mcs and dsp laser ap...dlam01en rev. 1.1 – ed. 20/11/2012 mcs and dsp laser ap instruction manual...

DLAM01EN Rev. 1.1 – Ed. 20/11/2012

MCS and DSP LASER AP

INSTRUCTION MANUAL

SAFETY DEVICE FOR PRESS BRAKES WITH

VISIBLE LASER EMISSION

Revision 1.1 of 20.11.2012 NUOVA ELETTRONICA s.n.c. di Pasqui F. & C. Via Parri ZI Moiano - 06062 Città Della Pieve - PG - ITALIA - UE Tel. : +39 (0)578 298066 Fax: +39 (0)578 297007 web: www.nuova-elettronica.com e-mail: [email protected]

mailto:[email protected]

Status of manual Manual code: DLAM01EN Revision: 1.1 Issue: 20/11/2012 Chronology of document revisions Date Revision Summary of changes 15/09/2012 1.0 Draft 20/11/2012 1.1 First issue Copyright information Possible information about copyright

DSP LASER AP with MCS

CONTENTS

1. Foreword ..................................................................................................................... 1

1.1. General information ...................................................................................................... 1

2. Symbols used in the manual ...................................................................................... 2

3. Warranty ...................................................................................................................... 3

4. Technical Service ....................................................................................................... 3

5. Safety precautions ...................................................................................................... 4

5.1. Checks ......................................................................................................................... 4

5.2. Spare parts ................................................................................................................... 4

5.3. Decommissioning ......................................................................................................... 4

6. Legend ......................................................................................................................... 5

7. Planning safety measures .......................................................................................... 7

8. Overview...................................................................................................................... 8

8.1. System composition ...................................................................................................... 8 8.1.1. MCS module ................................................................................................................. 8 8.1.2. DSP LASER AP .......................................................................................................... 13

8.2. Operating cycle of a press brake ................................................................................ 16

9. Signals and plate data .............................................................................................. 17

9.1. Leds and references: scheme and functions ............................................................... 17 9.1.1. MCS module ............................................................................................................... 17 9.1.2. DSP LASER AP .......................................................................................................... 24

9.2. Identification plates ..................................................................................................... 26 9.2.1. MCS module ............................................................................................................... 26 9.2.2. Receiver ..................................................................................................................... 26 9.2.3. Transmitter ................................................................................................................. 27

10. System Characteristics and Installation ................................................................. 28

10.1. Standard supply .......................................................................................................... 28

10.2. Transport and unpackaging ........................................................................................ 28

10.3. Mechanical installation ................................................................................................ 28 10.3.1. MCS module ............................................................................................................... 28 10.3.1.1. Preparation ................................................................................................................................... 29 10.3.1.2. Installation .................................................................................................................................... 30 10.3.2. DSP LASER AP .......................................................................................................... 30 10.3.2.1. Preparation ................................................................................................................................... 30 10.3.2.2. Installation .................................................................................................................................... 33

10.4. Electric connection ...................................................................................................... 34 10.4.1. List of signals managed by MCS ................................................................................. 34 10.4.2. MCS electric connection ............................................................................................. 40 10.4.2.1. Machine power supply connection ............................................................................................... 40 10.4.2.2. Foot Pedal Controls with “antipanic” and Emergency chain ........................................................ 41

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10.4.2.3. RH and LH side guards and other I/O .......................................................................................... 45 10.4.2.4. Emergency of auxiliary devices .................................................................................................... 47 10.4.2.5. Automatic tool clamping ............................................................................................................... 48 10.4.2.6. Connection to the Encoders monitoring Y1 and Y2 ..................................................................... 49 10.4.2.7. Commmunications to/from CNC via I/O and serial port ............................................................... 50 10.4.2.8. Machine movement command (upstroke/downstroke/STOP) ..................................................... 52 10.4.2.9. Hemming ...................................................................................................................................... 55 10.4.2.10. Rear guards .................................................................................................................................. 56 10.4.2.11. Robot function .............................................................................................................................. 57 10.4.3. Electric connection of DSP LASER AP ........................................................................58 10.4.4. Electric connection of other front protections ...............................................................58

11. Commissioning .........................................................................................................59

11.1. Power supply and first functional verification ...............................................................59

11.2. List, description and programming of MCS parameters ...............................................59 11.2.1. List of parameters and description ...............................................................................60

11.3. System Test ................................................................................................................67

11.4. First installation of TX and RX .....................................................................................71

11.5. Verification of the stop distance ...................................................................................75

11.6. Sheet Edge Acquisition ...............................................................................................75

11.7. Verification of Low Speed and High Speed ..................................................................76

11.8. Speed change point and Automuting ...........................................................................76

11.9. Blanking Modality of DSP LASER AP ..........................................................................80

11.10. Operation in Robot mode.............................................................................................86

12. Residual risks ............................................................................................................87

12.1. Risks typical of the laser source ..................................................................................87

12.2. Blanking ......................................................................................................................87

12.3. Risks deriving from dangers of mechanical type ..........................................................88 12.3.1. Manual support of the sheet ........................................................................................88 12.3.2. Installation and uninstallation of tools ..........................................................................89 12.3.3. Work organization .......................................................................................................89

13. Use .............................................................................................................................90

13.1. Light Indicators ............................................................................................................90

13.2. PCV setting .................................................................................................................90

13.3. Verification of stop distance .........................................................................................90

13.4. Sheet Edge Acquisition ...............................................................................................91

13.5. Adjustment after the tool change .................................................................................91

14. Maintenance ...............................................................................................................95

14.1. Alarms/errors and possible solution of the problems ....................................................95

15. Removal and reinstallation after the repair .............................................................99

16. Technical characteristics ........................................................................................ 100

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1. Foreword Purpose of this manual is to inform both the technical personnel responsible of the installation, manufacturer or overhauling the press brakes (from now on indicated with “manufacturer” for ease of writing) and the user of the machine where the device will be installed about the operations of assembly, installation, use and maintenance of the equipment. The information relevant to the use of the machine have to be integrated with the information present in this document. The instructions are addressed to the manufacturer’s personnel, in charge of integrating the equipment on the press, and to the personnel of the press brake user, devoted to the normal working activities once the equipment has been installed (use, setup, maintenance, ecc.). The installation of this device requires a minimum of technical know-how and the use foresees the respect of the current laws in force relevant to the safety in the work environment and to the accident prevention. The manual must be kept with care, both by the machine manufacturer and by the user, in such a place to be immediately available every time it is necessary. Contact Nuova Elettronica for explanations and to require possible additional copies or updates of the manual itself. Nuova Elettronica reserves the discretion to change the production and the manual without the obligation to update the previous production and manuals.

1.1. General information This manual has been written by the equipment manufacturer and constitutes integral part of the equipment itself. It defines the purpose which the equipment has been created for and contains all the information necessary to ensure a correct and safe use. Nuova Elettronica, in pursuing a policy of continue development and update of the product together with the evolution of the state-of-art of the laser safety devices for press brakes, can carry out changes without any notice. Nuova Elettronica declines any responsibility for changes made by the user to the device.

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2. Symbols used in the manual The important information has been highlighted and accompanied by the word:

Warning:

Lack of reading this information can cause serious dangers for the operator

Residual risk:

The information signals a risk which had been impossible to eliminate

Caution:

Indicates a situation of possible danger which, if not avoided, can cause minor damages

Information:

Additional information not relevant to safety

Technical information of major importance is highlighted with bold font.

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3. Warranty The manufacturer ensures his own products for a period of 12 months from the sale date. The warranty covers the parts of the device, if it is demonstrated that they are faulty in materials or assembly, respecting the following conditions: 1) With warranty we mean the replacement of all those parts which have been found

faulty for manufacturing in conditions of normal use. Warranty is not valid if not accompanied by the copy of the invoice attesting the

purchase. Moreover, the warranty is not valid in the following cases:

a) any kind of tampering of the device; b) use of the device in modes not in compliance with the warnings reported in this

manual; c) damages caused by the not suitability of the environment where the device

works and phenomena not depending on the normal operation (e.g.: wrong voltage or frequency values of the mains);

d) repair interventions carried out by persons or Technical Service Centres not authorized by Manufacturer.

2) The costs and the risks of the transport, of the packaging and of the possible labor necessary for this purpose are at Purchaser’s charge.

3) The replacement of the device, as even the extension of the warranty after the intervention for fault, is excluded.

4) No refund is foreseen for the possible inactivity period of the device during the period necessary for the repair.

4. Technical Service Technical and Repair Service, as the replies to the request of specific information or explanations, are provided directly by the equipment manufacturer:

NUOVA ELETTRONICA s.n.c. of Pasqui F. & C. Via Parri ZI Moiano - 06062 Città Della Pieve - PG - ITALIA - UE Tel. : +39 (0)578 298066 Fax: +39 (0)578 297007 web: www.nuova-elettronica.com e-mail: [email protected]

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http://www.nuova-elettronica.com/mailto:[email protected]


5. Safety precautions

5.1. Checks • Check the operating voltage of the device before use.

The operating voltage (24Vcc ± 10%) is indicated on the plate located on MCS module. The device is not disconnected from mains until MCS module is physically connected to the electric panel, even if the device seems “off”.

• Stop immediately using the device in case of penetration of liquids or objects

inside the device itself. Disconnect the device and take care that qualified personnel checks it. To disconnect the device, refer to the procedure described in the chapter relevant to the device removal.

5.2. Spare parts Spare parts can be supplied only by Nuova Elettronica.

5.3. Decommissioning If You decide to stop using DSP LASER AP and MCS device because obsolete or irremediable faulty, decommission it making the device itself not operating and deprived of risks. Seal the device within a robust package and dismantle it acting in compliance with the current laws in force, contacting the local bodies charged for these operations.

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6. Legend

TERM MEANING

HIGH SPEED Speed of the mobile part of the machine when closing or approaching the sheet

ANTIPANIC Alarm generated by the pressure of the third position of the downstroke pedal

BEND AXIS Axis of the section perpendicular to the punch length AUTOMUTING Automatic inhibition of a detection area

LOW SPEED Speed of the mobile part of the machine, when closing or approaching the sheet, equal to or lower than 10 mm/s

BLANKING Function inhibiting part of the detection area DETECTION CAPACITY

Minimum size of the test piece capable to be detected

COLLIMATION Procedure allowing the alignment of the laser beam generated by TX to the RX receiving area

SAFETY DISTANCE Distance between the punch tip and the lower edge of the detection area, equal to the sum of the maximum stop distance and 5 mm DSP LASER AP Name of the device charged to monitor the front part of the press ESPE Electro-Sensitive Protective Equipment

INHIBITION Automatic and temporary interruption of the safety functions executed by the safety parts of the control system BENDING LINE Line defined by the pungh tip along all the press

MCS Name of the module for the monitoring and control of the functions to use in safety state of the press brake

MONITORING Safety function ensuring the intervention of a safety measure if the capability of a component or an element in executing its function is reduced

MUTING Temporary inhibition of the device charged to safety monitoring

OSSD Output Signal Switching Devices

MUTE POINT Mute Point: point of the closing stroke where the speed changes from fast approaching speed (Fast Speed) to safety or work speed, lower than or equal to 10 mm/sec (Low Speed)

PROGRAMMING PARAMETERS

MCS parameters which can be changed, through proper procedure, to configure functions and outputs of MCS

BENDING LAYER Sliding layer of the bend line during the punch movement

PMI Bottom Dead Center: lowest point of the moveable table stroke, generally set by the numeric control to achieve the wished bend

PMS Top Dead Center: highest point of the moveable table stroke, generally set by the numeric control to achieve the wished bend

MPMS Maximum Top Dead Center: highest point of the stroke, achievable by the moveable table

REDUNDANCY Use of more than one device or system or parts of them with the aim of ensuring that, in case of fault of a single component during its function, another compont is capable to execute that function

RX Name of the receiver, part of DSP LASER AP, which includes the sensitive function and the leds

STOP DISTANCE Distance covered by the moveable table after the interception of the detection area of DSP LASER AP

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STATE OFF

State where the output circuit is open and interrupts the flow of current or is at potential 0V, if we deal with solid state outputs

STATE ON

State where the output circuit is closed and allows the flow of current or is at potential 24V, if we deal with solid state outputs

FEEDBACK TIME Maximum time between the moment when the test piece is introduced inside the detection area of DSP LASER AP device and the moment when MCS outputs switch to OFF state

TX Name of the transmitter part of DSP LASER AP. It generates and emits the laser beam and the system synchronism

RECEIVING AREA Area within which the beam emitted by the transmitter is detected by the receiver

DETECTION AREA Area within which the specified test is detected

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7. Planning safety measures The whole system has been developed and designed to achieve the necessary level SIL3 or PL=e, respecting the indications of the standards: CEI EN 62061 : 2005 and EN ISO 13849-1 : 2008 DSP LASER AP device has been, moreover, designed respecting even the indications specified by the standards CEI EN 61496-1:2005 and CEI CLC/TS 61496-2:2007. It can be classified as ESPE of type 4 MCS device has been, moreover, designed respecting even the indications specified by the standard EN 12622:2009 The laser contained in DSP LASER is classified as CLASS 1M, according to standard CEI EN 60825-1:2009. DSP LASER AP device, if properly installed and used as described in this Manual, is in compliance with the provisions of: • Machinery Directive 2006/42/CE and relevant reference laws and specifications:

o CEI EN 61496-1:2005 and CEI CLC/TS 61496-2:2007 o EN ISO 12100 : 2010

EN 12622:2009, CEI EN 60204-1:2006, CEI EN 60825-1:2009 • Low Voltage Directive 2006/95/CE and relevant reference laws

o CEI EN 61496-1:2005 o CEI EN 60204-1:2006

• Electromagnetic Compatibility Directive 2004/108/CE and relevant reference laws

o CEI EN 61496-1:2005 o CEI EN 61000-6-3 : 2007 and CEI EN 61000-6-2 : 2006

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8. Overview

8.1. System composition

8.1.1. MCS module MCS is an electronic module whose logic has been planned to monitor and operate the systems and the components, present on a press brake, which ensure a safe use of the press itself according to what foreseen by standard EN12622. The concepts used for its design and manufacturing allows achieving, for some safety functions, the category 4, PL=e according to standard EN ISO 13849-1 and SILCL3 according to standard EN 62061, the highest possible as regards the realization of equipment preposed to the costruction of safe machines. The structure is characterized by two processors and, then, two channels, usually named “Channel A” and “Channel B”. The system nature and its partial capability to be programmed allow the adaptation and the use of the press brake in different planning methods. Types of front protections controlled by MCS As you can see in Figure 1, MCS controls the photoelectric device DSP LASER AP as main component for the protection against the access to the front part of the bending machine. This generates a protection photoelectric area with advanced characteristics, allowing the achievement of high machine performances, ensuring however a very high protection degree for the operator. MCS can manage even the protection photoelectric area generated by DSP LASER or by a generic protection barrier. In this case, refer to the manual of the device you wish to use.

Information:

The standard version of MCS software is the PS version suitable to the use of DSP LASER AP. If you use MCS with a device different from DSP LASER AP, make sure to have purchased the version with the special PG software version installed.

Figure 1

DSP LASER AP

DSP LASER

PHOTOELECTRIC BARRIER

M C S

8 DLAM01EN


Section for the monitoring of speed/position/direction

Figure 2 Figure 2 shows a scheme of the section which allows connecting in parallel to channels A and B of the two, usually linear, encoders present on the synchronized press. They measure the stroke of the hydraulic jacks responsible of the movement and the operation of the moveable table. With this system, the machine speed is measured and controlled. Other controls and automatisms are moreover implemented, necessary to the management of the safety and of the operativity of the bending machine, as the monitoring of the direction of the moveable part movement and its position with respect to the fixed part. If the machine is not provided with encoders for the adjustment of the position of the jacks, proper encoders can be installed in order to carry out the measures and the monitoring mentioned above.

M C S

C N C

ENCODER Y1

ENCODER Y2

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Components and systems managed by MCS MCS module monitors and manages even other machine systems and components, some of them with safety functions and others complementary to these or, generally, as completion of the press brake operation and not devoted to safety functions.

Figure 3 Figure 3 represents the components which can be connected to MCS inputs to be controlled and monitored.

MAIN FOOT PEDAL CONTROL

SECOND FOOT PEDAL CONTROL

EMERGENCY CHAIN

RIGHT SIDE GUARD

LEFT SIDE GUARD

REAR GUARD

M C S

SELECTOR 1 or 2 FOOT PEDAL CONTROLS

TOLL AUTOMATIC CLAMPING

CUTTING SYSTEM for ROBOT

DSP LASER AP OPERATING MODES

HEMMING OPENING CONTROL

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Safety outputs and monitor inputs Figure 4 represents the MCS safety outputs which are realized at solid state, have high current in output and are synchronized with the MCS inputs available for the possible monitors of the devices they control. The already set MCS functional states can be assigned to these outputs. This easy, but effective, assignment function allows controlling different configurations of the actuators preposed to the machine closing.

Information:

Usually we refer to hydraulic components because the great part of the bending machines use them, but the safety outputs can control any type of actuator, as the command is electric.

Figure 4 Interface MCS – CNC / PRESS BRAKE

Figure 5

SOLENOID VALVE 2

SOLENOID VALVE 4

SOLENOID VALVE 5

SOLENOID VALVE 6

SOLENOID VALVE 7

M C S

SOLENOID VALVE 3

SOLENOID VALVE 8

SOLENOID VALVE 1

M C S

CNC

PRESS BRAKE

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For the operation, it is necessary that MCS transmits and receives some simple ON/OFF information to/from CNC and to/from the press brake (Figure 5). For this purpose, some digital I/O are available, not regarding the safety, whose state will be then ON /OFF. It is even possible, but not necessary, that some of these data are transmitted via serial port RS232. Interface MCS - Operator MCS manages a great number of signals and executes different machine functions. Then, an interface is necessary with the personnel devoted to its installation during the construction of the machine and with the personnel which then will use it. The module has two types of interface towards the external world (Figure 6). The first interface is realized with: • LEDs showing the I/O states. • Alpha-numeric display showing messages and data regarding the operation of the

system and of the machine. • Keys for the selection of the operation options.

Figure 6 The second interface is realized by the CNC display. The data and the messages to display are processed by CNC depending on the signals coming from MCS through the serial port.

DISPLAY

RS 232

M C S

KEYS

LED

CNC

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8.1.2. DSP LASER AP The safety device DSP LASER AP is a visible laser emission barrier which, realized and placed as described in Standard EN12622, protects the operator of the press brake against the danger to be squashed between the upper tool and the lower tool during the closing of the press in high speed. The device is constituted by a transmitter TX, which generates the laser emission, and by a receiver RX, which receives it and transmits the processing of the received signals to MCS module. Main task of DSP LASER AP is detecting, within the limits defined by its detection capability, the intrusion of any opaque physical element into the “detection area”. Figure 7 represents the position of DSP LASER AP on the machine and the section of the detection area with the sensors present in the receiver lighted by the laser beam.

Figure 7

Not during all the phases of the machine cycle or in the different operating modalities, all the receivers are necessarily enabled to detect an object entering the detection area. To be detected, the object has to interrupt the laser beams hitting at least, one of the enabled sensors. Detecting the object causes the intervention of the device, which must stop the movement of the machine or activate an action foreseen by the operating cycle, as the inhibition of a set of sensors in case of blanking. Figure 8 represents the section of the protection area and its logic of positioning with respect to the upper tool.

The horizontal protection layer is located from the tip of the tool at a safety distance equal to the maximum stop distance allowed for the safe use of the press brake with the DSP LASER AP device + 5mm. The maximum allowed values are, as described later, three: 14mm, 18mm and 24mm.

The safety area preempts the movement of the upper tool for such a distance which allows stopping the tool without this can squash any opaque object possibly between itself and the lower tool. The object possibly under the protection area, once penetrated it, should generate the command to stop the machine, which will stop within a distance called “machine stop distance”. As the stop command has been generated at a distance equal to “maximum allowed stop distance”+ 5mm, the tool has ended its movement at a distance = maximum allowed SA – machine SA + 5mm, clearly without even brushing on the object.

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Figure 8

As regards the Blanking function used for bending boxes, the detection area is subdivided in 3 different areas: a front area (towards the operator), a central area (under the tip of the upper tool and sligthly shifted towards the rear part of the press) and a rear area (towards the rear part of the press brake).

Area Task Front Protects the operator’s fingers too close to the working area. Moreover, it

protects against the risk of squashing between the die edge and the tip of the upper tool. This area can be inhibited for special machining.

Central Protects the operator against the squashing between the tip of the upper tool and the sheet/die.

Rear Avoid the squashing between the tip of the upper tool and the rear backgauges. This area can be inhibited for special machining or if the rear backgauges are intercepted.

As regards the Automuting function, the detection areas are 3: Area A, Area B and Area C.

Area Task Area A Area A is composed by the 3 lowest sensors: one front sensor, one central

sensor and one rear sensor. The set of sensors of the Area A is that intercepting first an obstacle during the downstroke. The detection of the sheet thickness is executed by the central sensor of the Area A. Note. If the machine Stop Distance, measured by MCS during the test, is less than 6mm, the Area A is automatically disabled by DSP LASER AP during the normal operation. It remains, however, active during the verification of the Stop Distance and the Sheet Edge Acquisition.

Area B Area B is composed by the 3 sensors located above the Area A: one front sensor, one central sensor and one rear sensor.

Area C Area C is composed by the 3 sensors located above the Area B: one front sensor, one central sensor and one rear sensor. This set of sensors is the closest to the tool tip.

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Foreseen use of the System DSP LASER AP device has been designed to create on the press brake, as described in par. 8.1.2, a detection area (volume), by means of the laser beam emitted by the transmitter and captured by the receiver, to protect the operator who should penetrate it.

Warning:

DSP LASER AP protects the operator only stopping the movement in progress of the upper table. Then, it cannot be used in case of material projection. Then take care in the choice of the material to process, of the tools and to the possible presence of foreign bodies within the tool movement area. Transparent objects penetrating the detection area are not detected.

The device has been designed and manufactured to ensure protection to the operator, accessing in front of the die area of a press brake, against the dangers due to the movement of the moveable table during the high speed downstroke. If the operator intercepts the detection area of DSP LASER AP during the high speed downstroke, the movement of the moveable table is stopped before the tool installed on it can touch the operator. The operator, however, must know the risks relevant to the processing on this type of press brakes.

Warning:

Pay special attention to the tool shape, which must not exceed the protection area generated by the laser.

Anyway the device does not replace the necessary training of the personnel and the information relevant to the residual risks described in chap. 12 Residual risks. MCS module has been designed to monitor the parts and the functions which the different press brake models usually have in common. Should the monitored parts not work as foreseen and the function assume logics or produce abnormal values, MCS ensures the STOP of what monitored. The typical use of the system foresees the mechanical installation of the transmitter and of the receiver on the upper table and the installation of MCS module inside the electric panel of the press brake. In case of machines with moveable upper table, they move together with the moveable table. Vice versa, in cases of machines with closing movement upwards, the transmitter and the receiver remain fixed with the upper tool, being understood all other considerations are the same. Electric installation must respect what reported in this manual and, in any case, be in compliance with what foreseen by the current laws regarding the safety installation for industrial use. Any use different from those clearly allowed and reported in this use and maintenance manual of DSP LASER AP and MCS module is, and must be considered, forbidden. For these uses not allowed and/or not foreseen by NUOVA ELETTRONICA s.n.c. of Pasqui F. & C., any kind of explicit and implicit warranty decays, as any responsibility for possible accidents.

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UP S T ROK E

8.2. Operating cycle of a press brake Here below is reported the operating chart of a work cycle for a hydraulic press brake with downstroke of the upper table.

Cycle State Centers and phases of the cycle

Cycle

HIGH SPEED DOWNSTROKE

PMSM Maximum Top Dead Centre

PMS

Top Dead Centre

Deceleration ramp PCV

Speed change point

LOW SPEED Sheet contact point DOWNSTROKE PD

Decompression point

PMI Bottom Dead Centre

The normal operating cycle foresees the start from the top dead centre (PMS), which does not necessarily coincide with the maximum top dead centre (PMSM). In fact, in order to minimize the down time, the stroke of the moveable table is usually limited to the lowest possible value, compatibly with the shape, the size and the bends to execute on the part. The synchronized axes of the moveable crossbeam are named Y1 and Y2. The pressure of a maintained contact device (usually a pedal) issues the High Speed (more than 10 mm/s) closing movement up to PCV, where the speed automatically decreases to a value lower than or equal to 10 mm/s, defined Low Speed. For special machining or maintenance operations requiring it, the machine is forced to Low Speed even in the part of the stroke the tool usually covers in High Speed, with the aim to deactivate the safety systems which, executing their task, would stop the downstroke. This speed limit is kept for all the closing stroke under the PCV until the press action which takes place within the PMI. Once ended the decompression, the punch can return to the PMS/PMSM, automatically or by the upstroke pedal.

Information:

The decompression phase belongs to the Low Speed downstroke, but with opposite direction. By the ING5 input, the system informs MCS that the machine is executing the decompression.

The activation of the safety outputs of MCS device, dedicated to the control of the movement of the moveable crossbeam, can be configured according to the following states of the working cycle of the press brake:

• High speed dowstroke • Low speed downstroke • Stop • Upstroke

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9. Signals and plate data

9.1. Leds and references: scheme and functions

9.1.1. MCS module FRONT PANEL MCS front panel (Figure 9) contains the LEDs indicating the state 1 (led on) or 0 (led off) of the safety inputs, the LEDs indicating the state ON (led on) or OFF (led off) of the safety outputs, the display and the keys, the digit numbering, the type and the numbering of the inputs and the outputs connected to the corresponding connectors, the type and the value of the power supply for the module, the numbering of some connectors. GREEN NUMBERS 1, 2, 3, 7, 8, 9 They indicate the number of the male connector, present on the module, which the female connector with the same number must be connected to.

Figure 9 CONNECTORS 7 and 8 INS1÷INS24 with relevant YELLOW LED: Safety inputs with input logic level 0-1. The relevant YELLOW LED indicates if a logic level 1 (24 Vcc)=LED ON or a logic level 0 (0Vcc)=LED OFF is present in input.

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INP1÷INP8 with relevant ORANGE LED: Safety inputs which accept, in input, the relevant pulsed signal generated by OUT P1÷OUT P8. The relevant ORANGE LED indicates if a logic level 1 (24 Vcc)=LED ON or a logic level 0 (0Vcc)=LED OFF is present in input. If a pulsed output different from the proper one is connected to the input, the led will be regularly ON, not detecting the error, which will instead detected by MCS logic. CONNECTOR 9 OUT P1÷OUT P8: Pulsed outputs which drive the relevant inputs INP1÷INP8. CONNECTORS 1 and 2 OUTS1÷OUTS8 with relevant GREEN LED: Safety outputs with capability to deliver up to 3,2A at 24Vcc. The relevant GREEN LED indicates the state of the output ON (24Vcc)=LED ON or OFF (0Vcc)=LED OFF. CONNECTOR 3 0Vcc, 24Vcc, : They indicate one of the two MCS connection to power supply by means of the clamps 0Vcc and 24Vcc the connection to ground (see par. 10.4.2.1). DISPLAY and KEYS The function of the display is to interface the personnel responible of the assembly, during the installation procedure, and the operator during the use of the machine, above all if MCS is not interfaced with CNC or if the machine is not equipped with CNC. The display shows the parameters and allows programming them through keys (operation possible only to the manufacturer and to the machine installer, who is provided with the access password). Moreover, it displays errors, alarms and other parameters useful to the user. The part of MCS front panel which regards the display and the keys is reported in Figure 10.

Figure 10

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The first screen on the display at switch-on is reported in Figure 11.

Figure 11 Screen 1: Line 1: Product name: MCS and factory model name: PSA 1B01C33 Line2: SA value (measured Stop Distance) expressed in mm (or xx if the SA test has not been executed yet) and result of AV (High Speed) measurement expressed in mm/s (or maximum value reachable from AV=330 mm/s if the SA test has not been executed yet). Pressing ARROW UP key, you access to the second screen (Figure 12).

Figure 12 Screen 2: Line 1: The label ING indicates that the state of the generic inputs is displayed. Line 2: State of the generic inputs ING1÷ING6. The input number is indicated by the numbers referring to the character position. State 1=24Vcc, state 0=0Vcc. Pressing ARROW DOWN key, you access to the third screen (Figure 13).

Figure 13 Screen 3: Line 1: The label OUTG indicates that the state of the generic outputs is displayed. Line 2: State of the generic inputs OUTG1÷OUTG14. The output number is indicated by the numbers referring to the character position. State 1(ON)=24Vcc, state 0(OFF)=0Vcc.

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Pressing ARROW UP key, you access to the fourth screen (Figure 14).

Figure 14 Screen 4: Line 1: Position (in mm) of axis Y1 with respect to sheet edge, with resolution of tenth of mm. Line 2: Position (in mm) of axis Y2 with respect to sheet edge, with resolution of tenth of mm. Pressing ARROW UP key, you access to the fifth screen (Figure 15).

Figure 15 Screen 5: Line 1: List of errors or alarms E1÷E3 of channel A sorted in chronological order. Line 2: List of errors or alarms E1÷E3 of channel B sorted in chronological order. Pressing ARROW UP key, you access to the sixth screen (Figure 16).

Figure 16 Screen 6: Line 1: List of errors or alarms E4÷E6 of channel A sorted in chronological order. Line 2: List of errors or alarms E4÷E6 of channel B sorted in chronological order.

20 DLAM01EN


LOWER PANEL On the face down of MCF module (Figure 17) you can see the type and the numbering of the inputs and the outputs connected to the relevant connectors and the numbering assigned to some connectors.

Figure 17 GREEN NUMBERS 4, 5 and label RS 232 Numbers of the male connector, present on the module, which the female connector marked with the same number must be connected to. RS 232 is the name of the serial port allowing the communication with CNC or other dedicated device. CONNECTOR 4 CH A E1, CH B E1, CH A E2, CH B E2, 0V ENC: Connections to the inputs of the channels A and B of the encoder 1 connected to the axis (or hydraulic cylinder) Y1 and connections to the inputs of channels A and B of encoder 2 connected to the axis (or hydraulic cylinder) Y2. 0V ENC indicates the 0V reference of the channels of the two encoders. EARTH, 0V TX, 24V TX, SINCR.: Connections between DSP LASER AP –TX and MCS (see par. 10.4.3). EARTH, 0V RX, 24V RX, SINCR., IN A RX, IN B RX, OUT L.: Connections between DSP LASER AP –RX and MCS (see par. 10.4.3). CONNECTOR 5 RIF 0V: One of the connections where the reference 0V of MCS power supply is available. 0Vcc, 24Vcc: One of the two connections to MCS power supply by means of terminals 0Vcc and 24Vcc (see par. 10.4.2.1). OUT V: Output which communicates, rapidly, to CNC that the lowest central sensor (Area A) of DSP LASER AP has intercepted the sheet. Output state is: ON(24Vcc)=1 or OFF(0Vcc)=0.

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OUTRL1, OUTRL2: Outputs suitable to control the relays to put in emergency the components connected to their NO contacts (see par. 10.4.2.4). Output state is: ON(24Vcc)=1 or OFF(0Vcc)=0. OUTG1÷OUTG10: Generic outputs with capability to deliver up to 0,4A at 24Vcc. The output state ON(24Vcc)=1 or OFF(0Vcc)=0 is shown on the display (Figure 13). RIGHT PANEL On the right face of MCS module (Figure 18) you can see the type and the numbering of the inputs and the outputs connected to the relevant connector and the numbering assigned to the connector.

Figure 18 GREEN NUMBER 6 Number of the male connector, present on the module, which the female connector marked with the same number must be connected to. CONNECTOR 6 OUTG11÷OUTG14: Generic outputs with capability to deliver up to 0,4A at 24Vcc. The output state ON(24Vcc)=1 or OFF(0Vcc)=0 is shown on the display (Figure 13). ING1÷ING6: Generic inputs. The state 1=24Vcc and the state 0=0Vcc are shown on the display (Figure 12). RIF 0V, RIF 0V : Two of the connections where the reference 0V of MCS power supply is available.

22 DLAM01EN


LEDs installed on machine board and controlled by MCS The LEDs installed on machine board by the Manufacturer must match the requirements regarding the colour and the position on the machine as required by the current laws.

• LED Reset Emergency: ON when the alarm of the Emergency chain has been activated. OFF when the alarm of the Emergency chain has not been activated or has been correctly reset.

• LED Reset Rear Guards:

ON when the alarm has been activated by the open rear guards or by the photoelectric barrier. OFF when the alarm of the rear guards has not been activated or has been correctly reset.

• LED Sheet Edge request: Fast Blinking: the Stop Distance Check function is active. It is necessary to execute the test pressing the downstroke pedal and wait for the machine automatically stops. Fixed ON: Sheet edge detection function active. You must make DSP LASER AP – RX detects the edge of the sheet to work placing it on the die, pressing the downstroke pedal and waiting for the machine stops. OFF: MCS in working mode.

• LED Foot Pedal control nr.1:

Fixed ON: Foot Pedal control nr.1 active and system ready to work. OFF: Foot Pedal control nr.1 not selected, the alarm of the Emergency chain has been activated or the alarm of open rear guards has been activated (or rear photoelectric barrier interrupted). In mode 2 Pedals Master-Slave, the pedal pressing sequence has not been carried out correctly. Slow Blinking: in mode 2 Pedals, the downstroke pedal of Foot Pedal control nr.2 is pressed. Fast Blinking: antipanic alarm activated.

• LED Foot Pedal control nr.2:

Fixed ON: Foot Pedal control nr.2 active and system ready to work. OFF: Foot Pedal control nr.2 not selected, the alarm of the Emergency chain has been activated or the alarm of open rear guards has been activated (or rear photoelectric barrier interrupted). In mode 2 Pedals Master-Slave, the pedal pressing sequence has not been carried out correctly. Slow Blinking: in mode 2 Pedals, the downstroke pedal of Foot Pedal control nr.1 is pressed. Fast Blinking: antipanic alarm activated.

• LED Upper Tool Holder:

Fixed ON: Upper tool holder open. OFF: Upper tool holder closed.

• LED Lower Tool Holder:

Fixed ON: Lower tool holder open. OFF: Lower tool holder closed.

• Yellow blinker:

Blinking ON: the machine can move in slow speed with the front protection (DSP LASER AP) inhibited.

DLAM01EN 23


9.1.2. DSP LASER AP RECEIVER RX front panel (Figure 19) contains the slots for the passage of the light necessary to the receiving elements of the three sensitive areas, the LEDs indicating operation modes and states and references to mechanically place RX with respect to the laser beam already set and, then, to the machine.

Figure 19 The BLUE LEDs ON indicate the corresponding Front, Central and Rear areas active, while the state OFF of the LED means the corresponding area is inhibited. With Mode 1, the LEDs ON will be: BLUE LED in FRONT AREA BLUE LED in CENTRAL AREA BLUE LED in REAR AREA With Mode 2, the LED ON will be: BLUE LED in CENTRAL AREA With Mode 3, the LEDs ON will be: BLUE LED in FRONT AREA BLUE LED in CENTRAL AREA The YELLOW LED OFF indicates the device is in Mode 1 or in Mode 2, but with the Blanking function not active yet, then with all the three detection areas enabled. The LED blinking ON means the device is in Blanking state, in Mode 2 or in Mode 3, then with the rear and front areas or only with the rear area disabled. The RED LED OFF indicates that all the active receivers are lighted. The LED ON means that at least one receiver of any active area has been shaded. The BLUE LED HORIZONTAL AREAS OFF indicates that no area is in Automuting. The LED fixed ON indicates that the first area is set in Automuting. The LED blinking slowly indicates that even the central area is in Automuting.

24 DLAM01EN


The LED blinking rapidly indicates that all the three areas have been set in Automuting. The GREEN LED OFF indicates that at least one receiver of any active area has been shaded. The LED ON indicates that all the active receivers are lighted. The WHITE LED OFF indicates MCS in active operation. The LED ON indicates MCS in lock state. TRANSMITTER TX front panel (Figure 20) displays the transparent area for the passage of the laser beam and the indication that the equipment emits a laser beam.

Figure 20

• The state of LASER EMISSION present indicates that power supply is connected to the transmitter.

• The state of LASER EMISSION absent indicates that the transmitter is not powered.

DLAM01EN 25


9.2. Identification plates

9.2.1. MCS module MCS identification plate (Figure 21) reports the following data: • Name, address and contact references of the device Manufacturer • Logo “Costruito in Italia” • Inputs and outputs, if properly connected, can reach SILCL3 • CE marking • Logo of the Notified Body which has executed the certification • Feedback time (TEMPO DI RISPOSTA): 2,5ms • MCS Protection rating (GRADO PROTEZIONE MCS): IP20 • Operating temperature (TEMPERATURA ESERCIZIO): 0-50°C • Power supply voltage and consumption (ALIMENTAZIONE): 24 Vcc 10W • Serial number (N.S.) and manufacturing date (DATA)

Figure 21

9.2.2. Receiver DSP LASER AP-RX rear identification plate (Figure 22) reports the following data: • Name, address and contact references of the device Manufacturer • Patent number (BREVETTO): 0001342651 • Device safety level: ESPE type 4 • Logo “Costruito in Italia” • CE marking • Logo of the Notified Body which has executed the certification • Detection capacity (CAPACITA’ DI RELEVAMENTO): e 10mm • Feedback time (TEMPO DI RISPOSTA): 5ms • TX-RX protection rating (GRADO PROTEZIONE TX-RX): IP65 • Operating temperature (TEMPERATURA ESERCIZIO): 0-50°C • Power supply voltage (ALIMENTAZIONE): 24Vcc from MCS module

Figure 22

26 DLAM01EN


DSP LASER AP-RX side plate (Figure 23) reports the following data: • Device part: DSP LASER AP-RX • Serial number (N.S.) and manufacturing date (DATA)

Figure 23

9.2.3. Transmitter DSP LASER AP-TX rear identification plate (Figure 24) reports the following data: • Name, address and contact references of the device Manufacturer • Number of the Patent (BREVETTO) which protects the device: 0001342651 • Device safety level: ESPE type 4 • Logo “Costruito in Italia” • CE marking • Logo of the Notified Body which has executed the certification • Indication of presence of the laser beam • Class of laser equipment according to EN 60825: classe 1M • Warning not to observe directly the laser beam with optical instruments

Figure 24 DSP LASER AP-TX side plate (Figure 25) reports the following information: • Device part: DSP LASER AP-TX • Serial number (N.S.) and manufacturing date (DATA)

Figure 25

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10. System Characteristics and Installation MCS with DSP LASER AP is high safety level system. It is however essential that it is correctly installed and used according the following instructions.

10.1. Standard supply MCS with DSP LASER AP consists in the following elements: • DSP LASER AP-TX • DSP LASER AP-RX • MCS • Tool for test and positioning of TX-RX • Copy of this instruction manual

10.2. Transport and unpackaging MCS with DSP LASER AP is provided into a proper package of rigid cardboard and with weight of 6 Kg. Weight and small dimension do not cause particular problems nor risks both for the transport and the unpackaging operations.

Caution:

The elements constituting the package must not be dispersed in the environment. Contact the specialized collection centres, equipped for the disposal in respect of the nature and the laws in force.

Caution:

Check, by sight, the presence and the integrity of all the components constituting the device, making sure that no evident damage has been suffered during the transport. If this is not the case, do not use the device and contact NUOVA ELETTRONICA.

10.3. Mechanical installation

10.3.1. MCS module MCS module is designed to be placed inside the electric panel of the press brake.

Warning:

MCS module must be installed inside an electrical panel with minimum protection rating IP 54.

28 DLAM01EN


10.3.1.1. Preparation Figure 26 indicates the module dimensions.

Figure 26

Figure 27 indicates the positions for the drilling of the panel on the four points, marked with the letter “F”, where MCS will be fastened. Then drill the four holes for the fastening and the relevant threads, if no self-threading screws will be used.

Figure 27

DLAM01EN 29


Leave, around the module, the space necessary for an easy insertion and extraction of the side connectors. The choice of the module position inside the electrical panel shall even allow an easy view of the display and an easy access to the keys under it.

10.3.1.2. Installation Fasten MCS module to the electric panel in stable way by means of four screws of proper size, for example TC M5, with length in function of the shape of the electric panel. It is mandatory to use, for the module fastening, the four holes present on the container of the module itself. It is strictly forbidden to drill other holes on the module container. If you wish to execute a fastening with different dimensions, but mechanically equivalent, realize the mechanical detail for the adaptation with the same drilling of the module and, then, fasten the module to the adaptation mechanical detail and then fasten this to the panel.

10.3.2. DSP LASER AP Special care shall be paid to the mechanical installation, because the detection area defines the limits of intervention of DSP LASER for the protection of the operator. The mechanical supports must, however, be equipped with setup devices to adjust this detection area in accurate way with respect to the tip of the upper tool of the machine. TX and RX containers are equal: RX and TX can be, however, immediately acknowledged by the plates applied to the relevant containers and by the front side. The detection area must be placed under the upper tool. The manufacturer of the press has to install the device properly on the machine, while the users has to adjust the device properly according to the indications of the manufacturer and depending on the different used tools.

Warning:

The transmitter must mandatorily be installed on the left side of the press, looking at the press from the front side. The receiver, as consequence, must be installed on the right side of the press. The arrow indicating the direction of the part insertion, present on the front sides of TX and RX, must always point the back of the press.

10.3.2.1. Preparation TX and RX devices must be fastened to the upper table of the press by means of moving supports which allows the operator of the press executing, as final movement, a sliding in longitudinal direction along the vertical axis or a rotation. This movement is allowed in order to execute the replacement of the upper tool. This movement does not directly create a danger, but generates a condition equivalent to that of laser obstructed. Then, it must be executed with care, respecting the rules and, above all, it must not be prolonged. Moreover a sliding in longitudinal direction is allowed along the vertical axis of calibration, made to adapt the protection area to a tool of different size. The moving supports must be equipped with adjustments, then not accessible to the user if not by means of tools, to allow the following adjustments: 1. Parallelism of TX, above all because source of the laser emission, and RX with the

lower edge of the upper tool. 2. Misalignment of TX and RX with respect of the bend axis.

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Figure 28 indicates the dimensions of TX and RX, which are identical.

Figure 28

The moving supports must be firmly fastened to the upper tool-holder table, for example by means of plates provided with extensions for the moving supports of TX and RX (Figure 29).

Warning:

The plates must be installed behind the upper table or on its sides. The front installation is discouraged, because the plates could create areas of mechanical danger due to the movement of the table and to the possible contact of the sheet against the table during the work.

The fastening must be made in such a way that: • Plates are made of rigid and indeformable material (e.g.: steel)

Information:

The stiffness of the mechanical system must be such that the setting must resist under the application of a force of, at least, 250 N along the support axes.

Figure 29

Upper table

Lock/unlock device

Moving support

Plate

DLAM01EN 31


• The distance between the front part of TX and RX and the basement of the press is

greater than or equal to 100 mm, with the purpose to avoid the hand squashing. • The design of the moving support of the device must be such not to create

entrapment points during the upward and downward movements of the press. • Additional protections must be used to eliminate the dangers which can arise from

DSP LASER (for example, between DSP LASER and the fixed part of the press) and to allow the access to the die area only passing through the front area.

• The device must be protected against the accidental shocks which could damage it or change its setting.

• The stroke of the supports is such to allow: • the correct use of the tools with minimum and maximum height, indicated by the

press manufacturer

Information:

Install the minimum height tool, move the TX and RX supports as high as possible and lock them in this position. Verify that the beam is interrupted by the tool. Install the maximum height tool, move the TX and RX supports as low as possible and lock them in this position. Verify that the beam is not interrupted by the tool.

• the removal of the tools without having to remove the devices and/or the supports (e.g: possibility to extract the tools with TX fully lifted)

• the fastening of the supports, once adjusted, is safe against the accidental loosening

Caution:

Use all the possible precautions in order to reduce the machine vibrations. Protect the devices and the supports with material protections in such a way to avoid the shocks.

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10.3.2.2. Installation TX and RX containers are provided with four stud bolts (Figure 28) for the fastening to the corresponding moving supports. Fasten, then, TX and RX to the supports by means of these couplings and tighten the supplied 5MA thread nuts.

Caution:

Make sure the nuts are tighten in such a way the machine vibrations do not loose them. The torque of the screws must not be less than 1.96 N*m (20 kgf*cm).

The devices must be fastened to the supports in such a way that: • The central vertical protection layer of TX and RX can be not more than 2mm

beyond the tool axis in direction of the rear part of the press, as visible in Figure 30.

Figure 30

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• The lower horizontal protection layer of TX and RX is perpendicular to the bending layer along all the adjustment stroke of the supports, as visible in Figure 31.

Figure 31 • The lower horizontal protection layer of TX and RX is parallel to the upper table, so

that the value of the safety distance is constant for all the length of the upper tool, as visible in Figure 32.

Figure 32

10.4. Electric connection

10.4.1. List of signals managed by MCS The pins (I/O) on the SAFETY CONTROL MODULE, called MCS, are listed in the following table which describes their function. The safety outputs, from OUTS1 to OUTS8 and the relevant inputs for the possible monitors of the controlled devices (OUTS8 is lacking), can be assigned to different operating states by means of a programming procedure, under password, and using only the display and the MCS keys.

Information:

The short circuit on the wiring of the outputs cannot be detected by MCS. Then, it is necessary to use suitable wiring techniques to avoid it.

This makes very easy, but absolutely safe, the adaptability of MCS to the different hydraulic, and not only, configurations which control the movement of the moveable part of the press to manage in safety, according to what required by Standard EN12622 and with a safety level up to SILCL3 as indicated in Standard EN62061. These outputs can manage a current of 3,2A at 24Vcc. This makes them suitable to any type of solenoid valve used in the market of the press brakes.

WRONG CORRECT WRONG

WRONG CORRECT WRONG

TX

RX TX RX TX

RX

90°

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Pin name Function Note

SAFETY INPUTS enabled by the relevant pulsed outputs

1

INP1 Input for pulsed Output, Antipanic chain A, NC INP2 Input for pulsed Output, Antipanic chain B, NC INP3 Input for pulsed Output, Emergency chain A, NC INP4 Input for pulsed Output, Emergency chain B, NC INP5 Input for pulsed Output, Right Side Protection, NC INP6 Input for pulsed Output, Left Side Protection, NC INP7 Input for pulsed Output, Rear Guard, NC 2 INP8 Available 2

PULSED OUTPUTS SYNCHRONIZED to relevant inputs

OUTP1 Antipanic chain A pulsed output OUTP2 Antipanic chain B pulsed output OUTP3 Emergency chain A pulsed output OUTP4 Emergency chain B pulsed output OUTP5 Right Side Protection pulsed Output OUTP6 Left Side Protection pulsed Output OUTP7 Rear Guard pulsed Output 2 OUTP8 Available 2

SAFETY INPUTS 24V 3mA (14mA peak)

INS1 Selector Blanking Mode2 input 3 INS2 Selector Blanking Mode3 input 3 INS3 Selector Foot Pedal1 Control input 4 INS4 Selector Foot Pedal2 Control input 4 INS5 Pedal “Downstroke1” (Main) NO INS6 Pedal “Downstroke1” (Main) NC INS7 Input for Monitor of EV1/OUT1 NC with EV OFF 5,6 INS8 Input for Monitor of EV2/OUT2 NC with EV OFF 5,6 INS9 Input for Monitor of EV3/OUT3 NC with EV OFF 5,6 INS10 Input for Monitor of EV4/OUT4 NC with EV OFF 5,6 INS11 DOWNSTROKE from CNC 0-24 V 8 INS12 LOW speed from CNC or from Selector 0-24 V 8 INS13 UPSTROKE from CNC 0-24 V 22 INS14 Input for Monitor of EV5/OUT5 NC with EV OFF 6 INS15 Contact monitor Relay1 of OUTRL1 NC 9 INS16 Contact monitor Relay2 of OUTRL2 NC 9 INS17 Ingresso per Monitor di EV6/OUT6 NC with EV OFF 6 INS18 Downstroke Pedal 2 NO 10 INS19 Downstroke Pedal 2 NC 10 INS20 Input for Monitor of EV7/OUT7 NC with EV OFF 6,7 INS21 Input for Selector Foot Pedal Controls 1 and 2 4 INS22 Robot function activation signal 11 INS23 Upper Tool Holder Pressure switch OFF/0V 12 INS24 Lower Tool Holder Pressure switch OFF/0V 12

SAFETY OUTPUTS 3,2A 24Vcc

13

OUTS1 OUT1/EV 1 5 OUTS2 OUT2/EV 2 5 OUTS3 OUT3/EV 3 5 OUTS4 OUT4/EV 4 5

DLAM01EN 35


OUTS5 OUT5/EV 5 OUTS6 OUT6/EV 6 OUTS7 OUT7/EV 7 7 OUTS8 OUT8/EV 8 14

GENERIC INPUTS 24Vcc 7mA

ING1 Upper Tool Holder Command ON/24V 12 ING2 Sheet Edge request button NO 15 ING3 Emergency Reset button NO ING4 Rear Guard Reset button NO ING5 Decompression and Stop for Stop Distance NO 16 ING6 Lower Tool Holder Command ON/24V 12

GENERIC OUTPUTS 0,4A 24Vcc

OUTG1 Led integrated in Rear Guard Reset button OUTG2 Led integrated in Sheet Edge request button OUTG3 Generic Output1 Programmable from MCS 17 OUTG4 Foot Pedal Control 1 Led active OUTG5 Generic Output2 Programmable from MCS 17 OUTG6 Led integrated in Emergency Reset button OUTG7 Signal LOW Speed for CNC 19 OUTG8 Generic Output3 Programmable from MCS 17 OUTG9 Foot Pedal Control 2 Led active 10 OUTG10 Led Upper Tool Holder Open 12 OUTG11 Yellow Blinker OUTG12 Generic Output4 Programmable from MCS 17, 18 OUTG13 Led Lower Tool Holder Open 12 OUTG14 Output DOWNSTROKE enabling for CNC 20

OUTPUTS with DEDICATED HW FUNCTION

OUTRL1 Output for Relay components to set in emergency 9 OUTRL2 Output for Relay components to set in emergency 9

OUTV Push-pull output for sheet interception for CNC 21

INPUTS from LINEAR ENCODERS 5V 8/10mA

CHAE1 Input of channel A of the linear encoder of jack Y1 CHBE1 Input of channel B of the linear encoder of jack Y1 CHAE2 Input of channel A of the linear encoder of jack Y2 CHBE2 Input of channel B of the linear encoder of jack Y2

1. When a pulsed input is not used, connect it to the relevant pulsed output. 2. When the rear protection is a mechanical element, signal its opening by means of a

device (e.g.: end-of-stroke) equipped with a NC (normally closed) contact which connects INP7 to OUTP7 and assign the value “SINGLE” to the programming parameter B6. When the rear protection is a Photoelectric Barrier, it is necessary to use its two outputs (OSSD) to pilot two relays, whose NO (normally open) contacts must be connected: one to INP7 and OUTP7 and the other to INP8 and OUTP8. In this case, it is necessary to assign the value “DOUBLE” to the programming parameter B6.

3. The Blanking Modes can be selected even via RS232. To activate this functionality, it is

necessary to assign the value “A CNC” or “B CNC” to the programming parameter B5. In this case, do not connect INS1 and INS2.

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4. The Foot Pedal Controls can be selected even via RS232. To activate this functionality,

it is necessary to assign the value “2P N CNC” or “2P MS CNC” to the programming parameter B2. In this case, it is necessary to connect INS3, INS4 to 24Vcc through a NO/NC selector. When INS3 is connected to 24Vcc and INS4 to 0V, only foot pedal control 1 will be activated. Connecting, instead, INS3 to 0V and INS4 to 24Vcc, the selection of the foot pedal controls will take place via RS232. Do not connect the input INS21.

5. It is suggested to use the safety outputs OUTS1 and OUTS2 to command the High

Speed solenoid valves, while the safety outputs OUTS3 and OUTS4 to command the solenoid valves of proportional, as the verification of the monitors relevant to these outputs depends the machine operating cycle.

6. The function of every Module can be activated through the programming parameters

C13 and C14. For example, if you wish to use Monitor1 and Monitor2 and not Monitor3 and Monitor4, assign the value 1100 to parameter C13: the first two digits (set to 1) mean Monitor active, while the others (set to 0) mean Monitor inactive.

7. The output OUTS7 and the relevant input INS20, for the Monitor of the actuator commanded by this output can be used if the hemming monitor function is not used. The programming parameter B8 allows activating the hemming control function. If this parameter is set to value “OFF”, the hemming function is not active and the output OUTS7, together with the input INS20 relevant to Monitor7, can be used as the other safety outputs. Instead, if the value “ON” is assigned to this parameter, the output OUTS7 is monitored by MCS to command the execution of hemming, while INS20 is used for the function enabling. If the parameter B8 is set to value “ON CNC”, output OUTS7 is monitored by MCS to command the execution of hemming, the enabling of hemming function is transmitted to CNC through RS232 while the input INS20 is not used.

8. Inputs INS11 and INS12 receive the CNC signals requiring to command the downstroke

in High Speed and in Low Speed. To command the High Speed downstroke, the signals must assume these values: INS11=24V and INS12=0V. To command the Low Speed downstroke, the signals must assume these values: INS11=24V and INS12=24V. In all the other cases, or if MCS detects locking conditions, downstroke is not enabled.

9. Outputs OUTRL1 and OUTRL2 with the relevant feedback inputs, IN15 and INS16, are

active if the value “ON1” or “ON2” has been assigned to programming parameter B1. Otherwise, do not connect.

• When the value “ON1” is assigned, these outputs will be active if the machine is not in emergency.

Information:

This configuration can be used to set other devices in emergency or to signal to other safety devices, as the safety PLC of a Robot, that MCS is in emergency.

• When the value “ON2” is assigned, these outputs will be active if the machine is

not in emergency and the side guards are not both open. When the side guards are opened or closed, the outputs deactivate for 1 second and re-activate if the conditions above are valid.

DLAM01EN 37


Information:

This last type of configuration is specially suitable if you wish to use these outputs to command the power supply and/or the enabling of the rear backgauges of the press (Axis X).

10. When you use two Pedals, make sure to have assigned, to the programming parameter B2, one of the value: “2P N”, “2P MS”, “2P N CNC” or “2P MS CNC”. Otherwise, if the value “1P” has been assigned to parameter B2, do not connect the inputs INS18 and INS19 and the output OUTG9.

11. For the activation of Robot function, call Nuova Elettronica snc to get the necessary

information.

12. When using the function for the control of the Upper and Lower Tool Holder, make sure that the value “ON” or “ON CNC” has been assigned to the programming parameter B7. When sending the command signals through RS232, make sure that the value “ON CNC” has been assigned to programming parameter B7. In this case, do not connect the inputs ING1 and ING6. Otherwise, if the value “OFF” has been assigned to parameter B7, do not connect the inputs INS22, INS23, ING1 and ING6 and the outputs OUTG10 and OUTG13.

13. The programming parameters allow selecting which safety outputs use and the state they must assume in the different machine states (Upstroke, Stop, Slow Downstroke, Fast Downstroke). The programming parameter C15 allows selecting which outputs, among OUTS1, OUTS2, OUTS3 and OUTS4, you wish to use as safety output controlled by MCS and which not. The selected outputs will be controlled by MCS and will assume, in the different machine states, the state assigned by parameters C1, C4, C7 and C10. Those not selected, downgraded to generic power outputs, can be controlled by CNC through RS232. Example: Values and corresponding meaning:

SETTING MEANING C15 : 1101 OUTS1, OUTS2 and OUTS4 used as safety

outputs by MCS OUTS3 used as generic output driven by CNC via RS232

C1 : 1100 Values assumed in High Speed OUTS1=24V, OUTS2=24V, OUTS4=0V

C4 : 0001 Values assumed in Low Speed OUTS1=0V, OUTS2=0V, OUTS4=24V

C7 : 0000 Values assumed in Stop OUTS1=0V, OUTS2=0V, OUTS4=0V

C10 : 1101 Values assumed in upstroke OUTS1=24V, OUTS2=24V, OUTS4=24V

Similarly, the programming parameter C16 allows selecting which output, among OUTS5, OUTS6, OUTS7 and OUTS8, you wish to use as safety output controlled by MCS and which not. The selected one will be controlled by MCS and will assume, in the different machine states, the state assigned by the parameters C2, C5, C8 and C11. Those not selected, downgraded to generic power outputs, can be controlled by CNC via RS232.

38 DLAM01EN


14. Output OUTS8 is without input for the Monitor relevant to controlled actuator. 15. The Sheet Edge request can be transmitted even via RS232. This functionality is always

active: if you wish to use it, ING2 cannot be connected.

16. This signal can provide two different indications to MCS, depending on the operation MCS is executing. First case: if the machine is executing the Low Speed Decompression, the signal must assume the value 24V for all the duration of the operation. Second case: MCS is executing the Stop Distance test. In this case, during the High Speed Downstroke, if you wish MCS executes the Stop before having reached the position assigned by the programming parameter A5, the signal must assume the value 24V for, at least, 30ms.

17. The programming parameter C17 allows selecting which outputs, among OUTG3,

OUTG5, OUTG8 and OUTG12, you wish to make active on the MCS command to assign, then, always by means of the programming parameters C3, C6, C9 and C12, the state ON or OFF they must assume in the four machine states (Upstroke, Stop, Slow Downstroke, Fast Downstroke). The outputs not controlled by MCS commands can be controlled by CNC via RS232 interface (see item 13, Safety Outputs).

18. It is suggested to use the generic output OUG12 to transmit the MCS Lock state to

CNC, when you do not wish to use the RS232 interface. To do this, the parameters C17, C3, C6, C9 and C12 must be programmed in the following way:

C17: xxx1 C3: xxx1 C6: xxx1 C9: xxx1 C12: xxx1

where x stands for “any value”. In this way, the signal OUTG12 will assume the value 24V when MCS will be in a state different from Lock, while it assume the value 0V when MCS will Be in Lock. Remember that, in Lock state, any movement of the upper table is inhibited.

19. This signal assumes the value 24V every time MCS does not allow the High Speed

Downstroke. 20. This signal assumes the value 24V every time MCS allows the Downstroke.

21. This signal assumes the value 24V every time MCS, during the Downstroke, intercepts

an object. It returns to 0V when the Upstroke is commanded.

22. The upstroke request signal is considered “active” when it assumes the value 24V and “not active” when it assumes the value 0V.

Information:

MCS transmits, via RS232 interface, the state of all the inputs and outputs, which can be then used by the numeric control. Remember that the numeric control cannot manage functions classified as “safety functions”.

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10.4.2. MCS electric connection Here below are reported the illustrations with the electric schemes subdivided by topics. Some schemes indicate a possible maximum configuration. The configuration can however be reduced depending on the machine needs.

10.4.2.1. Machine power supply connection Figure 33 illustrates how connect MCS to the 24 Vcc power supply line present in the machine electric panel. The power consumed by MCS is 10W and includes even the power supply of DSP LASER AP. Almost all the consumed power is used to supply solenoid valves and services, and it changes from machine to machine. As visible in the scheme, two power supply lines are foreseen to separate the power supply of the safety functions from that of the services. The terminals marked with RIF0Vcc are used to connect possible other devices for the exchange of data with MCS (for example, CNC) to the power supply zero reference.

Figure 33 40 DLAM01EN


10.4.2.2. Foot Pedal Controls with “antipanic” and Emergency chain

Foot Pedal Controls MCS can manage up to 2 foot pedal controls.

In “one foot pedal control” mode, it is not necessary to wire the selector Foot Pedals Controls (INS 3, 4 and 21) and the Foot Pedal Control 2 (INS 18 and 19). In this case, assign the value “1P” to the programming parameter B2.

In “two foot pedal controls” mode, through the three-position Selector Foot Pedal Controls, you can choose if using only Foot Pedal Control 1 (position 1 of selector), only Foot Pedal Control 2 (position 2 of selector) or both Foot Pedal Controls together (position 3 of selector). The two foot pedal controls mode can operate in two different ways, depending on the value assigned to the programming parameter B2. • If the value “2P N” (2 Pedals Normal) has been assigned to B2, the downstroke

request is acquired by MCS when both the pedals are pressed, independently from the order they are pressed.

• If the value “2P MS” (2 Pedals Master-Slave) has been assigned to B2, the downstroke request is acquired by MCS when both the pedals are pressed. In this case, however, the Slave (Pedal 2) must be pressed before the Master (Pedal 1), otherwise MCS will signal Error.

Always in “two foot pedal controls” mode, the pressure of one pedal is signalled to the other station by the blinking of the foot pedal control led. When Pedal 2 is pressed, for example, the led pedal 1 in the foot pedal control 1 will blink. Parameter B2 INS 3 INS 4 INS21 Selected Foot Pedal Control “1P” X X X Foot Pedal Control 1 “2P N“ o ”2P MS” 24V 0V 0V Foot Pedal Control 1 “2P N“ o ”2P MS” 0V 24V 0V Foot Pedal Control 2 “2P N“ o ”2P MS” 0V 0V 24V Foot Pedal Control 1 +

Foot Pedal Control 2

Information:

All the configurations of inputs INS3, INS4 and INS21 different from those reported in this table will cause a Lock of MCS, which will be restored when these inputs will return in a correct configuration.

The selection of the foot pedal controls can be even demandated to CNC through the use of the serial connection RS232. To use this functionality, it is necessary to assign the value “2P N CNC” to the parameter B2 for the Normal mode, or the value “2P MS CNC” for the Master-Slave mode. In this case, it is necessary to connect INS3, INS4 to 24Vcc by means of a NO/NC selector. When the selector is in default position 1 (INS3 = 24V, INS4 = 0V), only Foot Pedal Control 1 is active; when the selector is in default position 2 (INS3 = 0V, INS4 = 24V), the selection is executed by CNC via RS232. Parameter B2 INS 3 INS 4 RS232 Selected Foot Pedal

Control “2P N CNC“ o ”2P MS CNC” 24V 0V X Foot Pedal Control 1 “2P N CNC“ o ”2P MS CNC” 0V 24V Ped1 Foot Pedal Control 1 “2P N CNC“ o ”2P MS CNC” 0V 24V Ped2 Foot Pedal Control 2 “2P N CNC“ o ”2P MS CNC” 0V 24V Ped1+

Ped2 Foot Pedal Control 1+ Foot Pedal Control 2

“2P N CNC“ o ”2P MS CNC” 0V 24V X Foot Pedal Control 1 + Foot Pedal Control 2

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Information:

All the configurations of inputs INS3 and INS4 different from those reported in this table will cause a Lock of MCS, which will be restored when these inputs will return in a correct configuration.

Should the RS232 connection between CNC and MCS be interrupted or work in wrong way, with selector in position 2 (INS3=0V and INS4=24V), MCS will set to default configuration, where both the foot pedal controls are active: this to ensure the safety of the operator.

Selector Foot Pedal Controls For the selection of the foot pedal controls, a 3-position selector must be used with the 3 NO contacts connected to the 3 inputs IN3, INS4 and INS21 and the common connected to +24V. Position 1 of the selector must close the contact 1 connected to INS3 with the common +24V, leaving the others not connected. Position 2 of the selector must close the contact 2 connected to INS4 with the common +24V, leaving the others not connected . Position 3 of the selector must close the contact 3 connected to INS21 with the common +24V, leaving the others not connected.

Antipanic Antipanic alarm is raised when the third position of the downstroke pedal is pressed on foot pedal control 1 or on foot pedal control 2, if present. When this occurs, the leds of the foot pedal controls blink rapidly and MCS goes in STOP state (only the upstroke movement is allowed). To restore MCS after the occurrence of Antipanic alarm, there are two different ways which depending on the the value assigned to the programming parameter B4: • If B4 has value “RST AUTO” (Reset Auto), it is sufficient to release completely the

downstroke pedal in such a way it returns to the first position (rest position). • If B4 has value “RST UP P” (Reset with Upstroke pedal), it is necessary to release

completely the downstroke pedal in such a way it returns to the first position (rest position) and, moreover, to press the upstroke pedal and release it. This last pressure of the upstroke pedal does not cause the upstroke of the machine, but only clears the Antipanic alarm.

Emergency Emergency mushroom buttons and other possible emergency measures are managed as a chain (connected in series). When an emergency mushroom button is pressed, MCS goes in STOP state (only the upstroke movement is allowed) and turns on the led relevant to emergency. Moreover, the outputs OUTRL1 and OUTRL2, if enabled, go to OFF state and remain in this state until the emergency is active. To restore MCS, it is necessary to unlock the emergency mushroom button, setting it to OFF state, and press the emergency reset button. Once the reset button is pressed, if the procedure has been properly executed, the led relevant to emergency turns off. Downstroke Pedal Leds The downstroke pedal leds indicate which Foot Pedal Control is selected and gives information about MCS state. In detail:

• Fixed ON: Foot Pedal Control active. • OFF: Foot Pedal Control not selected, Emergency chain alarm active or rear guard

open alarm (or photoelectric rear barrier interrupted) active. In 2 Pedals Master-Slave mode, the pedal pressure sequence has not been executed correctly.

• Blinks Slowly: in 2 Pedals mode, the downstroke pedal of the other Foot Pedal Control has been pressed.

• Blinks rapidly: antipanic alarm activated.

42 DLAM01EN


Sheet Edge request light button The button allows the operator requiring the “Stop Distance Verification” function or the “Sheet Edge Acquisition” function. At MCS switch-on, the “Stop Distance Verification” function activates. Once this function has been correctly executed (Chap 11.5), the “Sheet Edge Acquisition” function activates. Once this function has been correctly executed (Chap. 11.6), MCS enters in work mode. Now, in order to execute the “Sheet Edge Acquisition” function once more, it is sufficient to press the Sheet Edge request button: the function will activate. Otherwise, if you wish to repeat the “Stop Distance Verification” function, after the request of the “Sheet Edge Acquisition” function it is necessary to press again the Sheet Edge request button and keep it pressed for at least 3 seconds. The button led indicates which function is active: • Blinks rapidly: Stop Distance Verification function active • Fixed ON: Sheet Edge Acquisition function active • OFF: MCS in work mode.

Connection of Upstroke pedal to CNC The Upstroke input of CNC must be connected to NO contact of the Upstroke pedal with common connected to +24V. In presence of two foot pedal controls, the NO contacts of the Upstroke pedals must be connected in parallel. Through this signal, CNC will receive the upstroke request and, if the conditions allows it, will transmit the upstroke command to MCS.

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Figure 34

44 DLAM01EN


10.4.2.3. RH and LH side guards and other I/O

Side Guards When a side guard is opened, MCS stops the moving crossbeam and inhibits the High Speed: then, it is possible to work only in Low Speed, after having released and pressed again the downstroke pedal. Then, even the upstroke command remains enabled.

Warning:

The installer is responsible to verify that no dangers are present due to the upward movement of the crossbeam with a side guard open.

When both the side guards are opened, MCS enters in Lock state (no movement allowed). To restore the correct operation, it is sufficient to close the side guards.

Warning:

The installer is responsible even to limit the speed of the rear backgauges along all their stroke, in order that they do not constitute a danger for the operators when a side guard is open.

Moreover, when the value “ON2” is assigned to parameter B1:

• At the opening of only 1 side guard, the outputs OUTRL1 and OUTRL2 will enter in OFF state for 1 second

• At the opening of both the side guards, the outputs OUTRL1 and OUTRL2 will enter in OFF state and will remain so until both guards remain open.

Selector Low Speed Request This contact allows forcing the machine downstroke in Low Speed, even if the conditions allow the downstroke in High Speed. This signal is connected in parallel, through the diode indicated in Figure 35, to the Low Speed request signal coming from CNC. Rear guards Opening a gate or passing through a photoelectric barrier (if present) causes MCS enters in Lock state (no movement allowed) and turns on the led relevant to the rear guards. Moreover, if enabled, the outputs OUTRL1 and OUTRL2 enter in OFF state and remain so until the alarm is active. To restore MCS, it is necessary to close the gate or to free the photoelectric barrier from obstruction and press the rear guard reset button. Once the reset button is pressed, if the procedure has been executed correctly, the led relevant to the rear guards turns off. Rear guard reset light button This button allows clearing the rear guard alarm, stated that the guard is closed (or the photoelectric barrier is not interrupted). The relevant led ON indicates that the alarm is active and MCS is in Lock state. The led OFF indicates that the alarm is not active. Emergency reset light button This button allows clearing the emergency alarm, stated that neither the mushroom button nor other switch of the emergency chain is pressed. The relevant led ON indicates that the alarm is active and MCS is in Stop. The led OFF indicates that the alarm is not active.

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Blinker The blinker indicates if the crossbeam is going down in Low Speed, and then with the front protection (DSP LASER AP) inhibited.

• Blinking ON: front protection (DSP LASER AP) inhibited. • OFF: front protection active.

Selector Blanking Modes For the selection of the Blanking Modes, a 3-position selector must be used with three NO contacts, two of which connected to inputs IN1 and INS2, one NO contact not connected to any input and the common connected to +24V. Position1 of the selector must close the contact1 not connected to common +24V, leaving the others not connected. Position2 of the selector must close the contact2 connected to INS1 with the common +24V, leaving the others not connected. Position3 of the selector must close the contact3 connected to INS2

mcs and dsp laser ap...dlam01en rev. 1.1 – ed. 20/11/2012 mcs and dsp laser ap instruction manual...

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