Light Curtain Repair Services

What’s a Safety Light Curtain, & What Does It Do Exactly?

What’s a safety light curtain? A light curtain is a safeguard which automatically stops the operation of potentially dangerous machinery or devices whenever a person gets too close. Light curtains go by many names, including light screens and optical guards. But no matter what you choose to call it, a safety light curtain can be a literal lifesaver during normal operations of your special machinery, as well as when it’s time to do some routine machine maintenance.

How does a safety light curtain work? A safety light curtain works on the same principle as the safety beam system, which is typically installed near the bottom of a modern automatic garage door. If a person, animal, or object crosses the infrared beam, the door will automatically stop closing and then reverse motion. Safety light curtains work on a similar concept, but often on a bigger scale and with more precision of design and application.

All light curtains include at least one transmitter and receiver, and the signal transmitted usually features specific frequencies of infrared light. If a person or object should break one of these beams, the connected machine or device receives an instant stop signal. Light curtains feature self-monitoring circuitry, as well. If a problem develops with the light curtain itself, then any connected machinery will immediately be shut down, and will remain shut down until the light curtain is back online and operating normally. In an industrial environment, light curtains are commonly used for both points of operation settings, as well as for perimeter control applications.

Typical Issues That Can Arise with Light Curtains

A light curtain system isn’t just a good idea; it’s really an essential safeguard for many industrial settings, and light curtains can be designed and engineered to meet many specific needs. Even so, there are common problems which can be encountered with light curtain applications. Here are a few:

Placement too close to the hazard

The goal of a safety light curtain circuit is to be able to stop the machinery before anyone gets too close. In some cases, the light curtain is simply placed too close to the unit to be able to provide the necessary response time for proper safety. In cases like these, we might recommend moving the light curtain to a safer distance, or we may also be able to make some appropriate tweaks to the drives and controls.

Inconsistent halting of the safety hazard

Inconsistent stoppage of the hazardous machinery is more prevalent with pneumatic and hydraulic systems. Sometimes, calculating the right stop distance for a light curtain can be a challenge in these applications. Pneumatic systems are particularly prone to having issues with trapped air, but issues can also arise from having a cylinder which is completely vented.

Guard gaps

A safety light curtain won’t protect your workers very well if the surrounding unit guards have openings which allow access underneath or around. For this reason, it’s important to be proactive about screening for any potential gaps in protection.

Bottom beam placed too high

If a light curtain is placed too high off the floor, then it could tempt some workers to try and duck underneath – which would obviously defeat the purpose. In order to avoid this temptation, it’s best to place the bottom beam no more than 12” off the floor, unless it is otherwise guarded.

Top beam placed too low

Another common issue is that a top light beam can be placed too low, which effectively allows people to reach over it. The light curtain really should be designed to cover the entire hazard space, including any height considerations.

Doesn’t control all hazardous movements

Some light curtains are well-designed for controlling the main hazard, but don’t offer enough protection from other potential hazards associated with the connected unit. For example, we’ve encountered light curtains with safety controls for the main hydraulics, but with no safety containment for individual pneumatic items. These are issues which need to be addressed in order to provide the proper safety for your workers.

Wiring connections tied to a non-safety controller

Sometimes we encounter a light curtain which includes all the right components for a safety system, but is then erroneously wired to the unit through a non-safety controller. In these cases, the light curtain needs to be re-routed within a self-contained safety circuit. This is something we can help with at AES!

Improper muting circuits

Muting describes the temporary automatic suspension of a safety light curtain to allow the passage of certain items. It must turn on automatically when sensors detect the item in question, and then automatically turn off once the item has passed. If muting is allowed to endure for too long, the light curtain can allow unnecessary access to the safety hazard, which can prove to be dangerous.

Using the wrong type of light curtain

Older light curtains found on some types of legacy equipment or machinery are of a Type 2 design, but modern machinery often requires a Type 4. It’s important to differentiate between these two types, and not confuse them with your particular application. Negligence in this area can lead to some real hazards.

Hazards that eject projectiles

Some industrial machinery can be prone to throwing out flying debris, like CNC machines, grinders, and other machining tools. With applications like these, a light curtain simply may not prove to be the best safety solution, as a light curtain can’t prevent the instance of any residual projectile impacts.

The Process of Light Curtain Repairs & Service with AES

Light curtains are an important resource for ensuring that your people stay safe around moving machinery and equipment. The team at AES understands that light curtain failure really isn’t an option when it comes to employee safety. That’s why we follow a rigorous light curtain testing and repair process.

Here are just a few of the things we’ll do in terms of the safety light curtain repair services we offer:

• We start by thoroughly inspecting your unit, and looking for any issues revealed through our troubleshooting process.
• Strain-test all cables and connections, using specific equipment designed for that purpose.
• Test communication ports with loopback testing, on stations specifically built for this purpose.
• Replace any scratched, broken, or damaged lenses or photosensors.
• Replace any defective or damaged cables, connectors, cases, chips, and/or controllers.

Why Choose AES for Your Light Curtain Repair Services?

Since our founding in 1992, AES has produced a solid track record of successful repairs for our customers and clients, including light curtain safety systems. We help to keep your essential equipment running, AND make it safe for your employees, too. Here’s what helps to set AES apart:

Faster Turnaround

A quality light curtain repair takes time to complete, but the AES team is poised to get it done faster! We offer a quick standard turnaround time of 8-10 business days for most repairs, but we can also put a RUSH of 1-3 business days on your order, if you so designate.

Quality Repair Work

At AES, we take what some might say is an old-fashioned approach. In other words, we simply believe in doing things right! We provide an exceptional quality of service with every repair we provide, for every client, every time. We’ve successfully serviced all sorts of light curtain systems for our customers and clients, and we know what it takes to get yours working again properly, too!

A Team of Real Professionals

We know we can serve your needs well at AES. How do we know? It’s because our team of repair technicians collectively owns a ton of relevant experience – we’ve worked on many varieties of industrial light curtain systems. We’re also intentional about providing regular ongoing training for our repair technicians, so we’ll continue to be ready to serve your needs now and in the future.

A More Cost-Effective Solution

Why pay to replace an expensive light curtain system, when all you really may need is some timely service and repairs? AES can take care of your needs, and we’ll get your light curtain back up and running properly. By choosing to partner with AES, you’ll also save time, money, and needless headaches or frustration.

The Best Repair Warranty!

And here’s another convincing reason to partner with AES. Naturally, everyone says they do good repair work, but sometimes all that amounts to be a bunch of talks. At AES, we stand behind every service we provide by offering you a 24-Month Limited Warranty! What does that mean? It means that if a problem arises during that time period, which is deemed to be a repair workmanship issue, AES will provide follow-up repair service for you at NO extra charge! How’s that for service with a smile?

Connect with AES for Your Light Curtain Repair Services

Ready to get your safety light curtain back online and working the way it should? We can take care of that; AES has you covered! Reach out today at (866) 386-1001, and let’s start the conversation! We’re here to help!