Sick V4000 User Manual

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V4000 Press Brake sensor system

for protecting the press brake

OPERATING INSTRUCTIONS

Operating instructions

V4000 PB

This document is protected by copyright. The SICK AG company retains this right. Reproducing this document in whole or part is only permissible within the limits of the statutory regulations of copyright law. Modifying or abridging the document is impermissible without the express written permission of from the SICK AG company.

Insert

V4000 PB

Update

Please take note of the following updates to this document!

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

Machinery Directive 98/37/EC Machinery Directive 2006/42/EC

Directive 93/68/EEC Directive 93/68/EC

EMC directive 89/336/EEC EMC directive 2004/108/EC

Low Voltage Directive 73/23/EC Low Voltage Directive 2006/95/EC

DIN 40050 EN 60529

IEC 536:1976 EN 61140

DIN EN 50178:1998-04/ VDE 0160:1998-04

EN 775 EN ISO 10218-1

EN 292-1 EN ISO 12100-1

EN 292-2 EN ISO 12100-2

EN 954-1 EN ISO 13849-1

EN 418 EN ISO 13850

EN 999 EN 999+A11)

EN 294 EN ISO 13857

EN 811 EN ISO 13857

EN 1050 EN ISO 14121-1

IEC 68, part 2-27 or IEC 68 EN 60068-2-27

IEC 68, part 2-29 EN 60068-2-27

IEC 68, part 2-6 EN 60068-2-6

EN 50178

prEN 501001 EN 61496-1

ANSI B11.19-1990 ANSI B11.19:200304, Annex D

EN 999 will be replaced by EN ISO 13855.

Insert

V4000 PB

Update

Electrical installation

Prevent the formation of a potential difference between the load and the protective

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 13849, EN 62061, IEC 61508:

V4000 PB: General system data

Type Type 4 (IEC 61496)

Safety Integrity Level2) SIL3 (IEC 61508),

SILCL3 (EN 62061)

Category Category 4 (EN ISO 13849)

Category 4 (EN 954

)

Performance Level2) PL e (EN ISO 13849)

PFHd (mean probability of a dangerous failure

1.52×10–8

per hour)

TM (mission time) 16.6 years (EN ISO 13849)

EC declaration of conformity

You can obtain the EC declaration of conformity with the standards used at: www.sick.com

2) For detailed information on the exact design of your machine/system, please contact your local SICK representative.

3) Only valid for the assumption of conformity until 28.12.2009. From then on it will only be permissible to use the successor EN ISO 13849.

Insert

V4000 PB

Update

Checklist for the manufacturer

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 138491/EN 62061 and the type according to EN 614961?

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, ASInterface Safety at Work) integrated in compliance with the required PL/SILCL according to EN ISO 13849/EN 62061 and does the integration comply with the circuit diagrams?

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.

Yes

No 

No  No 

No 

No  No  No 

No 

No  No  No  No  No 

No  No 

Insert

V4000 PB

Update

Operating instructions

V4000 PB

Contents

1 About this document ......................................................................................................6

1.1 Function of this document....................................................................................

1.2 Target groups ........................................................................................................

1.3 Scope .....................................................................................................................

1.4 Depth of information.............................................................................................

1.5 Abbreviations.........................................................................................................

1.6 Symbols used ........................................................................................................

6 6 6 6 7 8

2 On safety..........................................................................................................................

2.1 Specialist personnel..............................................................................................

2.2 Applications of the system ...................................................................................

2.3 Correct use of the system..................................................................................

2.4 General protective notes and protective measures.........................................

2.5 Safety in operation.............................................................................................

2.6 Environmental protection ..................................................................................

2.6.1 Disposal ............................................................................................

3 Product description .....................................................................................................

3.1 Special features .................................................................................................

3.2 Safety concept....................................................................................................

3.2.1 Protection principle of the V4000 PB .............................................

3.2.2 Protective volume during the operating cycle ................................

3.2.3 Intrusion of the protective volume during the operating cycle......

3.3 Range of use ......................................................................................................

3.4 Structure of the device ......................................................................................

3.4.1 Sender and receiver.........................................................................

3.4.2 Displays at the sender and receiver ...............................................

3.4.3 Interfaces at the receiver.................................................................

3.4.4 PBI (press brake interface)..............................................................

3.4.5 CDS (Configuration & Diagnostics Software)..................................

3.4.6 External operating elements ...........................................................

3.5 Possible system configurations.........................................................................

3.5.1 Source of the operator signals ........................................................

3.5.2 Baud rate communication interface ...............................................

3.5.3 Application name .............................................................................

3.5.4 Repetition interval of power-up cycle..............................................

3.5.5 Mounting of receiver........................................................................

3.5.6 Speed-dependent muting................................................................

3.5.7 Position-sensing system ..................................................................

3.5.8 External device monitoring (EDM)...................................................

3.5.9 Default value for braking distance..................................................

3.5.10 Travel for determining the braking distance ..................................

3.5.11 Braking offset ...................................................................................

3.5.12 Target speed v

3.5.13 Monitoring of the slow closing speed v

point..................................................................................................

3.5.14 Maximum closing speed and maximum overall machine

overrun..............................................................................................

3.5.15 Travel for determining the overall machine overrun......................

3.5.16 Standstill time for determining the top dead centre......................

3.5.17 Start delay for closing movement ..................................................

for determining the braking distance ............... 36

slow

from the pinch

crawl

9 10 10 11 16 16

17 18 18 20 21 22 23 23 24 26 28 29 31 31 33 33 33 33 34 34 34 35 35 36 36

37 38 38 39

Operating instructions

V4000 PB

Contents

3.5.18 Time for standstill detection ............................................................ 39

3.5.19 Settling times for inputs ...................................................................

3.5.20 Discrepancy times for inputs ...........................................................

3.5.21 Start signal at reduced protective volume ......................................

3.5.22 Minimum state time for standard outputs......................................

3.5.23 Minimum switch-off time for safety-relevant outputs.....................

3.5.24 Bypass...............................................................................................

3.6 Protective operation ...........................................................................................

3.6.1 Power-up cycle ..................................................................................

3.6.2 Teach-in.............................................................................................

3.6.3 Protective volume modes in protective operation..........................

3.7 System sequences in protective operation.......................................................

3.7.1 Power-up cycle in standard mode....................................................

3.7.2 Teach-in.............................................................................................

3.7.3 Operating cycle in standard mode...................................................

3.7.4 Operating cycle in box mode............................................................

3.7.5 Operating cycle in back-stop mode .................................................

3.8 Alignment mode..................................................................................................

39 40 40 41 41 41 42 42 43 43 46 47 51 53 55 57 59

4 Mounting.......................................................................................................................

4.1 Steps for mounting .............................................................................................

4.1.1 Mounting the sender or receiver using SICK mounting kit 1.........

4.1.2 Mounting the sender or receiver using SICK mounting kit 2.........

4.1.3 Sticker: Information for daily inspection .........................................

5 Electrical installation...................................................................................................

5.1 Connecting the receiver ....................................................................................

5.2 Connecting the sender.......................................................................................

5.3 Making up the connections for receiver and sender.......................................

5.4 Connecting the PBI............................................................................................

5.5 External device monitoring (EDM) .....................................................................

5.6 Bypass.................................................................................................................

5.7 Configuration connection (serial interface).......................................................

6 Configuration................................................................................................................

6.1 Delivery state ......................................................................................................

6.2 Configuration preparations ................................................................................

7 Commissioning.............................................................................................................

7.1 Test notes ...........................................................................................................

7.2 Aligning sender and receiver .............................................................................

7.2.1 Initial alignment ................................................................................

7.2.2 Alignment following a tooling change..............................................

7.3 Function check ...................................................................................................

7.4 Regular checks of the protective device by specialist personnel...................

7.5 Daily checks of the protective device by authorised commissioned

persons ...............................................................................................................

60 60 61 62

63 66 67 67 69 70 71

72 73

74 74 74 81 83 86

8 Operation ......................................................................................................................

8.1 Switching the machine on..................................................................................

8.2 Selecting protective volume mode ....................................................................

8.3 Resetting .............................................................................................................

8.4 Carrying out a power-up cycle............................................................................

8.5 Carrying out teach-in ..........................................................................................

8.6 Bending in standard mode.................................................................................

88 89 89 89 91 92

Operating instructions

V4000 PB

Contents

8.7 Bending in box mode ........................................................................................ 92

8.8 Bending in back-stop mode..............................................................................

8.9 Changing the sheet thickness...........................................................................

8.10 Tool changing .....................................................................................................

8.11 Care and maintenance ......................................................................................

92 92 93 93

9 Diagnostics...................................................................................................................

9.1 Response to errors and malfunctions...............................................................

9.2 Error displays of the LEDs..................................................................................

9.3 Error displays of the 7-segment display............................................................

9.4 Extended diagnostics via CDS...........................................................................

9.5 SICK support.......................................................................................................

10 Technical data..............................................................................................................

10.1 Device data sheet ..............................................................................................

10.1.1 V4000 PB technical data.................................................................

10.1.2 Technical data for PBI (press brake interface).............................

10.1.3 Incremental encoder technical data.............................................

10.2 Dimensional drawings .....................................................................................

10.2.1 Sender and receiver.......................................................................

10.2.2 SICK mounting kit 1 .......................................................................

11 Ordering information .................................................................................................

11.1 Scope of delivery..............................................................................................

11.2 Available systems.............................................................................................

11.3 Accessories.......................................................................................................

12 Glossary ......................................................................................................................

13 Annex .......................................................................................................................

13.1 Detailed system sequences in protective operation......................................

13.1.1 Power-up cycle................................................................................

13.1.2 Teach-in ..........................................................................................

13.1.3 Standard mode ..............................................................................

13.1.4 Box or back-stop mode with interruption of the protective

volume ............................................................................................

13.2 Declaration of Conformity................................................................................

13.3 Manufacturer’s checklist.................................................................................

13.4 List of tables.....................................................................................................

13.5 List of illustrations............................................................................................

13.6 Index .................................................................................................................

94 94 95 97 98

99 105 106 107 107 108

109

109 109 109

111

114

114 114 116 118

120 122 124 125 126 128

Chapter 1 Operating instructions

V4000 PB

About this document

1 About this document

Read this chapter carefully before working with the operating instructions and the V4000 Press Brake system.

For "V4000 Press Brake system" we shall use the abbreviation "V4000 PB" from now on.

1.1 Function of this document

These operating instructions are intended for the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, electrical installation,

configuration, commissioning, operation and diagnostics of the V4000 PB sensor.

These operating instructions do not provide instructions for operating machines on which the V4000 PB is, or will be, integrated. Information of this kind will be found in the operating instructions for the machine.

1.2 Target groups

These operating instructions are intended for manufacturers, operators and the users of press brakes which are to be protected by a V4000 PB. It also addresses people who integrate the V4000 PB into a machine, initialise its use, or who check the unit.

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".

 Error diagnostics and remedying

 Technical data and order numbers

 Conformity and approval

Operating instructions Chapter 1

V4000 PB

About this document

Note

ANSI

BWS

CDS

EDM

ESPE

HMI

LD LED

OMO

ORT

OSSD

PBDC

PBI

PTDC

SPLC

V4000 PB

We also refer you to the SICK homepage on the Internet at

http://www.sick.com

Here you will find:

 These operating instructions in different languages for viewing and printing

 The EC Declaration of Conformity

1.5 Abbreviations

American National Standards Institute

Electro-sensitive protective equipment (ESPE) (e. g. V4000 PB)

SICK Configuration & Diagnostic Software = software for configuring and diagnosing the V4000 PB system

External device monitoring

Electro-sensitive protective equipment

Human machine interface

Laser diode

Light-emitting diode

Mute point

Numerical control

Overall machine overrun

Overall response time

Output signal switching device = signal output of the protective device to the controller used for switching off the movement which is the source of danger

Programmed bottom dead centre

Press brake interface

Programmed top dead centre

Pinch point

to v

Switch-over point (from v

Safety programmable logic control

V4000 Press Brake (sensor system)

slow

)

Chapter 1 Operating instructions

V4000 PB

About this document

1.6 Symbols used

Recommendation

Note

;, , ;O(

O Yellow, Ö Yellow,

o Yellow

, 

> Action …

WARNING

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!

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.

Operating instructions Chapter 2

V4000 PB

On safety

2 On safety

This chapter deals with your own safety and the safety of the operators.

> Read this chapter carefully before working with the V4000 PB or with the machine

protected by the V4000 PB.

2.1 Specialist personnel

The V4000 PB must be mounted, connected, commissioned and serviced only by specialist personnel. Specialist personnel are defined as persons who

 due to their technical training and experience possess sufficient knowledge in the field

of safety equipment for making press brakes safe

and

 who have been instructed by the responsible machine operator in the operation of the

machine and the current valid safety guidelines

and

 have sufficient familiarity with the relevant national industrial safety regulations, work

safety regulations, directives and the generally recognised code of practice of the industry (for example, DIN standards, VDE specifications, technical codes of other EC member states) that they can judge whether the press brake is safe from the occupational safety point of view

and

 have access to and have read these operating instructions.

As a rule these will be specialist personnel, the manufacturer of the ESPE or even such persons who have been given the corresponding training by the ESPE manufacturer, who are mainly concerned with inspecting and testing ESPEs and have been commissioned by the ESPE operator in this regard.

2.2 Applications of the system

The V4000 PB is an ESPE (electro-sensitive protective equipment) device designed to protect the area beneath the die of press brakes at high closing speeds. As soon as an object enters the protective volume beneath the die, the ESPE issues the signal to the press controller to stop the fast closing movement and this system must then stop the closing movement.

The V4000 PB system consists of a sender and a receiver which are mounted on the press crosshead. The protective volume between the sender and the receiver moves with the press crosshead and thus ensures that the safeguarded area stays beneath the die.

The system is a Type 4 ESPE as defined by to IEC 61 496-1 and 2 and is therefore allowed for use with controls of safety category 4 in compliance with EN 954-1. It may be used in safety applications up to SIL 3 in accordance with IEC 61 508.

Chapter 2 Operating instructions

V4000 PB

On safety

Use of the V4000 PB in the open air or explosion hazard areas is not permitted. The V4000 PB can only be used in normal industrial environments.

Do not use the V4000 PB as a separating protective measure!

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

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

devices have to be sent back to the manufactorer.

Operating instructions Chapter 2

V4000 PB

On safety

 The national/international rules and regulations apply to the installation, commissioning

and periodic technical inspections of the V4000 PB, in particular:

– Machinery Directive 98/37/EC

– Provision and use of Work Equipment Directive 89/655/EEC

– The work safety regulations/safety rules

– Relevant national health and safety regulations

Manufacturers and operators of the machine on which the V4000 PB is used are responsible for obtaining and observing all applicable safety regulations and rules.

 The notices, in particular the test regulations (see Chapter

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

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.

Chapter 2 Operating instructions

V4000 PB

On safety

> Use gloves to prevent:

– Injuries caused by edges, corners and burr

– Residues and rust caused by sweat from the hands getting on dies and workpieces

– Deposits on the hands

– Slipping of smooth workpieces

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.

Operating instructions Chapter 2

V4000 PB

Fig. 4: Handling of pre-flanged sheets

On safety

Correct handling of pre-flanged sheets

Note

If pre-flanged sheets are not handled correctly, your hands could get caught between the sheet and the die or press crosshead.

> Hold the pre-flanged sheet by the left and right edges between the thumbs and index

fingers.

> Use both hands to hold the sheet firmly.

Chapter 2 Operating instructions

V4000 PB

Fig. 5: Handling of box-shaped workpieces

On safety

Correct handling with box-bending

Note

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

Operating instructions Chapter 2

V4000 PB

Note

On safety

 When automatically traversing rear stops are used:

– Crushing your hands or fingers between the rear stops and the female die during

traversing movements towards the operator

– The operator being crushed by large workpieces being pushed at him by the rear stops

 Risk of injury in the rear space arising from automatically traversing stops, moving tools,

workpieces or bending aids.

Access to the rear space or standing in the rear space must be prevented by means of the appropriate safety devices, such as a light grid.

Dangers arising from mounting of the V4000 PB

> When mounting the V4000 PB make sure that there will be no crushing or shearing

points between the moving sender and receiver and other stationary machine parts or devices in the vicinity of the machine.

> If hazardous points cannot be avoided, they must be made safe by other protective

measures or remedied by design changes.

Chapter 2 Operating instructions

V4000 PB

On safety

2.6 Environmental protection

The V4000 PB has been designed to minimise environmental impact. It uses only a minimum of power and natural resources.

> At work, always act in an environmentally responsible manner.

2.6.1 Disposal

Disposal of unusable or irreparable devices should always occur in accordance with the applicable country-specific waste-disposal regulations (e.g. European Waste Code 16 02 14).

Before you can turn over the devices for environmentally-friendly recycling, you must separate the different materials of the V4000 PB from one another.

> Separate the housing from the remaining components (especially the PCB).

> Press the front lens out of the lens holder.

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

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.

Paper/cardboard recycling

Plastic recycling

Operating instructions Chapter 3

V4000 PB

Product description

3 Product description

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

stop at box wall

Chapter 3 Operating instructions

V4000 PB

Product description

3.2 Safety concept

3.2.1 Protection principle of the V4000 PB

Fig.

: Press brake with

V4000 PB

Press crosshead

Receive

Die

Female die

Illumination field protective volume

Sende

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.

Operating instructions Chapter 3

V4000 PB

Product description

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.

Fig.

: Definitions

Die

Illumination fiel

Protective volume

Pressure axis

Workpiece

Female die

Chapter 3 Operating instructions

V4000 PB

Product description

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.

Operating instructions Chapter 3

V4000 PB

Product description

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.

Chapter 3 Operating instructions

V4000 PB

Product description

3.3 Range of use

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.

– 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

when they penetrate into the hazardous point.

3.5.13 "Monitoring of the slow

Operating instructions Chapter 3

V4000 PB

Product description

3.4 Structure of the device

The V4000 PB comprises the following components:

 Sender

 Receiver with interfaces

 PBI with interfaces

 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

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.

Chapter 3 Operating instructions

V4000 PB

Product description

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).

3.4.2 Displays at the sender and receiver

Display at the sender

Fig. 10: Display at the sender

Tab.

2: Display at the sender

LED: Yello

An LED on the sender displays the status.

Display Meaning

O Yellow Power supply OK.

The sender of the V4000 PB is switched on.

Operating instructions Chapter 3

V4000 PB

Product description

Displays at the receiver

The status of the system is displayed at the receiver by three LEDs and a 7-segment display.

Fig. 11: Displays at the receiver

Yello

LEDs:

Red

Green

-segment displa

The LEDs tell the operator whether an input is expected and whether the OSSDs are in the OFF or ON state.

The 7-segment display provides the operator with further information about the status of the V4000 PB.

Tab. the receiver display

Key to the LEDs on

Display Meaning

Ö Yellow

(10/90)

(90/10)

 Operator action (input) is required (On % / Off % at 1 Hz)

– Alignment mode

– Teach-in request

O Yellow  In production operation: Operator action (input) required

– In standard mode (release foot switch)

– In back-stop mode (first operation of the foot switch expected)

– In box mode (first operation of the foot switch expected)

 During configuration: CDS connected and Configuration operating mode

selected

O Red  System sending signals to switch off the machine

(OSSDs in the OFF state)

 Additional states in which the red LED is illuminated:

– Self-test (system initialisation)

– Configuration

– Box mode

– Back-stop mode

– Lock-out state

– Alignment mode

O Green System free (OSSDs in the ON state)

Chapter 3 Operating instructions

V4000 PB

Tab. 4:

Key to the 7-segment

display on the receiver

Product description

Display Meaning

6 System error. The device is defective. Replace the receiver. M Muting state ` Switch on. This is followed by self-testing of the V4000 PB

(system initialisation).

L Standard mode = Box mode } Back-stop mode

Note

Other

displays

Further explanations of the 7-segment display will be found in the following sections:

 Displays during system initialisation when the machine is switched on (see Section

Switching the machine on")

 Displays within alignment mode (see Section

 Error displays within lock-out state (see Section

All of the other displays are error messages, displays within alignment mode or displays during the self-test (system initialisation).

8.1

7.2 "Aligning sender and receiver")

9.2 "Error displays of the LEDs")

3.4.3 Interfaces at the receiver

The receiver of the V4000 PB has the following interfaces:

 Digital interface

 Serial interfaces for configuration and diagnostics

 Interface for connecting the sender

 Interface for connecting the PBI

Operating instructions Chapter 3

V4000 PB

Product description

Digital interface

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.

Chapter 3 Operating instructions

V4000 PB

Product description

3.4.4 PBI (press brake interface)

Fig. 12: PBI (press brake interface)

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.

Operating instructions Chapter 3

V4000 PB

Fig. 13: Display at the PBI

Product description

Display at the PBI

LED: Yello

Tab.

6: Display at the PBI

Note

Display Meaning

O Yellow Power supply OK.

Interface at the PBI

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.

For more information see the Sections

3.5 "Possible device configurations" and 9.4

"Extended diagnostics via CDS".

Chapter 3 Operating instructions

V4000 PB

Product description

System configuration: version A

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.

PBI

SPLC

Fig.

15: System configuration

without PC control

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.

PBI

SPLC

Incremental encoders

CDS

Incremental encoders

Operating elements

HMI

Star

Operating instructions Chapter 3

V4000 PB

Note

Recommendation

Product description

3.4.6 External operating elements

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.

WARNING

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".

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

Chapter 3 Operating instructions

V4000 PB

Tab.

: Configurable

parameters and functions

Product description

Basic settings

Description in Section

Source of the operator signals 3.5.1

Baud rate of communication interface 3.5.2

Application name 3.5.3

Repetition interval of power-up cycle 3.5.4

Mounting of receiver 3.5.5

Position-sensing system 3.5.7

Increments per mm stroke

Measurement direction during closing movement

Speed-dependent muting 3.5.6

External device monitoring 3.5.8

Standstill time for determining the top dead centre 3.5.16

Start delay for closing movement 3.5.17

Time for standstill detection 3.5.18

Braking distance

Default value for braking distance 3.5.9

Travel for determining braking distance 3.5.10

Braking offset 3.5.11

Target speed v

Monitoring of the slow closing speed v

3.5.12

slow

from the pinch

crawl

3.5.13

point

Overall machine overrun

Max. overall machine overrun 3.5.14

Travel for determining overall machine overrun 3.5.15

Maximum closing speed 3.5.14

Inputs

Settling times for standard inputs

3.5.19

Settling times for safety-relevant inputs

Discrepancy time for safety-relevant inputs

3.5.20

Discrepancy time for protective volume selection

Maximum duration of 1st operation

3.5.21

(confirmation of reduced protective volume)

Start signal Time for pause between 1st and 2nd operation

Outputs

Minimum state time for standard inputs 3.5.22

Minimum switch-off time of safety-relevant outputs 3.5.23

Bypass

Bypass 3.5.24

Discrepancy time for bypass inputs 3.5.20

Operating instructions Chapter 3

V4000 PB

Note

Product description

3.5.1 Source of the operator signals

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.2 Baud rate communication interface

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.3 Application name

When starting to configure the V4000 PB, you may save an application name with a maximum of 22 characters.

Here you should use unique designations with an evident relation to the concrete application name – such as "Machine name XYZ".

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.4 Repetition interval of power-up cycle

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

Chapter 3 Operating instructions

V4000 PB

Product description

3.5.5 Mounting of receiver

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.6 Speed-dependent muting

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!

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

has not yet been reached when the protective volume is

crawl

(≤ 10 mm/s) will also cause

crawl

is exceeded in

crawl

it is possible for the press brake to

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.

Operating instructions Chapter 3

OFF

V4000 PB

Product description

Measurement direction during closing movement

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

Note

90° signal

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.8 External device monitoring (EDM)

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

Note

3.5.9 Default value for braking distance

The Braking distance tab only has to be configured if the press brake supports two speeds (v

and v

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab

Chapter 3 Operating instructions

V4000 PB

Product description

3.5.10 Travel for determining the braking distance

During the power-up cycle, the braking distance (transition from the high closing speed to the target speed v

) is also determined. The travel for determing the braking distance is

slow

the distance the press requires to accelerate to the high closing speed and then brake down again to the target speed v

slow

The CDS includes a set value of 30 mm for the travel for determining the braking distance.

V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab

3.5.11 Braking offset

Tab. 8: Braking offset

During braking to the target speed v

, vibrations in the V4000 PB and braking distance

slow

fluctuations may occur.

The design of the V4000 PB specifies that the vibration tolerance of the V4000 PB for gap sizes from 6 mm to 26 mm increases from ±4 mm to ±7 mm.

With the braking offset the gap size at which the target speed v

Braking

offset

Gap at v

Availability with braking

slow

distance fluctuations

is reached is increased.

slow

Remark

6 mm 6 mm ± 4 mm Maximum productivity 26 mm 26 mm ± 7 mm Maximum availability

The braking offset is added to the braking distance calculated from the power-up cycle:

 With a braking offset of 6 mm the target speed v

is reached at the muting point (6

slow

mm above the pinch point).

 If a braking offset of more than 6 mm is selected, the switch-over point will be shifted

upwards. The V4000 PB requests the target speed v The press brakes earlier and thus reaches the target speed v

before the calculated switch-over point.

slow

before the muting point.

slow

V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab

3.5.12 Target speed v

for determining the braking distance

slow

In the determination of the braking distance, the target speed v

is the speed which the

slow

press must reach after the braking procedure.

The CDS specifies a set value of 10 mm/s for the target speed.

V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab

Operating instructions Chapter 3

V4000 PB

Product description

Note

3.5.13 Monitoring of the slow closing speed v

The slow closing speed (v

) is monitored from the pinch point at bending processes

crawl

from the pinch point

crawl

where the V4000 PB cannot be active (for example within a box).

If v

(≤ 10 mm/s) is exceeded, a stop command is output to the downstream control

crawl

system and the V4000 PB changes to the lock-out state.

V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab

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

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.

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

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Overall machine overrun tab

Maximum overall machine overrun

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

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.

Chapter 3 Operating instructions

V4000 PB

Note

Product description

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Overall machine overrun tab

Stopping distance

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

and maximum high closing speed v

max

* v

max

S ≤ 11 mm

+ D

max

can be adjusted with regard

max

Note

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Overall machine overrun tab

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

Operating instructions Chapter 3

OFF

V4000 PB

Product description

3.5.17 Start delay for closing movement

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.18 Time for standstill detection

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab

3.5.19 Settling times for inputs

Fig. 17: Settling times

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.

Signal

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:

 Standard inputs

 Safety-relevant inputs

V4000 PB device symbol, context menu Configuration draft, Edit, Inputs tab

Chapter 3 Operating instructions

OFF

ON OFF

OFF

V4000 PB

Product description

3.5.20 Discrepancy times for inputs

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

Channel 1

Signal

Channel 2

t 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 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

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.

2nd actuation

tart signal

Signal

1st actuation

tart signal

Pause

Operating instructions Chapter 3

V4000 PB

Note

Product description

Deselect double-click

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Inputs tab

3.5.22 Minimum state time for standard outputs

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Outputs tab

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.

V4000 PB device symbol, context menu Configuration draft, Edit, Outputs tab

Note

3.5.24 Bypass

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).

V4000 PB device symbol, context menu Configuration draft, Edit, Bypass tab

Chapter 3 Operating instructions

V4000 PB

Product description

3.6 Protective operation

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

controller or external operating elements.

Operating instructions Chapter 3

V4000 PB

Product description

3.6.2 Teach-in

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.

Chapter 3 Operating instructions

V4000 PB

WARNING

Fig. 21: Reduced protective volume in box mode

Product description

Box mode

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.

blanked

Operating instructions Chapter 3

V4000 PB

Recommendation

Note

WARNING

Product description

Variant B

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.

blanked

Chapter 3 Operating instructions

V4000 PB

Product description

3.7 System sequences in protective operation

Fig. 23: Definitions

Die

Note

Illumination field

PTDC

Protective volume

Pressure axis

Workpiece

Female die

slow

crawl

MP PP PBDC

vp High closing speed > 10 mm/s

Target speed following braking

slow

crawl

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

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").

Operating instructions Chapter 3

V4000 PB

Product description

3.7.1 Power-up cycle in standard mode

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

2 The operator gives the

signal to start the closing movement (foot switch). The die descends at maximum closing speed.

is measured.

PTDC

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.

PTDC

Stop

PBDC

O Red

System state

Ö Yellow o Green

7-segment display

Start signal for closing

movement

Request signal V

slow

OSSD

Request signal for teach-in

L L L

  

  

  

  

o Red o Yellow O Green

O Red o Yellow o Green

Chapter 3 Operating instructions

V4000 PB

Product description

Step

Protective volume

Speed; machine movement

4 The overall machine

overrun of the press brake is determined. The overall machine overrun must not exceed the configured value.

PTDC

5 The operator gives the

signal once more to start the closing movement (foot switch). The die descends at maximum closing speed v

PTDC

6 The target speed v

requested by the V4000 PB. The press controller starts the braking procedure. When v the braking distance is calculated.

is reached

slow

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

Request signal for teach-in

slow

PBDC

O Red o Yellow o Green

o Red o Yellow O Green

L L L

  

  

  

  

Operating instructions Chapter 3

V4000 PB

Product description

Step

Protective volume

Speed; machine movement

7 The request signal for

is cancelled.

slow

The die accelerates to the high closing speed v

8 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.

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).

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

Request signal for teach-in

PBDC

o Red o Yellow O Green

O Red

o Yellow o Green

o Red o Yellow O Green

L L &

  

  

  

  

Chapter 3 Operating instructions

V4000 PB

Product description

Step

Protective volume

Speed; machine movement

ß 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 V4000 PB has updated the parameters and the first bending without discarding of material can be made after giving a new start signal.

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

Request signal for teach-in

slow

crawl

o Red o Yellow O Green

&







MP PP PBDC

Operating instructions Chapter 3

V4000 PB

Product description

3.7.2 Teach-in

Start condition: press is wide open

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). The protective volume is active.

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.

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.

PTDC

Stop

PBDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

Request signal for teach-in

O Red Ö Yellow o Green

L L L

  

  

  

  

o Red o Yellow O Green

O Red o Yellow o Green

Chapter 3 Operating instructions

V4000 PB

Product description

Step

Protective volume

Speed; machine movement

4 The die must stop at

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.

PTDC

Stop

PBDC

slow

crawl

PP PBDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

Request signal for teach-in

O Red o Yellow o Green

& &

 

 

 

 

o Red o Yellow O Green

Operating instructions Chapter 3

V4000 PB

Product description

3.7.3 Operating cycle in standard mode

Step

Protective volume

Speed; machine movement

1 The die is at the

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

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.

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

v v

slow

crawl

PBDC

slow

crawl

MP PP PBDC

v v

slow

crawl

PP PBDC

o Red o Yellow O Green

L L L

  

  

  

Chapter 3 Operating instructions

Product description

V4000 PB

Step

Protective volume

Speed; machine movement

4 At the muting point MP

the gap size is 6 mm and the target speed has been reached. The protective volume becomes inactive.

5 The die contacts the

workpiece at the pinch point PP.

6 The die shapes the

workpiece. The operating cycle ends at the programmed bottom dead centre PBDC and the die goes back-up.

6 mm

PTDC

slow

PP PBDC

slow

crawl

PBDC

slow

crawl

MP PP

PBDC

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

o Red o Yellow O Green

& & &

  

o Red

o Yellow O Green

o Red o Yellow O Green

Operating instructions Chapter 3

V4000 PB

Product description

3.7.4 Operating cycle in box mode

Step

Protective volume

Speed; machine movement

1 The die is at the

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

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.

PTDC

v v

slow

crawl

MP PP PBDC

slow

crawl

MP PP PBDC

slow

crawl

PBDC

(If double-click is

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

O Red

deselected,

O Yellow

V4000 PB is green.)

o Green

= = =

  

  

  

o Red o Yellow O Green

Chapter 3 Operating instructions

Product description

V4000 PB

Step

Protective volume

Speed; machine movement

4 At the switch-over

point SP the target speed is requested by V4000 PB. The press controller starts the braking

5 At the muting point MP

the gap size is 6 mm and the target speed has been reached. The protective volume becomes inactive.

6 The die contacts the

workpiece at the pinch point PP. The bending process is the same as with

standard mode. procedure. The protective volume segment remains active in the gap opening behind the pressure axis.

PTDC

slow

crawl

MP PP

PBDC

slow

crawl

PBDC

slow

crawl

PBDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

o Red o Yellow O Green

= & &

  

o Red

o Yellow O Green

o Red o Yellow O Green

Operating instructions Chapter 3

V4000 PB

Product description

3.7.5 Operating cycle in back-stop mode

Step

Protective volume

Speed; machine movement

1 The die is at the

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

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.

PTDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

v v

slow

crawl

PBDC

slow

crawl

MP PP

PBDC

slow

crawl

MP PP

PBDC

(If double-click is

O Red

deselected, V4000 PB is

O Yellow

green.)

o Green

o Red o Yellow O Green

} } }

  

  

  

Chapter 3 Operating instructions

V4000 PB

Product description

Step

4 At the muting point MP

the gap size is 6 mm and the target speed has been reached. The protective volume becomes inactive.

5 The die contacts the

workpiece at the pinch point PP. The bending process is the same as with standard mode.

Protective volume

PTDC

Speed; machine movement

slow

crawl

PP PBDC

slow

crawl

PBDC

System state

7-segment display

Start signal for closing

movement

Request signal v

slow

OSSD

o Red o Yellow O Green

& &

 

o Red

o Yellow O Green

Operating instructions Chapter 3

V4000 PB

Product description

3.8 Alignment mode

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).

7.2 "Aligning sender and receiver").

Chapter 4 Operating instructions

V4000 PB

Mounting

4 Mounting

This chapter describes the preparation and completion of the mounting of the V4000 PB.

The following steps are necessary after mounting:

7.2)

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.

1 1

8.316.5 15

max. 40

max. 50

8.3

Free space for sensor mounting bolt

Operating instructions Chapter 4

Nut A

V4000 PB

Fig. 25: Mounting using SICK mounting kit 1

Mounting

Mounting your V4000 PB with the SICK mounting kit 1:

Spring washer

uxiliary alignment plate

lignment plate

Washer

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.

Chapter 4 Operating instructions

V4000 PB

Mounting

Fig. 26: SICK mounting kit 2

> Before mounting SICK mounting kit 2, please read the mounting instructions (SICK Art.

No. 8010988) which are supplied with the kit.

4.1.3 Sticker: Information for daily inspection

> Once mounting is completed, you will need to attach the self-adhesive information note

supplied entitled "Information for daily inspection".

– Use only the information label in the language which the operators of the machine

speak and understand.

– Affix the information label such that it is easily visible by the operators during

operation. After attaching additional objects and equipment, the information label must not be concealed from view.

Operating instructions Chapter 5

V4000 PB

Electrical installation

5 Electrical installation

Switch off the machine!

WARNING

The machine could start unintentionally during electrical installation work.

> Ensure that the entire system is de-energised during the electrical installation.

Note

Fig. 27: Pin assignments of digital interface

 To ensure the specified electromagnetic compatibility (EMC), functional earthing (FE)

must be connected.

 The external voltage supply of the devices must be capable of buffering brief mains

voltage failures of 20 ms as specified in EN 60 204. Suitable power supplies are available as accessories from SICK (Siemens type series 6 EP 1).

 Make sure the V4000 PB is protected by the appropriate fusing. The electrical data you

will need in order to ascertain the fuse ratings will be found in Chapter data" in Table

30 on Page 102.

10 "Technical

5.1 Connecting the receiver

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Chapter 5 Operating instructions

V4000 PB

Electrical installation

Tab. 9: Pin assignment of digital interface

Pin Signal Function

1 OSSD2 OSSD2 (switching output 2), 0.5 A

2 OSSD1 OSSD1 (switching output 1), 0.5 A

3 EDM Input, external device monitoring (EDM) (optional)

4 START Safe 24 V input,

gated signal for starting the closing movement

5 NSTART Safe 24 V input,

complementary, gated signal for starting the closing movement

6 BYPASS_OUT1 Pulsed output (bypass signal) (optional)

7 VSLOW_REQ Output, request signal for target speed (optional)

8 BYPASS_OUT2 Pulsed output (bypass signal) (optional)

9 TEACH_REQ Output, request signal for teach-in mode

10 BYPASS_IN1 Input, bypass signal (optional)

11 TEACH_BUTTON Input, signal for teach-in mode

12 BYPASS_IN2 Input, bypass signal (optional)

13 ADJ_BUTTON Input, signal for alignment mode

14 DMODE3 Input, signal for back-stop protective volume mode

15 DMODE2 Input, signal for box protective volume mode

16 DMODE1 Input, signal for standard protective volume mode

17 NC Reserved

18 GND 0 V DC input (voltage supply)

19 +24V 24 V DC input (voltage supply)

20 24V_SENDER 24 V DC output (sender voltage supply)

200 mA

21 GND 0 V DC input (sender voltage supply)

22 SEND- Output, for differential signal to the sender

23 SEND+ Output, for differential signal to the sender

24 ENCO1+ Input, signal from PBI

25 ENCO1– Input, signal from PBI

26 ENCO2+ Input, signal from PBI

27 ENCO2– Input, signal from PBI

28 ENCO_GND 0 V DC input

29 TXD_232 /

422_TXD–

30 RXD_232 /

422_TXD+

31 GND /

422_RXD–

Output, connection for serial configuration interface RS-232 / RS-422 (double assignment, can be set via switch S)

Input, connection for serial configuration interface RS-232 / RS-422 (double assignment, can be set via switch S)

32 422_RXD+ Input, connection for serial configuration interface

RS-422 (optional)

Operating instructions Chapter 5

V4000 PB

Electrical installation

Fig. 28: Connection diagram for receiver

+24

10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

EDM

Controller e. g. NC

1 2 3 4 5 6 7 8 9

OSSD2

OSSD1

EDM

Star

Request for

Teach-in reques

Teach-in

lignmen

Back-stop

Box

Standard

GND

1 2

4 3

29 30

31 32

PBI

RS-232

slow

RS-422

GND

Fig.

29: OSSDs connection

OSDD 1

OSDD 2

Chapter 5 Operating instructions

V4000 PB

Electrical installation

Note

Fig. 30: Pin assignments of the sender

The machine controller must process the signals from OSSD1 and OSSD2 separately. OSSD1 and OSSD2 must not be connected together.

> To ensure signal integrity connect OSSD1 and OSSD2 separately to the machine

controller (see also

Fig. 28).

5.2 Connecting the sender

Tab.

10: Pin assignments of

the sender

1234

Pin Signal Function

1 +24V 24 V DC input (voltage supply)

2 GND 0 V DC input (voltage supply)

3 SEND+ Input, signal from receiver

4 SEND– Input, signal from receiver

Operating instructions Chapter 5

Electrical installation

V4000 PB

5.3 Making up the connections for receiver and sender

> Always use EMC-type cable glands for all through-holes.

The following cable glands are supplied:

Tab. 11: Cable glands

12: Cable cross-sections

Tab.

Cable gland Cable diameter

Receiver wiring space (3 through-holes)

M20 7–12 mm

M16 (x 2) 3–7 mm

Sender wiring space (1 through-holes)

M16 3–7 mm

> Use the following cable cross-sections for the individual connections:

Cable Recommended cable

Receiver to control cabinet (M20)

18 wires,

0.34 - 0.5 mm²

Screened Usable as

trailing

cable

Yes Yes –

Other

requirements

Fig.

31: Pin assignments of

the PBI

Receiver to sender

4 wires, 0.34 mm² Yes No 2 twisted pairs

(M16)

Receiver to PBI

4 wires, 0.34 mm² Yes Yes 2 twisted pairs

(M16)

5.4 Connecting the PBI

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

for RS-422

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Chapter 5 Operating instructions

V4000 PB

Electrical installation

Tab. 13: Pin assignments of the PBI

Pin Signal Function

1 UA0+ Input (RS-422), reference mark (optional)

2 UA0– Input (RS-422), reference mark (optional)

3 UA1+ Input (RS-422), 0° signal from incremental encoder

4 UA1– Input (RS-422), 0° signal from incremental encoder

5 UA2+ Input (RS-422), 90° signal from incremental encoder

6 UA2– Input (RS-422), 90° signal from incremental encoder

7 Shield Shield

8 UP_5V 5 V DC output (voltage supply for incremental encoder)

9 UN_0V 0 V DC output (voltage supply for incremental encoder)

10 Sense_5V 5 V DC input (for measurement of voltage supply at incremental

encoder) (optional)

11 Sense_0V 0 V DC input (for measurement of voltage supply at incremental

encoder) (optional)

12 UAS Input, error signal from incremental encoder (optional)

13 Shield Shield

14 +5V_Opt. 5 V DC output (optional voltage supply for incremental encoder),

0.15 A (optional)

15 GND 0 V DC input (voltage supply)

16 +24V 24 V DC input (voltage supply), 0.5 A

17 UA0+ Output (RS-422), reference mark (optional)

18 UA0– Output (RS-422), reference mark (optional)

19 UA1+ Output (RS-422), signal to numerical control

20 UA1– Output (RS-422), signal to numerical control

21 UA2+ Output (RS-422), signal to numerical control

22 UA2– Output (RS-422), signal to numerical control

23 Shield Cable shield

24 UP_5V 5 V DC input (voltage supply from numerical control for

incremental encoder)

25 UN_0V 0 V DC input (voltage supply from numerical control for

incremental encoder)

26 Sense_5V 5 V DC output (for measurement of supply voltage at incremental

encoder) (optional)

27 Sense_0V 0 V DC output (for measurement of supply voltage at incremental

encoder) (optional)

28 UAS Output, error signal from the incremental encoder to numerical

control (optional)

29 ENCO1+ Output (RS-422), signal to the receiver

30 ENCO1– Output (RS-422), signal to the receiver

31 ENCO2+ Output (RS-422), signal to the receiver

32 ENCO2– Output (RS-422), signal to the receiver

Operating instructions Chapter 5

V4000 PB

Electrical installation

Fig. 32: PBI connection diagram

+24 V

Measurement guide

(incremental encoder)

GND

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16

PBI

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Controller e. g. NC

Notes

5.5 External device monitoring (EDM)

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

Chapter 5 Operating instructions

V4000 PB

Electrical installation

5.6 Bypass

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

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).

Operating instructions Chapter 5

V4000 PB

Electrical installation

5.7 Configuration connection (serial interface)

Fig. 34: Pin assignments for configuration interface

Tab.

14: Pin assignment of permanent configuration connection with RS-422

15: Pin assignments of

Tab. temporary configuration connection with RS-232

Switch S in position RS-422 (see Section

Pin Colour Meaning PC-side RS-422

6.1)

1 Brown 422 RxD+ Pin 3 (TxD+)

2 White 422 TxD+ Pin 2 (RxD+)

3 Blue 422 RxD– Pin 4 (TxD–)

4 Black 422 TxD– Pin 1 (RxD–)

Switch S in position RS-232, default (see Section 6.1)

Pin Colour Meaning PC-side RS-232 SubD

1 Brown – NC

2 White RxD Pin 3

3 Blue 0 V DC (voltage supply) Pin 5

4 Black TxD Pin 2

Notes

The following instructions only apply when the V4000 PB is connected temporarily with a PC.

> Connect the connecting cable to the configuration connection of the receiver.

> When configuration is finished, remove the connecting cable from the configuration

connection.

Chapter 6 Operating instructions

V4000 PB

Configuration

6 Configuration

6.1 Delivery state

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.

Operating instructions Chapter 6

V4000 PB

Configuration

6.2 Configuration preparations

To configure the V4000 PB you will need:

 CDS (Configuration & Diagnostic Software) on CD

 User manual for the CDS on CD

 A PC or notebook running Windows 9x / NT 4 / 2000 Professional / XP and with an

RS-232 serial interface (the PC or notebook is not supplied)

 Connecting cable for connecting the PC and the V4000 PB (SICK part no. 6 021 195)

How to prepare the configuration:

> Ensure that the V4000 PB is properly mounted and connected electrically.

> Plan all the necessary settings (operating modes etc.).

> To configure the device, please read the user manual for the CDS (Configuration &

Diagnostic Software) and use the on-line help function of the program.

Notes

Should the V4000 PB need to have repairs done by SICK, the configuration will be restored to its original state.

> For this reason you should back up your configuration on a separate data medium.

Chapter 7 Operating instructions

V4000 PB

Commissioning

7 Commissioning

Do not commission without a check by specialist personnel!

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).

Operating instructions Chapter 7

37:

V4000 PB

Fig. 36: Die segments

Commissioning

Fig.

lignment masks

Notes

lignment poin

Die tip

Focussing screen

lignment point for alignment beam

Sender

Die, left-hand

Die, right-hand

Receiver

Four alignment masks and the values appearing on the 7-segment display will help you align the sender and receiver.

The alignment beam must in each case pass through the hole (alignment point) in the masks.

Chapter 7 Operating instructions

V4000 PB

Fig. 38: directions

djustment

Commissioning

The sender and receiver can be adjusted in four directions.

III

Tab. 16: directions

djustment

Direction Meaning

I Adjustment in the vertical direction on the retaining arm

II Adjustment in the horizontal direction via the grooved guide in the alignment

plate

III Rotation of the sender on the horizontal plane in the slots of the alignment

plate

IV Rotation of the sender on the vertical plane by adjusting the screw on the

rear pin

Fig. 39: Fitting masks A and B

Notes

Alignment of the sender

> Use the corresponding operating element to access alignment mode.

If there is no alignment point saved, alignment mode will be requested automatically after switching on.

Mask A

Mask B

> Affix mask A in front of the front lens on the sender housing.

> On the sender side attach mask B to the die. Make sure that the die tip coincides with

the bottom edge of the half-moon-shaped cut-out and that it is on the longitudinal axis which is marked on the mask.

Operating instructions Chapter 7

V4000 PB

Commissioning

Fig. 40: directions I and II

Fig.

lignment in

41: Fitting mask B

Mask A

Mask B

> Move the sender bracket in directions I and II until the alignment beam goes through the

hole in mask B.

Mask B

> On the receiver side attach the second mask B to the die. Make sure that the die tip

coincides with the bottom edge of the half-moon-shaped cut-out and that it is on the longitudinal axis which is marked on the mask.

Chapter 7 Operating instructions

V4000 PB

Commissioning

Fig. 42: directions III and IV

lignment in

Notes

III

> 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.

> Fix the sender brackets in place.

Operating instructions Chapter 7

V4000 PB

Commissioning

Alignment of the receiver

Risk of injury if incorrectly aligned!

Fig. 43: receiver

WARNING

lignment of the

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

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

Alignment point or all points on left above the target zone

{

Alignment point or all points on right outside the target zone

Chapter 7 Operating instructions

V4000 PB

Commissioning

Display Meaning Action

H Alignment point or all points

below 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

8.4 "Carrying out a power-up cycle").

7.3 "Function check").

Operating instructions Chapter 7

V4000 PB

Commissioning

7.2.2 Alignment following a tooling change

Recommendation

WARNING

Fig. 44: Tracking without latching marks

Notes

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

8.4 "Carrying out a power-up cycle").

7.3 "Function check").

Chapter 7 Operating instructions

V4000 PB

WARNING

Commissioning

Tracking with 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.

> Align the sender and receiver on the brackets (manufacturer's brackets) vertically, that

is, in direction I.

> Carry out the function check using the test piece (see Section

> Initiate a reset by pressing the alignment and teach-in buttons simultaneously.

When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up cycle.

> 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

8.4 "Carrying out a power-up cycle").

7.3 "Function check").

Operating instructions Chapter 7

V4000 PB

Commissioning

7.3 Function check

During the function check the following aspects are checked:

 Protective function with the test rod (objects larger than 14 mm)

 Distance from the tool

 Emergency stop properties

 Overall machine overrun

Fig. 45: Test piece

h=10

h=15

h=35

h=40

Ø 14

How to prepare for the function check:

> Ensure that the press is fitted with a die which extends for its full working length.

> Ensure that sender and receiver have been correctly aligned at first alignment.

> Switch on the power supply to the V4000 PB.

> Select standard mode (see Section

> Carry out a power-up cycle (see Section

8.2 "Selecting protective volume mode").

8.4 "Carrying out a power-up cycle").

Chapter 7 Operating instructions

V4000 PB

Fig. 46: Function check with test rod

Commissioning

Function check with the test rod (handle of the test piece)

> Slowly pass the rod (the handle of the test piece) along the die tip for the full extent of

the protective volume.

The rod must be detected over the whole extent of the protective volume beneath the die tip.

During this test, the red LED on the receiver must stay on the whole time.

Operating instructions Chapter 7

V4000 PB

Commissioning

Function check with the test piece

Notes

Fig. 47: Function check with test piece (10 mm)

The pinch point must be known from teach-in.

> Place the section of the test piece having a height of 10 mm on the female die or on the

workpiece so that the section lies in the middle of the pressure axis.

> Start the closing movement with the maximum closing speed.

The protective volume is interrupted by the test piece and the closing movement stopped by the OFF state of the V4000 PB.

After the closing movement has stopped, the die tip must not be touching the test piece.

Fig. 48: Function check with test piece (15 mm)

It must then be possible to push the following section (having a height of 15 mm) into the remaining gap.

> Check whether the following section having a height of 15 mm can be pushed into the

remaining gap.

> Carry out the test on the outer left- and outer right-hand side and in the centre of the

press.

> In order to increase security, repeat the test with the 35mm-high section (40 mm for

checking the gap).

Chapter 7 Operating instructions

V4000 PB

Commissioning

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

13.3 "Manufacturer’s checklist").

Following a tool change

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 a power-up cycle using a workpiece.

Operating instructions Chapter 7

V4000 PB

Commissioning

> 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.

Chapter 8 Operating instructions

V4000 PB

Operation

8 Operation

Nuisance shutdowns due to air contamination!

WARNING

Tab. 19: Displays during the power-up cycle

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 7segment 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

volume mode"

 Device error: see Section

display"

9.3 "Error displays of the 7-segment

Operating instructions Chapter 8

V4000 PB

Operation

8.2 Selecting protective volume mode

> 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

cycle is acknowledged.

O Green

> Insert the workpiece. – O Green

Chapter 8 Operating instructions

V4000 PB

Operation

Action Result LED display

> Press the foot switch (start

signal for the closing movement).

> Release the foot switch (this

cancels the start signal).

> Press the foot switch again

(start signal for the closing movement).

> Release the foot switch (this

cancels the start signal).

> Press the foot switch again

(start signal for the closing movement).

 The press closes at high

closing speed.

 The V4000 PB switches the

OSSDs off.

 The high closing speed is

stopped.

 The overall machine overrun is

checked.

– O Green

 The V4000 PB requests the

target speed from the press

controller (only if v

connected).

 The press controller starts the

braking procedure.

 The V4000 PB detects and

accepts the target speed.

 The braking distance is

determined once the target

speed has been reached.

 The V4000 PB cancels the

request for target speed.

 The press controller can

accelerate up to the high

closing speed.

 The workpiece interrupts the

protective volume.

 The press stops.

 The pinch point is determined.

 The overall machine overrun is

checked.

O Green

The press finishes the operating cycle.

slow

O Green

O Red

O Green

O Red

O Green

> Carry out the function check

(see Section

7.3).

The press is now ready for operation.

O Green

Operating instructions Chapter 8

V4000 PB

Operation

8.5 Carrying out teach-in

Recommendation

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

> Insert the workpiece. – O Green

> Press the foot switch (start

signal for the closing movement).

 The press controller

accelerates up to the high

closing speed.

 The workpiece interrupts the

protective volume.

O Green

O Red

> Release the foot switch (this

cancels the start signal).

> Press the foot switch again

(start signal for the closing movement).

 The press stops.

 The pinch point is determined.

 The overall machine overrun is

checked.

O Green

 The press finishes the

O Green

operating cycle.

 The press is now ready for

operation.

Chapter 8 Operating instructions

V4000 PB

Operation

8.6 Bending in standard mode

> Select standard protective volume mode (7-segment display L).

> If the sheet thickness of the workpiece has changed, carry out teach-in (see Section

Carrying out teach-in").

> Insert the workpiece.

> Press the foot switch (start signal for the closing movement).

The press carries out the operating cycle.

8.5

8.7 Bending in box mode

Catching or crushing of fingers or hands due to partial blanking of the protective

WARNING

volume and also within the tolerance zone at the pressure axis!

Due to partial blanking of the protective volume, objects in the tolerance zone will not be detected.

> Make sure the workpiece is handled correctly (see Section

2.5 "Safety in operation").

WARNING

> Select box protective volume mode (7-segment display = ).

> If the sheet thickness of the workpiece has changed, carry out teach-in (see Section

Carrying out teach-in").

8.5

8.8 Bending in back-stop mode

Catching or crushing of fingers or hands due to partial blanking of the protective

volume and also within the tolerance zone!

Due to partial blanking of the protective volume, objects in the tolerance zone will not be detected.

> Make sure the workpiece is handled correctly (see Section

> Select back-stop protective volume mode (7-segment display } ).

> If the sheet thickness of the workpiece has changed, carry out teach-in (see Section

Carrying out teach-in").

2.5 "Safety in operation").

8.5

8.9 Changing the sheet thickness

If the sheet thickness of the workpiece changes you will need to carry out teach-in again (see Section

8.5 "Carrying out teach-in").

Operating instructions Chapter 8

V4000 PB

Operation

8.10 Tool changing

The following steps may be necessary after a tool change:

 Alignment following a tool change (see Section

 Standard protective volume mode (see Section

 Carrying out a power-up cycle (see Section

 Function check with the test piece (see Section

7.2.2)

8.2)

8.4)

7.3)

8.11 Care and maintenance

Hazardous radiation exposure by the laser beam during disassembling!

WARNING

The V4000 PB is maintenance-free. The V4000 PB does not contain any repairable components.

> Do not attempt to disassemble the V4000 PB for repair.

> Return a defective unit to the manufacturer.

Notes

The front lenses of the sender and receiver should not be cleaned unless they are dirty.

To avoid damage to the V4000 PB do not use aggressive or abrasive cleaning agents.

Cleaning the front lenses:

> Use a clean brush to remove dust from the front lens.

> Spray the lens with glass cleaning liquid containing alcohol so that the front lens is

wetted but no droplets form on the lens.

> To remove hard particles of grit or the like from the lens, carefully dab away the liquid

with the SICK lens cloth (SICK part no. 4 003 353).

> Spray the front lens again and with a dry part of the cloth wipe off the lens. Do not apply

pressure to remove the liquid since hard particles could then scratch the lens.

> After cleaning, check the positions of the sender and receiver to ensure the safety

function of the sensor is still present. If necessary, re-align the sender and receiver (see Section

> Carry out a function check (see Section

7.2 "Aligning sender and receiver").

7.3 "Function check").

Chapter 9 Operating instructions

V4000 PB

Diagnostics

9 Diagnostics

This chapter describes how to identify and remedy errors and malfunctions of the V4000 PB.

9.1 Response to errors and malfunctions

Cease operation if there is malfunctioning or other operational problems!

WARNING

> Stop the machine if you cannot clearly identify or allocate the error and if you cannot

safely remedy the malfunction.

Lock-out state

With certain errors or an erroneous configuration, the system can go into the lockout state.

To put the device back into operation, carry out the following steps:

> Correct the source of the problem as described in Section

LEDs" and

> Switch the V4000 PB power supply off and back on again:

– Either make a reset by pressing simultaneously the buttons for alignment mode and

for teach-in.

– Or switch the machine off and back on again.

9.3 "Error displays of the 7-segment display".

9.2 "Error displays of the

Tab. 23: Error displays of the sender LED

Tab. 24: Error displays of the receiver LEDs

9.2 Error displays of the LEDs

This section explains what the LED error displays mean and how you can respond.

Error displays of the sender LED

Display Possible cause Remedying the error

o Yellow No operating voltage, or

Error displays of the receiver LEDs

Display Possible cause Remedying the error

o Red and o Green

voltage too low.

The bypass function has been selected.

> Check the voltage supply and switch it on

if necessary.

> Check to see whether the bypass function

has been selected (configuration).

> Check whether there is adequate

operating voltage

Operating instructions Chapter 9

V4000 PB

Diagnostics

9.3 Error displays of the 7-segment display

This section explains the meaning of the error displays of the 7-segment display and how you can respond.

Tab. 25: Error displays of the 7-segment display

Display Possible cause Remedying the error

+ Erroneous input

signals

> Check the input signals, foot switch and the

protective volume mode selector switch.

- Configuration

incomplete

/ EDM error

(switch-on)

 EDM error

6O(

System error

7O( Overcurrent at

switching output 1

7O) Short-circuit at

switching output 1

7O* Short-circuit at

switching output 1

The display goes off automatically once the configuration has been successfully transferred.

If the - does not disappear:

> Check the configuration of the system using the

CDS (Configuration & Diagnostic Software).

> Re-transfer the corrected configuration to the

system.

> Check the contactors and their wiring, eliminate

any wiring errors, if necessary.

> Check the voltage level at the EDM input.

> Check to see whether the EDM configuration is

correct.

> Check the contactors and their wiring, eliminate

any wiring errors, if necessary.

> Check the voltage level at the EDM input.

> Check to see whether the EDM configuration is

correct.

> Due to an EDM error, the device is in the lock-

out state. Carry out a reset.

> Have the receiver replaced.

> Check the contactor. Replace, if necessary.

> Check the wiring for a short-circuit to 0 V.

> Check the wiring for a short-circuit to 24 V.

> Check the wiring for a short-circuit to 0 V.

7O+ Overcurrent at

switching output 2

7O, Short-circuit at

> Check the contactor. Replace, if necessary.

> Check the wiring for a short-circuit to 0 V.

> Check the wiring for a short-circuit to 24 V.

switching output 2

7O- Short-circuit at

> Check the wiring for a short-circuit to 0 V.

switching output 2

7O. Short-circuit between

> Check the wiring and rectify the error.

switching outputs 1 and 2

7O0 Internal error > Check the OSSD load.

> Have the receiver replaced.

Chapter 9 Operating instructions

V4000 PB

Diagnostics

Display Possible cause Remedying the error

TO+ Discrepancy time is

longer than configured

TO- No protective volume

mode selected, or several

TO/ Bypass input signals

are implausible

5O, Incremental encoder

signal is implausible

QO) Dazzle

2O( The maximum closing

speed taught in during the power-up cycle has been exceeded

> Re-configure the discrepancy time accordingly.

> Check the connection and the function of the

protective volume mode selector switch.

> Re-configure the discrepancy time accordingly.

> Check for a short-circuit in the connection of the

selector switch on the switching amplifier.

This message cannot appear unless the bypass has been activated in the configuration.

> Check the bypass wiring, eliminating any wiring

errors or short-circuits, if necessary.

> Check the configuration.

> Check the incremental encoder.

> Check the wiring.

> Cut out outside light from an external light

source, if necessary.

> Check the wiring from the sender or receiver,

eliminating any wiring errors, if necessary.

> Carry out a power-up cycle.

2O) The maximum closing

speed specified in the configuration has been exceeded

2O* The overall machine

overrun specified in the configuration has been exceeded

2O- The press is closing

although the foot switch has not been operated

The press is closing although the OSSDs have been deactivated

;O) Invalid configuration of

the EDM

> Reconfigure the maximum closing speed

accordingly.

> Check to see whether the incremental encoder

signals have got mixed up, eliminating the

wiring error, if necessary.

There may be a error in the press brake (see press brake operating instructions).

> Reconfigure the overall machine overrun

accordingly.

> Check to see whether the incremental encoder

signals have got mixed up, eliminating the

wiring error, if necessary.

There may be an error in the press brake (see press brake operating instructions).

> Verify that the machine-side EDM is connected.

Sick V4000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Update

Contents

1 About this document

1.1 Function of this document

1.2 Target groups

1.3 Scope

1.4 Depth of information

1.5 Abbreviations

1.6 Symbols used

2 On safety

2.1 Specialist personnel

2.2 Applications of the system

2.3 Correct use of the system

2.4 General protective notes and protective measures

2.5 Safety in operation

2.6 Environmental protection

2.6.1 Disposal

3 Product description

3.1 Special features

3.2 Safety concept

3.2.1 Protection principle of the V4000 PB

3.2.2 Protective volume during the operating cycle

3.2.3 Intrusion of the protective volume during the operating cycle

3.3 Range of use

3.4 Structure of the device

3.4.1 Sender and receiver

3.4.2 Displays at the sender and receiver

3.4.3 Interfaces at the receiver

3.4.4 PBI (press brake interface)

3.4.5 CDS (Configuration & Diagnostics Software)

3.4.6 External operating elements

3.5 Possible system configurations

3.5.1 Source of the operator signals

3.5.2 Baud rate communication interface

3.5.3 Application name

3.5.4 Repetition interval of power-up cycle

3.5.5 Mounting of receiver

3.5.6 Speed-dependent muting

3.5.7 Position-sensing system

3.5.8 External device monitoring (EDM)

3.5.9 Default value for braking distance

3.5.10 Travel for determining the braking distance

3.5.11 Braking offset

3.5.14 Maximum closing speed and maximum overall machine overrun

3.5.15 Travel for determining the overall machine overrun

3.5.16 Standstill time for determining the top dead centre

3.5.17 Start delay for closing movement

3.5.18 Time for standstill detection

3.5.19 Settling times for inputs

3.5.20 Discrepancy times for inputs

3.5.21 Start signal at reduced protective volume

3.5.22 Minimum state time for standard outputs

3.5.23 Minimum switch-off time for safety-relevant outputs

3.5.24 Bypass

3.6 Protective operation

3.6.1 Power-up cycle

3.6.2 Teach-in

3.6.3 Protective volume modes in protective operation

3.7 System sequences in protective operation

3.7.1 Power-up cycle in standard mode

3.7.2 Teach-in

3.7.3 Operating cycle in standard mode

3.7.4 Operating cycle in box mode

3.7.5 Operating cycle in back-stop mode

3.8 Alignment mode

4 Mounting

4.1 Steps for mounting

4.1.1 Mounting the sender or receiver using SICK mounting kit 1

4.1.2 Mounting the sender or receiver using SICK mounting kit 2

4.1.3 Sticker: Information for daily inspection

5 Electrical installation

5.1 Connecting the receiver

5.2 Connecting the sender

5.3 Making up the connections for receiver and sender

5.4 Connecting the PBI

5.5 External device monitoring (EDM)