Reer ADMIRAL Quick start guide

PHOTOELECTRIC
SAFETY BARRIER
ADMIRAL
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8540484 • 01/09/2016 • Rev.13
PHOTOELECTRIC
SAFETY
BARRIER
ADMIRAL
INSTALLATION USE AND MAINTENANCE
TABLE OF CONTENTS
INTRODUCTION...................................................................................................................2
OPERATION .........................................................................................................................3
INSTALLATION.....................................................................................................................4
POSITION......................................................................................................................................5
SAFETY DISTANCE CALCULATION............................................................................................6
VERTICAL POSITION OF THE BARRIER....................................................................................6
HORIZONTAL POSITION OF THE BARRIER ..............................................................................8
ELECTRICAL CONNECTIONS .....................................................................................................9
MULTIPLE SYSTEMS ................................................................................................................ 13
DISTANCE BETWEEN REFLECTING SURFACES .................................................................. 13
USE OF DEFLECTION MIRRORS............................................................................................. 15
MECHANICAL ASSEMBLY AND OPTIC ALIGNMENT ............................................................. 16
OPERATION AND TECHNICAL DATA................................................................................17
SIGNALS..................................................................................................................................... 17
TEST FUNCTION ....................................................................................................................... 18
OUTPUTS STATUS.................................................................................................................... 18
TECHNICAL SPECIFICATIONS................................................................................................. 19
DIMENSIONS (in mm).........................................................................................................21
CHECKOUTS AND MAINTENANCE...................................................................................23
TROUBLESHOOTING................................................................................................................ 24
SPARE PARTS....................................................................................................................26
GUARANTEE ......................................................................................................................27

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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 ADMIRAL 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.
The ADMIRAL barrier, which consists of an Emitter and a Receiver, is a type 4
optoelectronic safety device according to standards EN 61496-1 and prEN 61496-2.
The two built-in safe static PNP outputs enable the barrier to be connected to the
ADMIRAL SR safety modules or to a safety PLC or to another control system that satisfies
the specific requirements and safety level of the application.
A diagnostics display on the Emitter and receiver supplies the information that is necessary
for the correct use of the device and to evaluate any malfunctions.
ADMIRAL is ideal for protecting:
Presses, die cutting machines, punching machines, cutting and shearing machines,
robotized areas, 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.

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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 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 is available also in the Multibeam 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

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INSTALLATION
Before installing the ADMIRAL 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

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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 position of the ADE Emitter and the ADR 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

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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+ t3) + C
where:
S
minimum safety distance
mm
K
approach speed of object to the dangerous area
mm/sec
t1
response time of the safety barrier in seconds
sec
t2
response time of the safety interface in seconds
(e.g. PLC or safety module*)
sec
t3
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
* t2AD SR1 = 20 msec (refer to the technical manual of each single safety module, if different
from AD SR1).
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

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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+ t3) + 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+ t3) + 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 4
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+ t3) + 850
The 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 5
safety barrier
point of
danger
direction
of
approach
reference plane
safety barrier
point of
danger
direction
of
approach
reference plane

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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+ t3) + 850
The reccomended height Hfrom the base
(G) must be the following:
Figure 6
MODEL
BEAMS
Reccomended Height H (mm)
AD 2B
AD 3B
AD 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+ t3) + 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 7
safety barrier
point of
danger
direction
of approach
reference plane
safety
barrier
point of
danger
direction
of
approach
reference plane

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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 external power supply must comply with EN 60204 (it can bridge short-term
mains failures of up 20ms).
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.
To guarantee reliability of operation, when using a diode jumper supply unit, its output
capacity must be at least 2000µF for each absorbed A.
TEST COMMAND AND RANGE SELECTION
To select the “Low Range” mode, suggested for all installations below 6m, connect pin 2 to
+24Vdc and pin 4 to 0Vdc. In this mode you can give the test command by bringing pin 2 to
0Vdc too. To select the “High Range” mode, for all installations above 6m, connect pin 2 to
0Vdc and pin 4 to +24Vdc.
In this mode you can give the test command by bringing pin 4 to 0Vdc too. Please see table 2.