MERLIN MT SERIES

MT1000
MT2000
MT3000
_______________________________
Operator’s Manual

Version 1.3 August 2014 P/N 60-0128

 Read This First

Proper Equipment is an important factor in occupational safety but only

one of many. The Merlin Light Curtain meets the applicable National
Electric Code (NEC), Underwriters Laboratories (UL) and Canadian
Standards Association (CSA) requirements for equipment. The Merlin
Light Curtain is also intended to perform a function governed by the
Occupational Safety and Health Act (OSHA) and meets the requirements
of OSHA and ANSI (American National Standards Institute) but, Whether
a particular Merlin installation does in fact meet all applicable
requirements depends upon how Merlin units are applied, installed,
operated, and maintained. These are factors beyond the control of the
equipment manufacturer. Every effort has been made to provide complete
application, installation, operation and maintenance instructions in this
manual. Effective use of this information to provide full compliance with
OSHA and ANSI regulations is the responsibility of the equipment
purchaser and / or user.

1
WARNINGS

The Light Curtain may not prevent access Replace these labels if necessary with:
to all hazardous motions. Additional safe-
guarding or guards may be necessary to Merlin Warning Label – P / N 28-451
prevent access over, under or around the
Light Curtain or from other areas of a par- Merlin Safety Instructions Label - P/N 28-452
ticular machine, not protected by a Light
Curtain. The following labels are located
on the Merlin control box and should be
kept in readable condition.

2
 TABLE OF CONTENTS

SECTION A: General for all units

Read This First …………………………………………………... 1
Warnings …………………………………………………………. 2
Quick Tour – MT1000, MT2000, MT3000 ……………… 4
…………....
Introduction ………………………………………………………. 5
Equipment Description ………………………………………….. 6
General Specifications ……………………………………………. 12
General Operating Instructions …………………………………. 13
Installation - Information General ……………………………... 14
- Mechanical ……………………………………... 15
- Electrical ……………………………………….. 22
Unit Testing ……………………………………………………... 27
Options - Installation ……………………………………………... 28
General Operation – Status Indicators …………………………… 30

SECTION B: Features of MT1000 units ……………………… 13, 30, 31

………….
Standard
Options

SECTION C: Features of MT2000 units …………………………… 13, 34-45

…….
Standard
Options

SECTION D: Features of MT3000 units ……………………………… 46-55

……...
Standard
SECTION E: Recommended procedure for making parts ……………………… 56
on a Press Brake …….

SECTION F: Troubleshooting …………………………………………………. 59

SECTION G: Recommended Spare Parts ……………………………………... 63

SECTION H: Warranty …………………………………………………………. 64

3
3

4
INTRODUCTION

How it Works Where and How it is Used

The Merlin Light Curtain is a solid state Designed to protect operators of hazardous
electro-optical switch intended for use as a equipment such as punch presses, press
control device on production machines. brakes, and injection molding machines,
Merlin generates and monitors a totally the Merlin Light Curtain when used with a
invisible network of closely spaced, pulsed reliable control system can lead to a more
infrared light beams between separate ergonomic and productive machine.
Transmitter and Receiver Units. Output Intrusion of any part of the operator’s body
contacts, when energized, will remain (or any object) into the hazardous area
closed as long as equipment conditions are guarded by the infrared screen immediately
normal and the entire network of light signals the machine to stop. Benefits
beams remains intact. They will open include protection of pass-by personnel as
whenever one or more of the beams is well as operators, reduced operator fatigue,
interrupted or in its power source. and increased productivity.

Safety Features
Pulsed infrared rays, digital monitoring
circuitry, and self, supervisory design make ! WARNING
the Merlin insensitive to ambient light,
smoke, oil vapors, temperature, changes, DO NOT USE THIS PRESENCE SENSING
SAFETY DEVICE ON FULL
line voltage fluctuations and the proximity REVOLUTION CLUTCH PRESSES OR
of moving persons or objects. No external MACHINERY THAT IS NOT EQUIPPED
influence can delay or prevent contact WITH RELIABLE CONTROLS, AND
when a beam is interrupted. Any single BRAKE MECHANISMS TO STOP THE
component failure of the Merlin itself will HAZARDOUS MOTION ANYWHERE IN
THE MACHINE CYCLE, WHEN THE
also open the contacts. Ambient influences STOP SIGNAL IS HENERATED BY THE
that do not actually interrupt an infrared PRESENCE SENING SAFETY DEVICE.
beam will not cause nuisance machine
shutdowns.

5
EQUIPMENT DESCRIPTION

General Modular Design

Merlin Light Curtain System consists of a The Merlin units are designed with a
control box, a set of transmitter and modular construction. The control box is
receiver columns and 2 cables. common to all columns. The control box
automatically senses the column size
It is designed to meet NEMA 12, oil tight eliminating any setup adjustments. The
requirements. The columns are constructed cables are interchangeable to the
of rugged aluminum extrusions with built- transmitter and the receiver columns. The
in shock mounts. Shock mounts are columns are usable on all 3 model control
available for the control box if heavy shock boxes: MT1000, MT2000, MT3000.
exists.
Equipment Inventory
Object Sensitivity
Standard Systems:
The Merlin units are available in 0.5 inch - Control unit
beam spacing and 1.0 inch beam spacing. - Set of columns TX, RX
This changes the object sensitivity of the - Two cables
sensing field. The object sensitivity is the - Operator manual
size of an object that when placed any
place in the sensing field of the Light Other Items:
Curtain will cause the unit to go into a - Remote Learn Button
hazard condition. This assumes that no - Remote Learn Foot Switch
forms of blanking are activated. Objects - Mirrors
smaller than the size stated as the object - Pedestals
sensitivity will interrupt beams when - Side Guards
placed directly in line with a beam, but will - Two (2) Snubber devices
fit between beams allowing a safe output
condition. The object sensitivity can be If any items ordered are missing immedi-
tested by using a rod with a diameter equal ately contact the factory or the Distributor
to the object sensitivity rating of the Light from whom the equipment was purchased.
Curtain. If damage from shipping is evident,
immediately file a claim with the shipping
The object sensitivity for Merlin units with company.
0.5 inch beam spacing is 0.87” (22 mm)
and the object sensitivity with 1” beam
spacing is 1.5” (38 mm), see pg. 27 for
testing information.

6
EQUIPMENT DESCRIPTION

7
EQUIPMENT DESCRIPTION

8
 EQUIPMENT DESCRIPTION

MT series MT series
Transmitter column Receiver column

9
 EQUIPMENT DESCRIPTION

Sample Multiple Column Arrangement

MT series MT series
Transmitter column Receiver column
End (CTEXXX) End (CTEXXX)

MT series
MT series Receiver column
Transmitter column Master (CTMXXX)
Master (CTMXXX)

9A
EQUIPMENT DESCRIPTION

10 PIN FEMALE
10 PIN MALE

Replacement Cables for Merlin MT series units

Straight connectors at both ends. Consult the factory for right
angle connectors.
2 Foot cable 55-05xx-02-00
5 Foot Cable 55-05xx-05-00
10 Foot Cable 55-05xx-10-00
15 Foot Cable 55-05xx-15-00
25 Foot Cable 55-05xx-15-00
35 Foot Cable 55-05xx-35-00
50 Foot Cable 55-05xx-50-00

10
EQUIPMENT DESCRIPTION

11
GENERAL SPECIFICATIONS
Electrical Columns
Input Power 120VAC (50 or 60 Hz) Indicators TX Safe Green LED
Optional 220 VAC Hazard Red LED
Consumption 60 W (fused @ ½ A) Muted Yellow LED
Output Circuit Two captive-contact Blanking Blue LED
relays, self checking RX Beam indicators Red
LED
rated at 125 VA General

Relay Ratings Infrared Light Source

Solid state diodes
Output Circuit 4 A @ 220 VAC Narrow beam divergence
fused @ 3 A Object Sensitivity
Alarm / Status 5 A @ 220 VAC 0.87” (22 mm) or
1.5” (38 mm)
Control Box
Temperature Range
Indicators Safe Green LED 0 to 70° C
Hazard Red LED Mounting Brackets
Muted Yellow LED Includes shock mounts
Construction 14 gage steel NEMA Scanning Range
12 or NEMA 4 25 feet standard or
Dimensions 9.5” high by 11” wide 7.6m
by 241.3mm 279.4mm For 1” beam spacing
6.75 deep (inches) optional to 50 feet
171.4mm 15.2m
Self Checking
Columns Every 8 milliseconds
Response Time
Construction Extruded aluminum Less than 27 milliseconds
NEMA 12 or NEMA 4
with quick disconnects
Dimensions 1.75” deep by 2.1”
wide
44.4mm x 53.3mm
. Lengths in
6 inch increments
152.4mm
up to 96 inches
2438.4mm

12
GENERAL OPERATING INSTRUCTIONS
Depending on the Merlin model you have Beam Indicators Red Leds are located
purchased, there are numerous ways of in the receiver column adjacent to each
indicators signaling the status of the unit. beam. They indicated when a beam is
blocked or misaligned.
Basic common indicators:
Slave Relay Monitor (OPTIONAL)
Machine Run- “Green Light” located on
both the transmitter column as well as all
Merlin units. The controls for the 2000 and If the load for the output relays is greater
3000 models will also indicate this condi- than their capacity then a slave relay must
tion by indicating the word SAFE on the be used. The slave relay monitor checks
read out. This condition indicated that the that the slave relay correctly follows the
sensing field is not obstructed by any output relays. Improper slave relay oper-
object and the units are in normal operating ation causes the alarm relay to activate and
condition. the light curtain to go into hazard mode.

Machine Stop- “Red Light” this condi- Manual Reset (All Models)
tion is displayed when an active beam is
interrupted; a component failure has been This feature prevents the machine from
detected. In this condition the two restarting after a hazard has occurred.
normally open output contact relays will Then the light curtain must “see” a safe
prevent machine operation. condition and you must press the manual
reset switch to continue. See fig. 14.
Machine by-pass- “Amber Light” located
in the transmitter column; and the control Alarm Relay (Optional)
box when lit, indicates the output of the
light curtain has been muted by the Merlin The alarm relay functions in one of two
control. This is a common practice modes:
accepted by OSHA in the non-hazardous Alarm mode – internal light curtain faults
portion of a machine cycle i.e. the upstroke are reported. These faults include columns
of a press or a press brake. disconnected / failed or output relay
failures.
Beam Blank-out- “Blue Light” located on Status mode – the alarm relay contacts fol-
the transmitter column will turn on to low the output relay contacts. This can
indicate that one or any number of beams signal remote indicators or other devices.
are being blanked during the operation of
the light curtain.

NOTE: Merlin has taken all necessary mea- ! NOT FOR SAFETY USE
sures technologically feasible to insure that
no unnecessary portion of the light curtain
will be blanked without proper
authorization. If and when blanking is Auto Column Configuration (All)
required, read section C or section D and
be sure to instruct the proper use of Intelligent columns automatically report
blanking to all concerned. their size and beam spacing to the control
making installations foolproof.
13
INSTALLATION INFORMATION
This section must be read by a qualified 2) Check the control of the existing
installer. Improper installation may machine to insure it has reliable controls
jeopardize the level of protection provided and that a stop signal from the Merlin unit
by Merlin units. It is important that the can not be overridden by a failure within
installer as well as the user comply with all the control of the machine itself or that it
installation requirements, i.e. safe can not be allowed to operate without the
mounting distance, additional guarding proper operation of the Merlin unit.
requirements, proper wiring to existence
control as well as analyzing control failure 3) Connect the unit to the machine.
modes in their existing controls.
4) Test the unit and the machine for proper
1) Calculate the minimum safety distance operation and response according to the
required to install the Merlin unit. If instruction provided in section A, page 27.
additional guarding is required, try to
incorporate the additional guards with the
proper operation of the Merlin units and
make sure that people can not locate
themselves in an unprotected position, see
examples below.

14
MECHANICAL INSTALLATION
The Merlin Units are designed to withstand Safety Distance Formulas
the normal shock and vibration found on
punch presses and press brakes. If a OSHA states the safety distance as:
particular application has heavy shock due
to thick plate blanking or stainless steel Ds = 63 x Ts
blanking shock mounting the control box is
recommended. Your Merlin Light Curtain Where Ds = safety distance (inches)
was ordered with specific cable lengths,
which means that the approximate location 63 = the hand speed constant
of the control box with respect to the (inches/second)
column locations has already been
determined. Locate the cables and check Ts = stopping time of press at
the lengths. Remember the cables are approximately 90 degrees of crankshaft
universal for either the transmitter or the rotation (seconds). The Light Curtain and
receiver. control response times should be included
in Ts.
First determine the correct location for the
transmitter and receiver columns. The
distance between the beam barrier plane
and hazardous machine operating point
must be given careful consideration in
planning Merlin installation. As a basic
rule of thumb, this distance should never be For Metric Measurement:
less than 12 inches, but machine geometry,
area layout, machine shutdown response Dsm = 1600 x Ts
time plus the 27 millisecond Merlin
response time, and possible personnel Dsm = Safety Distance (mm)
motions all enter into the calculation of a
safe minimum distance. The barrier must 1600 = is the hand speed constant (mm/sec)
be far enough away from hazardous
machine points to ensure that even when Ts = Stopping time in seconds
moving under unusual stress, no part of an
operator’s or passerby’s body can reach a
machine danger point before machine
motion stops.

15
MECHANICAL INSTALLATION
The A.N.S.I. formula as stated in A.N.S.I. Tc = The response time of the press
B11.1©1988 for Mechanical Power control. If using a Merlin press control the
Presses. response time is 0 seconds.

Ds = K x (Ts + Tc + Tr + Tbm) + Dpf Tr = The response time of the light curtain.

The Merlin response time is less than 27
Merlin recommends using this A.N.S.I. milliseconds.
formula for added safety. The total
stopping time of the press should include TBM = The additional stopping time
the total response time of the light curtain, allowed by the stopping performance
the response time of the interface, the monitor before it detects stop time
response time of the control system, and deterioration.
the time it takes the press to cease slide
motion. DPF = The added distance due to the pene-
tration factor as recommended as
Ds = Safety distance recommended in fig. 8. The minimum
object sensitivity is stated by the
K = The hand speed constant = 63 inches manufacturer. If beam blank outs or
per second. floating beam features are used, these
figures should be added to the object sensi-
Ts = The stop time of the press measured tivity figure before using the chart below.
from the final de-energized control
element, usually the air valve. Note: Ts + Tc are usually measured by a
stop time measuring device.

16
MECHANICAL INSTALLATION
and brackets for up acting hydraulic press
! WARNING brakes are also available. In establishing
final Transmitter and Receiver Unit
CARE MUST BE TAKEN TO PREVENT locations, be sure there is no possibility of
AN OPERATOR OR OTHER PERSON access to a machine danger point from
FROM STANDING BETWEEN THE
PLANE OF PROTECTIVE BEAMS IN over, under, or around the ends of the
THE LIGHT CURTAIN AND THE Merlin beam barrier. Especially where a
HAZARDOUS MOTION AT THE POINT separate mounting stand is used for Merlin
OF OPERATION. IF THE CALCULATED Units, it may be necessary to close
SAFETY DISTANCE AND MACHINE peripheral spaces with fixed shields or
GEOMETRY WOULD ALLOW THIS,
SOME ADDITIONAL SAFEGUARDING screens. It may be necessary to interlock
OR GUARDS WILL BE NEEDED. these peripheral guards if they are easily
EITHER MECHANICAL RAILS OR AN removable. The Transmitter Unit is intend-
ADDITIONAL HORIZONTAL LIGHT ed for mounting at the left hand side of the
CURTAIN ARE POSSIBLE WAYS TO machine, and Receiver Units on the right.
PREVENT AN UNSAFE CONDITION.
Make sure that indicator lights are visible
to the operator. The connectors are
designed to come out the bottom of the
columns. When planning the column
mounting location leave room for the cable
and connectors. Finally, check all current
OSHA, state and local safety requirements
When a minimum safe barrier distance has that pertain to the specific application to be
been established, investigate the Unit sure the intended barrier location will
mounting possibilities. Wherever satisfy them. The construction and use of
possible, Transmitter and Receiver Units presence sensing device is covered by
should be mounted directly on the OSHA 1910.217
machine frame or on rugged mounting paragraph (c) (3) (iii).
adapters attached to the machine frame.
Where conditions dictate a separate
mounting stand, be sure it is very solidly
built. The objective in all cases is to keep ! WARNING
relative motion between Transmitter and
Receiver Units to a minimum. The Units DO NOT USE THIS PRESENCE
SENSING SAFETY DEVICE ON FULL
themselves are highly resistant to shock REVOLUTION CLUTCH PRESSES OR
and vibration, but if shock and vibration MACHINERY THAT IS NOT
are allowed to significantly affect EQUIPPED WITH RELIABLE
Transmitter and Receiver optical CONTROLS AND BRAKE
alignment, nuisance shutdowns may result. MECHANISMS TO STOP THE
HAZARDOUS MOTION ANYWHERE
Merlin offers a variety of mounting brackets IN THE MACHINE CYCLE. WHEN
and pedestals for installing the Merlin THE STOP SIGNAL IS GENERATED
Light Curtains. Custom built brackets are BY THE PRESENCE SENSING
available for OBI presses and press brakes. SAFETY DEVICE…
Standard brackets for straight side presses

17
MECHANICAL INSTALLATION

Columns Control Box

Drill and tap 1 / 4 - 20 or M 6 holes (see Two items must be considered for the
pg. 19 fig. 10) or drill clearance holes and location of the control box. 1) The cable
use bolts and nuts for mounting. lengths to the Transmitter and Receiver
Mechanically the two columns should be columns. 2) The accessibility and operator
close to parallel. Mount one side and visibility of the control, especially if it is a
secure in place. Using a string, locate the Merlin 2000 or 3000 system. When a
position to mount the second column by location has been determined, drill and tap
pulling the string tight so that it just 4 holes 1 / 4 – 20 or M 6 holes for
touches the side of the secured column, and mounting the box.
then move the second column so that it just
touches the string. Mark the location for
the mounting holes. Adjustments for final
unit alignment have been built into the
mounting brackets. If care is taken to get
the initial mechanical mounting close, the
final alignment should not be a problem.

18
MECHANICAL INSTALLATION

19
 The new MT universal mounting bracket allows the column to be mounted at “0” degrees
and plus and minus “45” and “90” degrees as shown above.

Fig. 10
19A
MECHANICAL INSTALLATION

20
21
ELECTRICAL INSTALLATION

! WARNING ! WARNING
BEFORE DOING ANY WIRING, BE ON MECHANICAL POWER
SURE TO TURN ALL POWER OFF PRESSES, DO NOT USE THE TOP
AND FOLLOW APPROPRIATE LOCK STOP CIRCUIT, AS THIS DOES NOT
OUT/TAG OUT REGULATIONS. CAUSE AN IMMEDIATE STOP.

120 VAC input power and the output Two basic types of control circuits are
contact wiring need to be connected from found on most machines.
the machine control to the Merlin control • Relay logic
box. Sealtite or conduit recommended, but • PLC (Programmable logic controller)
be sure to conform to all national or local
applicable electrical codes. Various wiring Relay logic machine controls
methods for interfacing the output contacts
into the machine control exist, for the The Merlin Unit is shipped with the two
different types of controls currently used output contacts jumpered together
on machinery. Determine the type of (terminals 2, and 3,) so that the contacts are
control to be interfaced to and follow the in series. Leave the jumper in place and
appropriate wiring section. If any question use terminals 1 and 4 for wiring into the
exists about which interface wiring should stop circuit. Select a location in the circuit
be used, consult the factory for assistance. that will disengage the clutch and apply the
brake whenever the light curtain is
AC input power wiring to the Merlin interrupted. The interruption of the light
requires 120 or 220 VAC + 10% - 15% at curtain should cause an immediate stop and
50 or 60 cycles and will draw appropriately require that all operating activators be
1 / 2 A. Run wires for the AC input, AC released and re-actuated after the light
hot, neutral or ground, to the correct curtain is no longer interrupted before
terminals of TB2 on the wiring plate motion can be restarted. Make sure that the
assembly of the control box. (See fig. 14) light curtain works in all modes of
operation; i.e. hand, foot, single inch and
Output contact wiring continuous. For assistance in connecting
the light curtain into the machine control
Two individual isolated relay contacts are circuit call the factory for help. See fig. 15.
used to stop the machine when the Light Go to initial start up on page 27.
Curtain beams are interrupted. These must
be wired into the control so that an
immediate stop occurs when the contacts
open.

22
ELECTRICAL INSTALLATION

23
ELECTRICAL INSTALLATION

Typical Relay Logic Machine Connection

Fig. # 15

24
ELECTRICAL INSTALLATION

Programmable logic controllers. must always both be in the same state.

(PLC’s) Anytime the program finds a disagreement
in the state of the two inputs the control
should latch in an off state and indicate a
When interfacing a light curtain to a PLC
fault exists in the monitoring of the light
special precautions must be taken. The
curtain. This will check for interface faults
Merlin output contacts are used separately
in the PLC inputs and the interface faults.
therefore the jumper that is installed
See figure 16 for example. Consult the
between terminals 2 and 3 must be
factory for assistance for the correct wiring.
removed. There are two methods of
Go to initial startup on page 27.
connecting a light curtain to a PLC. The
first method is preferred but if this cannot
be done use the second method. Transmitter and Receiver Column
Cables
1. Generally one input of the PLC machine
control is designed to monitor a light Always connect and disconnect these
curtain signal. Connect one output contact cables when the power to the Merlin Unit
for the Merlin, terminals 1 and 2 to this is off.
input. See figure 16 for example. The
second Merlin contact, terminals 3 and 4
should be connected in the power feed for ! CAUTION:
the output module that controls the
clutch/brake or the up/down solenoid DO NOT ROUTE THE CABLES IN
CLOSE PROXIMITY TO HIGH
valves of the machine. This will remove VOLTAGE ON THE MACHINE.
power directly from the final devices that
controls machine motion. Go to initial
startup on page 27.
Route the cables so that they will not easily
2. When one contact cannot be wired into be damages by the handling of parts or the
the output module to control the final installation and removal of dies. Secure in
device that controls motion, two separate place with tie wraps or other appropriate
inputs to the PLC should be used. Remove devices.
the jumper between terminals 2 and 3 on
the terminal block. The PLC must be Note: The collars of the connectors have a
programmed to use two separate inputs for detented locking position to prevent the
the light curtain and must check each input connector from getting loose due to
for correct operation. The program must vibration. Turn the collar so that it sets
compare the two inputs such that they into the detent, approximately 1 / 4 turn.

The female end goes to the bottoms of the

columns. See page 10 to order replacement
cables.

25
ELECTRICAL INSTALLATION

26
ELECTRICAL INSTALLATION

 IMPORTANT
Snubber network installation:
Every Merlin includes two (2) noise suppressors devices called “Snubber”
networks.

Dual safety valves can create rather large electrical spikes. In order to prevent
electrical nuisance problems, both suppressor devices need to be installed on the
dual safety valve solenoid coils. They should be installed physically as close to
the valve as possible, rather than in the control enclosure.

One suppressor device MUST be installed at EACH solenoid coil of the dual
safety valve, no matter the solenoid coil voltage used (high or low voltage).

The following diagram shows the connection of the snubber device to the
solenoid coil :

SOLENOID COIL

SNUBBER NETWORK

If you need assistance, please call Merlin technical support for help.

26A
UNIT TESTING
Initial Startup interrupted by the appropriate test rod.
NOTE: All beam blankout and floating
After completing the installation check that beam functions must be turned off. Move
machine motion will not start if a beam is the test rod up and down the entire sensing
interrupt in all modes of operation, single, field near each column and in the center of
inch, continuous, auto, etc… the sensing field. The RED, HAZARD
indicator should be on while the test rod is
Using a test rod or other device check to anywhere in the sensing field. If using
see that when running in each mode the multiple column systems check each
machine will stop when in the hazardous sensing field for the proper operation.
part of the cycle when any light beams are 2. Using the test rod, start the machine and
interrupted, check for object sensitivity. momentarily interrupt the sensing field.
The RED HAZARD indicator should be on
while the machine should stop
! WARNING immediately.
3. If any of the above requirements are not
DO NOT OPERATE THIS PRESENCE met DO NOT operate the machine and
SENSING SAFETY DEVICE UNLESS IT notify the supervisor immediately.
HAS BEEN PROPERLY INSTALLED
AND TESTED IN ACCORDANCE WITH
THE INSTALLATION MANUAL AND
ALL APPLICABLE OSHA, ANSI, AND
GOVERNMENTAL STANDARDS.
WHEN INSTALLED AT THE PROPER
SAFETY DISTANCE AS DETERMINED
BY THE STOP-PING TIME AND Tx Rx
SAFETY DISTANCE FORMULA IN THE
INSTALLATION MANUAL, MAKE
SURE THAT NO ONE CAN STAND
BETWEEN THE PRESENCE SENSING
SAFETY DEVICE AND THE POINT OF
OPERATION. OTHER DEVICES MAY
BE NECESSARY TO PREVENT THIS, Test Rod
OR ANY OTHER ACCESS TO THE
POINT OF OPERATION NOT
PROTECTED BY THE PRESENCE
SENSING SAFETY DEVICE.
Test Rod size: Diameter.
Daily test procedures For 1” Beam Spacing = 1.5” (38 mm)
For 1/2” Beam Spacing = 0.87” (22 mm)
To insure proper operation of the presence
sensing safety device and its interface to
the machine control, the following tests
must be done daily or at the very least after
maintenance, adjustments, or modifications
are done to the presence sensing safety
device or the machine.

1. Confirm that the RED, HAZARD status

indicator comes on when the beams are

27
 ELECTRICAL INSTALLATION OPTIONS

Alarm/Status output relay Slave relay monitor

The alarm / status output relay can function This option exists to monitor a slave relay
in one of two ways. for proper operation. If the load to be con-
trolled by the light curtain exceeds the
1. The alarm mode will cause a change specifications of the main output contacts,
of state in the output contacts when an a slave relay will need to be used. This
internal fault is detected within the must be a safety relay, which has
Merlin or when the slave relay monitor positively guided output contacts so that
is used and a fault occurs. a contact failure can be detected. One
contact of the slave relay is connected back
2. The status mode creates an additional to the Merlin unit for monitoring. If the
set of contacts that will follow the state of slave relay fails to follow the output
the main output relays. This can be used contacts an alarm signal is generated by the
for additional remote indicators or other alarm / status output relay to indicate the
functions. fault. This must be connected into the
control in a different location to inhibit
DIP switch 3 determines the operation of machine motion, or connected to signal a
the alarm / status output contacts. Off fault controlling and alarm device such as a
selects the alarm mode. On selects the light or audible signals.
status mode. Use terminals TB2- 9, 10,
and 11 on the output terminal block for this The Allen Bradley 700P series is one safety
signal. Be sure to adhere to the limitations relay with positively guided contacts.
of the contact rating for this output.
Consult the factory for assistance in using
the slave relay monitor or alarm / status.
! CAUTION:
External interrupt option.
THIS OUTPUT IS FOR AUXILIARY USE
ONLY AND IS NOT CHECKED FOR This option is standard on all units. It will
CONTACT FAILURE. DO NOT USE force the output contacts to open to satisfy
THIS CONTACT FOR PRIMARY LIGHT a check of the light curtain. To use this
CURTAIN OUTPUT WIRING.
mode connect a normally open contact to
TB1-1 and TB1-3, see fig. 14.

See troubleshooting Section for DIP switch

location.

28
SLAVE RELAY MONITOR OPTION

Install the slave contact first in line with curtain is interrupted. DIP switch #1 “on”
TB2-7 connected to 120 VAC HOT. selects manual reset and “off” selects auto
reset. To activate manual reset set Dip
When a heavy-duty relay is used to control switch #1 to “on”.
the load the relay can be monitored for
proper operation. Connect as shown. Dip Connect a normally open contact of a
switch #2 needs to be on, to enable the switch to terminals 1 and 4 of TBI on the
check. If the slave contact does not open wiring plate. A key operated switch may
within 128 msec. after the Merlin output be used to supervise the reset function.
contact opens a relay fail message will Activate the reset switch to reset the out-
appear on MT2000 series units and the put to the closed (safe) state when no
Merlin output will remain open. Also the beams are interrupted.
alarm relay will activate if set in the alarm
mode. (DIP sw. #3 off) On Merlin 1000 units an optional reset
button mounted on the door of the control
is available on Merlin 2000 and 3000 units
ELECRTICAL the clear key will reset the output.
INSTALLATION OPTIONS
Merlin offers pre-wired remote switches in
boxes with wire and armor cable protec-
Manual Reset:
tion. Consult the factory.
The Merlin control can be programmed to See troubleshooting section. For DIP
latch in an “off” state each time the light switch location.

29
GENERAL OPERATION – STATUS INDICATORS

The status indicators always show the light Yellow Muted Indicator ON
curtain condition. One indicator is located
on the control box front panel, the other on One or more beams are blocked and the
the Tx column. light curtain CANNOT prevent the
machine from operating. Causes:

• Muted by mute input on M 3000

series.
• Cables disconnected or swapped.

Blue Blanking Indicator ON

One or More beams are blanked. It is on
when using:

• Auto blanking.
• Manual blanking.
• Floating beams.
• Jobs.
Green Safe Indicator ON
It is located on the Tx column only.
No beams are blocked and the light curtain
allows the machine to operate. Green
Red Beam Indicator ON
Blinking – manual reset needed.
Each Beam has a Red LED adjacent to the
beam in the Receiver column. The LED
Red Hazard Indicator ON
will be on when the beam is blocked or
misaligned. NOTE: These indicators are
One or more beams are blocked, and the an aid for aligning the columns. The
light curtain prevents the machine from control logic is more sensitive than the Red
operating, or internal fault. LED’s, therefore with marginal alignment
the Red LED may be off while the control
logic does not have enough steady signal to
accept the beam as good.

30
MT1000 THE CONTROL BOX

31
 Merlin Default Password
FOR MT2000 and MT3000 SERIES

1914
In order to control access to the Merlin features
this password should be supervised. Remove this
page for safekeeping.

32
 Merlin Default Password
FOR MT2000 and MT3000 SERIES

1914
In order to control access to the Merlin features
this password should be supervised. Remove this
page for safekeeping.

33
MT2000 FUNCTION AND CONTROL KEYS

1-

2-
JOB FUNCTION KEYS DISDLAY FUNCTION KEYS
SELECT – Picks a job to run or program. LOCATION- Shows broken beam location
RUN - Runs a selected preprogrammed job and number.
PROGRAM – Learns a blanking setup. NUMBER- Allows number entries from
keypad.
BLANKING FUNCTION KEYS
CONTROL KEYS
AUTO – Learns blanking setup.
FLOAT – Activates and selects floating EXIT – Quit any function.
beams. ENTER- Acknowledge or change
MANUAL – Selects and blanks specific something.
beams. SCROLL- Display more choices from a list
CLEAR- Reset or cancel a numeric choice.
LIMIT FUNCTION KEYS PASSWORD- To control access to certain
functions.
UPPER– Sets blanking or float upper limits
LOWER-Sets blanking or float lower limits

34
3 – THE STATUS DISPLAY To view a list of all Broken-
Beam Locations
The status display appears when no 4
Press the LOCATION key. The
function is selected. It provides detailed Location
display shows the first beam in
information about the light curtain the list.
condition.

No Beams Broken – Safe

Press the SCROLL UP or SCROLL
SAFE
DOWN key to view more beams in the list.
Nothing = No Functions Broken beam list = 9 items
B = Auto or Manual Blanking
F# = Floating Beams
J = Job Running
scroll

No beams are blocked, and the status indi-

cator is green.
scroll

Output – Open – Hazard

HAZD 9
To Return to the Total Broken-
Total number of blocked beams Beam Display
4

One or more beams are blocked, and Loca

tion
Press the LOCATION key. The
the status indicator is red. display shows:
Also indicates Beams that are
blanked and not blocked.

HAZD 9

35
4- FUNCTION DISPLAYS 5- HOW TO SELECT BEAMS
Function displays generally consists of an Many functions require that a particular
abbreviated description followed by a beam beam be selected. When a function is first
number and, possible, other beam begun, the beam number is one of the
information. following:

• Last one previously selected.

F B# I • At the middle of the column.
• At a limit point.
Function active
Beam number To Select a New Beam Number
Beam information
Press the SCROLL UP key to
scroll
increase the number or the
To Begin Any Function
SCROLL DOWN key to
scroll
4 decrease the number.
Location
Press the desired yellow or
green function key.
To Quickly Scroll the Beam
Numbers
To Quit Any Function
Hold down either SCROLL key
4
Press the desired yellow or continuously
Location

green function key.

To Enter a Number Directly
A Press the NUMBER key. The
8
EXIT or press the exit key display changes to the number
NUMBER function:

All functions automatically time-out or quit

after about 10 seconds if no keypad activity Number NUM
unless the time out has been turned off in 0-9
the Password in the Password section.

This function allows the number located

the to left function keys to be used.
continued

36
5- HOW TO SELECT BEAMS 6- ENTERING THE
continued PASSWORD FUNCTION
To Enter a Number The features available in the Password
Function allow:
Press the desired numbered key.
1 - A user Password to be entered
SELECT - Locking & unlocking of Functions
NUM 1
- Time out ON/ OFF selection

5
To enter the Password Function
NUM 15 Press the PASSWORD key
RUN PASSWORD

PSWD
To Accept the Number
Use the Default Password to
A
Press the EXIT key. access this function.
EXIT The function display returns
with the new number. #

*SWD
If the number is out of range for a
particular function, it will not be accepted
or displayed. #
**WD

#
To Correct a Wrong Entry ***D

C Press the CLEAR key to

CLEAR remove the number. Re-enter #

the number NEW PSWD

appears if correct

- if the wrong Password is

NUM entered appears
WRONG

To enter a NEW PASSWORD

-Press ENTER

USER PSW appears

37
6- ENTERING THE
PASSWORD FUNCTION
continued
B
ENTER
Enter the 4 digit USER PASSWORD. Do
not use the PASSWORD key. Use the key to toggle the function
from LOCKED to OPEN.
#

*SER PSW When a Function is Locked and Access is

attempted.

**ER PSW
PSWD appears

#
***R PSW Enter either 4 Digit Password for direct
access to the locked function.

To set the Time-out Function scroll to

#
**** EXIT TIME OFF

Press EXIT
or
The Default Password or the New User
Password will allow access to the Password TIME ON
Function or Locked Functions.

To lock or unlock (Open) Functions scroll

to the desired Function. display

B
Run, Job, AB (Auto Blanking), MB ENTER

(Manual Blanking), Lim (Limits), FLT

(Floating Beam). Use the key to toggle the Time-
out ON / OFF

RUN OPEN or Press EXIT to leave the Password Function

RUN LOCK appears

38
7 – AUTO BLANKING FUNCTION
Auto blanking will “learn” a combination To Remove Auto Blanking
of blocked beams caused by tool holders,
conveyors, or jigs. At least 4 Beams must Clear your set-up; the light curtain returns
Remain unblocked. to a hazard condition.

To Use Auto Blanking 2

AUTO
Press the AUTO key.
Complete your set-up; the light curtain
goes into a hazard condition, if one or more The light curtain goes into a safe condition.
Beams are blocked. The display briefly shows:
2 AB CLEAR
AUTO
Press the AUTO key.

The blue blanking-light in the Tx column

AB LEARN turns off. The status display returns.

The light curtain goes into a safe condition.

The display shows that blanking is on. The SAFE
blue blanking-light in the Tx column goes
on.
SAFE B

If no beams are blocked and the AUTO key Remote Auto Blanking is possibly by con-
is pressed, the display briefly shows: necting a switch to the input terminal on
TB1 to input A from 12 VAC TB1-1 or
NO BLOCK TB1-2 to TB1-5.

Nothing can be “learned”. Complete your

set-up before using auto blanking.

If auto blanking does not work and the

following display appears

OVER LIM

The blanking limits are preventing auto

blanking from working. Change either
your set-up or the limit points (See Set
Limit Points).
4 Beams must remain active.

39
8- MANUAL BLANKING FUNCTION
Manual blanking will allow a combination NOTE: If blanking does not work and the
of blocked beams caused by tool holders, following display appears, blanking limits
conveyors, or jigs. Unlike the auto are exceeded. Reconsider your setup or
blanking, each beam must be individually change the limit points (see Limit Points).
selected and then blanked using the
keypad. OVER LIM

To Use manual blanking

To Unblank a Beam
Complete your set-up; the light curtain
goes into a hazard condition. If one or B Press the ENTER key to
ENTER
more Beams are blocked, use the location change the beam status from
function to determine which beams are BK (blanked) to ON (normal).
being blocked, then go to manual blanking. The display shows:
o
Press the MANUAL key.
MANUAL MB 9 ON
The display shows:

MB 9 ON To Unblank all Beams

Beam Number
C Press the CLEAR key. All
Beam Status
beam return to the ON or
ON = normal BK = Blanked CLEAR
unblanked status. The display
To select the beam number shows:

Press the SCROLL keys or use the MB NO BK

NUMBER key function (See How to Select
Beams).
To Complete Manual Blanking
To Blank a Beam
Select and blank all necessary beams until
B
ENTER
Press the ENTER key to the light curtain goes into a safe condition
change the beam status from and the status indicator goes green. The
ON (normal) to BK (blanked). largest number of blankable beams is the
The display shows: total-column number less 4. Press EXIT
or MANUAL key to quit the manual
blanking function.
MB 9 BK

40
9- FLOATING BEAM FUNCTION
The floating beam function allows one or
more beams to be blocked with no fixed
location. That is, they “float” about the FLOAT 0
guarded area.

You can float up to: ‫ ٱ‬To Quit Floating Beams

• 1 beam with a 1-inch beam spacing. Function
• 3 beams with a 1/2-inch beam spacing.
A
Press the EXIT key or the
Each floating beam is independent from EXIT
FLOAT key. The display
another. They are active only within the
shows the number of floating
float limit-points. Using floating beams
beams used.
increases the minimum object-sensitivity. 6

Floating beams can be used with auto or FLOAT

manual blanking and with jobs. Figure 19

SAFE F1
shows a typical application on press brakes.

To View / Change Floating Beams

in Use To Set Float Limit Points
See Limit Points.

FLOAT
Press the FLOAT key. The
display shows:

FLOAT 0

0, 1, 2, 3

To Select the Number of Beams

Press the SCROLL keys or use the

NUMBER key function (See How to
Select Beams).

To Remove All Floating Beams

C
Press the CLEAR key. All
CLEAR
floating beams are off. The
display shows:

41
10- LIMIT POINTS
Limit points restrict beam blanking to To Change the Limit Points
selectable upper and lower points in the
guarded area. Floating and blanking Press the SCROLL keys
functions are independently adjustable. scroll or use the NUMBER key
function (See How to Select
To View Floating Beam Limits Beams).
scroll
6

FLOAT
Press the FLOAT key. When selecting the limit
points, it is important to
understand that the beam
8 number limit displayed is
For lower limit For upper limit NUMBER
considered a blankable beam.
press the press the
LOWER key UPPER key Example 1:
LIM L 4
7 5

LOWER UPPER
Set the lower limit to beam 4. All beam
Switch between numbers from 1 to 3 cannot be blanked.

Example 2:
To View Manual or Auto LIM U 15
Blanking Limits
Set the upper limit to beam 15. All beam
o
MANUAL
Press the MANUAL key. numbers from 16 to the top of the column
cannot be blanked.

For lower limit For upper limit

press the press the
LOWER key UPPER key
7 5

LOWER UPPER

Switch between

LIM U 12

42
10- LIMIT POINTS continued
To Quickly Set the Lower Limit to To Quit All Limit Points
its Minimum
A

C Press the CLEAR key. EXIT

Press the EXIT key.
CLEAR The lower limit is set to
beam number 1. The or
display shows: 7

LOWER
Press the LOWER key if
LIM L 1 lower limits last used.

or
To Quickly Set the Upper Limit to 5
its Maximum Press the UPPER key if the
UPPER
upper limit last used.
Press the CLEAR key.
The upper limit is set to the
total number of beams. The
display for an 18 inch
column with 1 inch beam
spacing column shows:

LIM U 18

43
11- JOB FUNCTION
The job function lets you save one blanking To Program
setup and assign it to a fixed job number.
Like auto blanking, one key press “learns”
A Job that is Ready
a blanking setup. However, unlike auto
blanking, the job function saves the
blanking setup for as long as you need it. Complete your blanking setup; the light
You can save and recall up to 16 jobs. curtain goes into a hazard condition.
Also, each job can be reprogrammed easily.
1
To use the job function: Press the PROGRAM key.
SELECT

1. Select one of the jobs (1-16).

2. Program (learn) the blanking set-up.
3. Run the job. The job is now programmed, and the light
curtain goes into a safe condition. The
display now shows:
To Select a Job
Press the SELECT key. JOB 10 PR
The display shows:

A
Once the job is programmed,
EXIT
press the EXIT key.

NOTE: If programming does not work and

the following display appears, blanking
limits are preventing the programming
Press the SCROLL keys or use the from working. Reconsider your setup or
NUMBER key function (See How to change the limit points (see Limit Points).
Select Beams).

Jobs with a ready status (RD) are clear and

can be programmed. Jobs with a
programmed status (PR) have been OVER LIM
programmed previously; they can be
reprogrammed (see below).

Now program, following the instructions

given above in A job that is ready.
Or
Press the EXIT key to just clear the job.

44
11- JOB FUNCTION continued
To Run the Job

5
Press the RUN key. The
display briefly shows the job
RUN
selected.

RUN 10

The status display then returns, showing

that a job is running.

SAFE J

Job Running

To Stop Running the Job

5
Press the RUN key. The
RUN display shows the job selected.

RUN 10

EXIT Now press the EXIT key.

The status display returns, showing no job

running.

SAFE

45
MT3000 FUNCTION AND CONTROL KEYS

1-

2- JOB FUNCTION KEYS DISPLAY FUNCTION KEYS

SELECT-Picks a job to run or program. LOCATION – Shows broken beam

RUN-Runs a selected preprogrammed job. location or total number.
PROGRAM-Learns a blanking setup. NUMBER – Shows unit version and size
information.
BLANKING FUNCTION KEYS
AUTO – Not available. CONTROL KEYS
FLOAT – Activates and selects floating
beams. EXIT – Quit any function.
MANUAL – Not available. ENTER – Acknowledge or change
something.
SCROLL – Display more choices from a
LIMIT FUNCTION KEYS
list.
CLEAR – Reset or cancel a numeric
UPPER – Lets blanking or float upper
choice.
limits.
PASSWORD – To control access to
LOWER – Sets blanking or float lower
certain functions.
limits.

46
 MERLIN 3000 SERIES

3- VERSION 3.0 General information about using the Merlin

keypad:

The Merlin 3000 series unit is designed for

Press Brake operations especially where B
programmable back gauge systems are ENTER
- used to access menu items.
used. The Merlin light curtain is useful -used to enter numeric
when the part to be bent is large enough to changes made to particular
extend into the light curtain beams. It can items.
be taught the profile of the part when - used to toggle functions on /
making the first part. The part profile pat- A off.
tern can then be run from temporary EXIT
memory and / or stored for future use. -used to exit out of functions.
Only the bottom three inches can be per-
manently blocked. This allows for a work -used to scroll through menu
support table or arm. The rest of the beams items.
scroll
are not permanently blocked. -used to change
numeric values.
scroll
-used to scroll through a
! WARNING program.

WHEN USING BEAM BLANK OUT -used to clear numeric values.

C -used for manual reset.
FUNCTIONS, CARE MUST BE TAKEN
TO TRAIN THE OPERATORS IN THE CLEAR -used to clear bumping
CORRECT METHOD TO HOLD information.
PARTS SO THAT BOTH HANDS ARE
OUTSIDE THE LIGHT CURTAIN
PLANE AND KEPT AT A SAFE PASSWORD
-used to access setup
DISTANCE. information.

-numeric keys have dual

# functions. When numeric
entries are valid the numeric
function is active, otherwise
the main label is active.

47
MAIN FEATURES OF THE MERLIN 3000 SYSTEM:
4- LIMITS Use the scroll keys to change the current
setting or use the numeric keys to enter the
These functions are used to display the cur-
limit.
rent limits of the blanking and floating
beam features and to make changes to the A
Press the EXIT key.
limits. EXIT

To display current limits.

3
To leave this function, repeat the above
Press the UPPER key procedure for the lower limits.
UPPER

5- DISPLAY
This shows the current When the unit is in a safe condition the
floating limit, xx. location function will show the last
Changes the second line to. beam(s) that caused the last hazard
condition. When the unit is in a hazard
scroll
condition the location function will show
the current beam(s) not being satisfied. A
beam is not satisfied if it is blocked or not
Press the SCROLL key aligned, or if it has been blanked and is not
blocked.
scroll

To use location key.

When in a safe condition.

This shows the current blanking
limit, xx. 4

Location
Press LOCATION key.
To correct limits.
LAST LOCATIONS Y
If changes are needed, when at the correct XXXXX
item, FLOAT or BLANK
B Y Shows the total number of beams not
Press the ENTER key
ENTER
satisfied.
EDIT UPPER FLOAT X Shows the individual beams not
BEAM XX 1 to XX satisfied.

current limit maximum range

48
When in the hazard state the following is Manual
displayed and updated as the beam
conditions change. Manual blanking is not available on
MERLIN 3000 units.
BEAM LOCATIONS Y
XXXXX
Float
If more than 5 beams are causing the haz- The floating beam mode allows one beam
ard condition, use the SCROLL to view all in 1” units and three beams on 1/2” units
of the beams causing the hazard state. to be set to float. This means that 1 to 3
beams may be blocked without causing a
scroll hazard condition. Blocking more than the
allowed number will cause the output to of
Press SCROLL key open, stopping the machinery being contro-
scroll
lled. If limits are set for the floating beams
the floating function only works within the
limits. Interrupting any number of beams
To return to the previous display. outside the limit will cause a hazard
A condition.
Press EXIT key
EXIT
To activate floating beam(s),
6
‫ ٱ‬To view the unit version number FLOAT
Press FLOAT key

and the unit size and beam spacing FLOATING BEAMS

information without removing power to the 0 ACTIVE 0-1
unit.
8 To change the number of floating beams.
Press NUMBER key
NUMBER

scroll
Press SCROLL key
VERSION NUMBER 3.XX
XX” UNIT X” BEAM
or
This key can also be used to reinitialize the
display should it get locked up for any
reason. To reset the floating function
to zero.
6- BLANKING
C
Press CLEAR key
Auto CLEAR

Auto blanking is not available on Merlin

3000 units.

49
To activate the change. Use the scroll keys to select the desired
function and
B Press ENTER key
ENTER
B
ENTER
Press ENTER key
When in a safe mode the display will
indicate floating in the second line.

1 FLOATING BEAM
8- LOCK FUNCTIONS
Floating beam function;
Setting limits;
When in the create or run modes floating is Job mode;
indicators by a small “f” after the word These functions can be locked
safe. or unlocked (left open). Scroll
CREATE JOB SAFE f to the desired function.
Or
RUN # _______ SAFEf B
ENTER
Press ENTER key

Note: It must be remembered that using

floating beams increases the object sensi- To lock or unlock the function. If locked,
tivity of the sensing field. the Merlin control will prompt the user for
the password if access to the function is
attempted. When done with the lock mode
7- PASSWORD
A

-USED TO LOCK AND EXIT Press EXIT key

UNLOCK FUNCTIONS.
-USED TO CHANGE THE
Edit password
USER PASSWORD.
-USED TO SET TIMEOUT
FUNCTIONS. User password selection.
-USED TO TEST INPUTS. B
-USED TO RESET THE ENTER Press ENTER key
SYSTEM WHEN REQUIRED.

To access the above functions To edit the user password, enter a new user
password >_ _ _ _ <. You must enter all
D Press PASSWORD key four digits. Do not use the
PASSWORD

A
and enter the four digit default password or
the user password if one was previously EXIT Press EXIT key
created.
or the

50
 C
CLEAR Press CLEAR key scroll Press SCROLL key

in the user password. To the input to be tested. “ON” indicates

SET FUNCTION TIMEOUT that the switch is closed and “OFF”
indicates that the switch is open.
------Timeout for display reset.
A

This timeout determines the amount of EXIT

Press EXIT key
time allowed in between key entries. If no
key entry is detected within the timeout the
display and mode being used are cancelled To leave this mode.
and the SAFE or HAZARD display is
shown. Four choices are available. 9- JOB MODE
This mode is used to select the various
SAFE functions related to created and running
jobs.

HAZARD *Note: programming blanking in the job

mode is useable.

Timeout is none - no timeout 1

Timeout is short - =15 second timeout SELECT Press EXIT key
Timeout is medium - =50 second timeout
Timeout is long -=100 second timeout
This key brings up the job menu from
TEST INPUTS which you can select from the following
six job functions. Use the SCROLL keys
------This mode is used to test the eight “8”
possible external input signals.
scroll
------EXT-INTR--External interruption; Press SCROLL key
Active on.
------MAN RESET – Manual reset; Active
on. To select and
------INPUT A ------ Aux. Input A;
B
------INPUT B ------ Aux.input B; ENTER

------TOS ------------Top of stroke; Active Press ENTER key

off;
------MUTE --------- Mute point; active on.
------BOS ------------Bottom of stroke; To access a particular function.
active on. Create Job
------LEARN--------Remote learn; Active Store Job
on. Recall Job
Bumping Job
Erase Job
Job Info

51
JOB INFO BUMPING JOB SAFE
CLEAR / CYCLE PRESS
When Job information is selected the
number of jobs stored and the total number When cycling the press brake, the TOS
of jobs that can be stored will be displayed. (top of stroke) input will cancel the
blanking pattern or pressing
X JOBS OUT OF 243
C Press CLEAR key
A Press EXIT key CLEAR

EXIT
will cancel the blanking pattern.
To return to the Job menu.
See page 52 for more information on
BUMPING JOB running jobs, muting, etc.
This function is used when processing a
part whose position is difficult to determine A Press EXIT key
EXIT
or whose position tends to change from
stroke-to-stroke. The blanking pattern is
taught when the part is in place, and To leave this mode.
automatically resets at the top of the stroke.
Using a remote learn foot switch makes it CREATE JOB
easy to set the blanking pattern each stroke. To create a job either temporarily or to be
The program key may also be used to teach stored in memory, the same procedure is
the blanking pattern needed. used.
B
ENTER Press ENTER key
To access this mode.
B
ENTER at CREATE JOB
Press ENTER key
CREATE JOB SAFE
BUMPING JOB SAFE STEP 1 READY
PROGRAM / LEARN
Insert the part into place for the first bend
Position the part in place and or step.
9
9 Press PROGRAM key
PROGRAM

PROGRAM Press PROGRAM key

or the remote learn switch. Each step must

or the remote learn button. be programmed even if no beams are
blocked if the part is flat.

CREATE JOB SAFE

STEP 1 PROGRAMMED

52
Cycle the press brake or Enter a job number from 1 to 8 digits, then

Press SCROLL key B Press ENTER key

ENTER
scroll

To advance to step 2. Note; Job number 1 is different from job

number 10000000 is different from job
CREATE JOB SAFE number 00000001 etc.
STEP 2 READY
JOB # _ _ _ _ _ _ _ _
SAVING NOW
With the part in position for the second
bend
This message appears momentarily, then
9 Press PROGRAM key you will be back at the job menu. If the job
PROGRAM number already exists a message will
appear.
or the remote learn switch.
JOB EXISTS * EXIT
CREATE JOB SAFE
STEP 2 PROGRAMMED A Press EXIT key
EXIT

Repeat the above procedure for the number

of steps required. When done to return to the job menu. Select other job
functions or leave the job mode.
A To leave the job menu
EXIT Press EXIT key
A

EXIT
Press EXIT key
You can now choose to store the job into
memory or just run it from temporary
memory. It can be stored into memory RECALL JOB
anytime before power is turned off or a To recall a job when in the job select menu
new job is created.

scroll Press SCROLL key

STORE JOB

To store a job
to the RECALL JOB function and
Press SCROLL key
B
ENTER
Press ENTER key
to STORE JOB in the menu and
RECALL JOB
Press ENTER key
NUMBER X

53
 scroll ERASE JOB MENU
Press SCROLL key
> ALL JOBS?

through the existing job numbers to the

desired job or enter the correct job number and select this option by
and
B
ENTER
Press ENTER key B
ENTER Pressing ENTER key.

JOB # XXXX
RECALLING If you wish to erase one job, after pressing
ENTER key.
Selected job has now been placed in the
temporary memory location so that it can scroll
be run. Press SCROLL key

ERASE JOB through the job numbers or enter the

You can erase on or all jobs in memory. numeric job number that you wish to erase.
Be sure that you want to erase a job before
B
entering into this mode. To erase one or ENTER

more jobs from memory Press ENTER key

Press SCROLL key JOB # XX

scroll
JOB NOT FOUND * EXIT

through the job select menu until you are at will appear if the job does not exist. If the
ERASE JOB. job does exist;

B
ENTER
ERASE JOB
Press ENTER key ARE YOU SURE? * ENTER

ERASE JOB MENU B

ENTER Press ENTER key
> ONE JOB?

You can to erase the job or

B A
ENTER
Press ENTER key EXIT Press EXIT key

to select this option or to cancel the erase mode.

scroll Press SCROLL key

to;
54
RUNNING JOB

When running jobs, either step jobs or NOTE: If a separate BOS signal is not
bumping jobs, input signals are required for available, the mute & BOS
TOS (top of stroke), MUTE (1/4” posi- inputs need to be connected
tion), and the BOS (bottom of stroke) func- together.
tions.
See wiring section for the proper
NOTE: The top of stroke position connections for these inputs.
assumes a down acting press MUTE: The mute function mutes or
brake. This is the ram open bypasses the light curtain making it
position and would be the insensitive to obstructions in the sensing
bottom position on an up acting field. It is very important that the set-up
press brake. The TOS and BOS be done carefully so that the muting
signals would therefore be occurs when the die is 1/4 inch or less
reversed for an up acting brake. open. The muting is initiated when the
mute input is activated and stays in the
TOS mute mode until the TOS input cancels it.
This signal is active off. The Two separate timeouts will also deactivate
input is off or open at the top of the mute mode if the TOS signal is not
the stroke and generally closed received. The mute mode will timeout one
elsewhere. hundred (100) seconds after starting if the
mute input is left on, or ten (10) seconds
MUTE after the mute signal goes off, whichever
occurs first.
This signal is active on. This is the point at
which the light curtain is muted or The mute function is indicated by the status
bypassed to allow the part to bend up LED in the front panel changing to
through various beams of the light curtain. AMBER and by a mute message on the
This must be set for each set-up to be display. The mute function is active in the
where the die is no more than 1/4 inch RUN, CREATE, BUMPING and standard
open. SAFE / HAZARD modes of operation.

BOS
This signal is active on. This
signal enables the MERLIN to
step the program when the next
TOS signal is received. If the
bend is not made and the ram is
returned to the top, the program
will not step if the BOS signal
was not received.

55
 Merlin
Recommended procedures for making parts on press brakes.

WARNING: Never place your hands or arms in the

blanked out area of a light curtain while operating
the press brake.

There are basically two types of parts, small parts and large parts that are processed on a
press brake equipped with a light curtain. Small parts do not extend out into the plane of the
light curtain beams, and large parts do extend into the plane of the light curtain beams.

CAUTION: OPERATORS MUST ALWAYS BE TRAINED IN THE PROPER

PROCEDURES FOR SAFE OPERATION OF PRESS BRAKES.

Whenever possible the recommended procedure to process the parts whether small or large
is to fixture the part in place so that it does not have to be held at all, or cycle the press brake
to the point at which the die is no more than ¼ inch open without the part in the die area. This
if often referred to as the stroke stop point. With the press brake stopped at this point, insert
the part into position. The light curtain can be muted at this point so the part if small can be
held as necessary, and if the part is large the light curtain will not interfere with the process
because it can be muted.

By using the above procedure the hazardous portion of the cycle is protected by the active
light curtain and the actual process of bending the material is not hampered by the light
curtain because it can be muted from the point at which the die is ¼ inch or less open,
through the bending portion back to the open position.

Some light curtains require external muting devices to bypass the protection provided by the
light curtain at the ¼ inch point while others have built in muting features. The MERLIN
3000 series has the muting function built into the light curtain.

WARNING: The muting of the light curtain must be adjusted for each set
up so that muting does not occur before the ¼ inch point.

The MERLIN 3000 light curtains also have additional features which assist in the processing
of large parts on press brakes.

In all cases the part should be held with both hands outside the plane of the light
curtain during the hazardous portion of the cycle.

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FLOATING BEAM FEATURE:
The floating beam feature allows one or more beams to be blocked without the output
of the light curtain opening. This feature is useful when holding a large flat part in the
plane of the light curtain. The part may twist or bend slightly possibly blocking a beam.
The floating beam feature allows the part to move in and out of the beam without
shutting down the press brake.

PROGRAMMABLE BLANKING:
Many large parts are processed completely without putting the part down or changing
the set up. This is most often done when using automatic back gauges to reposition the
material stops so multiple bends can be processed. When this is done it is quite
common that a flange bent on a previous step will extend through the plane of the light
curtain blocking one or more beams on a subsequent step. Again, if the part can be
inserted at the ¼ inch position the programmable blanking feature is still not needed. If
the flange is relatively small the floating beam feature may be enough to allow
operation to continue. When it is not enough the programmable beam blank out feature
will allow operation of the press brake with the part in place.

WARNING: Never place your hands or arms

into the area where beams are blanked out The programmable blanking feature will
during the hazardous portion of the cycle. allow the light curtain to learn the shape
of the part the first time the part is made.
There after the light curtain will blank out the correct beams for each step of the part to
allow it to be in the path of the light curtain beams. The beams that are blanked out
exactly match the shape of the part. The light curtain will not go to a safe state unless
the blanked out beams are blocked by the correct shape of the part.

The only beams that can be permanently blocked in the standard program are the
bottom three inches of the light curtain to allow for tables or support arms. The other
beams that are blanked out must be active momentarily between strokes to allow the
next blanking pattern to be recalled.

Up to 16 steps can be programmed for each part on the MERLIN.

When using the programmable blanking feature it is helpful to activate the floating
beam feature after programming the entire part to allow slight mis-positioning of the
part without creating a stop signal.

57
CAUTION: NEVER PLACE YOUR HANDS OR ARMS INTO THE DIE AREA OF
THE PRESS BRAKE. WHEN ONE OR MORE BEAM(S) IS NOT ACTIVE KEEP
BOTH HANDS OUTSIDE THE PLANE OF THE LIGHT CURTAIN BEAMS.
BLANKED BEAMS ARE ONLY FOR THE PART TO BE IN POSITION.

Follow the procedures in the manual to check for the proper operation of the light
curtain prior to operating the press brake and / or after every set up.

The light curtain must be mounted at the correct safety distance as per the safety
distance formula considering no beams are blanked out.

If you have any questions concerning the correct use of the programmable light curtain
features call Merlin technical support for assistance.

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Troubleshooting
Symptom
CHECK / CAUSE
General for all models
No hazard or safe indication. • Input wiring to correct terminals.
• Input fuse.
• Proper voltage.

Hazard indication only. • Proper alignment of TX and RX.

• Separation distance RX to TX excessive.
• Proper cable connections to TX and RX.
• Cable connector locking ring not in
detent.
• Relay failed. (M2000 and M3000 units
have a relay failure message).
• On multiple column systems master
columns, (RX and TX) must be first from
the control, Model # CMxxx.

Safe indication but machine won’t run. • Output wiring at TB2-1,2,3,4.

• Fuses for Relay 1 and 2.
• Relay out of it’s socket.
Occasional blinks to hazard. • Marginal alignment of TX and RX.
• Cable connector locking ring not in
detent.
• Vibration of mounting brackets causing
misalignment.
• RX or TX cable close to high voltage.
• Marginal connection on opto boards in
columns.

Merlin 1000
Unit works but LED on door doesn’t. • Wiring harness to door unplugged.
Unit goes to hazard when interrupted and • Relay contacts worn or sticking. Replace
stays in hazard. Power down/up resets unit. relays.
Unit doesn’t work, blue and amber leds in TX • TX and RX cables swapped.
column on.

59
 Merlin 2000 and 3000 common symptoms
Merlin 2000 standard messages are “SAFE and HAZD #”. The number after HAZD
indicates the total number of beams not satisfied.
Pressing the “Location” button when in the Hazard state, changes the display to show
“BEAM #”. The number shows which beams are not satisfied starting at the first (closest to
the control box) beam. Using the “Scroll” buttons allows viewing of all of the beams not
satisfied.

Merlin 3000 standard messages are “SAFE and HAZARD Blocked Beams, Total #
Beams #” The total number and which ones not satisfied are shown.

Beams are not satisfied if they are blocked and not blanked, or if they are not blocked when
blanked.
If the number of beams indicated as not satisfied equals the total number of beams the unit
may be completely mis-aligned or the TX cable and or connector may be loose, off or
damaged.

Merlin 2000 and Merlin 3000

Unit works but LED and display on door • Wiring harness to door unplugged.
doesn’t.
Unit goes to hazard when interrupted and • Relay contacts worn or sticking. Replace
stays in hazard. Relay fail message. Power relays.
down/up resets unit.
Blanking functions not working properly. • Limits are set wrong.
• Too many beams trying to be blanked.
• Blanked beams must remain blocked.

Floating function not working properly. • Limits are set wrong.

• Floating function used for another beam
that is blocked and not blanked or one
that is blanked and not blocked.
Cannot access blanking, floating or job • Function locked in password section.
functions. • Auto and manual blanking not available
on Merlin 3000 units.
Display gets lost or partial messages. • Output wiring close to display when door
closed.
• Noise interference. Install suppressor on
AC input terminals.
• Defective program chip on display board.
Key pad doesn’t work, display does. • Key pad wire harness disconnected from
PC Board on door.
• Bad program chip on display board.

60
 Merlin 3000
No muting at ¼ “ point. • Mute input signal not on.
• Top input signal not on. ( TOS is active
off, at the top/open position).
Use Test Inputs mode in password to check
input status.
Unit won’t step through program created. • Missing BOS signal.
• Part? displayed. Permanent beam
blockage above allowable beam point.
The standard program allows only the
bottom 3 inches to be permanently
blocked.
Look for table or part support arms too high.
Won’t learn beam blockage. • Limits are set wrong.
• Too many beams blocked.
• Not in the create mode.
Stays in hazard at one or more steps. • One or more beams not satisfied; either
blocked when it shouldn’t be or not
blocked when it should be.
• Turn on floating function to allow minor
part misplacement.
Remote learn doesn’t work. • Remote input not coming on.
Use Test Inputs mode in password to check
input status.

61
Display messages including error messages and their causes;
Most of the messages that appear during normal functions are not listed here
because they are easily understood. Refer to the manual for help.

Merlin 2000

SAFE All beams satisfied. Output contacts closed.

HAZD # # = the number of beams not satisfied, Output contacts open.
SAFE B Auto or manual blanking active with all beams satisfied.
SAFE F1 Floating blanking active.
SAFE BF1 Auto or manual blanking active with all beams satisfied.
Floating blanking active.
FAIL RLY Failed relay. One relay failed or sticking when outputs open.
NO COLU No column. This indicates that the RX column is not being sensed.
Cables may be swapped.
FAIL CLM Column failed. Generally a problem in the RX column.
WRONG This indicates the wrong password was entered.

Merlin 3000
SAFE All beams satisfied. Output contacts closed.
HAZARD Blocked Beams Total number of beams not satisfied is shown with the beam
Total # Beams # number(s) scrolling. Output contacts open.
SAFE by Muting Output contacts closed. Unit is muted. Blocking beams will not
open the output contacts or stop the machine.
WAIT This indicates that the RX column is not being sensed. Cables may
be swapped.
Relay Failure Failed relay. One relay failed or sticking when outputs open.
# _ Contacts
Noise Retry Very marginal beam alignment when Learning a blanking pattern.
Noise Error Try realigning the TX, RX columns.
Shutdown by External The output contacts are forced open when the External interrupt
input is activated on by the machine control.
Step 0 Ready The CREATE mode was not properly exited. Enter into and exit
from the CREATE mode. Should say “Step 1 Ready” when
creating a new program.

62
Recommended spare parts/
Replacement parts
MTC1000 -Merlin 1000 T Series Control Box
MTC2000 -Merlin 2000 T Series Control Box
MTC3000 -Merlin 3000 T Series Control Box

Replacement Cables:

55-5xx-02-00 2 ft.
55-5xx-05-00 5 ft.
55-5xx-10-00 10 ft.
55-5xx-15-00 15 ft.
55-5xx-25-00 25 ft.
55-5xx-35-00 35 ft.
55-5xx-50-00 50 ft.

22-222 Output Relay

63
INFARED SECURITY BARRIERS

WARRANTY

Merlin warrants the products it manu- Merlin shall not be liable for consequential
factures to be free from defects in damages. All equipment returned to Merlin
material and workmanship provided for warranty service must be sent prepaid.
these defects are not caused by abuse, Merlin will not accept collect freight
accident, or neglect, and agrees to correct shipments. Any equipment returned to
by repair or replacement of the part, or out factory under this warranty shall be
parts, any such defect disclosed on returned UPS, Ground or Truck prepaid.
examination by us and which Authorization to return material must be
development under normal installation, first obtained from one of out branch
use and service for a period of 3 years offices, or from one of out Sales
from the date of shipment to the original Department.
purchaser when the equipment is For additional information, repair or
returned to our service facility. service, contact your local Merlin distributor
Normal wear on the relay output contacts or:
is not covered under this warranty, as it is
not considered a defect. 3517110 Canada Inc. dba Merlin
2300 Victoria Ave.
Merlin does not assume responsibility for Lachine Qc. Canada H8S 1Z3
Tel.: (514) 637-7000 Fax.: (514) 634-9868
unauthorized repairs to apparatus even
though defective.
This warranty is in lieu of all other
warranties expressed or implied, and no
representative or person is authorized to
assume for us any liability in connection
with the sale of our products.

64