SICK V4000 Operating Instructions Manual

Press brake sensor system

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O P E R A T I N G I N S T R U C T I O N S

V4000 Press Brake sensor system

for protecting the press brake

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Summary of Contents for SICK V4000

Page 1 O P E R A T I N G I N S T R U C T I O N S V4000 Press Brake sensor system for protecting the press brake...
Page 2 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.
Page 3 IEC 68, part 2-6 EN 60 068-2-6 prEN 50 1001 EN 61 496-1 ANSI B11.19-1990 ANSI B11.19:200304, Annex D EN 999 will be replaced by EN ISO 13 855. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 4 You can obtain the EC declaration of conformity with the standards used at: www.sick.com Note 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.
Page 5 (for example, catching between the device and parts of the machine)? This checklist does not replace the initial commissioning, nor the regular inspection by qualified safety personnel. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 7: Table Of Contents
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...
Page 8 Selecting protective volume mode ..............89 Resetting ......................89 Carrying out a power-up cycle ................89 Carrying out teach-in ..................91 Bending in standard mode................. 92 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 9 .................... 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...
Page 10: About This Document
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.
Page 11: Abbreviations
Programmed top dead centre PTDC Pinch point Switch-over point (from v to v slow Safety programmable logic control SPLC V4000 Press Brake (sensor system) V4000 PB 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 12: Symbols Used
(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.
Page 13: On Safety
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.
Page 14: Correct Use Of The System
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...
Page 15: Safety In Operation
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.
Page 16 Spread fingers will interrupt the protective volume of the V4000 PB. The protective Note 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.
Page 17 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...
Page 18 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 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 19 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.
Page 20: Environmental Protection
Paper/cardboard recycling Cardboard, paper Polyethylene packaging Plastic recycling We would be pleased to be of assistance on the disposal of the V4000 PB. Contact your Note local SICK representative. Material separation may only be performed by specialist personnel! Exercise care when disassembling the devices. The danger of injury is present.
Page 21: Product Description
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...
Page 22: Safety Concept
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.
Page 23 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.
Page 24: Protective Volume During The Operating Cycle
6 mm safety gap the programmed bottom required to reach the dead centre. The die target speed (v goes back up. slow The protective volume becomes inactive. Protective volume © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 25: Intrusion Of The Protective Volume During The Operating Cycle
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...
Page 26: Range Of Use
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: –...
Page 27: Structure Of The Device
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...
Page 28: Displays At The Sender And Receiver
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. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 29 – 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...
Page 30: 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 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 31 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.
Page 32: Pbi (Press Brake Interface)
(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.
Page 33: Cds (Configuration & Diagnostics Software)
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 &...
Page 34 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. Permanent – on-line - diagnostics and operation must be implemented solely via the Note RS-422 interface.
Page 35: External Operating Elements
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...
Page 36 Time for pause between 1st and 2nd operation Outputs Minimum state time for standard inputs 3.5.22 Minimum switch-off time of safety-relevant outputs 3.5.23 Bypass Bypass 3.5.24 Discrepancy time for bypass inputs 3.5.20 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 37: Source Of The Operator Signals
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.
Page 38: Mounting Of Receiver
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...
Page 39: 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.
Page 40: Travel For Determining The Braking Distance
The design of the V4000 PB specifies that the vibration tolerance of the V4000 PB for gap sizes from 6 mm to 26 mm increases from ±4 mm to ±7 mm. With the braking offset the gap size at which the target speed v is reached is increased.
Page 41: Monitoring Of The Slow Closing Speed V
The configured maximum closing speed in combination with the configured maximum Note 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...
Page 42: Travel For Determining The Overall Machine Overrun
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.
Page 43: Start Delay For Closing 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.
Page 44: Discrepancy Times For Inputs
Signal Channel 2 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.
Page 45: 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.
Page 46: Protective Operation
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.
Page 47: Teach-In
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.
Page 48 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. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 49 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...
Page 50: System Sequences In Protective Operation
The time context and the behaviour of the input and output signals are dealt with in Note Section 13.1 "Detailed system sequences in protective operation"). © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 51: Power-Up Cycle In Standard Mode
PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal V slow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 52 PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD Request signal for teach-in © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 53 PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 54 Speed; machine movement slow crawl PBDC System state Yellow Green 7-segment display Start signal for closing movement Request signal v slow OSSD Request signal for teach-in © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 55: Teach-In
PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD Request signal for teach-in 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 56 PBDC PBDC System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD Request signal for teach-in © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 57: Operating Cycle In Standard Mode
PBDC PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 58 PBDC PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 59: Operating Cycle In Box Mode
(If double-click is deselected, System state Yellow Yellow Yellow V4000 PB is Green Green Green green.) 7-segment display Start signal for closing movement Request signal v slow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 60 PBDC PBDC PBDC System state Yellow Yellow Yellow Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 61: Operating Cycle In Back-Stop Mode
(If double-click is deselected, System state Yellow Yellow Yellow V4000 PB is green.) Green Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 62 Speed; machine movement slow slow crawl crawl PBDC PBDC System state Yellow Yellow Green Green 7-segment display Start signal for closing movement Request signal v slow OSSD © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 63: Alignment Mode
The OSSDs are in the OFF state. The operator has no protection from the V4000 PB. In alignment mode the laser is visible. The V4000 PB meets the requirements of laser Note protection class 1 M. There is no hazard for the operator.
Page 64: Mounting
Chapter 4 Operating instructions V4000 PB 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)
Page 65: Mounting The Sender Or Receiver Using Sick Mounting Kit 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.
Page 66: Sticker: Information For Daily Inspection
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".
Page 67: Electrical Installation
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"...
Page 68 Input, connection for serial configuration interface 422_RXD– RS-232 / RS-422 (double assignment, can be set via switch S) 422_RXD+ Input, connection for serial configuration interface RS-422 (optional) © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 69 +24 V for receiver OSSD2 OSSD1 Controller e. g. NC Start Request for v slow Teach-in request Teach-in Alignment Back-stop Standard RS-232 /RS-422 Fig. 29: OSSDs connection 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 70: Connecting The Sender
Function the sender +24V 24 V DC input (voltage supply) 0 V DC input (voltage supply) SEND+ Input, signal from receiver SEND– Input, signal from receiver © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 71: Making Up The Connections For Receiver And Sender
(M16) for RS-422 Receiver to PBI 4 wires, 0.34 mm² 2 twisted pairs (M16) for RS-422 Connecting the PBI Fig. 31: Pin assignments of the PBI 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 72 Output (RS-422), signal to the receiver ENCO1– Output (RS-422), signal to the receiver ENCO2+ Output (RS-422), signal to the receiver ENCO2– Output (RS-422), signal to the receiver © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 73: External Device Monitoring (Edm)
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.
Page 74: Bypass
V4000 PB 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).
Page 75: Configuration Connection (Serial Interface)
Pin 5 Black Pin 2 The following instructions only apply when the V4000 PB is connected temporarily with a Notes Connect the connecting cable to the configuration connection of the receiver. When configuration is finished, remove the connecting cable from the configuration connection.
Page 76: Configuration
– 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 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 77: Configuration Preparations
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.
Page 78: Commissioning
V4000 PB 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 that the system is first checked and released by specialist personnel. WARNING To this regard please read the notes in Chapter 2 "On safety"...
Page 79 Four alignment masks and the values appearing on the 7-segment display will help you Notes 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...
Page 80 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. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 81 On the receiver side attach the second mask B to the die. Make sure that the die tip coincides with the bottom edge of the half-moon-shaped cut-out and that it is on the longitudinal axis which is marked on the mask. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 82 Make sure that the alignment beam goes through both B masks. You may need to make Notes realignment adjustments in directions I and II and in directions III and IV. Fix the sender brackets in place. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 83 Alignment point or all points on left above the target zone Alignment point or all points on right outside the target zone 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 84 For at least one second request alignment mode. The alignment point will be saved. When the request for alignment mode is cancelled, the V4000 PB will be reset. When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up cycle.
Page 85: Alignment Following A Tooling Change
The alignment point will be saved. When the signal for alignment mode is cancelled, the V4000 PB will be reset. When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up cycle.
Page 86 Carry out the function check using the test piece (see Section 7.3 "Function check"). Initiate a reset by pressing the alignment and teach-in buttons simultaneously. When the self-test (system initialisation) is completed, the V4000 PB calls for a power-up cycle.
Page 87: Function Check
Switch on the power supply to the V4000 PB. Select standard mode (see Section 8.2 "Selecting protective volume mode"). Carry out a power-up cycle (see Section 8.4 "Carrying out a power-up cycle"). 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 88 The rod must be detected over the whole extent of the protective volume beneath the die tip. During this test, the red LED on the receiver must stay on the whole time. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 89 Carry out the test on the outer left- and outer right-hand side and in the centre of the press. In order to increase security, repeat the test with the 35mm-high section (40 mm for checking the gap). 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 90: Regular Checks Of The Protective Device By Specialist Personnel
V4000 Press Brake (LED below the receiver lens) lights up permanently. Checking the protective volume Check whether the red LED at the receiver of the V4000 Press Brake lights up when the protective volume is interrupted with the test rod (handle of the test piece) below the die tip.
Page 91 Also carry out this test on the left and right side of the female die and in the centre of the female die. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 92: Operation
The functioning of the V4000 PB can be affected by air contamination and nuisance shutdowns may be the result. WARNING Keep the area around the V4000 PB free of smoke, fumes, steam and other types of air contamination (particularly contamination of the lenses, such as by oil). How to prepare for operation: Carry out the daily check (see Section 7.5 "Daily checks of the protective device by...
Page 93: Selecting Protective Volume Mode
Resetting A V4000 PB reset corresponds to a switch-on. After the reset, there will be a self-test and a power-up cycle. Make a reset by pressing simultaneously the buttons for alignment mode and for teach-in.
Page 94 The press finishes the operating Green (start signal for the closing cycle. movement). Carry out the function check The press is now ready for Green (see Section 7.3). operation. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 95: Carrying Out Teach-In
Once this has been done, teach-in can be carried out in any protective volume mode. If the V4000 PB does not detect the pinch point or does so only after a repeated request Recommendation for teach-in, use the magnetic plate supplied to cover the female die opening beneath the workpiece.
Page 96: Bending In Standard Mode
Changing the sheet thickness If the sheet thickness of the workpiece changes you will need to carry out teach-in again (see Section 8.5 "Carrying out teach-in"). © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 97: 8.10 Tool Changing
The front lenses of the sender and receiver should not be cleaned unless they are dirty. Notes To avoid damage to the V4000 PB do not use aggressive or abrasive cleaning agents. Cleaning the front lenses: Use a clean brush to remove dust from the front lens.
Page 98: Diagnostics
Red and The bypass function has Check to see whether the bypass function Green been selected. has been selected (configuration). Check whether there is adequate operating voltage © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 99: Error Displays Of The 7-Segment Display
2 Short-circuit between Check the wiring and rectify the error. switching outputs 1 and 2 Internal error Check the OSSD load. Have the receiver replaced. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 100 The press is closing although the OSSDs have been deactivated Invalid configuration of Verify that the machine-side EDM is connected. the EDM © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 101: Extended Diagnostics Via Cds
If you cannot remedy an error with the aid of the LED or 7-segment display error displays, Notes you can carry out extended diagnostics via the CDS or you can contact your local SICK branch. Extended diagnostics via CDS The CDS software supplied with the device (Configuration &...
Page 102: Sick Support
The telephone number is given on the last page of these operating instructions. Telephone number of your SICK branch Following repair work by SICK you will find that the configuration of your V4000 PB will Notes have been reset to its original state.
Page 103: Technical Data
Individual shock 15 g, 11 ms according to EN 60 068227 Repetitive shock 10 g, 16 ms according to IEC/EN 61 4961, Sections 5.1.2 and 5.4.4.2 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 104 2.6 kg alignment plate Ambient conditions – explosion protection No explosion protection is provided for the V4000 PB. The corresponding conditions do not usually occur with press brakes and the environment where they are used. Extraneous light The extraneous light requirements in IEC61496-2 Section 5.4.6 and also the corresponding function tests per IEC IEC61496-1 Section 5.2.3 apply to the V4000 PB.
Page 105 With cable cross-section 0.34 mm² 30 m + 6.6 mm in box or back-stop mode with protective volume on operator side Wire end ferrules are not required 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 106 –3 V Voltage for LOW Input capacitance 100 nF Static input current 4 mA 15 mA Starting currents of the input capacitors are not taken into account. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 107 When active, the outputs are tested cyclically (brief LOW). When selecting the downstream control elements, make sure that the test pulses do not result in deactivation. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 108 Stranded in pairs with braided copper shield Surge impedance of the cable to be connected Cable cross-section of the cable to be 0.25 mm² 0.6 mm² connected © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 109: Technical Data For Pbi (Press Brake Interface)
Stranded in pairs with braided copper shield 100 Ω Surge impedance Cable cross-section 0.25 mm² 0.6 mm² Dimensions Height 90 mm 45 mm Width Depth 130 mm Total weight 0.1 kg 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 110: Incremental Encoder Technical Data
Digital (RS-422) Galvanised decoupling Maximum voltage level –7 V +7 V 75 kHz Pulse frequency 100 Ω Terminating resistor Increments per mm Cable length (shielded) 10 m © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 111: 10.2 Dimensional Drawings
Complies with 21 CFR 1040.10 and 1040.11 except for deviations pursuant to laser notic No. 50, July 2001 Laser warning Keep cable exits free stickers Receiver: Receiver: front view rear view 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 112: Sick Mounting Kit 1
Technical data Chapter 10 Operating instructions V4000 PB 10.2.2 SICK mounting kit 1 Fig. 50: Dimensional drawing: SICK mounting kit 1 159.4 1.5 mm washer © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 113: Ordering Information
V4000 PB and serial Service cable, 2 m 6 021 195 interface of the PC Service cable, 8 m 2 027 649 M8*4-pin / D-Sub / 9-pin (DIN 41642) 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 114 Test piece for external Test piece device monitoring 4 040 724 Magnetic plate for covering Magnetic plate female die opening beneath 4 040 736 the workpiece © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 115: Glossary
Bridging, time-limited suppression of the protection function of the V4000 PB. Muting Point on the pressure axis from which the protective function of the V4000 PB is bridged in Muting point order to finish the operating cycle without the protective device responding. The muting point is located at a gap size of ≤...
Page 116 (v ≤ 10 mm/s). Slow closing speed crawl Gated signal from the press controller to the inputs of the V4000 PB and which is followed Start signal for closing by a movement of the press crosshead.
Page 117 Teach-in Standardised test piece with rod and body sections and used for triggering the sensor Test piece function of the V4000 PB during the function check. 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 118: Annex
Protective volume mode Standard Back-stop Signal for teach-in Signal for alignment Start signal for closing movement PTBC PBDC OSSD Request signal for teach-in Request signal for V slow © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 119 19 The press controller or if applicable the operator gives the start signal for opening the press. 20 The protective volume is clear. 21 Upon failure to reach the switch-over point the V4000 PB cancels the request for slow speed. 22 The opening movement is finished.
Page 120: Teach-In
Protective volume mode Standard Back-stop Signal for teach-in Signal for alignment Start signal for closing movement PTBC PBDC OSSD Request signal for teach-in Request signal for V slow © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 121 10 The press finishes the closing movement. 11 The press controller or if applicable the operator gives the start signal for opening the press. 12 Upon passing the switch-over point the V4000 PB cancels the request for slow speed. 13 The opening movement is finished.
Page 122: Standard Mode
Protective volume mode Standard Back-stop Signal for teach-in Signal for alignment Start signal for closing movement PTBC PBDC OSSD Request signal for teach-in Request signal for V slow © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 123 The press finishes the closing movement. The press controller or if applicable the operator gives the start signal for opening the press. Upon passing the switch-over point the V4000 PB cancels the request for slow speed. 10 The opening movement is finished.
Page 124: Box Or Back-Stop Mode With Interruption Of The Protective Volume
Protective volume mode Standard Back-stop Signal for teach-in Signal for alignment Start signal for closing movement PTBC PBDC OSSD Request signal for teach-in Request signal for V slow © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 125 The press finishes the closing movement. 10 The press controller or if applicable the operator gives the start signal for opening the press. 11 Upon passing the switch-over point the V4000 PB cancels the request for slow speed. 12 The opening movement is finished.
Page 126: 13.2 Declaration Of Conformity
Annex Chapter 13 Operating instructions V4000 PB 13.2 Declaration of Conformity Further testing certificates on request. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 128: 13.3 Manufacturer's Checklist
(for example, catching between the device and parts of the machine)? This checklist does not replace initial commissioning and regular tests by specialist personnel. © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 129: 13.4 List Of Tables
Tab. 37: Power-up cycle sequence..................115 Tab. 38: Teach-in request sequence.................. 117 Tab. 39: Standard mode sequence..................119 Tab. 40: Box or back-stop mode sequence ............... 121 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 130: 13.5 List Of Illustrations
Fitting masks A and B .................... 76 Fig. 40: Alignment in directions I and II................77 Fig. 41: Fitting mask B ......................77 Fig. 42: Alignment in directions III and IV................78 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 131 Fig. 48: Function check with test piece (15 mm)............... 85 Fig. 49: Dimensional drawings: sender and receiver............107 Fig. 50: Dimensional drawing: SICK mounting kit 1............108 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 132: 13.6 Index
..........46, 111 Function check ........83 maximum ........37, 111 test piece ........113 slow .........46, 112 with test piece ........85 with test rod ........84 Hazard point ........111 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 133 ... 27 connection ........67 Settling times ........39 Pinch point ........112 teach-in ..........112 Standard mode ......43, 53 bending in ........92 Position-sensing system ..... 34 8010505/TL63/2009-11-27 © SICK AG • Industrial Safety Systems • Germany • All rights reserved...
Page 134 ......112 carrying out a power-up cycle ..89 carrying out power-up cycle ....93 Tool-changing ........93 machine ...........88 power-up cycle .........42 Workpiece Switch-off time ........41 correct handling .......11 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8010505/TL63/2009-11-27...
Page 136 E-Mail support@sick.jp E-Mail info@sickusa.com Nederlands Phone +31 (0)30 229 25 44 E-Mail info@sick.nl Norge More representatives and agencies Phone +47 67 81 50 00 in all major industrial nations at E-Mail austefjord@sick.no www.sick.com SICK AG | Waldkirch | Germany | www.sick.com...

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