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.

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Connector pins
Figure 8
EMITTER
NUMBER
COLOR
NAME
MEANING
1
Brown
24 VDC
Power supply (positive)
2 (see table 2)
White
SEL RANGE/TEST1
Input 1 for range / TEST selection
3
Blue
0 VDC
Power supply (negative)
4 (see table 2)
Black
SEL RANGE/TEST2
Input 2 for range / TEST selection
5
Grey
PE
Ground connection
Table 1
RANGE and TEST SELECTION
PIN 2
PIN 4
MEANING
+24 Vdc
0 Vdc *
LOW range (0 6m) (0  2m for 14mm models)
0 Vdc *
+24 Vdc
HIGH range (1 18m) (0  5m for 14mm models)
0 Vdc *
0 Vdc *
EMITTER IN TEST CONDITION
+24 Vdc
+24 Vdc
Condition not allowed
* (0 Vdc or open circuit)
Table 2
If the working distance between the Emitter and Receiver is less than 6m (2m for
14mm resolution models), is recommended to use the low range (selectable on the
Emitter) (table 2).
RECEIVER
NUMBER
COLOR
NAME
MEANING
1
Brown
24 VDC
Power supply (positive)
2
White
OSSD1
Static output No. 1 (PNP active high)
3
Blue
0 VDC
Power supply (negative)
4
Black
OSSD2
Static output No. 2 (PNP active high)
5
Grey
PE
Ground connection
Table 3
EMITTER RECEIVER

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Example of connection of the ADMIRAL
barrier to the ReeR AD SR1 safety module
+
-+
-
*Refer to table 2, page 10 for the correct connection of pins 2 and 4
Figure 9
*

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Examples of connection of ADMIRAL barrier
Figure 10

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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.
MULTIPLE SYSTEMS
When more than one ADMIRAL 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 11 illustrates some examples of correct positioning when two photoelectric systems
are installed. Incorrect positioning could generate interference, and may result in
malfunctioning.
Figure 11
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 12, object Ais not
detected because surface Sreflects the beam and closes the optical path between the
Emitter and Receiver.
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 Emitter and the Receiver, considering that the angle of projection and
reception is 4°.
Figure 12
Figure 13 illustrates the values for the minimum distance dthat must be maintained when the
distance lbetween the Emitter and Receiver is changed.
Systems installed alongside each other: A
Installation of two adjacent Emitters
Overlapping systems: B
L-shaped installation: C
Crossed positioning of Emitters and receivers

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Figure 13
After installing the system, check whether any reflecting surfaces intercept the beams, first in
the centre and then in the vicinity of the Emitter and Receiver.
During these operations, the red LED on the Receiver should never, for any reason,
switch off.

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USE OF DEFLECTION MIRRORS
In order to protect or control areas that can be accessed from more than one side, in addition
to the Emitter and Receiver, one or more deflection mirrors can be installed.
These mirrors enable the optical beams generated by the Emitter to be deviated on one or
more sides.
If the beams emitted by the Emitter must be deviated by 90°, the perpendicular to the
surface of the mirror must form an angle of 45° with the direction of the beams.
The following figure illustrates an application in which two deviation mirrors are used to
provide a U-shaped protection.
Figure 14
The following rules should be taken into consideration when using deviation mirrors:
Place the mirrors so as to ensure compliance with the minimum safety distance S
(Figure 14) on each side from which the danger zone can be accessed.
The working distance (range) is given by the sum of the lengths of all the sides
that give access to the protected area. (Remember that for each mirror used the
maximum working range between the Emitter and the Receiver is reduced
by 15%).
During installation, take great care to avoid twisting along the longitudinal axis of
the mirror.
Make sure, by standing near to and on the axis of the Receiver, that the entire
outline of the Emitter is visible on the first mirror.
The use of more than three deviation mirrors is not recommended.

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MECHANICAL ASSEMBLY AND OPTIC ALIGNMENT
The Emitter and the Receiver must be assembled opposite each other (at a distance
specified in the technical data sheet). Use the fastening brackets and inserts supplied with
the system to place the Emitter and the Receiver so that these are aligned and parallel to
each other and with the connectors facing the same way.
Depending on the dimensions and the shape of the support on which they are to be installed,
the Emitter and Receiver must be assembled with the fastening inserts at the back, or else
by fitting these in the side groove (Figure 15).
Perfect alignment of the Emitter and Receiver is essential in order to assure correct barrier
operation. The indicator LEDs on the Emitter and Receiver facilitate this operation.
Figure 15
Position the optical axis of the first and last beam of the Emitter on the same
axis as that of the corresponding beams on the Receiver.
Move the Emitter in order to find the area within which the green LED on the
Receiver stays on, then position the first beam of the Emitter (the one close to
the indicator LEDs) in the centre of this area.
Using this beam as a pivot, effect small sideways movements of the opposite
end to move to the protected area clear condition. The green LED on the
Receiver will indicate this condition.
Lock the Emitter and Receiver in place.
During these operations it may be useful to check the yellow weak signal LED on the
Receiver. Upon completion of alignment, this LED must be off.
If the Emitter and the Receiver are 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
Emitter
LED
COLOUR
STATUS
DISPLAY (4)
CONDITION
1
Yellow
On
8
System activated. Initial TEST.
2
Red
On
1
Yellow
On
L / H
TEST condition
3
Green
On
3
Green
On
L
Normal operation, low range
3
Green
On
H
Normal operation, high range
2
Red
On
FAULT CODE
Malfunction *
Receiver
LED
COLOUR
STATUS
DISPLAY (8)
CONDITION
5
Yellow
On
8
System activated.
6
Red
On
6
Red
On
Off
Protected area engaged
5
Yellow
On
Off
Weak signal received
7
Green
On
Off
Protected area clear
6
Red
On
FAULT CODE
Malfunction *
* 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.
Figure 16
On the emitter of the multibeam models, near each beam, is present a red led
which permits an easy detection of the beam.

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TEST FUNCTION
The Admiral light curtain does not dispose of a start/restart interlock circuit. In most
applications this safety function is necessary. The safety relay Admiral ADSR1
permits to implement this function in a safe way according to IEC 61496-1.
Please consider the risk-analysis of your application about this matter.
By means of the test function, which simulates occupation of the protected area, it possible
to verify the operation of the entire system by means of an external supervisor (e.g. PLC,
control module, etc.).
The ADMIRAL barrier system features an automatic self-diagnosis function that enables it to
detect response time malfunctions (this time is declared for each model).
This safety system is permanently active and does not require any interventions from the
outside. The TEST function is available should the user wish to check equipment connected
downstream of the barrier (without physically entering the protected area).
By means of this function the OSSDs can be switched from ON to OFF as long as the
function remains active. Please see table 2 (page 10) for details about the use of the test
function. The minimum duration of the TEST function must be 80 msec.
OUTPUTS STATUS
The ADMIRAL features two static PNP outputs on the Receiver, 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
48. Maxim load capacity corresponds to 2.2F. 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
24VDC
Barrier clear condition
OSSD2
OSSD1
0VDC
Barrier engaged condition or failure
detected
OSSD2
Table 4
In the protected area clear condition, the Receiver supplies a voltage of 24 VDC on
both outputs. The required load must therefore be connected between the output
terminals and the 0DVC (Figure 17).
Figure 17

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TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS OF ADMIRAL BARRIERS
Protected height
mm
160 –1810
Resolutions
mm
14 –20 –30 –40 –50 –90
Working range (selectable)
14mm models
m
0 2 (low)
0 5 (high)
Working range (selectable)
20, 30, 40, 50, 90mm and
Multibeam models
m
0 6 (low)
1 18 (high)
Safety outputs
2 PNP –500mA @24VDC
Response time
ms
3 27 (see tables for specific models)
Power supply
Vdc
24 20%
Connections
Connectors M12 5-pole
Max. conn. length
m
100
Operating temp.
°C
0 55 °C
Protection rating *
IP 65
Dimensions of section
mm
35 x 45
Max. consumption
W
2 (Emitter)
3 (Receiver)
Light curtain lifetime
20 years
Safety level
Type 4
IEC 61496-1:2004
IEC 61496-2:2006
SILCL 3
IEC 62061:2005
PL e - Category 4
ISO 13849-1:2006
*) Devices are not suitable for outdoor use without supplementary measures
14 mm resolution
models
AD
151
AD
301
AD
451
AD
601
AD
751
AD
901
AD
1051
AD
1201
AD
1351
AD
1501
AD
1651
AD
1801
Number of beams
15
30
45
60
75
90
105
120
135
150
165
180
Response time
6
7,5
9,5
11,5
13,5
15,5
17
19
21
23
25
27
Overall barrier ht. mm
261
411
561
711
861
1011
1161
1311
1461
1611
1761
1911
PFHd *
1,02E-8
1,17E-8
1,33E-8
1,48E-8
1,63E-8
1,79E-8
1,94E-8
2,10E-8
2,25E-8
2,40E-8
2,56E-8
2,71E-8
DCavg #
97,77%
98,07%
98,25%
98,38%
98,47%
98,53%
98,58%
98,63%
98,66%
98,69%
98,71%
98,73%
MTTFd # years
100
92,14
81,96
73,80
67,12
61,55
56,83
52,79
CCF #
80%
20 mm
resolution models
AD
152
AD
302
AD
452
AD
602
AD
752
AD
902
AD
1052
AD
1202
AD
1352
AD
1502
AD
1652
AD
1802
Number of beams
15
30
45
60
75
90
105
120
135
150
165
180
Response time
6
7.5
9.5
11.5
13.5
15.5
17
19
21
23
25
27
Overall barrier ht. mm
261
411
561
711
861
1011
1161
1311
1461
1611
1761
1911
PFHd *
1,02E-8
1,17E-8
1,33E-8
1,48E-8
1,63E-8
1,79E-8
1,94E-8
2,10E-8
2,25E-8
2,40E-8
2,56E-8
2,71E-8
DCavg #
97,77%
98,07%
98,25%
98,38%
98,47%
98,53%
98,58%
98,63%
98,66%
98,69%
98,71%
98,73%
MTTFd # years
100
92,14
81,96
73,80
67,12
61,55
56,83
52,79
CCF #
80%
* IEC 62061
# ISO 13849-1