direction of the press crosshead.
Latching marks can be provided on the vertical profile of the retaining arm to allow rapid
adjustment of the V4000 PB for frequent tool changes.
The EDM checks if the contacts actually de-energise when the protective device responds.
If, after an attempted reset, the EDM does not detect a response from the switching
amplifier within 300 ms, the EDM will deactivate the OSSD switching outputs again.
External device monitoring is implemented in such a way that there is positive closing of
both N/C contacts (k1, k2) when the contact elements (K1, K2) reach their de-energised
position after the protective device has responded. 24 V is then applied at the input of the
EDM (see
means one of the contact elements is faulty and the external device monitoring prevents
the machine starting up again.
Contacts or relays monitored by EDM must be positively driven.
If you connect the contact elements to be monitored to the EDM input, then you must
activate the option EDM in the CDS (Configuration & Diagnostic Software). If you fail to
do so, after the V4000 PB is switched on the 7-segment display will show /.
If you later deselect the EDM option, pin 6 of the system plug must not remain
connected to 24 V.
Fig. 28). If 24 V is not present after the response of the protective device , this
In bypass mode the press brake can be operated without an activated V4000 PB
protective device. In bypass mode the OSSDs are in the ON state and all displays on the
receiver are switched off. The V4000 PB does not generate any output signals (targetspeed request, teach-in request).
To activate bypass mode, the bypass function should be enabled in the configuration and
the outputs of the bypass function at the receiver connected with its inputs.
The bypass is disabled by interrupting the electrical connection. When bypass mode is
disabled, the V4000 PB goes into restart interlock and requests a power-up cycle.
Fig. 33: Bypass connection
diagram
PIN 6
PIN 8
PIN 12
PIN 10
Notes
n
If you connect the bypass, you must activate the bypass function in the CDS (Configuration
& Diagnostic Software). Should implausible states of the two input signals occur, the
7-segment display will show the error message TO/.
The operator is responsible for the use and perfect functioning of additional safety devices
which ensure the safe operation of the press brake (such as using robots for material
handling).
The V4000 PB is delivered in a state which is safe.
The V4000 PB is in the Waiting for configuration device mode.
The switching outputs (OSSDs) are in the OFF state.
The 7-segment display shows -.
Notes
Fig. 35: Switch setting
The maximum overall machine overrun and the maximum closing speed must be
configured at installation such that they satisfy the condition of the stopping distance.
You can change this configuration with CDS.
The serial interface for configuration is switched to RS-232. In the case of a permanent –
on-line – connection, the interface will need to be changed over to RS-422 with the switch
S. The RS-422 interface must be supported on the PC or controller side and connected
properly.
Do not commission without a check by specialist personnel!
a
WARNING
Notes
> Before you operate a system protected by the V4000 PB for the first time, make sure
that the system is first checked and released by specialist personnel.
> To this regard please read the notes in Chapter 2 "
After replacing single components of the safety system a commissioning has to be done.
On safety" on Page 9.
7.1 Test notes
The purpose of the tests described below is to confirm the safety requirements specified in
the national and international rules and regulations, especially in the Machinery Directive
and the Use of Work Equipment Directive (EC Conformity).
These tests are also intended as a way of detecting whether protection is being affected by
sources of extraneous light or by other unusual environmental influences.
It is therefore essential that these tests be carried out.
Recommendation
Notes
7.2 Aligning sender and receiver
7.2.1 Initial alignment
Sender and receiver must be aligned exactly with respect to each other and with respect to
the die of the press brake in order to ensure the safety function of the sensor. This is done
with the alignment masks in alignment mode.
How to prepare for initial alignment:
> Ensure that the V4000 PB is properly mounted and connected electrically.
> Ensure that the press is fitted with at least one die segment.
> Switch on the power supply to the V4000 PB.
To increase the accuracy of initial alignment, the press crosshead should be fitted with one
die segment at the right-hand edge and one at the left.
The laser is visible in alignment mode. The V4000 PB meets the requirements of laser
protection class 1M. The operator is not at any risk.
> Do not look into the laser beam with optical devices (such as a binoculars).
> Move the sender bracket in directions III and IV until the alignment beam goes through
the hole of the second mask B.
Adjustment in direction III
With the aid of a steel plate with three notches (auxiliary alignment plate) which is
mounted between the front bolts and three notches in the alignment plate, the sender can
be rotated on the horizontal plane ±3° out of its central position. Here the sender rotates
in the slots in the alignment plate – in other words, the sensor is turned on the rear bolts
and relative to the alignment plate.
When aligning the sender, make sure that the nuts of the bolts on which the alignment
plate is mounted are only tightened up handtight. The spring washers will provide the
necessary tension.
> Insert the blade of a screwdriver (blade 4) into the middle notch of the alignment plate
or steel plate.
> Turn the screwdriver blade slowly clockwise or anti-clockwise in the middle notch until
the alignment beam goes through the hole in the second mask B.
> You can use the left-hand or right-hand notch to turn the sender even further clockwise
or anti-clockwise if this is necessary.
Make sure that the alignment beam goes through both B masks. You may need to make
realignment adjustments in directions I and II and in directions III and IV.
Incorrect alignment of the V4000 PB can result in serious injuries.
> After every alignment operation, carry out a function check.
lignment point
focussing screen
uxiliary points
focussing screen
lignment point
alignment beam
> Affix mask C in front of the front lens on the receiver housing.
Tab. 17: Display during
alignment of sender and
receiver
Notes
> Move the receiver bracket in directions I and II until the alignment beam goes through
the hole in the mask.
> Move the receiver bracket in directions III and IV until the three target points (alignment
point and two auxiliary points) coincide with the collecting zone on the focussing screen.
> Use the 7-segment display to carry out fine alignment.
The CDS provides a graphic representation of the alignment state of the receiver. You can
also carry out fine alignment with the aid of the CDS display.
Display Meaning Action
l Image detector not illuminated
> Check the connection of the sender.
> Check the rough alignment of the
sender and receiver and correct if
necessary.
> Check the masks. They may have
been mixed up or fitted at an angle.
1 Invalid pattern
m
Alignment point or all points on
left outside the target zone
E
Alignment point or all points
> Move the sender bracket in directions
I and II until the alignment point is in
the target zone.
above the target zone
Alignment point or all points on
right above the target zone
o
Alignment point or all points on
left above the target zone
{
Alignment point or all points on
right outside the target zone
Alignment point or all points on
left below the target zone
Alignment point or all points on
right below the target zone
Alignment point in the target
zone, position of the auxiliary
points at alignment point out of
tolerance (clockwise rotation)
Alignment point in the target
zone, position of the auxiliary
points at alignment point out of
tolerance (anti-clockwise
rotation)
Alignment point or all points
horizontally outside tolerance
Distance between the auxiliary
points outside tolerance
An attempt has been made to
save an invalid alignment point.
Alignment point in the target
range, auxiliary points in
tolerance
> Move the sender bracket in directions
I and II until the alignment point is in
the target zone.
> Move the sender bracket in directions
III and IV until the alignment point is
in the target zone and the auxiliary
points in tolerance.
> Check the masks.
> Replace the device (internal
mis-justment).
> Cancel the "Save alignment point"
request and continue with alignment.
> For at least 1 second request
alignment mode in order to save the
alignment point.
> Once the sender and receiver are in the right position (7-segment display %) fasten
down the receiver brackets.
> For at least one second request alignment mode.
The alignment point will be saved.
When the request for alignment mode is cancelled, the V4000 PB will be reset.
When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up
cycle.
> Remove all masks.
> Press the teach-in button.
The request for the power-up cycle is acknowledged and the cycle carried out (see
Section
> Carry out the function check using the test piece (see Section
Alignment may have to be readjusted after a tool change.
If you are working with only a few dies of different lengths, it is worth setting up latching
marks (defined, vertical bracket positions or markings on the bracket).
How to prepare for alignment following a tool change:
> Ensure that sender and receiver are correctly aligned at first alignment.
> Switch on the power supply to the V4000 PB.
Tracking without latching marks (checking and initial setting-up of latching marks)
Risk of injury if incorrectly aligned!
Incorrect alignment of the V4000 PB can result in serious injuries.
> After every alignment operation, carry out a function check.
Mask A
> Press the alignment mode button (signal for alignment mode).
> Affix mask A in front of the front lens on the sender housing.
> Move the sender bracket in direction I until the die tip alignment point is intersected by
the lower edge of the die.
> Move the receiver bracket in direction I until the correct position is confirmed via the
7-segment display (alignment tolerance ± 6 mm).
> Once the sender and receiver are in the right position (7-segment display %), hold down
the button for alignment mode for at least one second.
The alignment point will be saved.
When the signal for alignment mode is cancelled, the V4000 PB will be reset.
When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up
cycle.
> Remove mask A.
> Press the power-up cycle button.
The request for the power-up cycle is acknowledged and the cycle carried out (see
Section
> Carry out the function check using the test piece (see Section
7.4 Regular checks of the protective device by specialist
personnel
Regular checks will ensure that any changes to the machine or manipulation of the
protective device after commissioning are detected.
> Check the system at the inspection intervals specified in the national rules and
regulations.
> If major modifications have been made to the machine or the protective device, or if the
V4000 PB has been modified or repaired, the system must be checked again as
Tab. 18: Regular checks
specified in the checklist in the annex (see Section
Check Daily Annually/after
commissioning
Alignment x x
Protective function
with test rod
Emergency stop
properties of the
entire system
Overall machine
overrun
Configuration data
x x x
x x x
x
13.3 "Manufacturer’s checklist").
Following a tool change
x
a
WARNING
Number of
repetitions
1 10 1
7.5 Daily checks of the protective device by authorised
commissioned persons
The effectiveness of the protective device must be checked daily or prior to the start of
work by a specialist or by authorised commissioned persons, using the correct test rod.
The check must furthermore be carried out at each tool change.
Do not operate the machine if errors or faults are found during the checks!
If any of the following conditions is not fulfilled, no work may be carried out at the
machine.
> In this case have the installation of the V4000 Press Brake checked by specialist
personnel.
Visual inspection of the protective device
> Check the protective device (mounting, housing, electrical connection, optics) for
damage or wear.
> Switch the machine on and check whether at least one LED at the receiver of the
V4000 Press Brake (LED below the receiver lens) lights up permanently.
Checking the protective volume
> Check whether the red LED at the receiver of the V4000 Press Brake lights up when the
protective volume is interrupted with the test rod (handle of the test piece) below the die
tip. Carry out the test along the entire protective volume below the die tip.
> Carry out the following test on the left and right side of the female die and in the
centre of the female die.
– Place the section of the test piece having a height of 10 mm on the workpiece so that
the section lies in the middle of the pressure axis.
– Start the closing movement with the maximum closing speed.
– After the press has stopped, check whether the following section having a height of
15 mm can be pushed into the remaining gap.
> In order to increase security, repeat the test with the section of the test piece having a
height of 35 mm and check whether the following section having a height of 40 mm can
be pushed into the remaining gap after the press has stopped. Also carry out this test on the left and right side of the female die and in the centre of the female die.
The functioning of the V4000 PB can be affected by air contamination and nuisance
shutdowns may be the result.
> Keep the area around the V4000 PB free of smoke, fumes, steam and other types of air
contamination (particularly contamination of the lenses, such as by oil).
How to prepare for operation:
> Carry out the daily check (see Section
authorised commissioned persons").
7.5 "Daily checks of the protective device by
8.1 Switching the machine on
Display sequence during switch-on
After the system is switched on, the sender and receiver carry out a self-test (system
initialisation). The 7segment display indicates the device status during the self-test.
The display values have the following meaning:
Display Meaning
` Switch on. This is followed by the self-test of the V4000 PB.
D, E, F, G,
H, I, J, M
* It has not (yet) been possible to complete the self-test successfully.
Testing the 7-segment display. All segments are activated
sequentially.
+ The input states do not (yet) correspond to the values expected.
- V4000 PB requires configuration.
Other display Protective volume mode: see Section 8.2 "Selecting protective
> Use the selector switch to select protective volume mode (standard, box or back-stop
mode).
Depending on which protective volume mode you have selected you will see the following
displays on the 7-segment display:
Tab. 20: Protective volume
mode displays
Note
Display Meaning
L Standard mode
= Box mode
} Back-stop mode
> If the selector switch is pointing to box or back-stop, switch the selector switch to
standard protective volume mode first and then to the protective volume mode you
want.
The protective volume mode you have selected will be available thereafter with every start
signal.
In the case of the box or back-stop protective volume modes, the start signal for the
closing movement can be triggered either by double-clicking or by a single action. If single
triggering is used, non-operation is time-monitored. The operator will then be warned that
the machine is working in a special mode in which there is only limited protection due to a
reduction in the protective volume.
Tab. 21: Carrying out a
power-up cycle, for example
in standard mode
8.3 Resetting
A V4000 PB reset corresponds to a switch-on. After the reset, there will be a self-test and a
power-up cycle.
> Make a reset by pressing simultaneously the buttons for alignment mode and for
teach-in.
8.4 Carrying out a power-up cycle
Following machine switch-on and system initialisation the V4000 PB requests teach-in
mode. A power-up cycle will be requested if the V4000 PB has, during operation, detected
a time-out since the last power-up cycle, or the V4000 PB has been reset.
The power-up cycle cannot be carried out unless the standard protective volume mode has
been previously selected, if only for a brief period. After this the power-up cycle can be
carried out in any protective volume mode.
Action Result LED display
> If necessary, open the press. The press is open. O Red
Ö Yellow
(90/10)
> Press the teach-in button. The request for the power-up
Tab. 22: Carrying out
teach-in, for example in
standard mode
Note
From the pinch point the V4000 PB calculates all safety-relevant parameters (switch-over
point and muting point). For this reason the safety-relevant parameters cease to apply
after a change of material.
> This means you should carry out teach-in every time a material is changed.
Teach-in cannot be carried out unless the standard protective volume mode has been
previously selected. Once this has been done, teach-in can be carried out in any protective
volume mode.
If the V4000 PB does not detect the pinch point or does so only after a repeated request
for teach-in, use the magnetic plate supplied to cover the female die opening beneath the
workpiece.
The magnetic plate should be flush with the top surface of the female die. It must not
project above the level of the workpiece surface.
Action Result LED display
> Select standard protective
–
volume mode.
> Press the teach-in button. –
> If necessary, open the press. The press is open. O Green