Sick V4000 User Manual

V4000 Press Brake sensor system

for protecting the press brake

OPERATING INSTRUCTIONS

GB

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.

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

Insert

V4000 PB

Update

Update

Please take note of the following updates to this document!

a

WARNING

Based on Machinery Directive 2006/42/EC, we have added the following supplementary
data or change notices on our product to the following document.

Scope

This document is an original document.

Cited standards and directives

The standards and directives cited in these operating instructions might have changed.
The following list indicates the standards and directives that might have been cited and
their successive versions.

Kindly replace the standards and directives cited in these operating instructions with the
successive versions listed in the table.

Previous standard or directive Successive standard and directive

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

1)

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

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

Insert

V4000 PB

Update

Electrical installation

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

a

WARNING

device!

 If you connect loads that are not reverse-polarity protected to the OSSDs or the safety

outputs, you must connect the 0 V connections of these loads and those of the
corresponding protective device individually and directly to the same 0 V terminal strip.
This is the only way to ensure that, in the event of a defect, there can be no potential
difference between the 0 V connections of the loads and those of the corresponding
protective device.

OSSD1

Safety output 1

OSSD2

Safety output 2

OSSD1

Safety output 1

OSSD2

Safety output 2

Note

Technical specifications

Safety-related parameters according to EN ISO 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

3)

)

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.

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

Insert

V4000 PB

Update

Checklist for the manufacturer

L

Checklist for the manufacturer/installer for the installation of electro-

sensitive protective equipment (ESPE)

Details about the points listed below must be present at least during initial commissioning — they are, however,
dependent on the respective application, the specifications of which are to be controlled by the manufacturer/installer.

This checklist should be retained and kept with the machine documentation to serve as reference during recurring
tests.

1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to
the machine?

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

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No 

No 
No 

No 
No 

No 

No 

No 

No 
No 
No 

No 

No 
No 
No 
No 
No 

No 
No 

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

Insert

V4000 PB

Update

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

Operating instructions

V4000 PB

Contents

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

9

9
10
10
11
16
16

17

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

37
38
38
39

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 3

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
60
61
62

63

63
66
67
67
69
70
71

72

72
73

74

74
74
74
81
83
86

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

88
89
89
89
91
92

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

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
94
95
97
98

99

99

99
105
106
107
107
108

109

109
109
109

111

114

114
114
116
118

120
122
124
125
126
128

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 5

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

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

Operating instructions Chapter 1

V4000 PB

About this document

Note

ANSI

BWS

CDS

EDM

ESPE

HMI

LD

LD LED

MP

NC

OMO

ORT

OSSD

PBDC

PBI

PTDC

PP

SP

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

p

Safety programmable logic control

V4000 Press Brake (sensor system)

slow

)

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 7

Chapter 1 Operating instructions

V4000 PB

About this document

1.6 Symbols used

Recommendation

Note

;, , ;O(

O Yellow, Ö Yellow,

o Yellow

, 

> Action …

a

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!

n

s r

Software notes show the location in the CDS (Configuration & Diagnostic Software) where
you can make the appropriate settings and adjustments. Go to the View menu, Dialogue
windows of the CDS and activate the item tabs to view the named dialogue boxes as
required. Otherwise use the software wizard to make the desired settings.

Sender and receiver

In drawings and diagrams, the s symbol denotes the sender and the symbol r the
receiver.

The term "dangerous state"

In the drawings in these operating instructions, the dangerous state (standard term) of the
machine is always represented as a movement of a machine part. In practical operation
there may be a number of different dangerous states:

 Machine movements

 Electrical conductors

 Visible or invisible radiation

 A combination of several risks and hazards

Representation of the signals for teach-in, alignment mode and selection of protective
volume mode

These operating instructions also describe the V4000 PB input and output signals. As a
way of uniquely representing the signals for teach-in, alignment mode and selection of
protective volume mode (input signals), tactile switching amplifiers (buttons, switches) are
used. The signals can be generated at the inputs of the V4000 PB by, for example, foot
switches, alignment buttons, teach-in buttons, selector switches and key-operated
switches or by the corresponding switching elements on the HMI of the press controller.

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

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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 9

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!

a

WARNING

An opto-electronic protective device provides indirect protection, e.g., by switching off the
power at the source of the hazard. It cannot provide protection neither from parts thrown
out, nor from emitted radiation. Transparent objects are not detected.

Depending on its applications, mechanical protective devices may be needed in addition to
the V4000 PB.

2.3 Correct use of the system

The V4000 PB system is intended to be used solely at a fixed location on press brakes and
may only be used as defined by Section
only by specialist personnel and only on the machine where it has been mounted and
initially commissioned by specialist personnel in accordance with these operating
instructions.

SICK AG accepts no claims for liability if the equipment is used in any other way or if
modifications are made to the device, even in the context of mounting and installation.

2.2 "Applications of the system". It must be used

a

WARNING

Fig. 1: Warning regarding
laser class 1M

2.4 General protective notes and protective measures

Protective notes

Please observe the following protective notes in order to ensure the correct and safe use
of the V4000 PB.

 Warnings on the V4000 PB must be observed without fail.

 The V4000 PB meets the requirements of laser protection class 1 M. Do not look into

the laser beam neither with the naked eye nor using optical equipment (such as
binoculars).

LASER RADIATION

DO NOT STARE INTO THE BEAM OR VIEW

DIRECTLY WITH OPTICAL INSTRUMENTS

CLASS 1M LASER PRODUCT

ACCORDING TO IEC 60825-1:2001

Max. output: < 5mW
Puls duration: < 2ms

Wavelength: 620 TO 650 nm

Complies with 21 CFR 1040.10 and 1040.11 except

for deviations pursuant to laser notice No. 50, July 2001

 This device meets the norms: CDRH 21 CFR 1040.10, 1040.11 as well as DIN EN 60

825:2001. There the following note is required:”Caution – use of controls or
adjustments or performance of procedures other than those specified herein may result
in hazardous radiation exposure!”

 The V4000 PB components must not be opened for maintenance work. Defective

devices have to be sent back to the manufactorer.

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

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

a

WARNING

2.5 Safety in operation

Dangers which the V4000 PB does not protect against!

The different ways in which the press brake can be used in manufacturing means that
indirect dangers may arise.
Please observe and comply with the following points in order to protect yourself against
dangers during machine operation.

The V4000 PB safeguards the hazardous point beneath the die at high closing speeds
(over 10 mm/s) or irrespective of the speed up to a gap of 6 mm. The maximum height of
the protective volume up to the lower edge of the die is 26 mm.

Maximum protection is provided in standard protective volume mode.

In the case of box-bending or back-stop operation, use of a restricted protective volume is
possible. With this kind of work, the reduced dimensions of the protective volume means
that only limited protection against getting caught or crushed is possible.

If parts of the body are brought into the hazardous point within a box, they will only be
detected behind the tolerance zone around the pressure axis. There is a danger of injury
by being caught or crushed.

For a time interval of 100–150 ms (just before the gap height of 6 mm is reached) there is
the possibility of an object which is moving into the space between the die and the
workpiece being crushed.

Correct handling of the workpiece

By handling the sheet properly you can avoid your hands or fingers being caught or
crushed.

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

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.

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

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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 13

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

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

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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 15

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

a

WARNING

Packaging

Cardboard, paper

Polyethylene packaging

We would be pleased to be of assistance on the disposal of the V4000 PB. Contact your
local SICK representative.

Material separation may only be performed by specialist personnel!

Exercise care when disassembling the devices. The danger of injury is present.

Paper/cardboard recycling

Plastic recycling

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

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

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 17

Chapter 3 Operating instructions

6

r

/

r

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.

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

Operating instructions Chapter 3

7

d

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

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 19

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.

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

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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 21

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.

or

– the press, should the lock-out state occur, does not start up again.

 The V4000 PB must be mounted and configured in such a way that it can detect objects

when they penetrate into the hazardous point.

3.5.13 "Monitoring of the slow

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

Operating instructions Chapter 3

r

7

y

r

t

C

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

N

PBI

SPLC

Fig.

9: Sender and receiver

Incremental
encoders

3.4.1 Sender and receiver

Incremental
encoders

Operating
elements

HMI

CDS

Star

Receive

LEDs

-segment displa

Sende

LED

Sender and receiver are mounted on the press crosshead and follow the movements of
the crosshead. At start-up and every time there is a change of tooling, they need to be
precisely aligned to the length of the die used and to each other.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 23

Chapter 3 Operating instructions

w

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.

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

Operating instructions Chapter 3

3:

w

7

y

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)

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 25

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

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