Reer JANUS TRX Quick start guide

Dichiarazione CE di conformità
EC declaration of conformity
Torino, 1/1/2010
REER SpA
via Carcano 32
10153 – Torino
Italy
dichiara che le barriere fotoelettriche JANUS TRX / M TRX sono Dispositivi Elettrosensibili di
Sicurezza (ESPE) di :
Tipo 4 (secondo la Norma CEI EN 61496-1:2005; CEI EN 61496-2:2007)
SIL 3 (secondo la Norma CEI EN 61508:2002)
SILCL 3 (secondo la Norma CEI EN 62061:2005 + CEI EN 62061/EC2:2008)
PL e (secondo la Norma UNI EN ISO 13849-1:2008)
declares that the JANUS TRX / M TRX photoelectric safety barriers are :
Type 4 (according the Standard IEC 61496-1:2004; IEC 61496-2:2006)
SIL 3 (according the Standard IEC 61508:1998)
SILCL 3 (according the Standard IEC 62061:2005)
PL e (according the Standard ISO 13849-1:2006)
Electro-sensitive Protective Equipments (ESPE)
realizzati in conformità alle seguenti Direttive Europee:
complying with the following European Directives:
2006/42/CE "Direttiva Macchine"
"Machine Directive"
2004/108/CE "Direttiva Compatibilità Elettromagnetica"
"Electromagnetic Compatibility Directive"
2006/95/CE "Direttiva Bassa Tensione"
"Low Voltage Directive"
e sono identiche all'esemplare esaminato ed approvato con esame di tipo CE da:
and are identical to the specimen examined and approved with a CE - type approval by:
TÜV SÜD Rail GmbH – Ridlerstrasse 65 – D-80339 – Muenchen – Germany
Carlo Pautasso Giancarlo Scaravelli
DirettoreTecnico Presidente
Technical Director President

8540568 • 23/12/2009 • Rev.3
PHOTOELECTRIC
SAFETY
BARRIER
JANUS TRX
INSTALLATION USE AND MAINTENANCE
INDICE
INTRODUCTION ..................................................................................................................... 2
PRINCIPLE OF OPERATION.................................................................................................. 3
INSTALLATION ....................................................................................................................... 4
POSITION ..................................................................................................................................... 5
MULTIPLE SYSTEMS .................................................................................................................. 5
SAFETY DISTANCE CALCULATION........................................................................................... 6
VERTICAL POSITION OF THE BARRIER ................................................................................... 7
ELECTRICAL CONNECTIONS .................................................................................................... 7
EXTERNAL CONNECTION.......................................................................................................... 8
DISTANCE BETWEEN REFLECTING SURFACES .................................................................... 9
MOUNTING AND OPTICAL ALIGNMENT ................................................................................. 11
OPERATION AND TECHNICAL DATA ................................................................................. 12
SIGNALS..................................................................................................................................... 12
CONFIGURATION AND OPERATION MODES......................................................................... 13
K1/K2 EXTERNAL CONTACTORS CONNECTION................................................................... 16
OUTPUT STATUS ...................................................................................................................... 16
TECHNICAL SPECIFICATIONS................................................................................................. 17
DIMENSIONS ........................................................................................................................ 18
CHECKOUTS AND MAINTENANCE .................................................................................... 18
TROUBLESHOOTING ................................................................................................................ 19
SPARE PARTS...................................................................................................................... 21
GUARANTEE ........................................................................................................................ 22

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This symbol stands by a very important warning concerning the safety of persons.
Its non-observance can cause a very serious risk for the exposed personnel.
INTRODUCTION
The JANUS TRX photoelectric barrier is a double-beam optoelectronic safety system.
It belongs to the family of Type 4 electrosensitive devices for the protection of personnel
exposed to risks arising from the use of hazardous machinery or plant, according to
standards IEC 61496-1,2 and EN 61496-1.
This barrier is composed of one active element J TRX E/R (containing the emitter and the
receiver units) and one passive element J TRX RR with a retroreflector
pre-aligned inside) which reflects the infrared beam (Figure 1).
The distance between the axis of the 2 beams (emitted and reflected) is 500mm (value
required by the EN999 European Normative for a 2-beams System).
A diagnostic display available on the active element provides the necessary informations for
a correct use of the device and the valuation of the possible operation failures.
JANUS TRX is ideal for protecting:
Automatic palletizing/depalletizing systems, packing and packaging machines, metal, wood,
marble and glass tool machines, materials handling.
If necessary, for any safety-related problems contact the competent safety
authorities or industrial associations in the country of use.
For applications in the food industry, please contact the manufacturer to ensure that
the barrier contains materials that are compatible with the chemical agents utilized.
The protective function of the optoelectronic devices is not effective in the following cases:
If the machine stopping control cannot be actuated electrically and it is not possible
to stop all dangerous machine movements immediately and at any time during the
operating cycle.
If the machine generates dangerous situations due to material being expelled or
falling from overhead.

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PRINCIPLE OF OPERATION
Figure 1 shows the JANUS TRX way of operation :
The active element J TRX E/R contains the emitter and the receiver units;
the emitted infrared beam, correctly reflected by the two pre-aligned deflection mirrors
of the passive element J TRX RR, is received by the receiver of the J TRX E/R.
With the protected area clear, the two PNP outputs of the active elements are in ON
condition (24VDC) and guarantee the normal operation of the connected machine.
When an object interrupts the infrared beams, the TRX PNP outputs are de-energized
(OFF condition - 0VDC). This condition permits to stop the moving body of the machine
(thanks to a specific stopping circuit).
ACTIVE
ELEMENT
J TRX E/R
EMITTER
RECEIVER
Figure 1
PASSIVE
ELEMENT
J TRX RR
1° MIRROR
2° MIRROR

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INSTALLATION
Before installing the JANUS TRX safety system, make sure that:
The safety system is only used as a stopping device and not as a machine control
device.
The machine control can be actuated electrically.
All dangerous machine movements can be interrupted immediately. In particular, the
machine stopping times must be known and, if necessary, measured.
The machine does not generate dangerous situations due to materials projecting or
falling from overhead; if that is not the case, additional mechanical guards must be
installed.
The minimum dimensions of the object that must be intercepted are greater than or
equal to the resolution of the JANUS TRX.
Knowledge of the shape and dimensions of the dangerous area enables the width and height
of the relative access area to be calculated.
Compare these dimensions with the maximum working range and the height of the
protected area in relation to the JANUS TRX.
The general instructions set out below must be taken into consideration before placing the
safety device in position.
Make sure that the temperature of the environment in which the system is to be
installed is compatible with the temperature parameters contained in the technical
data sheet.
Do not install the active unit close to bright or high-intensity flashing light sources.
Certain environmental conditions may affect the monitoring capacity of the
photoelectric devices. In order to assure correct operation of equipment in places
that may be subject to fog, rain, smoke or dust, the appropriate correction factors Cf
should be applied to the maximum working range values. In these cases:
where Pu and Pm are, respectively, the working and maximum range in meters.
Pu = Pm x Cf

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The recommended Cf factors are shown in the table below:
ENVIRONMENTAL CONDITION CORRECTION FACTOR Cf
Fog 0.25
Steam 0.50
Dust 0.50
Dense fumes 0.25
If the device is installed in places that are subject to sudden changes in temperature,
the appropriate precautions must be taken in order to prevent the formation of
condensation on the lenses, which could have an adverse effect on monitoring.
POSITION
The active J TRX E/R and passive elements J TRX RR must be positioned in such a way
that the access to the dangerous zone from overhead, bottom and from the opposite sides is
impossible without intercepting at least one of the two optical beams.
Figure 2
MULTIPLE SYSTEMS
JANUS TRX is composed of one active and one reflecting element; when more than
one JANUS TRX system is used, precaution must be taken to avoid optical interference
between them.
We recommend to interpose between two adjacent systems, opportune NOT
TRANSPARENT surfaces to stop the passage of the infrared beam.
WARNING
To reach the perfect JANUS TRX
installation, position both the
units as showed in Figure 2
(REER labels in the same side)
FRONT WINDOW
JANUS JANUS

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SAFETY DISTANCE CALCULATION
The barrier must be installed at a distance that is greater than or equal to the minimum
safety distance S, so that a dangerous point can only be reached after all hazardous
machine movements have stopped (Figure 3).
According to European standard EN999, the minimum safety distance Smust be calculated
using the following formula:
S = K (t1+ t2) + C
where:
S minimum safety distance mm
K approach speed of object to the dangerous area mm/sec
t1response time of the safety barrier in seconds sec
t2
machine response time, in seconds, meaning the time
required for the machine to interrupt the dangerous movement
following transmission of the stop signal
sec
c additional distance mm
The non-observance of the correct safety distance reduces or cancels the protective
action of the light curtain.
If the position of the barrier does not prevent the operator from having access to the
dangerous area without being detected, additional mechanical guards must be
installed to complete the system.
S=Safety distance
Figure 3
HAZARDOUS
MACHINE
S
PASSIVE
ELEMENT
ACTIVE
ELEMENT
MECHANICAL
PROTECTIONS

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VERTICAL POSITION OF THE BARRIER
These models are suitable for the protection of
the entire body and must not be used to protect
arms or legs.
The minimum safety distance Sis calculated
according to the following formula:
S = 1600 (t1+ t2) + 850
ÎThe recommended height H from the
reference surface G (ground) is as follows:
Figure 4
MODEL BEAMS Reccomended Height H (mm)
J TRX E/R 2 400 – 900
ELECTRICAL CONNECTIONS
WARNINGS
Before making the electrical connections, make sure that the supply voltage complies with
the one specified in the technical data sheet.
Janus TRX must be supplied with 24Vdc±20% power supply. The external power
supply must comply with the standard EN 60204-1.
The electrical connections must be made according to the diagrams in this manual. In
particular, do not connect other devices to the connectors of the active unit.
To guarantee reliability of operation, when using a diode jumper supply unit, its output
capacity must be at least 2000µF for each absorbed A.
safety
barrier
point of
dan
g
e
r
direction
of
approach
reference plane

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8540568 • 23/12/2009 • Rev.3
Connector pins.
Figure 5
EXTERNAL CONNECTION
PIN COLOR NAME TYPE DESCRIPTION OPERATION
2 Brown 24VDC - 24VDC power supply -
7 Blue 0VDC - 0VDC -
8 Red PE - Ground connection -
1 White OSSD1 OUTPUT
3 Green OSSD2 OUTPUT Safety static outputs PNP active high
5 Grey EXT_SEL_A INPUT
6 Pink EXT_SEL_B INPUT
Barrier
configuration
4 Yellow EXT_K1_K2 INPUT Feedback external
contactors
According the normative
EN61131-2
(ref. Table 2 and Table 3)
Table 1
Warnings regarding the connection cables
•For connections over 50m long, use cables with a cross-section area of
1 mm2.
•The power supply to the barrier should be kept separate from that to other
electric power equipment (electric motors, inverters, frequency converters) or
other sources of disturbance.
•Connect the active element to the ground output.
•The connection cables must follow a different route to that of the other
power cables.

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DISTANCE BETWEEN REFLECTING SURFACES
The presence of reflecting surfaces in proximity of the photoelectric barrier may generate
spurious reflections that prevent monitoring. With reference to Figure 6, object Ais not
detected because surface Sreflects the beam and closes the optical path between the active
and passive elements.
A minimum distance dmust therefore be maintained between any reflecting surfaces and
the protected area. The minimum distance dmust be calculated according to the distance l
between the active and passive unit, considering that the angle of projection and
reception is 4°.
Figure 6
Figure 7 illustrates the values for the minimum distance dthat must be maintained when the
distance lbetween the active and passive elements is changed.

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8540568 • 23/12/2009 • Rev.3
Figure 7
After installing the system, check whether any reflecting surfaces intercept the beams, first in
the centre and then in the vicinity of the active unit.
During these operations, the red LED on the active elements should never, for any reason,
switch off.

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MOUNTING AND OPTICAL ALIGNMENT
The active element J TRX E/R and the the passive element J TRX RR must be mounted the
first in front of the other with the same (or less) distance showed in the technical data.
Using the fastening brackets and inserts (available on request) fix the active element
J TRX E/R and the passive element J TRX RR aligned and parallel.
The fastening inserts can be located in the rear or in the side spline of the units, depending
on the dimensions and shape of the machine rest (Figure 8). The bracket supplied with the
barrier must be fixed in the vertical center of the columns.
The perfect alignment between the two units is essential for the correct barrier operation; the
control of the signal leds makes this function easier.
Figure 8
•Place the optical axis of the photoemitter and photoreceiver on the same axis
of the reflecting mirrors of the passive element.
•Hold the passive element and move J TRX E/R to find the area within which
the green led stays on, then position the first beam (the one close to the
indicator leds) in the centre of this area.
•Lock the two units in place.
During these operations it may be useful to check the orange weak signal LED on the
passive element. Upon completion of alignment, this LED must be off.
If the active element is assembled in areas that are subject to strong vibrations, the use of
vibration-damping supports is recommended, in order to prevent circuit malfunctions.

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OPERATION AND TECHNICAL DATA
SIGNALS
The symbols showed on the 7 segments display of the active elements,
The symbols showed on the 7 segments display and the leds of the active elements are
visualized depending on the system operation phase. The tables below shows the different
signals (ref. Figure 9).
Figure 9
Normal operation (FIX SIMBOLS)
LED
SYMBOL RED (2) GREEN (3) YELLOW (4) ORANGE (1) MEANING
8 ON ON ON ON System power on. Initial TEST
OFF OFF OFF OFF Manual with feedback disabled
OFF OFF ON OFF Manual with feedback enabled
OFF OFF OFF ON Automatic with feedback disabled
C
Lighted
for
10seconds OFF OFF ON ON Automatic with feedback enabled
- ON OFF OFF OFF BREAK condition (A)
- OFF OFF ON OFF CLEAR condition (B)
- OFF ON OFF OFF GUARD condition (C)
- OFF OFF ON ON CLEAR condition with weak signal
- OFF ON OFF ON GUARD condition with weak signal
(A) Barrier occupied - output disabled
(B) Barrier free - output disabled - Waiting for restart
(C) Barrier free - output enabled
Configuration errors (BLINKING SYMBOLS)
LED
SYMBOL
RED (2) GREEN (3) YELLOW (4) ORANGE (1)
MEANING
C ON OFF OFF OFF Customer configuration rejected
2 ON OFF OFF OFF OSSD erroneously connectedt o 24VDC
E ON OFF OFF OFF External Feedback contactors missed
N.B.: For the meaning of the number that is displayed in case of a malfunction, please refer to
the “TROUBLESHOOTING” paragraph in this manual.
2
1
3
4

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CONFIGURATION AND OPERATION MODES
The JANUS TRX operation mode is selected realizing appropriate connections on the M12
8 poles of the active element (Table 1 and Table 2).
AUTOMATICO MODE
In this operation mode the OSSD1 and OSSD2 safety outputs follow the barrier status :
•with proteceted area clear, the safety outputs are active.
•with proteceted area intercepted, the safety outputs are disabled.
CONNECTION OPERATION MODE
EXT_SEL_A (PIN 5)
connected to :
ext_OSSD1 (PIN 1)
EXT_SEL_B (PIN 6)
connected to :
ext_OSSD2 (PIN 3)
EXT_K1_K2 (PIN 4)
connected to :
0VDC
AUTOMATIC without
K1-K2 feedback
EXT_SEL_A (PIN 5)
connected to :
ext_OSSD2 (PIN 3)
EXT_SEL_B (PIN 6)
connected to :
ext_OSSD1 (PIN 1)
EXT_K1_K2 (PIN 4)
connected to : 24VDC
(through series of contatcts
N.C. of external relays)
AUTOMATIC with
K1-K2 feedback
Table 2
Figure 10
Example of connection of TRX barrier in AUTOMATIC mode with feedback K1K2

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8540568 • 23/12/2009 • Rev.3
Figure 11
Example of connection of TRX barrier in AUTOMATIC mode without feedback K1K2
MANUAL MODE
In this operating mode the safety outputs OSSD1 and OSSD2 are activated (+24VDC) only if
the protected area is free and after the reception of the RESTART signal, using a push
button or thank to an appropriate control on the SEL_A or SEL_B input (ref.Table 3).
After an interception of the protected area, the safety outputs will be de-activated.
To re-activate them it will be necessary to repeat the sequence described above.
The RESTART command is active with a voltage of +24VDC.
The minimum duration of the RESTART command is 400ms.
Use of manual mode (start/restart interlock activated) is compulsory if the safety
device controls an opening to protect a danger area and a person, after passing
through the opening, may remain in the danger area without being detected (use as
'trip device' according to IEC 61496). Failure to comply with this rule may result in
very serious hazards for the persons exposed.
CONNECTION OPERATION MODE
EXT_SEL_A (PIN 5)
connected to :
24VDC (PIN 2)
EXT_SEL_B (PIN 6)
connected to :
24VDC (PIN 2)
(through the RESTART
pushbutton)
EXT_K1_K2 (PIN 4)
connected to :
0VDC
MANUALE senza
feedback K1-K2
EXT_SEL_A (PIN 5)
connected to :
24VDC (PIN 2)
(through the RESTART
pushbutton)
EXT_SEL_B (PIN 6)
connected to :
24VDC (PIN 2)
EXT_K1_K2 (PIN 4)
connected to : 24VDC
(through series of contatcts
N.C. of external relays)
MANUALE con
feedback K1-K2
Table 3

8540568 • 23/12/2009 • Rev.3 15
Figure 12
Example of connection of TRX barrier in MANUAL mode with feedback K1K2
Figure 13
Example of connection of TRX barrier in MANUAL mode without feedback K1K2

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8540568 • 23/12/2009 • Rev.3
K1/K2 EXTERNAL CONTACTORS CONNECTION
In every operating mode is activable the K1/K2 external contactors feedback.
If you want to use this check, connect the pin 4 of 8 poles M12 connector with the power
supply (+24VDC) through the series of N.C. contacts (feedback) of external contactors.
OUTPUT STATUS
Janus TRX features two static PNP outputs on the active element, the status of which
depends on the condition of the protected area.
The maximum load allowed is 500mA at 24VDC, which corresponds to a resistive load of
48Ω. Maxim load capacity corresponds to 2.2µF. The meaning of the status of outputs is
defined in the table below. Any short circuit between outputs or between outputs and 24VDC
or 0VDC power supplies is detected by the barrier.
NAME OF SIGNAL CONDITION MEANING
OSSD1
OSSD2 24VDC Condizione di barriera libera.
OSSD1
OSSD2 0VDC Condizione di barriera occupata
o guasto riscontrato
Table 4
In the protected area clear condition, the active element supplies a voltage of 24 VDC
on both outputs. The required load must therefore be connected between the output
terminals and the 0DVC (Figure 14).
Figure 14

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TECHNICAL SPECIFICATIONS
GENERAL DATA
Safety category 4
Response time ms ≤7
Working range m 0 ÷6
Reset automatic or manual selectable
Power supply Vcc 24 ±20%
Connections M12 – 8 poles (male)
Protection rating IP 65
Max. length of
electrical connections m 100
Dimensions light
curtain section mm 50 x 60
Operating temperature °C 0 ÷55
Storage temperature °C -20 ÷70
Max operative humidity % 95
Safety outputs 2 PNP auto-controlled – 500 mA @ 24 Vdc
with short-circuit, overload, reversal of polarity protection
Max. output current mA 500
System Status signal current mA 100
Max. capacitive load µF 2,2
Max. off-state voltage V < 1
Max. resistance of
connections between OSSDs
and the loads
Ohm < 25
Max. consumption W 6
Number of beams 2
Distance between beams mm 500
Overall barrier ht. mm 736 (J TRX E/R) - 723 (J TRX RR)
Light curtain lifetime 20 years
Type 4 IEC 61496-1:2004
IEC 61496-2:2006
SIL 3 IEC 61508:1998
SILCL 3 IEC 62061:2005
Safety level
PL e - Cat. 4 ISO 13849-1 : 2006
PFHd * 3,96E-10
DCavg # 92,56%
MTTFd # years 100
CCF # 80%
* IEC 61508
# ISO 13849-1

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8540568 • 23/12/2009 • Rev.3
DIMENSIONS
Figure 15
CHECKOUTS AND MAINTENANCE
Verification of barrier efficiency.
Before each work shift or before switching on, check the correct operation of the
photoelectric barrier.
To execute this operation, Proceed as follows :
•Intercept each beam with an opaque object, first in the center of the detection
zone and then close to the active and passive element.
•Verify that moving the test object close to the two beams, the red led (Figure 9)
lights on.
The JANUS TRX barrier does not require any specific maintenance operations; however,
periodic cleaning of the front protective surfaces of the active and passive unit optics is
recommended.
Wipe using a clean, damp cloth; in particularly dusty environments, after cleaning the front
surface, the use of an anti-static spray is recommended.
Never use abrasive or corrosive products, solvents or alcohol, which could damage
parts. Do not use woollen cloths, that could electrify the front surface.
If the orange weak signal LED on the active uniit switches on (LED 1 in Figure 9), check that:
–the front surfaces are clean;
–the active and passive elements are aligned correctly.
If the LED stays on, contact the REER service department.
J TRX E/R J TRX RR

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TROUBLESHOOTING
The instructions shown on the display of the active element enable the user to identify the
cause of a number of system malfunctions. As described in the “SIGNALS” paragraph of
this manual, in case of a failure, the system is set to the stop condition and the display of the
active element shows the letter F followed by a numerical code that identifies the type of
failure. (See the tables below).
SYSTEM ERRORS (FIX SYMBOLS)
7 SEGMENTS DISPLAY LED
SYMBOL MEANING RED GREEN YELLOW ORANGE REMEDY
6 Short-circuit between the
OSSD outputs ON OFF OFF OFF
Carefully check the connection of
terminals 1 and 3 (OSSD) on the
connector.
0 Overload of the OSSD
outputs ON OFF OFF OFF
Carefully check the connection of
terminals 1 and 3 (OSSD) on the
connector. If necessary, adjust
load reducing the current required
to max 500 mA (2.2 µF).
1
Interfering dangerous
Emitter detected.
The receiver is able to
receive simultaneously
the beams from two
different Emitters
ON OFF OFF OFF
Carefully locate the interfering
Emitter and take action in one of
the following ways:
•Move the interfering Emitter to
avoid this illuminating the
Receiver.
•Shield the beams coming from
the interfering Emitter using
opaque protections.
SYSTEM ERRORS (BLINKING SYMBOLS)
7 SEGMENTS DISPLAY LED
SYMBOL SYMBOL RED GREEN YELLOW ORANGE REMEDY
F Displayed alternatively
to the error code ON OFF OFF OFF -
3 Internal error
(master board) ON OFF OFF OFF
4 Internal error
(master board) ON OFF OFF OFF
5 OSSD static outputs error ON OFF OFF OFF
A Internal error
(master board analog input) ON OFF OFF OFF
Send the equipment for
repair to the REER
laboratories.
C Configuration error ON OFF OFF OFF Carefully check the system
configuration
H User configuration changed
without system restart ON OFF OFF OFF Operate a system restart
In any case, when faced with a system stoppage, switch the system off and then on again, to
exclude any occasional electromagnetic disturbances.
Should the problem persist, contact REER’s service department. In case of continued
malfunctioning:
•verify the integrity of electrical connections and check that these have been
made correctly;
•check that the supply voltage levels comply with those specified in the
technical data sheet;