SICK V4000 (01) PDF MANUAL


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PDF Content Summary: 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

WARNING Please take note of the following updates to this document! Based on Machinery Directive 2006/42/EC, we have added the following supplementary data or change notices on our product to the following document. Scope This document is an original document.

Cited standards and directives The standards and directives cited in these operating instructions might have changed. The following list indicates the standards and directives that might have been cited and their successive versions. Kindly replace the standards and directives cited in these operating instructions with the successive versions listed in the table. Previous standard or directive Successive standard and directive Machinery Directive 98/37/EC Machinery Directive 2006/42/EC Directive 93/68/EEC Directive 93/68/EC EMC directive 89/336/EEC EMC directive 2004/108/EC Low Voltage Directive 73/23/EC Low Voltage Directive 2006/95/EC DIN 40 050 EN 60 529 IEC 536:1976 EN 61 140

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

EN 775 EN ISO 10 218-1 EN 292-1 EN ISO 12 100-1 EN 292-2 EN ISO 12 100-2 EN 954-1 EN ISO 13 849-1 EN 418 EN ISO 13 850 EN 999 EN 999+A11) EN 294 EN ISO 13 857 EN 811 EN ISO 13 857 EN 1050 EN ISO 14 121-1 IEC 68, part 2-27 or IEC 68 EN 60 068-2-27 IEC 68, part 2-29 EN 60 068-2-27 IEC 68, part 2-6 EN 60 068-2-6 prEN 50 100L1 EN 61 496-1 ANSI B11.19-1990 ANSI B11.19:2003L04, 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 Update V4000 PB Electrical installation Prevent the formation of a potential difference between the load and the protective device! WARNING ➢ If you connect loads that are not reverse-polarity protected to the OSSDs or the safety outputs, you must connect the 0 V connections of these loads and those of the corresponding protective device individually and directly to the same 0 V terminal strip. This is the only way to ensure that, in the event of a defect, there can be no potential difference between the 0 V connections of the loads and those of the corresponding protective device. Technical specifications Safety-related parameters according to EN ISO 13 849, EN 62 061, IEC 61 508: V4000 PB: General system data Type Type 4 (IEC 61 496) Safety Integrity Level2) SIL3 (IEC 61 508), SILCL3 (EN 62 061) Category Category 4 (EN ISO 13 849) Category 4 (EN 9543)) Performance Level2) PL e (EN ISO 13 849)

PFHd (mean probability of a dangerous failure per hour) 1.52 × 10–8 TM (mission time) 16.6 years (EN ISO 13 849) EC declaration of conformity Note You can obtain the EC declaration of conformity with the standards used at: http://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 Checklist for the manufacturer/installer for the installation of electro- sensitive protective equipment (ESPE) Details about the points listed below must be present at least during initial commissioning — they are, however, dependent on the respective application, the specifications of which are to be controlled by the manufacturer/installer. This checklist should be retained and kept with the machine documentation to serve as reference during recurring tests. 1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to the machine? Yes˜ No ˜ 2. Are the applied directives and standards listed in the declaration of conformity? Yes˜ No ˜ 3. Does the protective device fulfil the required PL/SILCL and PFHd according to EN ISO 13 849­1/EN 62 061 and the type according to EN 61 496­1? Yes˜ No ˜ 4. Is the access to the hazardous area/hazardous point only possible through the protective field of the ESPE? Yes˜ No ˜ 5. Have appropriate measures been taken to prevent (mechanical protection) or monitor unprotected presence in the hazardous area when protecting a hazardous area/hazardous point and have these been secured against removal? Yes˜ No ˜ 6. Are additional mechanical protective measures fitted and secured against manipulation which prevent reaching under, over or around the ESPE? Yes˜ No ˜ 7. Has the maximum stopping and/or stopping/run-down time of the machine been measured, specified and documented (at the machine and/or in the machine documentation)? Yes˜ No ˜ 8. Has the ESPE been mounted such that the required safety distance from the nearest hazardous point has been achieved? Yes˜ No ˜ 9. Are the ESPE devices correctly mounted and secured against manipulation after adjustment? Yes˜ No ˜ 10. Are the required protective measures against electric shock in effect (protection class)? Yes˜ No ˜ 11. Is the control switch for resetting the protective device (ESPE) or restarting the machine present and correctly installed? Yes˜ No ˜ 12. Are the outputs of the ESPE (OSSDs, AS­Interface Safety at Work) integrated in compliance with the required PL/SILCL according to EN ISO 13 849/EN 62 061 and does the integration comply with the circuit diagrams? Yes˜ No ˜ 13. Has the protective function been checked in compliance with the test notes of this documentation? Yes˜ No ˜ 14. Are the given protective functions effective at every setting of the operating mode selector switch? Yes˜ No ˜ 15. Are the switching elements activated by the ESPE, e.g. contactors, valves, monitored? Yes˜ No ˜ 16. Is the ESPE effective over the entire period of the dangerous state? Yes˜ No ˜ 17. Once initiated, will a dangerous state be stopped when switching the ESPE on or off and when changing the operating mode, or when switching to another protective device? Yes˜ No ˜ 18. Has an information label for the daily check been attached so that it is easily visible for the operator? Yes˜ No ˜ 19. Have you made sure that the protective device itself when mounted is not a source of danger during machine operation (for example, catching between the device and parts of the machine)? Yes˜ No ˜ This checklist does not replace the initial commissioning, nor the regular inspection by qualified safety personnel. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved Insert V4000 PB Update © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Contents Operating instructions V4000 PB Contents 1 About this document ......................................................................................................6 1.1 Function of this document....................................................................................6 1.2 Target groups ........................................................................................................6 1.3 Scope.....................................................................................................................6 1.4 Depth of information.............................................................................................6 1.5 Abbreviations.........................................................................................................7 1.6 Symbols used ........................................................................................................8 2 On safety..........................................................................................................................9 2.1 Specialist personnel..............................................................................................9 2.2 Applications of the system ...................................................................................9 2.3 Correct use of the system.................................................................................. 10 2.4 General protective notes and protective measures......................................... 10 2.5 Safety in operation............................................................................................. 11 2.6 Environmental protection .................................................................................. 16 2.6.1 Disposal ............................................................................................ 16 3 Product description ..................................................................................................... 17 3.1 Special features ................................................................................................. 17 3.2 Safety concept.................................................................................................... 18 3.2.1 Protection principle of the V4000 PB ............................................. 18 3.2.2 Protective volume during the operating cycle ................................ 20 3.2.3 Intrusion of the protective volume during the operating cycle...... 21 3.3 Range of use ...................................................................................................... 22 3.4 Structure of the device ...................................................................................... 23 3.4.1 Sender and receiver......................................................................... 23 3.4.2 Displays at the sender and receiver ............................................... 24 3.4.3 Interfaces at the receiver................................................................. 26 3.4.4 PBI (press brake interface).............................................................. 28 3.4.5 CDS (Configuration & Diagnostics Software).................................. 29 3.4.6 External operating elements ........................................................... 31 3.5 Possible system configurations......................................................................... 31 3.5.1 Source of the operator signals ........................................................ 33 3.5.2 Baud rate communication interface ............................................... 33 3.5.3 Application name ............................................................................. 33 3.5.4 Repetition interval of power-up cycle.............................................. 33 3.5.5 Mounting of receiver........................................................................ 34 3.5.6 Speed-dependent muting ................................................................ 34 3.5.7 Position-sensing system .................................................................. 34 3.5.8 External device monitoring (EDM)................................................... 35 3.5.9 Default value for braking distance.................................................. 35 3.5.10 Travel for determining the braking distance .................................. 36 3.5.11 Braking offset ................................................................................... 36 3.5.12 Target speed vslow for determining the braking distance ............... 36 3.5.13 Monitoring of the slow closing speed vcrawl from the pinch point.................................................................................................. 37 3.5.14 Maximum closing speed and maximum overall machine overrun.............................................................................................. 37 3.5.15 Travel for determining the overall machine overrun...................... 38 3.5.16 Standstill time for determining the top dead centre...................... 38 3.5.17 Start delay for closing movement .................................................. 39 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 3 Contents Operating instructions V4000 PB 3.5.18 Time for standstill detection ............................................................ 39 3.5.19 Settling times for inputs ................................................................... 39 3.5.20 Discrepancy times for inputs ........................................................... 40 3.5.21 Start signal at reduced protective volume ...................................... 40 3.5.22 Minimum state time for standard outputs......................................41 3.5.23 Minimum switch-off time for safety-relevant outputs..................... 41 3.5.24 Bypass...............................................................................................41 3.6 Protective operation ........................................................................................... 42 3.6.1 Power-up cycle .................................................................................. 42 3.6.2 Teach-in.............................................................................................43 3.6.3 Protective volume modes in protective operation .......................... 43 3.7 System sequences in protective operation....................................................... 46 3.7.1 Power-up cycle in standard mode.................................................... 47 3.7.2 Teach-in.............................................................................................51 3.7.3 Operating cycle in standard mode...................................................53 3.7.4 Operating cycle in box mode............................................................ 55 3.7.5 Operating cycle in back-stop mode ................................................. 57 3.8 Alignment mode.................................................................................................. 59 4 Mounting.......................................................................................................................60 4.1 Steps for mounting ............................................................................................. 60 4.1.1 Mounting the sender or receiver using SICK mounting kit 1 ......... 60 4.1.2 Mounting the sender or receiver using SICK mounting kit 2 ......... 61 4.1.3 Sticker: Information for daily inspection ......................................... 62 5 Electrical installation................................................................................................... 63 5.1 Connecting the receiver .................................................................................... 63 5.2 Connecting the sender ....................................................................................... 66 5.3 Making up the connections for receiver and sender.......................................67 5.4 Connecting the PBI............................................................................................67 5.5 External device monitoring (EDM) ..................................................................... 69 5.6 Bypass.................................................................................................................70 5.7 Configuration connection (serial interface)....................................................... 71 6 Configuration................................................................................................................72 6.1 Delivery state ...................................................................................................... 72 6.2 Configuration preparations ................................................................................ 73 7 Commissioning ............................................................................................................. 74 7.1 Test notes ........................................................................................................... 74 7.2 Aligning sender and receiver ............................................................................. 74 7.2.1 Initial alignment ................................................................................ 74 7.2.2 Alignment following a tooling change.............................................. 81 7.3 Function check ................................................................................................... 83 7.4 Regular checks of the protective device by specialist personnel...................86 7.5 Daily checks of the protective device by authorised commissioned persons ............................................................................................................... 86 8 Operation ...................................................................................................................... 88 8.1 Switching the machine on.................................................................................. 88 8.2 Selecting protective volume mode .................................................................... 89 8.3 Resetting.............................................................................................................89 8.4 Carrying out a power-up cycle ............................................................................ 89 8.5 Carrying out teach-in .......................................................................................... 91 8.6 Bending in standard mode................................................................................. 92 4 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Contents Operating instructions V4000 PB 8.7 Bending in box mode ........................................................................................ 92 8.8 Bending in back-stop mode.............................................................................. 92 8.9 Changing the sheet thickness........................................................................... 92 8.10 Tool changing ..................................................................................................... 93 8.11 Care and maintenance ...................................................................................... 93 9 Diagnostics................................................................................................................... 94 9.1 Response to errors and malfunctions............................................................... 94 9.2 Error displays of the LEDs.................................................................................. 94 9.3 Error displays of the 7-segment display............................................................ 95 9.4 Extended diagnostics via CDS........................................................................... 97 9.5 SICK support....................................................................................................... 98 10 Technical data.............................................................................................................. 99 10.1 Device data sheet .............................................................................................. 99 10.1.1 V4000 PB technical data................................................................. 99 10.1.2 Technical data for PBI (press brake interface)............................. 105 10.1.3 Incremental encoder technical data ............................................. 106 10.2 Dimensional drawings ..................................................................................... 107 10.2.1 Sender and receiver....................................................................... 107 10.2.2 SICK mounting kit 1 ....................................................................... 108 11 Ordering information ................................................................................................. 109 11.1 Scope of delivery .............................................................................................. 109 11.2 Available systems............................................................................................. 109 11.3 Accessories....................................................................................................... 109 12 Glossary......................................................................................................................111 13 Annex .......................................................................................................................114 13.1 Detailed system sequences in protective operation...................................... 114 13.1.1 Power-up cycle................................................................................ 114 13.1.2 Teach-in .......................................................................................... 116 13.1.3 Standard mode .............................................................................. 118 13.1.4 Box or back-stop mode with interruption of the protective volume ............................................................................................ 120 13.2 Declaration of Conformity................................................................................ 122 13.3 Manufacturer’s checklist ................................................................................. 124 13.4 List of tables ..................................................................................................... 125 13.5 List of illustrations............................................................................................ 126 13.6 Index ................................................................................................................. 128 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 5 About Chapter 1 this document Operating instructions V4000 PB 1 About this document Read this chapter carefully before working with the operating instructions and the V4000 Press Brake system. For "V4000 Press Brake system" we shall use the abbreviation "V4000 PB" from now on. 1.1 Function of this document These operating instructions are intended for the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, electrical installation, configuration, commissioning, operation and diagnostics of the V4000 PB sensor. These operating instructions do not provide instructions for operating machines on which the V4000 PB is, or will be, integrated. Information of this kind will be found in the operating instructions for the machine. 1.2 Target groups These operating instructions are intended for manufacturers, operators and the users of press brakes which are to be protected by a V4000 PB. It also addresses people who integrate the V4000 PB into a machine, initialise its use, or who check the unit. 1.3 Scope Note 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 Error diagnostics and remedying Electrical installation Technical data and order numbers Configuration and commissioning Conformity and approval 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". 6 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 About Operating instructions this document Chapter 1 V4000 PB Note 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 ANSI American National Standards Institute BWS Electro-sensitive protective equipment (ESPE) (e. g. V4000 PB) CDS SICK Configuration & Diagnostic Software = software for configuring and diagnosing the V4000 PB system EDM External device monitoring ESPE Electro-sensitive protective equipment HMI Human machine interface LD Laser diode LED LD Light-emitting diode MP Mute point NC Numerical control OMO Overall machine overrun ORT Overall response time OSSD 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 PBDC Programmed bottom dead centre PBI Press brake interface PTDC Programmed top dead centre PP Pinch point SP Switch-over point (from vp to vslow) SPLC Safety programmable logic control V4000 PB V4000 Press Brake (sensor system) 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 7 About Chapter 1 this document Operating instructions V4000 PB 1.6 Symbols used Recommendation Recommendations are designed to provide some assistance for your decision-making process regarding application of a certain function or technical measure. Note Notes provide special information about the device. ;, , ;O( Display 7 indicators show the status of the 7-segment display of the receiver: Constant display of the letter F Flashing display of the letter F 7O) Alternating display of F and 2 Yellow, Yellow, LED symbols describe the state of an LED: Yellow The LED is illuminated constantly. The LED is flashing. The LED is off. ■, □ ON or OFF state: ■ ON □ OFF Action ... 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. WARNING Read warnings carefully and abide by them! Software notes show the location in the CDS (Configuration & Diagnostic Software) where you can make the appropriate settings and adjustments. Go to the View menu, Dialogue windows of the CDS and activate the item tabs to view the named dialogue boxes as required. Otherwise use the software wizard to make the desired settings. Sender and receiver In drawings and diagrams, the symbol denotes the sender and the symbol 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

On Operating instructions safety Chapter 2 V4000 PB 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 On Chapter 2 safety Operating instructions V4000 PB Use of the V4000 PB in the open air or explosion hazard areas is not permitted. The V4000 PB can only be used in normal industrial environments. Do not use the V4000 PB as a separating protective measure! An opto-electronic protective device provides indirect protection, e.g., by switching off the WARNING power at the source of the hazard. It cannot provide protection neither from parts thrown out, nor from emitted radiation. Transparent objects are not detected. Depending on its applications, mechanical protective devices may be needed in addition to the V4000 PB. 2.3 Correct use of the system The V4000 PB system is intended to be used solely at a fixed location on press brakes and may only be used as defined by Section 2.2 "Applications of the system". It must be used only by specialist personnel and only on the machine where it has been mounted and initially commissioned by specialist personnel in accordance with these operating instructions. SICK AG accepts no claims for liability if the equipment is used in any other way or if modifications are made to the device, even in the context of mounting and installation. 2.4 General protective notes and protective measures Protective notes Please observe the following protective notes in order to ensure the correct and safe use WARNING 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). Fig. 1: Warning regarding laser class 1M 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 for Complies deviations with pursuant 21 CFR to 1040.10 laser notice and 1040.11 No. 50, July except 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 On Operating instructions safety Chapter 2 V4000 PB The national/international rules and regulations apply to the installation, commissioning and periodic technical inspections of the V4000 PB, in particular: – Machinery Directive 98/37/EC – Provision and use of Work Equipment Directive 89/655/EEC – The work safety regulations/safety rules – Relevant national health and safety regulations Manufacturers and operators of the machine on which the V4000 PB is used are responsible for obtaining and observing all applicable safety regulations and rules. The notices, in particular the test regulations (see Chapter 7 "Commissioning") of these operating instructions (e.g. on use, mounting, installation or integration into the existing machine controller) must be observed. The tests must be carried out by specialist personnel or specially qualified and authorised personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time. The operating instructions must be made available to the operator of the machine where the V4000 PB is fitted. The machine operator is to be instructed in the use of the device by specialist personnel and must be instructed to read the operating instructions of the V4000 PB and of the machine. 2.5 Safety in operation Dangers which the V4000 PB does not protect against! The different ways in which the press brake can be used in manufacturing means that WARNING 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

On Chapter 2 safety Operating instructions V4000 PB 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 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) Fig. 3: Handling of the workpiece 2 When holding the sheet, be sure not to spread your fingers. Note 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

On Operating instructions safety Chapter 2 V4000 PB Correct handling of pre-flanged sheets Fig. 4: 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

On Chapter 2 safety Operating instructions V4000 PB Correct handling with box-bending Fig. 5: Handling of box-shaped workpieces 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

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

Product Operating instructions description Chapter 3 V4000 PB 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

Product Chapter 3 description Operating instructions V4000 PB 3.2 Safety concept 3.2.1 Protection principle of the V4000 PB Fig. 6: Press brake with V4000 PB Press crosshead Receiver Die Female die Illumination field/ protective volume Sender

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 three- dimensional 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 back- stop). 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

Product Operating instructions description Chapter 3 V4000 PB 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. 7: Definitions

Die Illumination field Protective volume Pressure axis Workpiece Female die 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 19 Product Chapter 3 description Operating instructions V4000 PB 3.2.2 Protective volume during the operating cycle This sequence shows the protective volume during one operating cycle. Step The die is at the The die descends at At the switch-over point programmed top dead high speed the target speed is centre. (> 10 mm/s). requested by the The operator gives the The entire protective V4000 PB. signal to start the volume is active. The press controller closing movement (foot initiates the braking switch). procedure. The protective volume stays active in the gap opening. Protective volume Step The calculation of the The die contacts the switch-over point workpiece (pinch point). includes an additional 6 mm safety gap required to reach the target The protective speed (vvolume slow). becomes inactive. Protective volume 20 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 The die shapes the workpiece. The operating cycle ends at the programmed bottom dead centre. The die goes back up. Product Operating instructions description Chapter 3 V4000 PB 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 The die is at the The die descends at Part of the protective programmed top dead high speed volume is interrupted by centre. (> 10 mm/s). the object. There is a foreign object The entire protective The OSSDs go into the on the workpiece or volume is active. OFF state and generate female die. a safe stop signal. The operator gives the The press controller signal to start the must ensure the stop closing movement (foot procedure is switch). implemented. Protective volume Step The die continues to The object is now move in accordance removed. with the overall machine The protective volume is overrun and stops at clear again. least 5 mm above the object. Protective volume 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 21 The operator gives the signal once more to start the closing movement (foot switch). The closing movement starts and the operating cycle resumes.

Product Chapter 3 description Operating instructions

V4000 PB 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 3.5.13 "Monitoring of the slow 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. 22 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Product Operating instructions description Chapter 3 V4000 PB 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 NC PBI SPLC Incremental Incremental encoders encoders Operating elements HMI CDS Start 3.4.1 Sender and receiver Fig. 9: Sender and receiver Receiver LEDs 7-segment display Sender LEDSender 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

Product Chapter 3 description Operating instructions V4000 PB 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 LED: Yellow An LED on the sender displays the status. Tab. 2: Display at the sender Display Meaning

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 Product Operating instructions description Chapter 3 V4000 PB 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 LEDs: Red Yellow Green 7-segment display 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. 3: Key to the LEDs on the receiver display Display Meaning Yellow Operator action (input) is required (On % / Off % at 1 Hz) (10/90) – Alignment mode (90/10) – Teach-in request 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 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 Green System free (OSSDs in the ON state) 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 25 Product Chapter 3 description Operating instructions V4000 PB Tab. 4: Key to the 7-segment display on the receiver 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 Other All of the other displays are error messages, displays within alignment displays mode or displays during the self-test (system initialisation). Note 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 8.1 "Switching the machine on") Displays within alignment mode (see Section 7.2 "Aligning sender and receiver") Error displays within lock-out state (see Section 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 Product Operating instructions description Chapter 3 V4000 PB 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 Inputs with safety and outputs relevance Function 2 Actively tested semiconductor For the switch-off signal to the press controller switching outputs (OSSDs) 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. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 27

Product Chapter 3 description Operating instructions V4000 PB 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. 28 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27

Product Operating instructions description Chapter 3 V4000 PB Display at the PBI Fig. 13: Display at the PBI LED: Yellow Tab. 6: Display at the PBI Display Meaning 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. Note For more information see the Sections 3.5 "Possible device configurations" and 9.4 "Extended diagnostics via CDS".

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 29 Product Chapter 3 description Operating instructions V4000 PB 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 Permanent – on-line - diagnostics and operation must be implemented solely via the RS-422 interface. Fig. 14: System configuration with PC control NC PBI SPLC Incremental Incremental encoders encoders Operating elements HMI CDS Start 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. Fig. 15: System configuration without PC control NC PBI SPLC Incremental Incremental encoders encoders Operating elements HMI CDS Start 30 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Product Operating instructions description Chapter 3 V4000 PB 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). Note 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. Recommendation All switching elements should be large and sturdy. It must be possible to operate them reliably and simply while wearing gloves. 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 WARNING 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 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 31 Product Chapter 3 description Operating instructions V4000 PB Tab. 7: Configurable parameters and functions 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 vslow 3.5.12 Monitoring of the slow closing speed vcrawl from the pinch 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 Settling times for safety-relevant inputs 32 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 3.5.19 Discrepancy time for safety-relevant inputs Discrepancy time for protective volume selection 3.5.20 Maximum duration of 1st operation (confirmation of reduced protective volume) Start signal Time for pause between 1st and 2nd operation 3.5.21 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

Product Operating instructions description Chapter 3 V4000 PB 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. Note 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 power- up cycle if the configured value (≤ 24 h) is exceeded. V4000 PB device symbol, context menu Configuration draft, Edit, Basic settings tab 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 33

Product Chapter 3 description Operating instructions V4000 PB 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 In addition a closing movement at a low closing speed vcrawl (≤ 10 mm/s) will also cause 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 vcrawl is exceeded in the muting state, muting will be deactivated and the protective volume activated. With automatic muting at the slow closing speed vcrawl it is possible for the press brake to close at slow closing speed despite an interruption of the protective volume. If slow closing speed vcrawl has not yet been reached when the protective volume is 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. Note 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

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

Product Operating instructions description Chapter 3 V4000 PB

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 ON 0° signal OFF

90° signal ON OFF Note 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 3.5.9 Default value for braking distance Note The Braking distance tab only has to be configured if the press brake supports two speeds (vp and vslow) and Vslow is connected. During the power-up cycle, the braking distance (transition from the high closing speed to the target speed vslow) is also determined. 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

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 35 Product Chapter 3 description Operating instructions V4000 PB 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 vslow) is also determined. The travel for determing the braking distance is the distance the press requires to accelerate to the high closing speed and then brake down again to the target speed vslow. 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 During braking to the target speed vslow, vibrations in the V4000 PB and braking distance 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 vslow is reached is increased. Tab. 8: Braking offset Braking Gap at vslow Availability with braking offset distance fluctuations 36 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 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 vslow is reached at the muting point (6 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 vslow before the calculated switch-over point. The press brakes earlier and thus reaches the target speed vslow before the muting point. V4000 PB device symbol, context menu Configuration draft, Edit, Braking distance tab 3.5.12 Target speed vslow for determining the braking distance In the determination of the braking distance, the target speed vslow is the speed which the 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

Product Operating instructions description Chapter 3 V4000 PB 3.5.13 Monitoring of the slow closing speed vcrawl from the pinch point The slow closing speed (vcrawl) is monitored from the pinch point at bending processes where the V4000 PB cannot be active (for example within a box). If vcrawl (≤ 10 mm/s) is exceeded, a stop command is output to the downstream control 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: vmax = maximum closing speed (depends on machine design), held in the configuration vP = high closing speed which is reached in the current operating cycle and is measured by the V4000 PB During configuration the maximum closing speed of the press is input as the maximum closing speed vmax. This speed must not be exceeded in any operating cycle. The press crosshead travels at high closing speed (>10 mm/s) up to the switch-over point. The high closing speed vp 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 vp 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. Note 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: Dmax = maximum overall machine overrun (depends on machine design), held in the 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 Dmax. This overall machine overrun must not be 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 Dmax. If the distance exceed the maximum machine overrun, Dmax, the V4000 PB will require a new power-up cycle. During the power-up cycle, the high closing speed vp 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. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 37

Product Chapter 3 description Operating instructions V4000 PB 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 well- founded value for the overall machine overrun. Note 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 = T1 * vmax + Dmax S ≤ 11 mm The response time T1 of the V4000 PB is constant. The parameters maximum overall machine overrun Dmax and maximum high closing speed vmax can be adjusted with regard 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. Note 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. 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. Note 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

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

Product Operating instructions description Chapter 3 V4000 PB 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 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. Fig. 17: Settling times ON Signal OFF t An undefined state will result in an error following logic checking by the V4000 PB and will thus initiate the lock-out state. To prevent this from happening, a time period (the settling time) is configured via the CDS for which the V4000 PB will ignore the undefined state. Settling times can be configured for the following inputs and outputs: Standard inputs Safety-relevant inputs V4000 PB device symbol, context menu Configuration draft, Edit, Inputs tab 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 39

Product Chapter 3 description Operating instructions V4000 PB 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 ON Channel 1 OFF Signal ON Channel 2 OFF 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 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.

Fig. 19: Start signal (double-click) 1st actuation start signal ON Signal OFF t1 t2 Pause 2nd actuation Pause 2nd actuation start signal

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

Product Operating instructions description Chapter 3 V4000 PB Deselect double-click At this setting the operator only has to trigger the start signal once (for example by operating the foot switch once). Note 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 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. Note 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

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 41

Product Chapter 3 description Operating instructions

V4000 PB 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. 42 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27

Product Operating instructions description Chapter 3 V4000 PB 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 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. Fig. 20: Protective volume in standard mode 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 43

Product Chapter 3 description Operating instructions V4000 PB 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! WARNING 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 2.5 "Safety in 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. Fig. 21: Reduced protective volume in box mode Box location in front space Box location in rear space blanked blanked Note 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.

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

Product Operating instructions description Chapter 3 V4000 PB 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. Recommendation If possible use Variant B of box mode for bending boxes since the operating cycle is mostly carried out in standard mode. Note 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! WARNING 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 2.5 "Safety in operation"). 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. Fig. 22: Reduced protective volume in back-stop mode blanked blanked 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 45 Product Chapter 3 description Operating instructions V4000 PB 3.7 System sequences in protective operation Fig. 23: Definitions Die Illumination field PTDC Protective volume vp SP Pressure axis Workpiece vslow vcrawl MP PP PBDC Female die vp High closing speed > 10 mm/s vslow Target speed following braking vcrawl Slow closing speed ≤ 10 mm/s (after the pinch point) Braking from vP to vslow PTDC Programmed top dead centre of the press SP Switch point = V4000 PB switch-over point – request for target speed vslow MP Mute point – protective volume inactive PP Pinch point PBDC Programmed bottom dead centre of the press 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 vslow is supported by the press controller. Note 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"). 46 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Product Operating instructions description Chapter 3 V4000 PB 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 The die is at any point in The operator gives the After about 20 mm the the operating cycle. signal to start the OSSDs go into the OFF The operator gives the closing movement (foot state and generate a signal for teach-in switch). The die safe stop signal. (teach-in button). descends at maximum The high closing speed closing speed. must be stopped. vp is measured. The V4000 PB determines the overall machine overrun. Protective volume Speed; machine movement v=0 PTDC vp PTDC PTDC Stop PBDC PBDC PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal Vslow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 47 Red Yellow Green L L L □ ■ ■ □ □ □ □ ■ □ ■ □ □ Product Chapter 3 description Operating instructions V4000 PB Step The overall machine overrun of the press The operator gives the signal once more to The target speed requested by the vslow is brake is determined. start the closing V4000 PB. The overall machine movement (foot switch). The press controller overrun must not The die descends at starts the braking exceed the configured maximum closing procedure. value. speed vP. When the braking vslow is distance reached is calculated. Protective volume Speed; machine movement v=0 PTDC vp PTDC PTDC vslow PBDC PBDC PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD Request signal for teach-in 48 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Red Yellow Green L L L ■ ■ ■ □ □ ■ □ ■ ■ □ □ □ Product Operating instructions description Chapter 3 V4000 PB Step The request signal for The workpiece The die must stop at vThe slow die is cancelled. accelerates to interrupts the protective least 5 mm above the volume. The OSSDs go workpiece. the high closing into the OFF state and The positions for the speed vP. generate a safe stop switch-over and muting signal. points are calculated. From this the pinch The operator cancels point PP (workpiece the start signal (foot surface) is obtained. switch). Protective volume PTDC PTDC PTDC Speed; machine movement vp Stop v=0 PBDC PBDC PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 49 Red Yellow Green L L & ■ ■ □ □ □ □ ■ □ ■ □ □ □ Product Chapter 3 description Operating instructions V4000 PB Step 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. Protective volume PTDC Speed; machine movement vp SP vslow vcrawl MP PP PBDC Red System state Yellow Green 7-segment display & Start signal for closing movement □ Request signal vslow ■ OSSD ■ Request signal for teach-in □ 50 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Product Operating instructions description Chapter 3 V4000 PB 3.7.2 Teach-in Start condition: press is wide open Step The die is at any point in The operator gives the The workpiece the operating cycle. signal to start the interrupts the protective The operator gives the closing movement (foot volume. signal for teach-in switch). The die The OSSDs go into the (teach-in button). descends at high OFF state and generate The protective volume is active. closing The entire speed protective vP. a safe stop signal. From this the pinch volume is active. point PP (workpiece surface) is obtained. Protective volume Speed; machine movement v=O PTDC PTDC PTDC vp Stop PBDC PBDC PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 51 Red Yellow Green L L L □ ■ ■ □ □ □ □ ■ □ ■ □ □ Product Chapter 3 description Operating instructions V4000 PB Step The die must stop at The operator gives the least 5 mm above the signal once more to workpiece surface. start the closing The positions for the movement (foot switch). switch-over and muting The operating cycle points are calculated. 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. Protective volume Speed; machine movement PTDC PTDC vp PP PBDC vslow vcrawl U Stop MP PP PBDC Red Red System state Yellow Yellow Green Green 7-segment display & & Start signal for closing movement □ ■ Request signal vslow □ □ OSSD □ ■ Request signal for teach-in □ □ 52 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Product Operating instructions description Chapter 3 V4000 PB 3.7.3 Operating cycle in standard mode Step The die is at the The die descends at At the switch-over point programmed top dead high closing speed SP the target speed is centre PTDC. The operator gives the (≤ The vP). entire protective signal to start the closing movement (foot switch). requested by the V4000 PB. volume is active. The press controller starts the braking procedure. The protective volume stays active in the gap opening. Protective volume Speed; machine movement PTDC PTDC PTDC vp SP SP SP MP MP MP vcrawl PP PBDC vp vslow vcrawl PP PBDC vp vslow vslow vcrawl PP PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 53 Red Yellow Green L L L ■ ■ ■ □ □ ■ ■ ■ ■ Product Chapter 3 description Operating instructions V4000 PB Step At the muting point MP The die contacts the The die shapes the the gap size is 6 mm workpiece at the pinch workpiece. The and the target speed point PP. operating cycle ends at has been reached. the programmed bottom The protective volume dead centre PBDC and becomes inactive. the die goes back-up. Protective volume PTDC PTDC PTDC Speed; machine movement vp SP SP vslow MP PP vp vslow vp PBDC vcrawl SP MP PP PBDC vvcrawl slow MP PP PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD 54 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Red Yellow Green & & & ■ ■ ■ ■ ■ ■ ■ ■ ■ Product Operating instructions description Chapter 3 V4000 PB 3.7.4 Operating cycle in box mode Step The die is at the The die descends at If the box projects into programmed top dead high closing speed the protective volume in centre PTDC. The operator gives the (≤ The vP). entire protective signal to start the closing movement (e.g. double-click with the foot switch). front of the pressure axis, the protective volume is active. volume in front of the pressure axis will be automatically blanked. The die continues to descend at maximum speed The part vp. of the protective volume behind the pressure axis remains active. Protective volume PTDC PTDC Speed; machine movement SP SP MP MP PP PP PBDC PBDC Red System state Yellow Green 7-segment display Start signal for closing movement Request signal vslow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 55 PTDC vp vp SP vcrawl vcrawl vslow vcrawl MP PP PBDC (If double-click is deselected, V4000 PB is green.) vp vslow vslow Red Yellow Green Red Yellow Green = = = ■ ■ ■ □ □ □ □ ■ ■ Product Chapter 3 description Operating instructions V4000 PB Step At the switch-over At the muting point MP The die contacts the point SP the target the gap size is 6 mm workpiece at the pinch speed is requested by and the target speed point PP. V4000 PB. has been reached. The bending process is The press controller The protective volume the same as with starts the braking becomes inactive. standard mode. procedure. The protective volume segment remains active in the gap opening behind the pressure axis. Protective volume PTDC PTDC PTDC Speed; machine movement vp SP vp SP vp SP vslow MP vcrawl vslow vcrawl MP PP PBDC vslow vcrawl MP PP PP PBDC PBDC Red Red System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal vslow OSSD 56 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Red Yellow Green = & & ■ ■ ■ ■ ■ ■ ■ ■ ■ Product Operating instructions description Chapter 3 V4000 PB 3.7.5 Operating cycle in back-stop mode Step The die is at the The die descends at At the switch-over programmed top dead high closing speed point SP the target centre PTDC. The operator gives the (≤ A reduced vP). protective signal to start the closing movement (e.g. double-click with the foot switch). speed is requested by the V4000 PB. volume segment behind The press controller the pressure axis is starts the braking active. procedure. The protective volume segment stays active in the gap opening. Protective volume PTDC PTDC Speed; machine movement SP SP MP MP PP PP PBDC PBDC Red System state Yellow Green 7-segment display Start signal for closing movement Request signal vslow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 57 PTDC vp SP MP vcrawl PP PBDC vp vslow vcrawl (If double-click is deselected, V4000 PB is green.) Vp vslow vslow vcrawl Red Yellow Green Red Yellow Green } } } ■ ■ ■ □ □ ■ □ ■ ■ Product Chapter 3 description Operating instructions V4000 PB Step At the muting point MP The die contacts the the gap size is 6 mm workpiece at the pinch and the target speed point PP. has been reached. The bending process is The protective volume the same as with becomes inactive. standard mode. Protective volume PTDC PTDC Speed; machine movement vp SP vp SP vslow vcrawl MP PP PBDC Red System state Yellow Green 7-segment display Start signal for closing movement Request signal vslow OSSD 58 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 vslow vcrawl MP PP PBDC Red Yellow Green & & ■ ■ ■ ■ ■ ■

Product Operating instructions description Chapter 3 V4000 PB 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 volume to the die (see also Section 7.2 "Aligning sender and receiver"). 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. Note 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). 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 59 Mounting Chapter 4 Operating instructions V4000 PB 4 Mounting This chapter describes the preparation and completion of the mounting of the V4000 PB. The following steps are necessary after mounting: Electrical installation (Chapter 5) Configuration of the V4000 PB (Chapter 6) Aligning sender and receiver (Section 7.2) 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 WARNING 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 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. Fig. 24: Groove for accommodating the sliding nut 1 1 14 32 16.5 8.3 8.3 15 7 7 max. 40 max. 50 Free space for sensor mounting bolt 60 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Mounting Operating instructions Chapter 4 V4000 PB Mounting your V4000 PB with the SICK mounting kit 1:

Fig. 25: Mounting using SICK mounting kit 1 Nut Spring washer Auxiliary alignment plate Alignment 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. Note 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. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 61 Mounting Chapter 4 Operating instructions V4000 PB 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. 62 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Electrical Operating instructions installation Chapter 5 V4000 PB 5 Electrical installation Switch off the machine! The machine could start unintentionally during electrical installation work. WARNING Ensure that the entire system is de-energised during the electrical installation. Note 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 10 "Technical data" in Table 30 on Page 102. 5.1 Connecting the receiver Fig. 27: Pin assignments of digital interface 1 2 3 4 5 6 7 8 9 10111213141516 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 63 Electrical Chapter 5 installation Operating instructions V4000 PB 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 / Output, connection for serial configuration interface 422_TXD– RS-232 / RS-422 (double assignment, can be set via switch S) 30 RXD_232 / 422_TXD+ 64 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Output, connection for serial configuration interface RS-232 / RS-422 (double assignment, can be set via switch S) 31 GND / 422_RXD– 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) Electrical Operating instructions installation Chapter 5 V4000 PB Fig. 28: Connection diagram for receiver +24 V PIN 1 23OSSD2 OSSD1 EDM EDM k1 k2 Controller e. g. NC 45Start 67Request for vslow 89Teach-in request 1011Teach-in 1213141516Alignment Back-stop Box Standard 1718GND 19201212224233K2 K1 24292530 2631PBI 2732282930RS-232 31/RS-422 32GND Fig. 29: OSSDs connection 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 65

Electrical Chapter 5 installation Operating instructions V4000 PB Note 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 Fig. 30: Pin assignments of the sender 1 2 3 4

Tab. 10: Pin assignments of the sender 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 66 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Electrical Operating instructions installation Chapter 5 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 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: Tab. 12: Cable cross-sections Cable Recommended cable Screened Usable as Other trailing requirements cable Receiver to control cabinet (M20) Fig. 31: Pin assignments of the PBI 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 67 18 wires, 0.34 - 0.5 mm2 Yes Yes – Receiver to sender (M16) 4 wires, 0.34 mm2 Yes No 2 twisted pairs for RS-422 Receiver to PBI (M16) 4 wires, 0.34 mm2 Yes Yes 2 twisted pairs for RS-422 5.4 Connecting the PBI 17118219320421522623724825926102711281229133014311532 16

Electrical Chapter 5 installation Operating instructions V4000 PB 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 68 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Electrical Operating instructions installation Chapter 5 V4000 PB Fig. 32: PBI connection diagram +24 V PIN 1172e diugt nemerusaeM345678910111213141516 GND Notes 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 69 ) redocnel atnemercni(181920PBI 212223Controller e. g. NC 242526272829303132 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 Fig. 28). If 24 V is not present after the response of the protective device , this 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.

Electrical Chapter 5 installation Operating instructions V4000 PB 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 (target- speed 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).

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

Electrical Operating instructions installation Chapter 5 V4000 PB 5.7 Configuration connection (serial interface) Fig. 34: Pin assignments for configuration interface 4 23 1 Switch S in position RS-422 (see Section 6.1) Tab. 14: Pin assignment of permanent configuration Pin Colour Meaning PC-side RS-422 connection with RS-422 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) Tab. 15: Pin assignments of temporary configuration Pin Colour Meaning PC-side RS-232 SubD

connection with RS-232 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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 71 Configuration Chapter 6 Operating instructions V4000 PB 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 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. Fig. 35: Switch setting 72 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Configuration Operating instructions Chapter 6 V4000 PB 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.

8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 73 Commissioning Chapter 7 Operating instructions V4000 PB 7 Commissioning Do not commission without a check by specialist personnel! Before you operate a system protected by the V4000 PB for the first time, make sure WARNING that the system is first checked and released by specialist personnel. To this regard please read the notes in Chapter 2 "On safety" on Page 9. Notes After replacing single components of the safety system a commissioning has to be done. 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. 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. Recommendation 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. Notes 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). 74 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27 Commissioning Operating instructions Chapter 7 V4000 PB Fig. 36: Die segments Fig. 37: Alignment masks Alignment point Die tip Focussing screen A B B C Alignment point for alignment beam Sender Die, left-hand Die, right-hand Receiver Notes 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. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 75 Commissioning Chapter 7 Operating instructions V4000 PB The sender and receiver can be adjusted in four directions.

Fig. 38: Adjustment directions II III IV I Tab. 16: Adjustment directions 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 Alignment of the sender Use the corresponding operating element to access alignment mode. Notes If there is no alignment point saved, alignment mode will be requested automatically after switching on. Fig. 39: Fitting masks A and B

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


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