Reer JANUS Installation, Use And Maintenance Manual

TYPE 4 SAFETY LIGHT CURTAIN
JANUS
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8540573 • 16/09/2016 • Rev.20
1
TYPE 4 SAFETY LIGHT CURTAIN
JANUS
SUMMARY
INTRODUCTION ............................................................................................................................................... 3
PRINCIPLE OF OPERATION ........................................................................................................................... 4
LIGHT CURTAIN ............................................................................................................................................ 4
MUTING FUNCTION ..................................................................................................................................... 5
SERIES "ML" - PREASSEMBLED KIT OF JANUS LIGHT CURTAIN AND SENSOR ELEMENT “Ml
S” Integrated Muting sensors only for one-way openings with pallet exit. ........................................ 5
SERIES "MT" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS ELEMENTS “MT SI” and “MT SE” Integrated Muting sensors – for two-way openings with pallet entrance/exit. .. 6 SERIES "MT S4" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS
ELEMENTS “MT S” Integrated Muting sensors – for two-way openings with pallet entrance/exit. .... 6
SERIES "ML S2" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS
ELEMENTS “ML S” Integrated Muting sensors – for one-way openings with pallet exit. ................... 7
MODEL "MI" – external sensors 3 selectable methods of Muting. ...................................................... 7
MI models used with “l” operational logic.............................................................................................. 9
INSTALLATION ................................................................................................................................................ 9
POSITIONING .............................................................................................................................................. 11
POSITIONING OF THE MUTING SENSORS ("MI" SERIES). ........................................................... 11
POSITIONING AND ADJUSTMENT OF SENSOR ELEMENTS FOR "ML" and "MT" SERIES: ...... 13
CALCULATION OF THE SAFETY DISTANCE .................................................................................. 14
VERTICAL POSITIONING OF THE LIGHT CURTAIN ....................................................................... 15
MULTIPLE SYSTEMS ........................................................................................................................ 17
DISTANCE FROM REFLECTIVE SURFACES .................................................................................. 17
LIGHT SIGNALS .......................................................................................................................................... 19
Emitter SIGNALS ................................................................................................................................ 19
Receiver SIGNALS ............................................................................................................................. 20
ELECTRICAL CONNECTIONS AND CONNECTORS ................................................................................ 22
EMITTER Connections (Male Connector) ......................................................................................... 22
RECEIVER CONNECTIONS (Main Connector - Male) ...................................................................... 23
Connections CONNECTOR M12 n. 1 (for muting sensor) ("MI" MODELS) (Female Connector) ...... 24
Connections CONNECTOR M12 n. 2 (for muting sensor) ("MI" MODELS) (Female Connector) ..... 24
RECEIVER CONNECTIONS J LR M12 MODELS ............................................................................. 25
SELECTION OF CONFIGURATION AND OPERATING MODE ................................................................. 25
SELECTION FEEDBACK EXTERNAL CONTACTORS K1/K2 .......................................................... 25
SELECTION OF MANUAL/AUTOMATIC FUNCTIONING ................................................................. 26
SELECTION OF THE MAXIMUM DURATION AND TYPE OF MUTING .......................................... 27
OVERRIDE CONFIGURATION .......................................................................................................... 27
MUTING OVERRIDE FUNCTION (“M” MODELS) ............................................................................. 28
"SYSTEM STATUS" OUTPUT (“M” MODELS) .................................................................................. 29
TEST FUNCTION ............................................................................................................................... 29
SAFETY MODULES MJB1 - MJB2 - MJB3 - MJB4 ........................................................................... 29
EXAMPLE OF CONNECTION WITH EXTERNAL CONTACTORS K1/K2 WITH start/restart interlock
activated .............................................................................................................................................. 30
EXAMPLE OF CONNECTION WITH AD SR0 WITH start/restart interlock activated ....................... 31
MUTING STATUS AND LIGHT ("M" MODELS) .............................................................................. 31
CONFIGURATION AND OPERATION MODES J LR M12 ......................................................................... 32
AUTOMATICO MODE ........................................................................................................................ 32
MANUAL MODE ................................................................................................................................. 33
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DIMENSIONS .................................................................................................................................................. 34
JANUS "MI" - "J" .......................................................................................................................................... 34
JANUS "ML" ................................................................................................................................................. 35
JANUS "MT" ................................................................................................................................................. 35
JANUS "ML S2" - "MT S4" ........................................................................................................................... 36
TECHNICAL DATA ......................................................................................................................................... 37
CHECKOUTS AND MAINTENANCE ........................................................................................................... 41
TROUBLESHOOTING ................................................................................................................................. 42
ACCESSORIES ........................................................................................................................................... 44
GUARANTEE .................................................................................................................................................. 45
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INTRODUCTION
This symbol indicates an important personal safety warning. Failure to comply with the warning may result in very high risks for exposed personnel.
The JANUS safety light curtain is a multi-beam opto-electronic safety system of the Type 4 category of electro-sensitive devices (in accordance with IEC 61496-1,2; EN 61496-1) – if necessary equipped with MUTING function (“M” models) - for the protection of persons exposed to dangerous machines or plants.
The two PNP auto-controlled static outputs permit connection of the light curtain to a control system complying with the requirements and level of safety required for the application.
The light curtain integrates the start/restart interlock and EDM functions (control of external relays K1 and K2). In this way, the light curtain can be connected to a simple pair of relays or external safety contactors without having to install additional modules.
A diagnostic display on the Emitter and Receiver provide the information required for correct use of the device and to check for any operating faults.
The diagnostic output (see TROUBLESHOOTING, page 42) makes it possible to obtain weak signal and light curtain status information from a single wire.
JANUS is ideal for protecting:
automatic palletizing/depalletizing systems  materials handling and storage systems;  packing and packaging machines;  assembly lines;  industrial automatic warehouses;  AGV transit openings;  metal, wood, marble and glass tool machines;  presses, die cutting machines.
For problems regarding safety, if necessary, consult the competent safety authorities of your country or the related industrial association.
For applications in the food industry, consult the manufacturer to check compatibility between the materials of the light curtain and the chemical agents used.
The guarding function of opto-electronic safety devices is not effective in the case in which the machine cannot be electrically controlled and is unable to stop the dangerous movement immediately at any time during the work cycle.
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PRINCIPLE OF OPERATION
LIGHT CURTAIN
If the area guarded is clear, the two outputs on the Receiver are active and permit normal functioning of the machine connected to these.
When an object larger than or equal to the resolution of the system interrupts the sensing field of one or more beams, the Receiver de-activates its outputs.
This condition makes it possible to block the dangerous movement of the machine (using a suitable machine stop circuit).
Resolution is the smallest diameter object that will be reliably detected by at least one of the optical beams generated by the light curtain (Figure 1).
Figure 1- Light curtain resolution
Resolution is constant regardless of working conditions as it depends only on the geometrical characteristics of the lenses and the center distance between two adjacent lenses. The height of the guarded area is the height effectively protected by the safety light curtain.
If the curtain is positioned horizontally, this value indicates the depth of the guarded zone. The useful range is the maximum operating distance that can exist between the Emitter and Receiver.
JANUS is available with the following resolutions (MODEL "MI") :
30mm (protected heights from 300mm to 1200mm) ("MI" models):
PROTECTION OF THE HANDS.
40mm (protected heights from 300mm to 1800mm) (“MI”, "MILR" and “JLR” models):
PROTECTION OF THE HANDS.
90mm (protected heights from 300mm to 1800mm) ("MI" models):
PROTECTION OF THE LIMBS.
JANUS is also available in a Multibeam version ("MI", "MT" and "ML" models) with a pitch between the lenses of:
500mm (2 beams), 400mm (3 beams), 300mm (4 beams only models "MI"), "MILR"
”J” and “JLR”. PROTECTION OF THE BODY.
P = Pitch bewteen two lenses D = Diameter of one lens R = Resolution = P+D
Emitter
Receiver
Opaque Object
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MUTING FUNCTION
The Muting function is a temporary suspension of the safety light curtain’s protective function. Carefully check your risk analysis in order to assess whether the Muting function is compatible with your application and what additional measures have to be taken.
The Muting function generates a temporary, automatic interruption of safety light curtain functioning in order to permit normal transit of material through the guarded opening.
The Muting function is activated when the system detects the object that interrupts the opening protected. In other words, when the system recognizes the material and distinguishes between this and any operator (in a potentially dangerous situation), it is enabled to bypass the light curtain temporarily, allowing the material to pass through the opening.
The Muting sensors – which can be integrated in the light curtain (models "ML" and "MT") or be external (model "MI") – form the sensing system that decides whether the Muting function is to be activated (or not). Control of the dangerous opening can be de-activated only by a correct sequence of interruption of the beams of the Muting sensors.
The JANUS system is available in the “ML" and "MT” models (with 2 integrated opto-electronic sensors) and "MI" models to which 2 or 4 sensors of various type can be connected (proximity, optical, capacitive etc).
SERIES "ML" - PREASSEMBLED KIT OF JANUS LIGHT CURTAIN AND SENSOR ELEMENT “ML S” Integrated Muting sensors – only for one-way openings with pallet exit.
In this model, the sensors 1 and 2 are on the same side of the vertical light curtain and are placed in front of the guarded opening (Figure 2). This model is one-way and is useful for protecting pallet exit openings. The Muting function is activated following concurrent interruption (within max. 4 sec) of sensors S1 and S2. The Muting function remains active as long as both sensors remain occupied. When the first of the 2 sensors is cleared, the material has four seconds to abandon the guarded area delimited by the light curtain. The Muting condition will be disabled as soon as the protected area is cleared. After 4 seconds, if the light curtain is still occupied, the OSSD outputs are disabled, interrupting functioning of the machine. For this model, the maximum duration of the Muting condition (timeout) can be set to 30 seconds or 90 minutes.
To guarantee the safety operation of the ML series, the horizontal muting sensor must be mounted INSIDE the dangerous area (dashed on Figure 2).
When using a ML series JANUS, the minimum distance between two consecutive pallet must be less than 10cm or more than 32cm.
Figure 2
Emitter
Receiver
Sensor 1
Sensor 2
DDAANNGGEERROOUUSS
AARREEA
A
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SERIES "MT" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS ELEMENTS “MT SI” and “MT SE” Integrated Muting sensors – for two-way openings with pallet entrance/exit.
In this model, the Muting sensors are the first on one side and the second on the other in relation to the vertical light curtain (Figure 3). This model is therefore two-way and is useful for protecting pallet entrance/exit openings.
The point of intersection of the two muting sensors (Figure 11) must be inside the dangerous area in order to avoid accidental actuation of the Muting function.
The Muting function is activated following concurrent interruption (within max. 4 sec) of sensors S1 and S2. The Muting function remains active as long as both sensors remain occupied. When the first of the two sensors is cleared, the Muting function is disabled. Also for this model, the maximum duration of the Muting condition (timeout) can be set to 30 seconds or 90 minutes.
Figure 3
SERIES "MT S4" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS ELEMENTS “MT S” Integrated Muting sensors – for two-way openings with pallet entrance/exit.
This model is two-way and is useful for protecting pallet entrance/exit openings (Figure 4). Using this model, two methods of operation are possible:
Concurrent
The Muting function is activated following concurrent interruption of sensors S1 and S2 (within maximum 4sec) (or S4 and S3 with material transiting in the opposite direction). Muting status ends after clearing
of the opening and of S3 (or S2 with material transiting in the opposite direction).
Sequential
The Muting function is activated following sequential interruption of sensors S1 and S2, of the opening and of sensors S3 and S4. It is important to remember that,
for correct actuation of the Muting function, the sequence indicated in Figure 8 and Table 1 is required (without time restrictions).
The MT S4 models have two
available timeouts: 1) 30 sec;
2) infinite (Sequential operation).
The pallet minimum length (in both
operation modes) must be 70cm (all the 4 sensors have to be simultaneously occupied).
Figure 4
Emitter
Receiver
Sensor 1
Sensor 2
Sensor 3
Sensor 4
DDAANNGGEERROOUUSS
AARREEA
A
Emitter
Receiver
Sensor 1
Sensor 2
DDAANNGGEERROOUUSS
AARREEA
A
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SERIES "ML S2" - KIT PREASSEMBLED OF JANUS LIGHT CURTAIN AND SENSORS ELEMENTS “ML S” Integrated Muting sensors – for one-way openings with pallet exit.
In this model, the sensors 1 and 2 are on the same side of the vertical light curtain and are placed in front of the guarded opening (Figure 5). This model is one-way and is useful for protecting pallet exit openings. The Muting function is activated following concurrent interruption (within max. 4 sec) of sensors S1 and S2. The Muting function remains active as long as both sensors remain occupied. When the first of the 2 sensors is cleared, the material has four seconds to abandon the guarded area delimited by the light curtain. The Muting condition will be disabled as soon as the protected area is cleared. After 4 seconds, if the light curtain is still occupied, the OSSD outputs are disabled, interrupting functioning of the machine. For this model, the maximum duration of the Muting condition (timeout) can be set to 30 seconds or 90 minutes.
To guarantee the safety operation of the ML S2 series, the horizontal muting sensor must be mounted INSIDE the dangerous area (dashed in Figure 5).
When using a ML series JANUS, the minimum distance
between two consecutive pallet must be 40cm.
Figure 5
MODEL "MI" – external sensors 3 selectable methods of Muting.
The "MI" model can use 2 or 4 sensors that must be connected to the M12 connectors on the front part of the vertical light curtain. These sensors may be of various types (proximity, optical, capacitive with PNP or electromechanical type output and with DARK-ON switching (i.e. output active when material is present). If 4 sensors are connected, it is possible to choose two methods of operation: 1) Concurrent; 2) Sequential.
CONNECTION WITH 2 EXTERNAL SENSORS (Figure 6)
This model is two-way and is useful for protecting pallet entrance/exit openings.
The point of intersection of the two sensors must be located inside the dangerous area to prevent accidental and dangerous activation of the Muting function.
The Muting function is activated following concurrent interruption (within max. 4s) of sensors S1 and S2. The Muting function continues as long as both sensors are occupied. When the first of the two sensors is cleared, the Muting function is disabled. Also for this model, the maximum duration of the Muting condition (timeout) can be set to 30 seconds or 90 minutes.
Figure 6
Receiver
Emitter
Sensor 2
Sensor 1
DDAANNGGEERROOUUSS
AARREEA
A
Emitter
Receiver
Sensor 1
Sensor 2
DDAANNGGEERROOUUSS
AARREEA
A
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CONNECTION WITH 4 EXTERNAL SENSORS
Using 4 sensors, two methods of operation are possible:
Sequential (figure 7)
The Muting function is activated following sequential interruption of sensors S1 and S2 and of sensors S3 and S4. It is important to
remember that, for correct actuation of the Muting function, the sequence indicated in Figure 8 and Table 1 is required (without time restrictions).
It is also possible to enable a control of the activation time of the 4 sensors.
Concurrent
The Muting function is activated following concurrent interruption of sensors S1 and S2 (within maximum 4sec) (or S4 and S3 with material transiting in the opposite direction).
Muting status ends after clearing of the opening and of S3 (or S2 with material transiting in the opposite direction).
The MI models connected with 4 external
sensors, have two available timeouts:
1) 30 sec; 2) infinite.
Figure 7
sensor1
sensor2
sensor3
sensor4
Muting
Figure 8
Sequential muting: activation sequence.
SENSOR 1
SENSOR 2
SENSOR 3
SENSOR 4
LIGHT CURTAIN STATUS
0 0 0
0
LIGHT CURTAIN ACTIVE
1 0 0
0
LIGHT CURTAIN ACTIVE
1 1 0 0 MUTING
1 1 1 0 MUTING
1 1 1 1 MUTING
0 1 1 1 MUTING
0 0 1 1 MUTING
0 0 0
1
LIGHT CURTAIN ACTIVE
0 0 0
0
LIGHT CURTAIN ACTIVE
Table 1
LEGEND: 0 = SENSOR FREE; 1 = SENSOR ENGAGED
SENSOR 1
SENSOR 2
SENSOR 3
SENSOR 4
MUTING
ENGAGED
CLEAR
Emitter
Receiver
Sensor 4
Sensor 3
Sensor 2
Sensor 1
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Both operating modes with 4 sensors are TWO-WAY. The correct Muting sequence can start either from sensor 1 or from sensor 4.
MI MODELS USED WITH “L” OPERATIONAL LOGIC
In this model the sensors 1 and 2 are on the same side with respect to the vertical curtain and are positioned in front of the dangerous opening (Figure 9 and Figure 10). This model is unidirectional and is useful for protecting openings with pallet exit. The activation of the Muting function takes place following the simultaneous interruption (within max. 4 sec) of sensors S1 and S2. The Muting function remains while both sensors are occupied. On release of the first of the 2 sensors, the material will still have 4 seconds available to abandon the protected area delimited by the curtain. The Muting condition will be disabled as soon as the protected area is released. If the curtain is still occupied after the 4 seconds, the OSSD outputs are disabled, interrupting machine functioning. For this model, the maximum duration of the Muting condition (timeout) can be selected in 30 seconds or 90 minutes (Table 13).
It is indispensable that a Muting sequence is completed (release of controlled area) in order to
guarantee the correct activation of the successive sequence.
For safe functioning of the MI series (with L logic), it is necessary that the muting sensors are positioned inside the dangerous area (traced in Figure 9 and Figure 10).
Figure 9 - Crossed sensors
Figure 10 - Parallel sensors
INSTALLATION
Before installing the JANUS safety system, check that:
The safety system is used only as stopping device and not as machine control device.
The machine can be controlled electrically.
Any dangerous action of the machine can be promptly interrupted. In particular, the stopping time of the machine must be known, if necessary measure this.
The machine must not cause dangerous situations due to flying or dropping of material; otherwise, additional mechanical guards are required.
The minimum size of the object that must be detected must be greater than or equal to the resolution of the model selected.
DDAANNGGEERROOUUSS
AARREEA
A
Emitter
Receiver
Sensor 2
Sensor 1
DDAANNGGEERROOUUSS
AARREEA
A
Emitter
Receiver
Sensor 2
Sensor 1
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Knowing the shape and dimensions of the dangerous area, it is possible to assess the width and height of its access area:
Compare these dimensions with the maximum useful range and the height of the area protected of the model used.
Before positioning the safety device, take into account the following general indications:
Check that the temperature of the environments where the system is installed is compatible with the temperature operating parameters indicated in the technical data.
Do not position the Emitter and Receiver close to sources of bright light or high intensity flashing lights.
Particular environmental conditions may impair the detection efficiency of light curtains. In places with the possibility of mist, rain, fumes or dust, for correct functioning of the equipment it is advisable to apply suitable correction factors Fc to the values of useful operating range.
In these cases: Pu = Pm x Fc
where Pu and Pm are respectively the useful and maximum operating range in meters.
The recommended Fc factors are indicated in the table below.
ENVIRONMENTAL
CONDITION
CORRECTION FACTOR Fc
Mist
0,25
Vapors
0,50
Dust
0,50
Dense fumes
0,25
Table 2
If the device is installed in areas liable to sudden changes in temperature, suitable measures must be taken in order to avoid formation of condensation on the lenses which could impair detection efficiency.
If JANUS light curtains are used with palletizers, depalletizers and stacking/destacking machines for empty pallets, refer to European standard EN 415-4.
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POSITIONING
Protection of the guarded opening by JANUS must be integrated with suitable mechanical guards.
While the "MI" model permits various types of installation (2, 4 sensors, one- or two-way), the "ML" and "MT" have been designed for "dedicated" use.
In particular, "ML" manages the muting function in one-way mode (normally for
pallet exit); in this case, the horizontal arms must be positioned between the dangerous area and the light curtain.
The "MT" model manages the muting function in two-way mode using four horizontal
arms. This model is useful when the pallets, once the process has been carried out by the dangerous machine, must be returned outside using the same palletizer.
POSITIONING OF THE MUTING SENSORS ("MI" SERIES).
2 sensors
The Emitter and receiver of the light curtain must be positioned so as to permit access to the dangerous area from above, from below and from the sides without first of all intercepting at least one of the optical beams.
Indications for correct positioning of the light curtain are provided in the figure below.
Figure 11
For correct positioning of sensors 1 and 2, i.e. those that manage enabling and disabling of the Muting function, take into account the following:
the two beams must be crossed and pass diagonally through the zone guarded by
the light curtain;
the point of intersection of the two beams must be in the dangerous area beyond
the light curtain;
the angle between the two Muting beams must be calculated according to the size of
the pallet and its speed, taking into account that the Muting function is activated only if the interception delay between the two sensors is less than 4 seconds;
the pallet must interrupt the two beams before intercepting the light curtain;  the two beams must be interrupted continuously by the pallet for the entire period
during which the pallet passes between the sensors;
make sure that the two beams are effectively intercepted by the material on the pallet
and not by the empty pallet;
the zone identified by the points of interception and clearing of the beams of sensors
1 and 2 by pallet must be limited as far as possible (or suitably protected) so as
S1 = Sensor 1 S2 = Sensor 2
R1 = Reflector 1 (or Receiver 1) R2 = Reflector 2 (or Receiver 2)
B = Light curtain
Material
Dangerous area
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to avoid the possibility of accidental passing through the light curtain with Muting active (Figure 12).
Figure 12
4 sensors
For correct positioning of sensors 1, 2, 3 and 4, i.e. those that manage enabling and disabling of the Muting function, take into account the following:
Figure 13
SEQUENTIAL (Figure 8, Figure 13 Table 1):
the distance between the first and the
last sensor must never exceed the length of the pallet (in one of the phases of
the sequence, the 4 sensors must all be intercepted simultaneously);
the pallet must interrupt sensors S1 and
S2 (or S4 and S3 in the opposite direction) before intercepting the light curtain;
make sure that the two beams are
intercepted by the material on the pallet and not by the empty pallet
Figure 14
CONCURRENT (Figure 14):
The Muting function is activated following
concurrent interruption (within max. 4
sec) of sensors S1 and S2 (or S4 and S3 in the opposite direction).
also in this operating mode, for correct
activation of the Muting function, for a
short period of time, all 4 sensors must be intercepted simultaneously.
Dimension to be reduced to a minimum
Mechanical guards
Material
DANGEROUS
AREA
Mechanical guards
DANGEROUS
AREA
Material
Mechanical guards
DANGEROUS
AREA
Material
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POSITIONING AND ADJUSTMENT OF SENSOR ELEMENTS FOR "ML" AND "MT" SERIES:
As already mentioned, the pre-assembled JANUS "ML" and "MT" kit consist of a vertical light curtain and of one ("ML" series) or two ("MT" series) horizontal sensor element in which the Muting sensors are integrated.
The system is equipped with a VERTICAL adjustment of the sensor elements to solve the following problems:
Incorrect and non-continuous sensor beam interception by the material in movement.  Need to reduce the beam intensity when transparent objects (i.e. glass, plastic, etc)
are detected.
At the operating range limits (1 ÷ 2,5m) or in dusty environments, it would be necessary to use the ANGULAR adjustment to reach the maximum signal intensity. (REER advise against this operation with transparent materials).
Figure 15 shows the two axes (horizontal and vertical) on which to operate. To make the adjustment:
loosen the Allen screws;  operate on the arms to make the adjustments;  tighten the Allen screws.
Figure 15
NOTE: For installations that do not require any particular adjustments, the ML and MT models are pre-aligned and do not require further regulation.
MAXIMUM VERTICAL ADJUSTMENT PERMITTED: + 70mm
MAXIMUM ANGULAR ADJUSTMENT PERMITTED: + 8°
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CALCULATION OF THE SAFETY DISTANCE
The light curtain must be positioned at a distance exceeding or equal to the minimum safety distance S so that a dangerous point can be reached only after stopping the dangerous action of
the machine (Figure 16). Referring to European standard EN999, the minimum safety distance S must be calculated
according to the following formula:
S = K (t1 + t
2
) + C
where:
S
minimum safety distance
mm
K
speed of approach of the body to the danger area.
mm/sec
t1
total response time in seconds of the safety light curtain
sec
t2
response time of the machine in seconds, i.e. the time taken by the machine
to interrupt the dangerous action from the moment in which the stop signal is
transmitted
sec
C
additional distance
mm
Failure to comply with the safety distance reduces or defeats the protective function of the light curtain.
If the position of the light curtain does not exclude the possibility of the operator accessing the danger area without being detected, the system must be equipped with additional mechanical guards.
Figure 16
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