Reer Admiral AX Series 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 ADMIRAL 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 ADMIRAL 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

8540569 • 4th February 2011 • Rev.12 1
PHOTOELECTRIC
SAFETY
BARRIER
ADMIRAL AX
INSTALLATION USE AND MAINTENANCE
INDICE
INTRODUCTION..................................................................................................................... 2
OPERATION............................................................................................................................ 3
INSTALLATION....................................................................................................................... 4
POSITION..................................................................................................................................... 5
MASTER/SLAVE POSITIONING.................................................................................................. 6
SAFETY DISTANCE CALCULATION........................................................................................... 7
VERTICAL POSITION OF THE BARRIER................................................................................... 8
HORIZONTAL POSITION OF THE BARRIER ............................................................................. 9
ELECTRICAL CONNECTIONS.................................................................................................. 10
EMITTER CONNECTIONS......................................................................................................... 11
RECEIVER CONNECTIONS...................................................................................................... 11
WARNINGS REGARDING THE CONNECTION CABLES......................................................... 12
CONFIGURATION AND OPERATION MODES......................................................................... 18
K1/K2 EXTERNAL CONTACTORS CONNECTION................................................................... 19
MULTIPLE SYSTEMS ................................................................................................................19
USE OF DEFLECTION MIRRORS............................................................................................. 20
DISTANCE BETWEEN REFLECTING SURFACES .................................................................. 21
MECHANICAL ASSEMBLY AND OPTICAL ALIGNMENT......................................................... 22
OPERATION AND TECHNICAL DATA................................................................................. 23
SIGNALS..................................................................................................................................... 23
TEST FUNCTION ....................................................................................................................... 25
OUTPUT STATUS...................................................................................................................... 26
TECHNICAL SPECIFICATIONS................................................................................................. 27
DIMENSIONS........................................................................................................................ 30
CHECKOUTS AND MAINTENANCE .................................................................................... 32
VERIFICATION OF BARRIER EFFICIENCY ............................................................................. 32
TROUBLESHOOTING................................................................................................................ 33
SPARE PARTS...................................................................................................................... 36
GUARANTEE ........................................................................................................................ 37

2 8540569 • 4th February 2011 • Rev.12
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 ADMIRAL AX photoelectric barrier is a multi-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.
Admiral AX is available in two different versions :
1. ADMIRAL AX (STANDARD)
Type 4 photoelectric barrier composed of Emitter and Receiver with integration of additional
functions, such as the external contactors feedback control and the manual/automatic
operation management.
2. ADMIRAL AX MASTER/SLAVE
Type 4 (STANDARD) photoelectric barrier composed of two TX/RX couples (connected in
series). The first of the couples is the MASTER barrier (with additional functions) and the
second is the SLAVE barrier.
A diagnostic display available on Emitter and Receiver provides the necessary information
for a correct use of the device and the evaluation of the possible operation defects.
ADMIRAL AX is ideal for the protection of :
Presses, die cutting machines, punching machines, cutting and shearing machines,
assembly lines, palletization lines, etc.
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.

8540569 • 4th February 2011 • Rev.12 3
OPERATION
If the protected area is clear, the two outputs on the Receiver are active and enable the
machine to which they are connected to operate normally.
Each time that an object bigger than or equal in size to the resolution of the system
intercepts the optical path of one or more beams, the Receiver deactivates the outputs.
This condition enables hazardous machine movements to be stopped (by means of an
adequate machine emergency stop circuit).
The resolution is the minimum dimensions that an object must have so that, on
crossing the protected area, it will certainly intercept at least one of the optical
beams generated by the barrier (Figure 1).
Figure 1
The resolution is constant irrespectively of work conditions, as it only depends on the
geometric characteristics of the lenses and the distance between the centres of two adjacent
lenses.
The height of the protected area is the height that is actually protected by the safety
barrier. If the latter is placed horizontally, this value refers to the depth of the protected area.
The working range is the maximum operative distance that can exist between the Emitter
and the Receiver.
ADMIRAL AX is available with the following resolutions:
–14 mm and 20 mm (protected height from 150 mm to 1800 mm)
PROTECTION OF FINGERS
–30 mm (protected height from 150 mm to 1800 mm)
PROTECTION OF HANDS
–40 mm (protected height from 300 mm to 1800 mm)
PROTECTION OF HANDS
–50 mm and 90 mm (protected height from 300 mm to 1800 mm)
PROTECTION OF ARMS AND LEGS
ADMIRAL AX is available also in the Multibeam and Long Range configuration with the
following lens pitch:
–500mm (2 beams), 400mm (3 beams), 300mm (4 beams).
PROTECTION OF BODY
P = Pitch between two lenses
D = Diameter of one lens
R = Resolution = P+D

4 8540569 • 4th February 2011 • Rev.12
INSTALLATION
Before installing the ADMIRAL AX 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 specific model.
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 specific model.
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 Emitter and Receiver 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

8540569 • 4th February 2011 • Rev.12 5
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 position of the AXE Emitter and the AXR Receiver must prevent access to the danger
zone from above, below and from the sides, unless at least one of the optical beams has
been intercepted. Some useful information regarding the correct position of the barrier is
shown in the figure below.
Incorrect positioning of barrier
Correct positioning of barrier
Figure 2

6 8540569 • 4th February 2011 • Rev.12
MASTER/SLAVE POSITIONING
In addition to the standard ADMIRAL models, ADMIRAL AX is available in the
MASTER/SLAVE configuration. Such configuration is made of two pairs of light curtains,
where the two emitters and the two receivers are respectively connected in series.
The most common application is shown in Figure 3: the horizontal light curtain (A) has been
installed to detect the presence of a person between the vertical light curtain (B) and the
dangerous machine at system power-up or restart.
Figure 3
The length of the connection cable between the master and the slave can be up to 50 m.
This makes it possible to install two light curtains - one at the front and the other at the rear
of the machine – with just one connection to the power and control circuits of the machine.
PROTEZIONE MECCANICA
PROTEZIONE MECCANICA
MACCHINA
PERICOLOSA
TX1 TX2
RX1 RX2
BARRIERA
MASTER BARRIERA
SLAVE
Figure 4
MECHANICAL GUARD
MASTER
BARRIER SLAVE BARRIER
DANGEROUS
MACHINE
MECHANICAL GUARD
Barrier B
(SLAVE)
Barrier A
(MASTER)
Reference plane
Point of danger

8540569 • 4th February 2011 • Rev.12 7
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 5).
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
t2machine 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 5
HAZARDOUS
MACHINE
S

8 8540569 • 4th February 2011 • Rev.12
VERTICAL POSITION OF THE BARRIER
14 mm and 20 mm resolution models.
These models are suitable for the protection of
fingers.
30 mm and 40 mm resolution models.
These models are suitable for the protection of
hands.
The minimum safety distance Sis calculated
according to the following formula:
S = 2000(t1+ t2) + 8(D-14)
(D=resolution)
This formula is valid for distances Sbetween 100
and 500 mm. If this formula results in Sbeing
greater than 500 mm, the distance can be reduced
to a minimum of 500 mm by means of the following
formula:
S = 1600(t1+ t2) + 8(D-14)
If, due to the specific configuration of the machine,
the dangerous area can be accessed from above,
the highest beam of the barrier must be at a height
Hof at least 1800 mm from the base Gof the
machine.
Figure 6
50 mm and 90 mm resolution models.
These models are suitable for the protection of
arms or legs and must not be used to protect
fingers or hands.
The minimum safety distance Sis calculated
according to the following formula:
S = 1600(t1+ t2) + 850
ÎThe height Hof the highest beam from the
base Gmust never be less than 900 mm,
while the height of the lowest beam P
must never be more than 300 mm.
Figure 7
safety barrier point of
dan
g
e
r
direction
of
approach
reference plane
safety barrier point of
dan
g
e
r
direction
of
approach
reference plane

8540569 • 4th February 2011 • Rev.12 9
Multibeam Models.
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 reccomended height Hfrom the base
(G) must be the following:
Figure 8
MODEL BEAMS Reccomended Height H (mm)
AX 2B
AX 3B
AX 4B
2
3
4
400 – 900
300 – 700 – 1100
300 – 600 – 900 - 1200
HORIZONTAL POSITION OF THE BARRIER
When the object’s direction of approach is parallel to
the floor of the protected area, the barrier must be
installed so that the distance between the outer limit
of the dangerous area and the most external optical
beam is greater than or equal to the minimum safety
distance Scalculated as follows:
S = 1600(t1+ t2) + 1200 – 0.4H
where His the height of the protected surface from
the base of the machine;
H = 15(D-50)
(D=resolution)
In this case, Hmust always be less than 1 meter.
Figure 9
safety barrier
point of
dan
g
e
r
direction
of approach
reference plane
safety
barrier
point of
dan
g
e
r
direction
of
approach
reference plane

10 8540569 • 4th February 2011 • Rev.12
ELECTRICAL CONNECTIONS
WARNINGS
Before making the electrical connections, make sure that the supply voltage complies with
that specified in the technical data sheet.
Emitter and Receiver units must be supplied with 24Vdc±20% power.
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 Emitter and Receiver.
For reliability of operation, when a diode jumper supply unit is used, its output capacity must
be at least 2000µF for each absorbed A.
MASTER/SLAVE CONNECTORS LOCATION
Figure 10
SLAVE CONNECTOR
SECONDARY MASTER CONNECTOR
PRIMARY
MASTER
CONNECTOR

8540569 • 4th February 2011 • Rev.12 11
EMITTER CONNECTIONS
AX/AXM/AXS - 5 poles M12 connector (POWER-SUPPLY).
AXM (Master models) - 5 poles M12 Secondary connector.
PIN COLOR NAME TYPE DESCRIPTION FUNCTIONING
1 Brown 24VDC +24 VDC power supply -
3 Blue 0VDC 0 VDC power supply -
5 Grey PE Ground connection -
2 White RANGE0*
4 Black RANGE1*
INPUT
Barrier configuration According the normative EN61131-2
(ref. Table 2)
* OUTPUT only on MASTER Secondary connector
Table 1
TEST and RANGE SELECTION
PIN 4 PIN 2 FUNCTIONING
24VDC 0VDC HIGH range
0VDC 24VDC LOW range
0VDC 0VDC Emitter in test mode
24VDC 24VDC Selection error
Table 2
RECEIVER CONNECTIONS
AX - 8 poles M12 connector.
AXM (Master models) - 8 poles M12 Primary connector.
PIN COLOR NAME TYPE DESCRIPTION FUNCTIONING
2 Brown 24VDC - +24 VDC power supply -
7 Blue 0VDC - 0 VDC power supply -
8 Red PE - Ground connection -
1 White OSSD1 OUTPUT
3 Green OSSD2 OUTPUT Safety static outputs PNP active high
5 Grey SEL_A INPUT
6 Pink SEL_B INPUT Barrier configuration
4 Yellow K1_K2 INPUT External contactors Feedback
According the normative
EN61131-2
(ref. Par. "Configuration and
operation modes" - page 18)
Table 3

12 8540569 • 4th February 2011 • Rev.12
AXS (Slave models) - 5 poles M12 connector (POWER-SUPPLY)
PIN COLOR NAME TYPE DESCRIPTION FUNCTIONING
1 Brown 24VDC - +24 VDC power supply -
3 Blue 0VDC - 0 VDC power supply -
5 Grey PE - Ground connection -
2 White OSSD1 OUTPUT
4 Black OSSD2 OUTPUT
Safety static outputs PNP active high
Table 4
AXM (Master models) - 5 poles M12 Secondary connector.
PIN COLOR NAME TYPE DESCRIPTION FUNCTIONING
1 Brown 24VDC -
+24 VDC power supply -
3 Blue 0VDC -
0 VDC power supply -
5 Grey PE -
Ground connection -
2 White SLAVE1 INPUT
4 Black SLAVE2 INPUT
Slave OSSD outputs
readout
According the
normative EN61131-2
(PNP active high)
Table 5
WARNINGS REGARDING THE CONNECTION CABLES
•For connections over 50 m 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 Emitter and the Receiver to the ground outlet.
•The connection cables must follow a different route to that of the other power
cables.

8540569 • 4th February 2011 • Rev.12 13
Example of MASTER-SLAVE connection in
MANUAL mode without external contactors K1-K2
Figure 11
ÎIn order to assure a correct barrier operation, it is necessary to
connect the pins 2 and 4 of the Emitter according to table 2 (page 11) and
to the "TEST FUNCTION" paragraph of page 25.
(Ref. Table 2
Page 11)

14 8540569 • 4th February 2011 • Rev.12
Example of MASTER-SLAVE connection in
MANUAL mode with external contactors K1-K2
Figure 12
ÎIn order to assure a correct barrier operation, it is necessary to
connect the pins 2 and 4 of the Emitter according to table 2 (page 11) and
to the "TEST FUNCTION" paragraph of page 25.
(Ref. Table 2
Page 11)

8540569 • 4th February 2011 • Rev.12 15
Example of MASTER-SLAVE connection in
AUTOMATIC mode without external contactors K1-K2
Figure 13
ÎIn order to assure a correct barrier operation, it is necessary to
connect the pins 2 and 4 of the Emitter according to table 2 (page 11) and
to the "TEST FUNCTION" paragraph of page 25.
(Ref. Table 2
Page 11)

16 8540569 • 4th February 2011 • Rev.12
Example of MASTER-SLAVE connection in
AUTOMATIC mode with external contactors K1-K2
Figure 14
ÎIn order to assure a correct barrier operation, it is necessary to
connect the pins 2 and 4 of the Emitter according to table 2 (page 11) and
to the "TEST FUNCTION" paragraph of page 25.
(Ref. Table 2
Page 11)

8540569 • 4th February 2011 • Rev.12 17
Example of connection in MANUAL mode
with external contactors K1-K2
Figure 15
Example of connection in AUTOMATIC mode
with external contactors K1-K2
Figure 16
ÎIn order to assure a correct barrier operation, it is necessary to
connect the pins 2 and 4 of the Emitter according to table 2 (page 11) and
to the "TEST FUNCTION" paragraph of page 25.
(Ref. Table 2
Page 11)
(Ref. Table 2
Page 11)

18 8540569 • 4th February 2011 • Rev.12
CONFIGURATION AND OPERATION MODES
The ADMIRAL AX operation mode is selected realizing appropriate connections on the M12
8 poles of the Receiver (Table 6 and Table 7).
AUTOMATIC MODE
The ADMIRAL AX light curtain does not dispose of a start/restart interlock circuit in
automatic mode. In most applications this safety function is necessary. Please
consider the risk-analysis of your application about this matter.
In AUTOMATIC functioning, the two static outputs OSSD1 and OSSD2 follow the status of
the guarded opening.
•with the area guarded clear, the outputs will supply +24VDC
•with the area occupied they will supply 0VDC.
CONNECTION OPERATION MODE
SEL_A (PIN 5)
connected to :
OSSD1 (PIN 1)
SEL_B (PIN 6)
connected to :
OSSD2 (PIN 3)
K1_K2 (PIN 4)
connected to :
0VDC
AUTOMATIC without
K1-K2 feedback control
SEL_A (PIN 5)
connected to :
OSSD2 (PIN 3)
SEL_B (PIN 6)
connected to :
OSSD1 (PIN 1)
K1_K2 (PIN 4)
connected to : 24VDC
(through series of contatcts
N.C. of external relays)
AUTOMATIC with
K1-K2 feedback control
Table 6
MANUAL MODE
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.
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 7).
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 100ms.
CONNECTION OPERATION MODE
SEL_A (PIN 5)
connected to :
24VDC (PIN 2)
SEL_B (PIN 6)
connected to :
24VDC (PIN 2)
(through the RESTART
pushbutton)
K1_K2 (PIN 4)
connected to :
0VDC
MANUAL without K1-K2
feedback control
SEL_A (PIN 5)
connected to :
24VDC (PIN 2)
(through the RESTART
pushbutton)
SEL_B (PIN 6)
connected to :
24VDC (PIN 2)
K1_K2 (PIN 4)
connected to : 24VDC
(through series of contatcts
N.C. of external relays)
MANUAL with
K1-K2 feedback control
Table 7

8540569 • 4th February 2011 • Rev.12 19
K1/K2 EXTERNAL CONTACTORS CONNECTION
In every operating mode the K1/K2 external contactors feedback is activable.
If you want to use this control feature, connect the pin 4 of 8 poles M12 connector with the
power supply (+24VDC) through the series of N.C. contatcts (feedback) of external
contactors.
MULTIPLE SYSTEMS
When more than one ADMIRAL AX system is used, precautions must be taken to avoid
optical interference between them: install units so that the beam emitted by the Emitter of
one system can only be received by the relative Receiver.
Figure 17 illustrates some examples of correct positioning when two photoelectric systems
are installed. Incorrect positioning could generate interference, and may result in
malfunctioning.
Figure 17
ÎThis operation is not necessary in case of coexistence of a MASTER
and a SLAVE.
Systems installed alongside each other:
A
Installation of two adjacent Emitters
Overlapping systems: B
L-shaped installation: C
Crossed positioning of Emitters and receivers
+24VDC
4
RX
K1 K2