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96M0810

PJ-V Series Instruction Manual


Instruction
Manual
Extendable Safety Light Curtain

PJ-V Series
NOTICE
Do not attempt to operate or service this machine until you have read
and understand the instructions written in this manual.

Specifications are subject to change without notice.


AFFILIATED COMPANIES
KEYENCE CORPORATION OF AMERICA KEYENCE SINGAPORE PTE LTD KEYENCE (HONG KONG) CO., LTD
Phone: 201-930-0100 Fax: 201-930-0099 Phone: 6392-1011 Fax: 6392-5055 Phone: 3104-1010 Fax: 3104-1080

KEYENCE DEUTSCHLAND GmbH KEYENCE (MALAYSIA) SDN BHD KEYENCE INTERNATIONAL TRADING
KEYENCE CORPORATION Phone: 06102-36 89-0 Fax: 06102-36 89-100 Phone: 03-2092-2211 Fax: 03-2092-2131 (SHANGHAI) CO., LTD.
1-3-14, Higashi-Nakajima, Phone: 021-68757500 Fax: 021-68757550
Higashi-Yodogawa-ku, Osaka, KEYENCE (UK) LIMITED KEYENCE (THAILAND) CO., LTD
Phone: 01908-696900 Fax: 01908-696777 Phone: 02-369-2777 Fax: 02-369-2775 KEYENCE KOREA CORPORATION
533-8555, Japan
Phone: 02-563-1270 Fax: 02-563-1271
Phone: 81-6-6379-2211 KEYENCE FRANCE S.A. KEYENCE TAIWAN CO., LTD
Fax: 81-6-6379-2131 Phone: 01 47 92 76 76 Fax: 01 47 92 76 77 Phone: 02-2627-3100 Fax: 02-2798-8925

KEYENCE CORPORATION, 1999 0010-8 96M0810 Printed in Japan


Introduction
Thank you for purchasing Keyences PJ-V Series Extendable Safety Light Curtain.
This instruction manual has been designed to give you information on installation,
operation, and maintenance, including simple routine inspection and servicing of
your Keyence Extendable Safety Light Curtain. This manual should be read care-
fully; the correct operating and maintenance procedures must be clearly under-
stood and carefully followed to ensure the best results from your equipment over a
prolonged period of time. Below are some instructions that require your attention.
If there are any ambiguous points, incorrect descriptions, or omissions, please
contact your Keyence distributor.
All information given herein is subject to change at any time without notice. We
reserve the right to make alterations.

Symbols
This mark is the safety alert symbol. This symbol calls for your particular
attention in order to operate the system safely. Operators must read all labels
attached to this system and follow safe operating procedures before performing
any operation or maintenance.

Warning Items

Failure to comply with this warning may cause severe


DANGER injury or death.

WARNING
Failure to comply with this warning may possibly cause
severe injury or death.
WARNING

CAUTION
Failure to comply with this warning may cause slight or
medium injury or mechanical damage.
CAUTION

Important Items

IMPORTANT

Note: The PJ-V40/41/42 are available only in Japan.

i
Label
Controller
PJ-V90 (Main controller) PJ-V91 (Sub-controller)
WARNING KEYENCE CORPORATION
WARNING 1-3-14,Higashi-nakajima,Higashi-yodogawa-ku,
See the Instruction manual for installation, testing, operation See the instruction manual Osaka 533-8555, JAPAN
and maintenance. Be sure to check all the functions before for installation, test and
for use with PJ-V90
you start operation. Do not open or modify the product. control. See Instruction Manual
MADE IN JAPAN
Failure to follow all instructions could cause serious injury
to personnel. CAUTION PJ-V91 Serial No.
0000130 / 1998
Electric shock hazard
DIP SWITCH 1 START INTERLOCK may exist.
2 RESTART INTERLOCK Serial number
3 MPCE (Monitoring)
4 NOT USED Manufacturing date
5 NOT USED
CONTROLLER PJ-V90, V91
SENSOR HEAD PJ-V20, V21,V22
PJ-V40, V41,V42 CAUTION
(See Instruction Manual)
DETECTION ZONE 120mm 1260mm Do not remove the
(See Instruction Manual) protective cover
OPERATING RANGE 0m 7m under this sticker
DETECTION CAPABILITY 28mm, 48mm except when the
(See Instruction Manual) PJ-V91 is connected.
RESPONSE TIME 15ms max Otherwise,the unit
SUPPLY VOLTAGE 24 VDC 10 % will not operate.
POWER CONSUMPTION 20W max
FSD1,FSD2,SSD,RELAY 4A, 230V AC/2A, 30V DC
AUXILIARY MONITORING 0.5A, 125V AC/2A, 30V DC
RELAY
ENCLOSURE RATING IP-20 (CONTROLLER)
IP-65 (SENSOR HEAD)
AMBIENT TEMPERATURE -10 55C
EFFECTIVE APERTURE 2.5 max(When operating
ANGLE range is 3m or more.)
TYPE OF ESPE TYPE 4

c UL us
KEYENCE CORPORATION
1-3-14,Higashi-nakajima,Higashi-yodogawa-ku LISTED AOPD
Osaka,533-8555, JAPAN 4S31

PJ -V90 MADE IN JAPAN

Serial No. 000050 / 1998


DIP SWITCH: The Mode is set using the following numbered DIP switches:
1. START INTERLOCK 4. NOT USED
2. RESTART INTERLOCK 5. NOT USED
3. MPCE (Monitoring)
CONTROLLER: Controller models
SENSOR HEAD: Sensor head models See the Instruction Manual
DETECTION ZONE: Detection zone See the Instruction Manual
OPERATING RANGE: Operating range
DETECTION CAPABILITY: Minimum object sensitivity See the Instruction Manual
RESPONSE TIME: 15 ms max. (ON to OFF) [The SSD relay's response time varies
depending on the type of the fault.]
SUPPLY VOLTAGE: Supply voltage
POWER CONSUMPTION: Power consumption
FSD1, FSD2, SSD RELAY: Relay rating (FSD1, FSD2, and SSD relays)
AUXILIARY MONITORING RELAY: Relay rating (Auxiliary monitoring relay)
ENCLOSURE RATING: Enclosure rating
AMBIENT TEMPERATURE: Ambient temperature
EFFECTIVE APERTURE ANGLE: 2.5 max. (When operating range is 3 m or more.)
TYPE OF ESPE: Type of ESPE (Electro-Sensitive Protective Equipment).
Categorized as category 4 in accordance with EN 954-1, and as
type 4 in accordance with IEC 61496.
: CE marking. The mark, when affixed to a product, shows that the
product complies with requirements stipulated by EMC directives.
c UL us
LISTED
: The c UL us mark, when affixed to a product, shows that the product is UL
LISTED
listed and displays the same effectiveness as when it is CSA listed.

ii
Sensor head
PJ-V20 series
(Optical axis pitch: 20 mm, Detection capability: 28 mm dia.)
Base unit [8 axes]
Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Base Unit Receiver Base Unit

for use with PJ-V90 for use with PJ-V90


PJ-V20T See instruction Manual PJ-V20R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

Extension unit [8 axes]


Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Extension Unit Receiver Extension Unit

for use with PJ-V90 for use with PJ-V90


PJ-V21T See instruction Manual PJ-V21R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

Extension unit [4 axes]


Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Extension Unit Receiver Extension Unit

for use with PJ-V90 for use with PJ-V90


PJ-V22T See instruction Manual PJ-V22R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

PJ-V40 series
(Optical axis pitch: 40 mm, Detection capability: 48 mm dia.)
Base unit [4 axes]
Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Base Unit Receiver Base Unit

for use with PJ-V90 for use with PJ-V90


PJ-V40T See instruction Manual PJ-V40R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

Extension unit [4 axes]


Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Extension Unit Receiver Extension Unit

for use with PJ-V90 for use with PJ-V90


PJ-V41T See instruction Manual PJ-V41R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

Extension unit [2 axes]


Transmitter Receiver
Safety Light Curtain Safety Light Curtain
Transmitter Extension Unit Receiver Extension Unit

for use with PJ-V90 for use with PJ-V90


PJ-V42T See instruction Manual PJ-V42R See instruction Manual

KEYENCE CORPORATION KEYENCE CORPORATION

MADE IN JAPAN MADE IN JAPAN

Serial No. 000130 / 1998 Serial No. 000130 / 1998

Test piece

TEST PIECE
28 mm / 1.1inch
OP-31608

iii
Part Names
The PJ-V series Extendable Safety Light Curtain is constructed of three assemblies
(controller, sensor head, and connector cable).
Receiver (PJ-VxxR)

Transmitter (PJ-VxxT)

Intermediate support
(OP-31785)
Included with the base unit.

Mounting bracket
Detection (OP-31784)
zone Included with the base unit.

Detection
zone

Cable 500 mm

Transmitter cable (PJ-VCxT)

Receiver cable (PJ-VCxR)


Main controller
(PJ-V90) Sub-controller (PJ-V91)

Controller
Main controller : Model PJ-V90
Sub-controller : Model PJ-V91

Sensor head
Base unit:
Model PJ-V20 Optical axes: 8, Optical axis pitch: 20 mm
(Paired transmitter and receiver)
Model PJ-V40 Optical axes: 4, Optical axis pitch: 40 mm
(Paired transmitter and receiver)
Extension unit:
Model PJ-V21 Optical axes: 8, Optical axis pitch: 20 mm
(Paired transmitter and receiver)
Model PJ-V22 Optical axes: 4, Optical axis pitch: 20 mm
(Paired transmitter and receiver)
Model PJ-V41 Optical axes: 4, Optical axis pitch: 40 mm
(Paired transmitter and receiver)
Model PJ-V42 Optical axes: 2, Optical axis pitch: 40 mm
(Paired transmitter and receiver)
End cap: Included with the base unit. (OP-31786, 2 pcs/set)
Mounting bracket: Included with the base unit. (OP-31784, 2 pcs/set)
Intermediate support: The intermediate supports for side and rear mounting are
included with the base unit (OP-31785).
When increasing the number of optical axes to 36 or more
with the PJ-V20 series, and to 18 or more with the PJ-V40
series, be sure to mount the specified number of intermedi-
ate supports included with the base unit (PJ-V20, PJ-V40) to
the specified position, and use the PJ-V.
In addition, when mounting the units where there is visible
vibration, use the intermediate supports regardless of the
number of optical axes to be used.
See page 45

iv
Connector cable
Transmitter cable: 2 m cable: Model PJ-VC2T
5 m cable: Model PJ-VC5T
7 m cable: Model PJ-VC7T

Receiver cable: 2 m cable: Model PJ-VC2R


5 m cable: Model PJ-VC5R
7 m cable: Model PJ-VC7R

When you want to extend the cable length to longer than 7 meters, see page 48(3.4.2).

Accessories
PJ-V90 (Main controller)

2 instruction 2 Lockout Release 1 Slotted 1 shorting bar 1 relay boad unit


manuals keys (OP-31787) screwdriver (connected to (OP-31788)
(Japanese: 1 terminals 1 and 2) (already installed on the
English: 1) PJ-V90)

PJ-V91 (Sub-controller)
No accessories included.

PJ-V20/V40 (Base unit)

2 sets of 2 mounting 2 end caps (OP-31786) 1 test piece 1 release tool


brackets (OP-31784) (one each for the transmitter (included only with the PJ-V20) (OP-31609)
and receiver) (OP-31608)

2 fixing side pieces 4 fixing side pieces 2 unit side pieces


for side mounting for rear mounting*

2 sets of intermediate supports (OP-31785)


* Standard and wide types available.

PJ-V20/V21/V22/V40/V41/V42

1 release tool (OP-31609)

PJ-VCxx (Connector cable)


No accessories included.

v
Features
The PJ-V is designed to improve productivity and working efficiency while enhanc-
ing the safety of the workers. Compared to mechanical guard mechanisms such as
safety barriers, machine visibility is vastly improved. Machine downtime is de-
creased because it is not necessary to remove safety barriers during maintenance
or when replacing products or tooling. Human errors, such as someone forgetting
to reset barriers or close safety doors, is reduced.

Original extension system


The detection zone can be selected in smaller increments.
The PJ-V system consists of 3 units, making it unnecessary to stock up with
extra units or parts.
The detection zone can be increased or decreased.

Space-saving and high rigidity


The sensor head is slim, therefore saves space.
The entirely metallic housing provides high rigidity.

Easy-to-see indicator consisting of a bar of LEDs


The optical axes can be easily aligned while checking the indicator LEDs for
illumination.
The detection status and various alarm information are displayed in real time.

High level fail-safe system


The PJ-V itself detects the failure of even a single part, providing high-level
safety.

PJ-Vs safety design


The PJ-V checks itself with two independent self-diagnostic circuits. If a failure
occurs, the machine stops immediately.

Transmitter: Element failure, Circuit failure, Cable disconnection or short-circuit

Receiver: Element failure, Circuit failure, Light interference, Cable disconnection


or short-circuit

Controller: Welded contact, Drive circuit failure, LSI failure

vi
Connectable sub-controller
The low-cost sub-controller can be used as the second controller.
The mutual interference function is automatically set when the sub-controller is
connected to the main controller.
The main controller and sub-controller can be connected using the connector,
requiring no extra wiring.

Compliance with international standards


The PJ-V series complies with the following standards. The EC type meets the
requirements of EN954-1 category 4 (IEC61496 type 4).
Country/area Standards Qualifying organization Marking
EN 61496-1, 2
Europe EN 954-1 DEMKO *2
EN 60204-1
IEC 61496-1, 2 c UL us *3
UL
UL491 LISTED

U.S.A./Canada OSHA 1910.212*1


OSHA 1910.217 (C)*1

ANSI B11.1 to B11.19*1
ANSI/R1A R15.06-1999*1

*1 ANSI and OSHA do not qualify products for compliance. Therefore, conformity
to these standards is decided by the machinery manufacturer.
*2 The mark, when affixed to a product, shows that the product complies with
requirements stipulated by EMC directives.
UL us
*3 The c LISTED
mark, when affixed to a product, shows that the product is UL listed
and displays the same effectiveness as when it is CSA listed.

vii
Important Safety Message
The precautions described below are important safety messages.
WARNING Be sure to observe them.

The PJ-V Extendable Safety Light Curtain is Active Opto-Electronic Protective


Device (AOPD) designed to increase protection for personnel from hazards arising
around moving machinery. The use of the PJ-V regulated by national or local
safety agencies, such as the Occupational Safety and Health Administration
(OSHA) in the United States, and in Europe, the European Committee for Stan-
dardization. These organizations provide information on proper safety devices.

Applying the PJ-V to a specific machine must meet full compliance with safety
regulations based on diverse items including proper application, installation, main-
tenance, and operation. The purchaser, installer, and employer all have the re-
sponsibility to follow these items and apply the PJ-V.

The employer is also responsible for training the personnel necessary to properly
install, operate, and maintain the safeguarding system and protected machine. Any
person other than the qualified person must not perform installation, inspection, or
maintenance of the PJ-V. A "qualified person" is a person or persons who, by
possessing a recognized degree or certificate of professional training, or who, by
extensive knowledge, training, and experience, has successfully demonstrated the
ability to solve problems relating to the subject matter and work.
The user of the PJ-V system is that person(s) identified and recognized by the
employer as being appropriately trained and appropriate for executing the correct
operations.

The machine operator must receive proper professional training to reliably protect
the machine using the PJ-V applied as a safety device. The machine operator must
understand and follow the companys safety rules, and use the safeguards and
proper tools provided by the employer. The machine operator must notify the
employer if the machine is not operating properly. Never operate the machine if the
safeguarding system is not properly operating.

Additional Requirements
Failure to comply with the items described below may result in a serious
DANGER accident including serious injury or death.

User
The employer must follow all procedures described in this instruction manual to
properly operate the PJ-V.
When the PJ-V is used to enhance prevention of a machine operator from
accessing a hazardous area, or any other installation where the PJ-V is utilized
as a safety device, employer must observe all applicable national and local
requirements, and other rules, codes, regulations, and laws.
Only qualified person who have received professional training should install
and test the PJ-V. Do not perform any tests or repairs other than described in
this instruction manual. All electrical wiring must be installed in accordance with
local electrical codes, regulations, and laws.

Operating environment
Do not use the PJ-V in an environment outside of the specification ranges
(temperature, humidity, ambient light, etc.).
Do not use a portable telephone or transceiver in close proximity to the PJ-V.
Do not use the PJ-V in an environment with flammable or explosive gas.
Do not use the PJ-V in an environment where severe smoke, particulate matter,
or corrosive chemicals in the air may degrade the quality of the PJ-V.

viii
Be sure that any rapid start or high-frequency type fluorescent light or similar
DANGER light does not enter the receiver.

Machinery on which the PJ-V is installed


The machine on which the PJ-V is installed must be able to stop its motion at
any point in its operating cycle. For example, do not use the PJ-V on a power
press that has a full revolution clutch.
Do not use the PJ-V for direct control (stopping a run, etc.) of transportation
equipment, nor use it on any aircraft, space equipment, or nuclear equipment.
Do not use the PJ-V on any machinery with inconsistent stop times, or with
inadequate control devices or inadequate mechanisms.
Do not use the PJ-V in a PSDI mode because it does not meet the OSHA
1910.217(h) requirements. For information on PSDI, refer to OSHA 1910.217.
The PJ-V is not subjected to Type Testing as executed under Article 44.2 of
the Industrial Safety and Health Law. Therefore, if using it in Japan, do not use
the PJ-V as a safety device for a press or shear as stipulated by Article 42 of
the Law.

Installation
It is very important to correctly calculate the safety distance. Never install the
PJ-V in just any convenient location without regard to the safety distance.
Mount the transmitter and receiver with their cable extruded ends oriented in the
same direction, as illustrated in Fig. 3-8 on page 40.
Mount the transmitter and receiver in a location with no indirect-reflection
interference. Indirect-reflection interference may cause an obstruction in the
detection zone that wont be detected.
If the PJ-V does not protect all areas of the hazardous zone, the areas unpro-
tected by the PJ-V must be protected by additional safeguards such as safety
barriers. A machine operator must not be able to stand between the machine
and the PJ-V in any way or detour the PJ-V detection zone to reach the hazard-
ous area of the machine. Install some protections in front of the hazardous area
of the machine to prevent personnel from standing between the PJ-V and
machine.

Circuit design and wiring


Be sure to turn off the power supply before starting any electrical wiring.
All electrical connections must be made in accordance with applicable national
electrical codes, regulations, and laws. Any person other than qualified person
must not perform any electrical wiring.
All safety-related machinery (including machines controlled by pneumatic,
hydraulic, and electrical systems) must be designed so that faults of or damage
to the control circuit must not lead to a failure resulting in a hazard.
For advice on where to wire the PJ-V to your machine control circuit, contact the
manufacturer of the machine protected by the PJ-V.
Do not use the power supply inside the controller for any device other than the
PJ-V.
Do not install the PJ-V power supply lines, transmitter/receiver cables, or input/
output lines in the same conduit as or parallel to high voltage lines or power
lines.
Do not extend either of the transmitter and receiver cables longer than 21
meters. See page 48
Never use only a single FSD1 or FSD2 relay to control the machine.
Never use only the SSD relay to control the machine. The SSD relay is only a
secondary switching device which is held open only in a Lockout status.
Never use the auxiliary monitoring relay as a part of the machine safety circuit.
This relay is strictly a non-safety output for monitoring only.
When installing the PJ-V for machine perimeter safeguarding, do not set the PJ-
V so that the machine is allowed to automatically restart. When using the LOCK
REL. key, locate the controller outside the area where any hazardous motion
may occur.

ix
Test and maintenance
DANGER
Always perform the test according to the test procedures after maintenance,
adjustment, or modification of the machine, as well as maintenance or adjust-
ment of the PJ-V, and before machine operation startup.
If the PJ-V does not function exactly as described in the test procedures, do not
operate the machine. If safety devices, braking system, or control system does
not operate properly, hazardous machine motion cannot be stopped.
Regularly inspect all brakes and other stopping mechanisms and controls to
ensure reliable and proper operation.
Test the operation of the installed PJ-V after any maintenance, adjustments,
modifications, or repairs are made to the control circuits or to the PJ-V itself.
The test procedures are described in this instruction manual. Employer must
regularly perform (at least every six months) the maintenance procedures for
hazard prevention. See page 64 (Chapter 4)
While performing the test procedures, the employer must ensure that PJ-V
detection ability is not adversely affected by any reflective surface or working
object on the machine. This situation will cause a fault where the BLOCKED
(red) indicator on the controller is not illuminated and a stop signal is not sent to
the machine, even when the test piece is placed in the detection zone. This lack
of response by the PJ-V may occur because the light emitted from the transmit-
ter reflects off an adjacent reflective surface and returns via an alternate path to
the receiver, as described on page 37 (3.2.2). Either relocate the detection zone
farther away from the reflective surface or reduce reflection from the surface by
masking or painting the surface. After solving the above problem on the ma-
chine, repeat the test procedures.
When it is necessary to replace a relay, only use a Keyence supplied relay
board unit.
In order to comply with the specifications and requirements of the PJ-V, reinstall
all covers opened or removed during maintenance prior to placing the PJ-V
back in service.
Any attempt to repair or troubleshoot the PJ-V, except as limited to user re-
placeable components and troubleshooting guide ( see 5. Troubleshooting on
page 74), will void the warranty described in this instruction manual. The PJ-V
contains complex electronics which may only be repaired by Keyence-trained
technicians.

Others
The PJ-V does not offer protection from flying objects.
Do not use the PJ-V to detect any transparent or translucent objects. Light
penetration may cause the PJ-V to fail to detect correctly.
When increasing the number of optical axes to 36 or more with the PJ-V20
series, and to 18 or more with the PJ-V40 series, be sure to mount the specified
number of the intermediate support (OP-31785) included with the base unit (PJ-
V20, PJ-V40) to the specified position and use the PJ-V.
And, when mounting the units onto a place with visible vibration, use the inter-
mediate support, regardless of the number of optical axes to be used.
See page 45.

Enforcement of these requirements is beyond KEYENCEs control. The employer


has the sole responsibility to follow the preceding requirements, and any other
procedures, conditions, and requirements specific to your machinery.

x
Contents

Introduction ....................................................................................................... i
Symbols ............................................................................................................. i
Label ................................................................................................................. ii
Part Names ...................................................................................................... iv
Accessories ...................................................................................................... v
Features ........................................................................................................... vi
Important Safety Message ............................................................................ viii

Chapter 1 Outline and Specifications 1


1.1 System Configuration ............................................................................ 2
1.2 Pulsed Light Emission Method ............................................................. 3
1.3 Self-Diagnostic Circuit .......................................................................... 3
1.4 Fail-safe .................................................................................................. 3
1.5 Transmitter/Receiver Extension ........................................................... 4
1.5.1 Number of extension units vs. detection zone .......................................... 4
1.5.2 Sensor head extension procedures .......................................................... 5
1.6 Controller Extension .............................................................................. 6
1.7 Specifications ......................................................................................... 7
1.8 Dimensions ............................................................................................. 9

Chapter 2 System Outline 15


2.1 Operation Modes .................................................................................. 17
2.2 Controller Indicators ............................................................................ 18
2.2.1 Status indicators ..................................................................................... 18
2.2.2 Diagnostic indicators ............................................................................... 21
2.2.3 Operation Mode indicators ...................................................................... 21
2.2.4 Signal Input indicators............................................................................. 21
2.2.5 Connected indicator ................................................................................ 21
2.3 Sensor Head Indicators ....................................................................... 22
2.3.1 Normal status indicators (When no alarm or fault occurs) ...................... 22
2.3.2 Alarm and fault indicators ....................................................................... 22
2.4 Relays ................................................................................................... 23
2.4.1 FSD (Final Switching Device) relay ........................................................ 23
2.4.2 SSD (Secondary Switching Device) relay ............................................... 24
2.4.3 Auxiliary monitoring relay ........................................................................ 24
2.5 Signal Inputs ........................................................................................ 25
2.5.1 LOCKOUT input ...................................................................................... 25
2.5.2 LOCK REL. (Lockout Release) input ...................................................... 25
2.5.3 FSD OFF input ........................................................................................ 25
2.6 MPCE Monitoring input ....................................................................... 25

xi
Chapter 3 System Installation and Startup 27
3.1 Usage Requirements ........................................................................... 28
3.2 Calculating the Mounting Distance (STEP 1) .................................... 31
3.2.1 Minimum safety distance ........................................................................ 31
3.2.2 Indirect-reflection interference ................................................................ 37
3.3 Mounting the Sensor Head (STEP 2) .................................................. 39
3.3.1 Checking the present situation................................................................ 39
3.3.2 General mounting precautions ................................................................ 39
3.3.3 Precautions on mounting multiple PJ-V sensor heads ........................... 42
3.3.4 Mounting the sensor head ...................................................................... 43
3.4 Wiring between the Sensor Head
and Controller (STEP 3) .......................................................... 48
3.4.1 Checking the present situation................................................................ 48
3.4.2 Connection between the sensor head and connector cable ................... 48
3.4.3 Connection between the controller and connector cable ........................ 49
3.4.4 Mounting the controller ........................................................................... 50
3.5 Setting the Mode (Setting the Dip SW) (STEP 4) ............................... 51
3.5.1 Checking the present situation................................................................ 51
3.5.2 Operation mode ...................................................................................... 52
3.6 Electrical Connections (STEP 5) ........................................................ 53
3.6.1 Checking the present situation................................................................ 53
3.6.2 Power supply wiring ................................................................................ 54
3.6.3 Connecting to the controller .................................................................... 55
3.7 Supplying Power
and Final Optical Alignment (STEP 6) ................................... 61
3.7.1 Checking the present situation................................................................ 61
3.7.2 Final optical alignment ............................................................................ 61
3.8 Operation Test (STEP 7) ...................................................................... 62
3.8.1 Checking the present situation ............................................................... 62
3.8.2 Test procedures after installation ........................................................... 62

Chapter 4 Test Procedures and Maintenance 63


4.1 Test Procedures after Installation ...................................................... 64
4.2 Test Procedures after Machine Adjustment,
Modification or Maintenance, and before Startup ................ 66
4.3 Periodic Inspection Procedures ......................................................... 69
4.3.1 Inspecting and replacing the relay board unit ......................................... 70
4.3.2 Mounting the relay board unit for replacement ....................................... 70
4.4 Preventive Maintenance ...................................................................... 72
4.4.1 Cleaning the PJ-V .................................................................................. 72
4.5 Testing the Sensor Head Indicators .................................................. 72

Chapter 5 Troubleshooting 73
5.1 Troubleshooting ................................................................................... 74

xii
Chapter 6 Information 77
6.1 Reference information ......................................................................... 78

Chapter 7 Optional Items 79


7.1 Connector cable ................................................................................... 80
7.2 Relay board unit ................................................................................... 81
7.3 Mounting bracket ................................................................................. 81
7.4 Intermediate support ........................................................................... 81
7.5 Release tool .......................................................................................... 82
7.6 End cap ................................................................................................. 82
7.7 LOCK REL. (Lockout Release) key ..................................................... 82
7.8 Test piece ............................................................................................. 82

PJ-V Glossary ................................................................................................. 83


Warranty .......................................................................................................... 85
Disclaimer ....................................................................................................... 85
Index ................................................................................................................ 86

xiii
Chapter 1
Outline and Specifications

1.1 System Configuration .......................................................... 2

1.2 Pulsed Light Emission Method ........................................... 3

1.3 Self-Diagnostic Circuit ......................................................... 3

1.4 Fail-safe ................................................................................. 3

1.5 Transmitter/Receiver Extension .......................................... 4


1.5.1 Number of extension units vs. detection zone ......................... 4
1.5.2 Sensor head extension procedures ......................................... 5
1.6 Controller Extension ............................................................ 6

1.7 Specifications ....................................................................... 7

1.8 Dimensions ........................................................................... 9


Chapter 1 Outline and Specifications

1.1 System Configuration


PJ-V20, PJ-V40
Sensor head (Receiver)
Receiving circuit consisting of phototransistors.
1 Sensor head (Transmitter)
Transmitting circuit consisting of infrared LEDs. The transmitter has the same
dimensions as the receiver.

PJ-V90, PJ-V91*
Controller
Control circuit consisting of a power supply, control circuit, output relays, and a
terminal block for wiring.
* The PJ-V91 is a sub-controller connected to the PJ-V90. The PJ-V91 cannot be used
independently.

End cap(Included with the PJ-V20/V40. OP-31786)


Mounting bracket or Extension unit B(PJ-V22, PJ-V42)
(Included with the PJ-V20/V40
OP-31784. 2 pieces/set)

Transmitter Extension unit A


PJ-V21, PJ-V41

Receiver

Base unit
(PJ-V20, PJ-V40)
Transmitter cable
PJ-VCxT

Receiver cable
PJ-VCxR

Main controller
PJ-V90

Lockout release key


(OP-31787)
Sub-controller
PJ-V91

Fig.1-1

Note: The PJ-V40/41/42 are available only in Japan.

2
Chapter 1 Outline and Specifications

1.2 Pulsed Light Emission Method


The infrared LEDs of the sensor head transmitter emit light sequentially when
triggered by timing signals from the controller. The receiver performs detection
in synchronization with light emission. Therefore, optical axes adjacent to each
other do not mutually interfere with each other, allowing stable detection.
1
The controller turns on the control output when all optical axes are clear of any
obstructions. The output is turned off when at least one optical axis is blocked.

Transmitter Receiver

LEDs are sequentially


turned on.

Pulsed light emission method

Fig. 1-2

1.3 Self-Diagnostic Circuit


This circuit detects an internal fault in the PJ-V. When the self-diagnostic circuit
detects an internal fault in the PJ-V, the circuit sends a stop signal to the connected
machine.

PJ-Vs safety design


The PJ-V checks itself with two independent self-diagnostic circuits. If a failure
occurs, the machine stops immediately.

Transmitter: Element failure, Circuit failure, Cable disconnection or short-circuit

Receiver: Element failure, Circuit failure, Light interference, Cable disconnection


or short-circuit

Controller: Welded contact, Drive circuit failure, LSI failure

1.4 Fail-safe
The controller utilizes dual circuits, so if an internal circuit is damaged and the
results of the dual circuits are inconsistent with each other, the controller triggers a
Lockout status and stops the machine.

3
Chapter 1 Outline and Specifications

1.5 Transmitter/Receiver Extension


The sensor head includes two types of units; a base unit and an extension unit.
The detection zone can easily be changed based on the number of added exten-
sion units.

1 1.5.1 Number of extension units vs. detection zone


PJ-V20 series (20-mm optical axis pitch)
Number of units connected
Number of Detection
PJ-V20 PJ-V21 PJ-V22
optical axes zone
Base unit Extension unit A Extension unit B
8 optical axes 8 optical axes 4 optical axes
Base unit Extension Extension
8 140mm 1 0 0
unit A unit B
12 220mm 1 0 1
16 300mm 1 1 0
20 380mm 1 1 1
24 460mm 1 2 0
28 540mm 1 2 1
32 620mm 1 3 0
36 700mm 1 3 1
40 780mm 1 4 0
44 860mm 1 4 1
48 940mm 1 5 0
52 1020mm 1 5 1
56 1100mm 1 6 0
60 1180mm 1 6 1
64 1260mm 1 7 0
When increasing the number of optical axes to 36 or more, be sure to mount
WARNING the specified number of intermediate supports (OP-31785) included with the
base unit (PJ-V20) to the specified position, and use the PJ-V.
Also, when mounting the units where there is visible vibration, use the
intermediate supports regardless of the number of optical axes to be used.
See page 45.

PJ-V40 series (40-mm optical axis pitch)


Number of units connected
Number of Detection
PJ-V40 PJ-V41 PJ-V42
optical axes zone
Base unit Extension unit A Extension unit B
4 optical axes 4 optical axes 2 optical axes
4 120mm 1 0 0
Base unit Extension Extension
unit A unit B 6 200mm 1 0 1
8 280mm 1 1 0
10 360mm 1 1 1
12 440mm 1 2 0
14 520mm 1 2 1
16 600mm 1 3 0
18 680mm 1 3 1
20 760mm 1 4 0
22 840mm 1 4 1
24 920mm 1 5 0
26 1000mm 1 5 1
28 1080mm 1 6 0
30 1160mm 1 6 1
32 1240mm 1 7 0

When increasing the number of optical axes to 18 or more, be sure to mount


WARNING the specified number of intermediate supports (OP-31785) included with the
base unit (PJ-V40) to the specified position, and use the PJ-V.
Also, when mounting the units where there is visible vibration, use the
intermediate supports regardless of the number of optical axes to be used.
See page 45.

4
Chapter 1 Outline and Specifications

1.5.2 Sensor head extension procedures


Add the extension unit(s) in the following order.
Connecting extension unit(s)
1) As shown in Fig. 1-3, insert extension unit A into the base unit. At this time,
pay attention not to confuse the transmitter with the receiver.
Also check, that even if you pull the connected unit, it does not disconnect. 1
2) Connect the required number of extension units A in the same way.
Up to 64 optical axes can be used with the PJ-V20, and up to 32 with the PJ-
V40. Do not increase the number of optical axes to more than specified
above.
3) Finally attach the end cap or extension unit B*. See Fig. 1-3
* When extension unit B is used, no end cap is required.
Extension connector
Extension unit A

Base unit

End cap/Extension unit B

Fig.1-3

Disconnecting extension unit(s)


1) Insert the release tool into the release hole in the extension unit, as shown in
Fig. 1-4.
2) Pull out the extension unit with the tool inserted.
Release hole

Release tool

Fig. 1-4

When increasing the number of optical axes to 36 or more with the PJ-V20 series,
WARNING and to 18 or more with the PJ-V40 series, be sure to mount the specified number
of intermediate supports (OP-31785) included with the base unit (PJ-V20, PJ-V40)
to the specified position, and use the PJ-V.
Also, when mounting the units where there is visible vibration, use the intermedi-
ate supports regardless of the number of optical axes to be used. See page 45.

Place the release tool under the control of the employer who is made responsible.
CAUTION Only a qualified person (as defined on page viii) should connect and disconnect
the sensor head.
Do not confuse the transmitter with the receiver when connecting the units
(including the end cap). If the transmitter and receiver are connected, the PJ-V will
not operate.
Up to 64 optical axes can be used with the PJ-V20, and up to 32 with the PJ-V40. If
the number of optical axes is increased to more than specified above, the PJ-V will
not operate correctly.
Before starting sensor head extension, check that the extension connector of each
unit is free from dust or dirt. Dust or dirt on the connector may make PJ-Vs
operation unstable or degrade the sensor head enclosure rating from IP 65.
Do not connect a PJ-V20 series sensor head with a PJ-V40 series sensor head. As
well, do not connect the PJ-V series sensor head with the PJ-L or PJ-G series
extension units. If the different series sensor heads are connected intermixedly,
correct operation cannot be guaranteed.
Before extending sensor head, be sure to turn OFF the PJ-V90.
Note: The PJ-L and PJ-G are available in Japan.

5
Chapter 1 Outline and Specifications

1.6 Controller Extension


Up to two controllers can be connected together. In this case, the first and second
units are called the main controller (PJ-V90) and sub-controller (PJ-V91), respec-
tively. The sensor heads connected to these controllers can suppress interference
with each other.
1 The sub-controller is used to allow the main controller to simultaneously control two
detection zones. When the optical axis is blocked in the detection zone of the
sensor head connected to the sub-controller (PJ-V91), a signal for detection is
output from the main controller (PJ-V90). When independent detection of two
detection zones is required, use two main controllers (PJ-V90). This allows you to
differentiate in which of two detection zones the optical axis is blocked and then
independently output a detection signal in the respective zones.

PJ-V90 PJ-V91

Power Output
supply
Fig. 1-5

Controller extension procedure


Connect the sub-controller (PJ-V91) to the main controller (PJ-V90) in the following
order:
1. Peel off the label shown in Fig. 1-6.
2. Use a slotted screwdriver to remove the cap*, as shown in Fig. 1-7.
3. When removing the cap, you can see the connector. Now connect the PJ-
V90 connector and the PJ-V91 connector.
4. Tighten the screws shown in Fig. 1-6.
The screw tightening torque is 0.686 Nm or less.
* When the PJ-V91 is not connected to the PJ-V90, the PJ-V90 cannot operate
with the cap removed. When only using the PJ-V90, be sure to use the PJ-V90
with the cap still in place.

When only using the PJ-V90, be sure to use the PJ-V90 with the cap still in
CAUTION place. If the cap is removed, the PJ-V90 will not operate.

PJ-V90

Label Insert a slotted


screwdriver into the
Cap PJ-V91 aperture, and raise the
cap using leverage.

Screw
Slotted screwdriver
Cap

Fig. 1-6 Fig. 1-7

6
Chapter 1 Outline and Specifications

1.7 Specifications
Sensor head
1.
Model PJ-V2x PJ-V4x
2.
Controller to be combined PJ-V90, PJ-V91
Detection zone
Number of optical axes
140 to 1260 mm 3.
8 to 64 axes
120 to 1240 mm 3.
4 to 32 axes
1
Optical axis pitch 20 mm 40 mm
Operating range 7m
Detection capability Opaque materials Opaque materials
(28 mm dia. min.) (48 mm dia. min.)
Light source Infrared LED (880 nm)
Operating form LIGHT-ON
Indicator Bar of 8 two-color (red and green) LEDs both
on transmitter and receiver
Effective aperture angle 4. 2.5 max.
(when operating range is 3 m or more)
Enclosure rating IP-65
Ambient light Incandescent lamp: 5,000 lux max
Sunlight: 20,000 lux max
Ambient temperature -10 to +55C (non-freezing)
Relative humidity 35 to 95% (non-condensing)
Vibration 10 to 55 Hz, 0.7 mm double amplitude in X, Y,
and Z directions, 20 times each axis.
Shock 100 m/s2 , 16 ms pulses in X, Y, and Z
directions, 1000 times each axis.
Material Housing: Aluminum, Lens cover: Polyarylate
Weight PJ-V20: 430 g, PJ-V21: 320 g, PJ-V22: 290 g
PJ-V40: 410 g, PJ-V41: 320 g, PJ-V42: 300 g
End cap: 140g, Mounting bracket: 50 g (each)
Intermediate support: 5 g (each)
Cable Transmitter 500 mm 3-core shielded cable with connector
(0.5 mm2, AWG20)
Receiver 500 mm 4-core shielded cable with connector
(0.5 mm2, AWG20)
Extension Transmitter and receiver cable lengths can
each be extended up to 21 m (excluding 500
mm length of cable extruded from base unit).
Combine optional cables to extend cable length
as required. ( See page 48)
1.
PJ-V4x models are available only in Japan.
2.
The PJ-V91 cannot operate independently. It is a sub-controller connected to
the PJ-V90. Even if you purchase only the PJ-V91, it will not operate independ-
ently.
3.
For the relationship between the number of connected units and the detection
zone, refer to 1.5.1 Number of extension units vs. detection zone on page 4.
4.
In accordance with IEC61496 (EN61496).

7
Chapter 1 Outline and Specifications

Controller
Model PJ-V90, PJ-V91 1.
Sensor head to be combined PJ-V2x, PJ-V4x
Power supply 24 V DC 10%, Ripple (p-p): 5% max.
Power consumption 20 W max. (including consumption by sensor head)
Current consumption PJ-V90+PJ-V20: 350 mA PJ-V90+PJ-V40: 340 mA
1 PJ-V91+PJ-V20: 110 mA PJ-V91+PJ-V40: 110 mA
PJ-V21: 25mA PJ-V41: 21 mA
PJ-V22: 15mA PJ-V42: 19 mA
Output FSD1, FSD2, 4 A at 230 VAC, 2 A at 30 VDC (resistive load)
SSD 2 A at 230 VAC (COS = 0.3) (inductive load)
1 A at 30 VDC (COS = 0.3) (inductive load)
AUX 0.5 A at 125 VAC, 2 A at 30 VDC (resistive load)
0.25 A at 125 VAC (COS = 0.3) (inductive load)
1 A at 30 VDC (COS = 0.3) (inductive load)
Service life Mechanical: 10 million operations or more
Electrical:100,000 operations or more
(Use of an RC snubber is recommended for inductive
loads.)
Response FSD1, FSD2, 15 ms max. (ON to OFF)
time SSD 2., AUX (including sensor head response time)
Signal input Input method Non-voltage input
Enclosure rating IP-20 (Mount controller inside control panel with IP-54
or higher level enclosure rating.)
Protection circuit Power supply section:
Reversed polarity protection, surge absorber
Ambient temperature -10 to +55C (non-freezing)
Relative humidity 35 to 95% (non-condensing)
Vibration 10 to 55 Hz, 0.7 mm double amplitude in X, Y, and Z
directions, 20 times each axis.
Shock 100 m/s2 , 16 ms pulses in X, Y, and Z directions, 1000
times each axis.
Material Polycarbonate
Weight PJ-V90: 520 g, PJ-V91: 150 g
Maximum working speed of
2.5 m/sec (in accordance with IEC61496-2)
test piece
Compliance with Can be used in U.S.A., Canada, and European
international standards countries. See page vii
Category Category 4 ESPE according to EN954-1 (type 4 AOPD
according to IEC61496)
1.
The PJ-V91 has neither power supply nor I/O terminals.
2.
The SSD relay's response time varies depending on the type of the fault.

8
Chapter 1 Outline and Specifications

1.8 Dimensions

Receiver (PJ-VxxR)

Transmitter (PJ-VxxT)
1

Intermediate support
(OP-31785)
Included with the base unit.

Mounting bracket
Detection (OP-31784)
zone Included with the base unit.

Detection
zone

Cable 500 mm

Transmitter cable (PJ-VCxT)

Receiver cable (PJ-VCxR)


Main controller
(PJ-V90) Sub-controller (PJ-V91)

9
Chapter 1 Outline and Specifications

Outline Drawings
PJ-V20 Series
Rear mounting Side mounting
3
40 (46)*
22.5
3
32 (38)*
22 17.5 18

1 33
Dead
zone

Detection
zone

Y X Z
25

790 30*2 790 30*2

1
470 30* 470 30*1

(Optical axis pitch)20

33 Dead
50 40 zone

Cable length: 0.5 m


18
29

27.5 32
17.5

Number of
X Y Z Mounting bracket
optical axes
8 240 220 206
12 320 300 286
11
16 400 380 366 18
20 480 460 446 28
24 560 540 526
28 640 620 606
*2 x slot
32 720 700 686 18 4
36 800 780 766
40 880 860 846
44 960 940 926
48 1040 1020 1006
4
52 1120 1100 1086 27.5
56 1200 1180 1166 17.5
5
60 1280 1260 1246
*Detail of slot
64 1360 1340 1326 29

When increasing the number of optical axes to 36 or more, be sure to mount the
specified number of intermediate supports (OP-31785) included with the base unit
(PJ-V20) to the specified position, and use the PJ-V. Also, when mounting the units
where there is visible vibration, use the intermediate supports regardless of the
number of optical axes to be used.
*1 Mounting position for the intermediate support 1. See page 45.
*2 Mounting position for the intermediate support 2. See page 45.
*3 The value in parentheses shows the dimensions using the wide type fixing side
piece for rear mounting.
When increasing the number of optical axes to 36 or more, be sure to mount
WARNING the specified number of intermediate supports (OP-31785) included with the
base unit (PJ-V20) to the specified position, and use the PJ-V.
Also, when mounting the units where there is visible vibration, use the
intermediate supports regardless of the number of optical axes to be used.
See page 45.

10
Chapter 1 Outline and Specifications

PJ-V40 Series
Rear mounting Side mounting
3
40 (46)* 22.5
3
32 (38)* 17.5 18
22

33
Dead
zone 1

Detection
zone

Y X Z
25

2
770 30* 770 30*2

450 30*1 450 30*1

(Optical axis pitch) 40

33 Dead
50 40 zone

Cable length: 0.5 m


18
29

27.5 32
17.5

Number of
optical axes
X Y Z Mounting bracket
4 220 200 186
6 300 280 266 11
8 380 360 346 18
10 28
460 440 426
12 540 520 506
14 620 600 586 *2 x slot
16 700 680 666 18 4
18 780 760 746
20 860 840 826
22 940 920 906
24 1020 1000 986 4
26 1100 1080 1066 27.5
28 1180 1160 1146 17.5
5
30 1260 1240 1226 *Detail of slot
32 1340 1320 1306 29

When increasing the number of optical axes to 18 or more, be sure to mount the
specified number of intermediate supports (OP-31785) included with the base unit
(PJ-V40) to the specified position, and use the PJ-V. Also, when mounting the units
where there is visible vibration, use the intermediate supports regardless of the
number of optical axes to be used.
*1 Mounting position for the intermediate support 1. See page 45.
*2 Mounting position for the intermediate support 2. See page 45.
*3 The value in parentheses shows the dimensions using the wide type fixing side
piece for rear mounting.
When increasing the number of optical axes to 18 or more, be sure to mount
WARNING the specified number of intermediate supports (OP-31785) included with the
base unit (PJ-V40) to the specified position, and use the PJ-V.
Also, when mounting the units where there is visible vibration, use the
intermediate supports regardless of the number of optical axes to be used.
See page 45.

11
Chapter 1 Outline and Specifications

Respective units 14

43

22 22

1
164 186 184 206

2000/5000/7000

72 92

32
22

32
22

500 500 45

45
45

14

14 14
Transmitter/
Receiver cable
22 22
(PJ-VCxx)
12 12

29 29

Base unit PJ-V40T/R Base unit PJ-V20T/R


29

22

7.2

77

172 183

77

160

22 77

29

Extension unit B (4 optical axes) Extension unit A (8 optical axes)


PJ-V22T/R PJ-V21T/R
Extension unit B (2 optical axes) Extension unit A (4 optical axes)
PJ-V42T/R PJ-V41T/R

12
Chapter 1 Outline and Specifications

Main controller (PJ-V90)

34

28.5

82 28
1

8.5 26

90
(93)
70 10
15.5

*4 x slot (55)
(Mounting hole)

35.4

125 115 120


5.1 56.1
79

18.3

4 5 12.1
14.6

5.3
7
*Detail of slot

13
Chapter 1 Outline and Specifications

Main controller (PJ-V90) and sub-controller (PJ-V91) connected together

34 69

28.5

1 82 28 85.5

8.5 26

116
(93)
10
70
26 15.5

*4 x slot (55)
(Mounting hole)

35.4

125115 120

79

4 5

5.3
7
*Detail of slot

14
Chapter 2
System Outline

2.1 Operation Modes ................................................................ 17

2.2 Controller Indicators .......................................................... 18


2.2.1 Status indicators .................................................................... 18
2.2.2 Diagnostic indicators .............................................................. 21
2.2.3 Operation Mode indicators ..................................................... 21
2.2.4 Signal Input indicators ........................................................... 21
2.2.5 Connected indicator ............................................................... 21
2.3 Sensor Head Indicators ...................................................... 22
2.3.1 Normal status indicators (When no alarm or fault occurs) ..... 22
2.3.2 Alarm and fault indicators ...................................................... 22
2.4 Relays .................................................................................. 23
2.4.1 FSD (Final Switching Device) relay ....................................... 23
2.4.2 SSD (Secondary Switching Device) relay .............................. 24
2.4.3 Auxiliary monitoring relay ....................................................... 24
2.5 Signal Inputs ....................................................................... 25
2.5.1 LOCKOUT input ..................................................................... 25
2.5.2 LOCK REL. (Lockout Release) input ..................................... 25
2.5.3 FSD OFF input ....................................................................... 25
2.6 MPCE Monitoring input ...................................................... 25
Chapter 2 System Outline

This chapter describes the PJ-V operating modes and safety circuitry.
Please read this chapter thoroughly before installing the PJ-V on your machine.

Controller inputs/outputs
Transmitter Receiver
Controller

FSD1 and FSD2 relays: Sends a stop signal to the machine.


See page 23 (2.4.1).
SSD relay: Turns off the power supply of the related hazardous section.
See page 24 (2.4.2).
AUX (Auxiliary monitoring) relays: Signals whether the FSD1 and FSD2 relay
2 status is open or closed, to the PLC, etc. See page 24 (2.4.3).
LOCKOUT input: Forces a lockout. See page 25 (2.5.1).

LOCK REL. (Lockout Release) input: Releases the lockout.


See page 25 (2.5.2).

FSD OFF input: Forces open the FSD. See page 25 (2.5.3).
MPCE Monitoring input: Input used to monitor MPCE's fault.
See page 25 (2.6).

Fig.2-1

Controller indicators
PJ-V90 PJ-V91
(Main Controller) (Sub-controller)

STATUS
Indicates the status of the PJ-V. CLEAR
See page 18 (2.2.1) BLOCKED
LOCKOUT
OPERATION MODE
Indicates which operation mode is START I/L
active. RESTART I/L Indicates whether power is supplied
See page 21 (2.2.3) MPCE OFF to the PJ-V91.
See page 21 (2.2.5)
SIGNAL INPUT
Indicates the status of the signal LOCKOUT
input. LOCK REL. CONNECTED
Sensor head indicator
See page 21 (2.2.4) FSD OFF
DIAGNOSTICS DIAGNOSTICS
TRANSMITTER
TRANSMITTER
Indicates which of the PJ-V RECEIVER RECEIVER
assemblies has a fault. CONTROLLER
Sensor head indicator
See page 21 (2.2.2) FSD 1
See page 22 (2.3).
FSD 2
SSD
MPCE

LOCKOUT RELEASE

LOCK REL. (Lockout release) key.


See page 20

PJ-V90 PJ-V91

Fig. 2-2 Fig. 2-3

16
Chapter 2 System Outline

2.1 Operation Modes


The PJ-V provides the following two operation modes. These two modes can be
used in combination with each other. (Two modes may be selected simultane-
ously.)
The operation mode(s) is set with the PJ-V90. When the PJ-V91 is used, the
transmitter and receiver connected to the PJ-V91 operate in the same operation
mode(s) as that set with the PJ-V90.

Start Interlock
Restart Interlock 2
See page 51 (3.5) for mode setting procedures.

Start Interlock
In this mode, the PJ-V enters LOCKOUT status when power is supplied to the PJ-
V. Lockout status means the status in which all outputs (FSD1, FSD2, and SSD)
are opened and the machine is stopped. By rotating the LOCK REL. key or closing
(terminals 3 and 4 short-circuited) the LOCK REL. input, the PJ-V can restart.
Refer to the Flowchart in Fig. 2-4

Status indicators Output relays (N.O. contact)


CLEAR (Green) BLOCKED (Red) LOCKOUT (Yellow) FSD1,2 SSD AUX (Auxiliary monitoring) relay
Power supply is off.

Power supply
is turned on.

Release Lockout
status. (See page 20)

Machine runs.

Optical axis
is blocked.

Machine stops.

Obstruction is
removed from
detection zone.
Start Interlock Mode
Functional Flowchart Indicator ON OPEN
Indicator OFF CLOSED
Fig. 2-4.

17
Chapter 2 System Outline

Restart Interlock
In this mode, the PJ-V enters Lockout status when an object is placed in the
detection zone and blocks one or more optical axes. Lockout status means the
status in which all outputs (FSD1, FSD2, SSD) are opened and the machine is
stopped. To restart the PJ-V, you need to remove the obstruction from the detec-
tion zone, and then rotate the LOCK REL. key or close (terminals 3 and 4 short-
circuited) the LOCK REL. input.
Refer to the Flowchart in Fig. 2-5.

Status indicators Output relays (N.O. contact)


CLEAR (Green) BLOCKED (Red) LOCKOUT (Yellow) FSD1,2 SSD AUX (Auxiliary monitoring) relay
2 Power supply is off.

Power supply
is turned on.

Release Lockout
status. (See page 20)

Machine runs.

Optical axis
is blocked.

Machine stops.

Obstruction is
removed from
detection zone.
Restart Interlock Mode
Functional Flowchart Indicator ON OPEN
Indicator OFF CLOSED

Fig. 2-5

2.2 Controller Indicators


The controller contains several indicators. A description of these indicators is given
below.

2.2.1 Status indicators


STATUS Three indicators provide an operation status of the PJ-V.
CLEAR
BLOCKED
LOCKOUT CLEAR (green) : Illuminated when the PJ-V is in Run status.
ON BLOCKED (red) : Illuminated when the PJ-V is in Stop or Lockout status.
OFF
LOCKOUT (yellow) : Illuminated when the PJ-V is in Lockout status.

Run status
STATUS When all of the following conditions are satisfied,Clear (green) indicator is illumi-
CLEAR
BLOCKED nated and all output relays (FSD1, FSD2, and SSD) are closed, allowing the
LOCKOUT machine to operate. This status is called Run status.
ON
OFF Conditions (All of the following conditions should be satisfied.)
The transmitter and receiver are in proper optical alignment.
All optical axes are clear of any obstructions.
The control device has no faults.
The installation environment has no hindrances such as ambient light.

18
Chapter 2 System Outline

The FSD OFF input is opened(terminals 5 and 6 are open-circuited).


See page 60 (FSD OFF input).
The LOCKOUT input is closed(terminals 1 and 2 are short-circuited).
See page 59 (LOCKOUT input).
Stop status
STATUS
CLEAR
When any of the following conditions occur with the Restart Interlock mode not
BLOCKED selected, the BLOCKED (red) indicator is illuminated, the two control outputs
LOCKOUT (FSD1 and FSD2) are opened, and the other control output (SSD) is closed,
ON causing the machine to stop. This status is called Stop status.
OFF

Conditions (When any of the following conditions are met.)


2
The transmitter and receiver are mounted out of the operating range.
The transmitter and the receiver are not in proper alignment.
The optical axis is blocked.
The FSD OFF input is closed (terminals 5 and 6 are short-circuited.)
See page 60 (FSD OFF input).

Lockout status
STATUS In Lockout status, the LOCKOUT (yellow) indicator and BLOCKED (red) indicator
CLEAR
BLOCKED
are illuminated and all control outputs (FSD1, FSD2, and SSD) are opened, caus-
LOCKOUT ing the machine to stop.
ON
OFF There are three types of Lockout status, as shown below.

Lockout status by mode selection


When the Start Interlock (START I/L) or Restart Interlock (RESTART I/L) mode
is selected, a Lockout status occurs when power is supplied (START I/L) or
each time the optical axis is blocked (RESTART I/L).

Lockout status by LOCKOUT input


When the LOCKOUT input is opened (terminals 1 and 2 are open-circuited.), a
Lockout status occurs.

Lockout status by detection of control device fault


This status occurs when any control device fault is detected. This status is
caused when any of the following conditions occurs. When this status occurs,
the Diagnostic indicator is illuminated.

Conditions (When any of the following conditions occurs.)


An error, such as disconnection, is detected in the transmitter or receiver.
The FSD1, FSD2, or SSD does not operate. Or, the FSD1, FSD2 or SSD does
not respond within the preset time.
An internal fault is detected in the controller.
Ambient light continues to enter.
The Mode switch is set incorrectly.
The Mode switch setting is changed during Run status.
The connector cap on the PJ-V90 is removed. See page 6.
The PJ-V91 is disconnected from the PJ-V90 while using the PJ-V91.
Though the MPCE Monitoring function is set, the MPCE Monitoring input is not
activated; or, MPCE response is delayed. (The response time is 250 ms or
more.)

19
Chapter 2 System Outline

How to release Lockout status


LOCK REL. key and LOCK REL. input
To restart the PJ-V from the Lockout status, you need to remove the obstruction,
and then use the LOCK REL. key or LOCK REL. input.

LOCK REL. key LOCK REL. input


1. Remove any obstructions from the 1. Remove any obstructions from the
detection zone. detection zone.
2. Insert the key into the PJ-V90 keyhole. 2. Short-circuit PJ-V90's terminals 3 and 4.
LOCKOUT RELEASE

3
2 Key 4

PJ-V90

3. Rotate the key to the LOCKOUT


RELEASE position. 3
LOCKOUT RELEASE

PJ-V90

4. Release your hold of the key to return 3. Open-circuit PJ-V90's terminals 3 and 4.
the key to the original position, and then
extract the key from the PJ-V90's keyhole. 3
LOCKOUT RELEASE

PJ-V90

However, in the case of a Lockout status by detection of control device fault


status, you cannot restart the PJ-V unless the power supply is turned off one time
and the fault is corrected.

When an obstruction is present in the detection zone with the Restart Interlock
mode not selected, rotating the LOCK REL. key or activating the LOCK REL. input
closes only the SSD but holds the FSD1 and FSD2 open. When the Restart Inter-
lock mode is selected in this case, the FSD1, FSD2, and SSD are held open.

When the LOCK REL. key operation, LOCKOUT input, and LOCK REL. input are
activated simultaneously, priority is given to the LOCKOUT input, invoking a Lock-
out status.

Example
1. When the LOCKOUT input is turned on with the LOCK REL. key operation or
LOCK REL. input activated, Lockout is invoked.

2. Even when the LOCK REL. key operation or LOCK REL. input is activated with
the LOCKOUT input turned on, the Lockout is not released.

Access to the LOCKOUT input, LOCK REL. input, and LOCK REL. key must
DANGER be placed under the control of the employer or a person who is made respon-
sible. Only a qualified person (as defined on page viii) should operate
LOCK REL. key.

20
Chapter 2 System Outline

2.2.2 Diagnostic indicators


DIAGNOSTICS When a fault is detected in the following assemblies, the corresponding indicator is
TRANSMITTER
RECEIVER illuminated.
CONTROLLER
FSD 1
FSD 2
Transmitter
SSD Receiver
MPCE
Controller
FSD1 (Final Switching Device 1)
FSD2 (Final Switching Device 2)


SSD (Secondary Switching Device)
MPCE (Machine Primary Control Element)
2
The Diagnostic indicators should be used as a troubleshooting guide only. If
multiple faults occur at the same time, generally only the indicator for the assembly
with the first detected fault is illuminated. Turn off the power supply, correct the
fault and resupply power. Then, the indicator for the assembly with the second
detected fault is illuminated. Proceed with your troubleshooting in order until no
indicator is illuminated. (However, if a fault is detected in the receiver or the control-
lers receiving circuit when power is supplied, the Controller and Receiver Diagnos-
tic indicators are illuminated at the same time.)

2.2.3 Operation Mode indicators


OPERATION MODE When the following operation mode(s) is selected, the corresponding indicator(s) is
START I/L
RESTART I/L illuminated green.
MPCE OFF

Start I/L (Start Interlock)


Restart I/L (Restart Interlock)
MPCE OFF

When the MPCE monitoring function is not selected, the MPCE OFF indicator is
illuminated.
For mode setting procedures, refer to page 51 (3.5).

2.2.4 Signal Input indicators


SIGNAL INPUT When any of the following signal inputs are activated, the corresponding indicator
LOCKOUT
LOCK REL.
is illuminated green.
FSD OFF

LOCKOUT
LOCK REL.
FSD OFF

The LOCK REL. (Lockout Release) indicator is illuminated when the LOCK REL.
input is closed (terminals 3 and 4 are short circuited), or the LOCK REL. key
operation is activated. The FSD OFF indicator is illuminated when the FSD OFF
input is closed (terminals 5 and 6 are short-circuited). In addition, the LOCKOUT
indicator is illuminated when the LOCKOUT input is open (terminals 1 and 2 are
open-circuited).

2.2.5 Connected indicator


CONNECTED
When the power is being supplied to the PJ-V91 through the PJ-V90, the
PJ-V91
CONNECTED indicator is illuminated green. After connecting the PJ-V91 to the PJ-
V90 and supplying power to the PJ-V90, check that this indicator is illuminated.

21
Chapter 2 System Outline

2.3 Sensor Head Indicators


The transmitter and receiver are equipped with an indicator consisting of eight bar
LEDs. The status of LEDs illuminated depends on the status of the controller and
sensor head.
Sensor head indicator status
Green ON
Red ON
OFF
Red Flashes
CLEAR BLOCKED
2

100%

Ratio of clear optical axes to all axes

0%
Fig.2-6

2.3.1 Normal status indicators (When no alarm or fault occurs)


In normal operating status, all LEDs are illuminated green when all optical axes are
clear. When one or more optical axes are blocked, a number of LEDs change to
red depending on the ratio of clear optical axes to all axes. When no optical axis is
clear, one LED flashes red.

2.3.2 Alarm and fault indicators


Sensor head indicator status
Flashes green Flashes red Flashes green and red OFF

Received lignt
quantity low Ambient light
Transmitter fault detected Receiver fault detected
(Unstable detected
detection)

OR OR
Transmitter and Transmitter and Receiver indicator Transmitter indicator
receiver indicators receiver indicators

Transmitter indicator Receiver indicator


Other fault
detected

Transmitter and
receiver indicators

22
Chapter 2 System Outline

2.4 Relays
The PJ-V controller is equipped with three control output relays (FSD1, FSD2, and
SSD) and an auxiliary monitoring relay. Explanation of these four relays is given
below.

2.4.1 FSD (Final Switching Device) relay


Function
The FSD relay is wired to the MPCE and used to control the MPCE.
See page 56 (MPCE: Machine Primary Control Element). 2
Control flow

FSD relay MPCE (relay, contactor, etc.) Machine

Contact structure
FSD1, 2 relays: Provide an N.O. output.

The N.O. contacts of the FSD1, 2 relays are held closed in a machine Run status.

Features
Relay fault monitoring circuit
The FSD1 and FSD2 relays are wired as shown in Fig. 3-35 on page 57. Each
relay is monitored by the relay fault monitoring circuit. If a fault occurs in either
relay, both control output relays' contacts (FSD1 and FSD2) open and send a stop
signal to the machine. In addition, the SSD relay contact also opens.(Except for
welded contacts.)
The FSD1 and FSD2 are safety relays. These are special relays in which one A-
and B-contact are interconnected and move together. If one relay becomes immo-
bilized by a welded contact, the welded contact can be detected based on the
contact gap of the other relay.

Safety relay
Contact A Contact B

One A and B contact are


interconnected by a joint and
mechanicaly forced to move together.

Interconnected
Fig.2-7

Never use only a single relay, the FSD1 or FSD2, to control the machine.
DANGER Should this single relay fail, the machine may not stop, resulting in severe
operator injury. Use both control output relays (FSD1 and FSD2) to control
the machine.

When it is necessary to replace a relay, use only a Keyence supplied relay


board unit (OP-31788). Never attempt to replace an output relay with
another manufacturers part, or the PJ-V will not operate normally, possi-
bly resulting in a severe hazard to the operator.

23
Chapter 2 System Outline

2.4.2 SSD (Secondary Switching Device) relay


Function
The SSD relay is used to control the MSCE (Machine Secondary Control Element:
See page 57). The MSCE is the last control element to start or stop the motion of
the related hazardous section on the machine.
Control flow
SSD relay MSCE (relay, contactor, etc.) Related hazardous section on
machine

2 Contact structure
SSD relay: Provides an N.O. output.
The N.O. contact of the SSD relay is held open only in a Lockout status.

Features
Relay fault monitoring circuit
The SSD relay is wired as shown in Fig. 3-35 on page 57. Like the FSD relays, a
safety relay is used for the SSD relay, which is monitored by the relay fault monitor-
ing circuit.

Never use only the SSD relay to control the machine. The SSD relay is
DANGER only a secondary switching device which is held open only in a Lockout
status. Control using only the SSD relay may result in a serious accident
including serious injury or death.

When it is necessary to replace a relay, use only a Keyence supplied relay


board unit (OP-31788). Never attempt to replace an output relay with
another manufacturers part, or the PJ-V will not operate normally, possi-
bly resulting in a severe hazard to the operator.

2.4.3 Auxiliary monitoring relay


Function
The auxiliary monitoring relay is used to signal whether the FSD relay status is held
open or closed, to the PLC, etc.

Contact structure
Auxiliary monitoring relay: Provides an N.O. output.
The auxiliary monitoring relay operates in the same way as the FSD relays. The
N.O. contact of this relay is held open in a Lockout status and Stop Status.

Features
Relay for monitoring only (This is not a safety output)
The auxiliary monitoring relay is an auxiliary, non-safety output. The auxiliary
monitoring relay cannot be used as a safety output because its operating status is
not monitored by the PJ-V. Even if a fault occurs in this relay, it does not cause a
Lockout status.

Never use the auxiliary monitoring relay as a part of the machine safety
DANGER circuit. This relay is strictly a non-safety output for monitoring only. Using
the auxiliary monitoring relay as a part of the machine safety circuit may
result in a serious accident including serious injury or death.

When it is necessary to replace a relay, use only a Keyence supplied relay


board unit (OP-31788). Never attempt to replace an output relay with
another manufacturers part, or the PJ-V will not operate normally, possi-
bly resulting in a severe hazard to the operator.

24
Chapter 2 System Outline

2.5 Signal Inputs


Signal inputs include the following.

LOCKOUT input
LOCK REL. input
FSD OFF input

2.5.1 LOCKOUT input


When the LOCKOUT input is opened(terminals 1 and 2 are open-circuited), the
2
Lockout status is forced on.
See page 59 (LOCKOUT input).

The LOCKOUT input terminals are numbered 1 and 2. When the PJ-V is shipped,
terminals 1 and 2 are short-circuited with a shorting bar. When using the LOCK-
OUT input, remove the shorting bar.

2.5.2 LOCK REL. (Lockout Release) input


When the LOCK REL. input is closed (terminals 3 and 4 are short-circuited) with
the Lockout status release conditions satisfied, the Lockout status can be released.
See page 59 (LOCK REL. input).

2.5.3 FSD OFF input


When the FSD OFF input is closed (terminals 5 and 6 are short-circuited), the FSD
is forced open.
See page 60 (FSD OFF input).

2.6 MPCE Monitoring input


The MPCE Monitoring input is utilized when the MPCE is a safety relay. This input
is used to monitor whether the MPCE is operating correctly or not.
See page 58 [MPCE monitoring (When using the MPCE Monitoring function)].

25
Chapter 2 System Outline

26
Chapter 3
System Installation and Startup

3.1 Usage Requirements .......................................................... 28

3.2 Calculating the Mounting Distance (STEP 1) ................... 31


3.2.1 Minimum safety distance ....................................................... 31
3.2.2 Indirect-reflection interference ............................................... 37
3.3 Mounting the Sensor Head (STEP 2) ................................ 39
3.3.1 Checking the present situation .............................................. 39
3.3.2 General mounting precautions ............................................... 39
3.3.3 Precautions on mounting multiple PJ-V sensor heads .......... 42
3.3.4 Mounting the sensor head ..................................................... 43
3.4 Wiring between the Sensor Head
and Controller (STEP 3) ..................................................... 48
3.4.1 Checking the present situation .............................................. 48
3.4.2 Connection between the sensor head and connector cable .. 48
3.4.3 Connection between the controller and connector cable ....... 49
3.4.4 Mounting the controller .......................................................... 50
3.5 Setting the Mode (Setting the Dip SW) (STEP 4) .............. 51
3.5.1 Checking the present situation .............................................. 51
3.5.2 Operation mode ..................................................................... 52
3.6 Electrical Connections (STEP 5) ....................................... 53
3.6.1 Checking the present situation .............................................. 53
3.6.2 Power supply wiring ............................................................... 54
3.6.3 Connecting to the controller ................................................... 55
3.7 Supplying Power
and Final Optical Alignment (STEP 6) .............................. 61
3.7.1 Checking the present situation .............................................. 61
3.7.2 Final optical alignment ........................................................... 61
3.8 Operation Test (STEP 7) ..................................................... 62
3.8.1 Checking the present situation ............................................. 62
3.8.2 Test procedures after installation .......................................... 62
Chapter 3 System Installation and Startup

Outline of installation procedures


Please read this chapter in the following order. The installation procedures are
outlined below.

Step Procedure Refer to


General Understanding the usage requirements 3.1 "Usage Requirements"
Calculating the mounting distance of 3.2 "Calculating the Mounting Distance"
1
the PJ-V
2 Mounting the sensor head 3.3 "Mounting the Sensor Head"
Connecting between the sensor head 3.4 "Wiring between the Sensor Head
3
and controller and Controller"
4 Setting the PJ-V mode 3.5 "Setting the Mode (Setting the Dip SW)"
5 Electrical wiring 3.6 "Electrical Connection"
Final optical alignment: 3.7 "Supplying Power and Final Optical
6
Alignment"
3 7 Testing the PJ-V and machine for operation 3.8 "Operation Test"

Before starting your installation procedures, please read this chapter care-
WARNING fully to understand the contents completely. The PJ-V must only be installed,
inspected, and maintained by qualified person (as defined on page viii). It
is important that the user is familiar with the installation requirements, safety
distance, controls, and features of the PJ-V before using the PJ-V Safety
Light Curtain.

3.1 Usage Requirements


Failure to follow the usage requirements described below may result in a
DANGER serious accident including serious injury or death.

The usage requirements to be satisfied before installing or using the PJ-V are
given below.

User
The employer must follow all procedures described in this instruction manual to
properly operate the PJ-V.
When the PJ-V is used to enhance prevention of a machine operator from
access to a hazardous area, or any other installation where the PJ-V is utilized
as a safety device, employer must observe all applicable national and local
requirements, and other rules, codes, regulations, and laws.
Only qualified person who have received professional training should install
and test the PJ-V. Do not perform any tests or repairs other than those de-
scribed in this instruction manual. All electrical wiring must be installed in
accordance with local electrical codes, regulations, and laws.

Operating environment
Do not use the PJ-V in an environment outside of the specification ranges
(temperature, humidity, ambient light, etc.).
Do not use a portable telephone or transceiver in close proximity to the PJ-V.
Do not use the PJ-V in an environment with flammable or explosive gas.
Do not use the PJ-V in an environment where severe smoke, particulate matter,
or corrosive chemicals in the air may degrade the quality of the PJ-V.
Be sure that any rapid start or high-frequency type fluorescent light or similar
light does not enter the receiver.

28
Chapter 3 System Installation and Startup

Machinery on which the PJ-V is installed


WARNING The machine on which the PJ-V is installed must be able to stop its motion at
any point in its operating cycle. For example, do not use the PJ-V on a power
press that has a full revolution clutch.
Do not use the PJ-V for direct control (stopping a run, etc.) of transportation
equipment, nor use it on any aircraft, space equipment, or nuclear equipment.
Do not use the PJ-V on any machinery with inconsistent stop times, or with
inadequate control devices or inadequate mechanisms.
Do not use the PJ-V in a PSDI mode because it does not meet OSHA
1910.217(h) requirements. For information on PSDI, refer to OSHA 1910.217.
The PJ-V is not subjected to Type Testing as executed under Article 44.2 of
the Industrial Safety and Health Law. Therefore, if using it in Japan, do not use
the PJ-V as a safety device for a press or shear as stipulated by Article 42 of
the Law.

Installation 3
It is very important to correctly calculate the safety distance. Never install the
PJ-V in just any convenient location without regard to the safety distance.
Mount the transmitter and receiver with their cable extruded ends oriented in the
same direction, as illustrated in Fig. 3-8 on page 40.
Mount the transmitter and receiver in a location with no indirect-reflection
interference. Indirect-reflection interference may cause an obstruction in the
detection zone that wont be detected.
If the PJ-V does not protect all areas of the hazardous zone, the areas unpro-
tected by the PJ-V must be protected by additional safeguards such as safety
barriers. A machine operator must not be able to stand between the machine
and the PJ-V in any way or detour the PJ-V detection zone to reach the hazard-
ous area of the machine. Install some protections in front of the hazardous area
of the machine to prevent personnel from standing between the PJ-V and
machine.

Circuit design and wiring


Be sure to turn off the power supply before starting any electrical wiring.
All electrical connections must be made in accordance with applicable national
electrical codes, regulations, and laws. Any person other than qualified person
must not perform any electrical wiring.
All safety-related machinery (including machines controlled by pneumatic,
hydraulic, and electrical systems) must be designed so that faults of or damage
to the control circuit must not lead to a failure resulting in a hazard.
For advice on where to wire the PJ-V to your machine control circuit, contact the
manufacturer of the machine protected by the PJ-V.
Do not use the power supply inside the controller for any device other than the
PJ-V.
Do not install the PJ-V power supply lines, transmitter/receiver cables, or input/
output lines in the same conduit as or parallel to high voltage lines or power
lines.
Do not extend either of the transmitter and receiver cables longer than 21
meters. See page 48.
Never use only a single FSD1 or FSD2 relay to control the machine.
Never use only the SSD relay to control the machine. The SSD relay is only a
secondary switching device which is held open only in a Lockout status.
Never use the auxiliary monitoring relay as a part of the machine safety circuit.
This relay is strictly a non-safety output for monitoring only.

29
Chapter 3 System Installation and Startup

When installing the PJ-V for machine perimeter safeguarding, do not set the PJ-
V so that the machine is allowed to automatically restart. When using the LOCK
REL. key, locate the controller outside the area where any hazardous motion
may occur.

Test and maintenance


Always perform testing according to the test procedures after maintenance,
adjustment, or modification to the machine or the PJ-V, and before machine
operation startup.
If the PJ-V does not function exactly as described in the test procedures, do not
operate the machine. If safety devices, braking system, or control system does
not operate properly, hazardous machine motion cannot be stopped.
Regularly inspect all brakes and other stopping mechanisms and controls to
ensure reliable and proper operation.
Test the operation of the installed PJ-V after any maintenance, adjustments,
3 modifications, or repairs are made to the control circuits or the PJ-V itself. The
test procedures are described in this instruction manual. Employer must regu-
larly perform (at least every six months) the maintenance procedures for pre-
vention of any hazard. See page 64 (Chapter 4)
While performing the test procedures, the employer must ensure that the PJ-V
detection ability is not adversely affected by any reflective surface or working
object on the machine. This situation will cause a fault where the BLOCKED
(red) indicator on the controller is not illuminated and a stop signal is not sent to
the machine, even when the test piece is placed in the detection zone. This lack
of response by the PJ-V may occur because the light emitted from the transmit-
ter reflects off an adjacent reflective surface and returns via an alternate path to
the receiver, as described on page 37 (3.2.2). Either relocate the detection zone
farther away from the reflective surface or reduce the reflection of the surface
by masking or painting the surface. After solving the above problem on the
machine, repeat the test procedures.
When it is necessary to replace a relay, only use a Keyence supplied relay
board unit.
In order to comply with the specifications and requirements of the PJ-V, reinstall
all covers opened or removed during maintenance prior to placing the PJ-V
back in service.
Any attempt to repair or troubleshoot the PJ-V, except as limited to user re-
placeable components and troubleshooting guide ( see 5. Troubleshooting on
page 74), will void the warranty described in this instruction manual. The PJ-V
contains complex electronics which may only be repaired by Keyence-trained
technicians.

Others
The PJ-V does not offer protection from flying objects.
Do not use the PJ-V to detect any transparent or translucent objects. Light
penetration may cause the PJ-V to fail to detect correctly.
When increasing the number of optical axes to 36 or more with the PJ-V20
series, and to 18 or more with the PJ-V40 series, be sure to mount the specified
number of the intermediate support (OP-31785) included with the base unit (PJ-
V20, PJ-V40) to the specified position and use the PJ-V.
And, when mounting the units onto a place with visible vibration, use the inter-
mediate support, regardless of the number of optical axes to be used.
See page 45

The enforcement of these requirements is beyond KEYENCEs control. The em-


ployer has the responsibility to follow the preceding requirements and any other
procedures, conditions, and requirements specific to your machinery.

30
Chapter 3 System Installation and Startup

3.2 Calculating the Mounting Distance (STEP 1)


The first thing to do when installing the PJ-V is to calculate the mounting distance
for the PJ-V. It is very important to correctly calculate and find this distance. Never
install the PJ-V in just any convenient location without regard to the minimum
safety distance.
To determine the mounting distance of the transmitter and receiver, the following
two points must be taken into consideration.

1) Minimum safety distance:


The distance at which the PJ-V is mounted far enough away from the hazard-
ous area so that the machine can stop before the operators hand or other body
part reaches the hazardous area.

2) Distance to avoid to indirect-reflection interference:


The distance at which the PJ-V is mounted so that no reflective surface is 3
present inside the effective aperture angle of the transmitter and receiver.

3.2.1 Minimum safety distance


The detection zone must be located at a distance from the nearest recognized
hazard so that the machine operator or other personnel cannot reach the hazard
with hands or other body part before cessation of motion during the hazardous
portion of the machine cycle. This distance is called the minimum safety distance
and is based on the stopping time of your machine. It is calculated based on a
formula.
See page 38.

The proper calculation of the safety distance is very important. Never install
DANGER the PJ-V in just any convenient location without regard to the safety dis-
tance. Mounting the PJ-V very close to a hazardous area may result in a
severe hazard including serious injury or death to the machine operator.

Measuring the machine stop time


A device used to measure how long a machine requires to stop hazardous motion
is called a brake monitor. This brake monitor is also used to monitor the deteriora-
tion of the machine stopping time resulting from a decrease in the brake perform-
ance.

The PJ-V is not equipped with a brake monitor.


IMPORTANT
For machines requiring a brake monitor, follow all national laws, codes, and regula-
tions. OSHA requires use of a brake monitor in applications using certain types of
power presses to which workpieces are manually fed. Refer to OSHA 1910.217
(b)(14).

31
Chapter 3 System Installation and Startup

Direction of Approach
The formula to calculate the minimum safety distance varies depending on the
direction of approach to the detection zone. Be sure to check the direction of
approach, before starting the calculation. See Figs. 3-1, 3-2, 3-3.
S is the minimum safety distance between the light curtain detection zone and the
point of operation hazard.

Normal Approach Direction of


Approach
S
PJ-V detection zone

Direction of
Approach
S

3 PJ-V detection zone

Fig. 3-1

Parallel Approach

PJ-V detection zone

Direction of
Approach

Fig. 3-2

Angle of Approach greater than 30 Angle of Approach less than 30


S

PJ-V
detection zone Direction of 30>
Approach

Direction of
PJ-V detection zone
Approach 30<

Fig. 3-3

If the anticipated angle of approach to the detection zone is greater than 30, this
should be considered a normal approach. If the angle is less than 30, this applica-
tion should be considered a parallel approach.

32
Chapter 3 System Installation and Startup

Minimum safety distance formulas (Reference)


The minimum safety distance formulas used by the respective standards are given
below for reference. Regard the values in the following examples as reference
values only. Before actually designing the system configuration, please read all
applicable national standards, and then install the PJ-V in accordance with those
standards.
S = minimum safety distance

Direction of
Approach

PJ-V detection zone

Fig. 3-4

Using EN standards formula -


Formula (from EN 999)

S=KxT+C
Where:
S = minimum safety distance on a line or surface between the nearest hazardous
area and detection zone (mm), but not less than 100 mm.

K = Operator's approach speed (mm/sec)

T = total response time (sec), T = T1 + T2


T1: PJ-Vs maximum response time (0.015 sec)
T2: Machines maximum stopping time (sec)

C = additional distance (mm)


additional safety distance in mm, depending on the minimum object sensitivity
(d) of the safety light curtain. The value of C is never less than zero.

Normal Approach
C = 8 (d-14) where d <
= 40 mm
d = Minimum object sensitivity
PJ-V20: d = 28mm
PJ-V40: d = 48mm

In industrial applications where the PJ-V may be used in the presence of


children, the rules are further revised. In these situations, only use
K = 2000 mm/sec, and add 75 mm to the calculated value of S.

C = 1200 - 0.4H where 40 < d


H = The height of the uppermost beam in mm.
The height of the uppermost beam will be >= 900 mm
The height of the lowest beam will be <
= 300mm

Where it is foreseeable that persons under 14 years old are at risk from
inadvertent access, the height of the lowest beam shall be <
= 200 mm

33
Chapter 3 System Installation and Startup

The following identifies several factors which affect calculation of the Minimum
safety distance Formula:

First, the value of K, the operators approach speed, depends on the application,
the approach direction, the minimum safety distance (S), and the detection capabil-
ity (d) of the PJ-V.

S K d
100 < S < 500 mm 2000 mm/sec <
d = 40 mm
500 mm < S 1600 mm/sec d<= 40 mm
850 mm < S 1600 mm/sec 40 mm < d <
= 70 mm

In applications where S is calculated to be greater than 500 mm using K=2000


mm/sec, then the formula must be recalculated using K=1600 mm/sec. In this
case the minimum value of S shall not be less than 500 mm.

3 Parallel Approach
For parallel approach applications, the formula for C becomes:

C=1200 - 0.4H
H=the height (in mm) of the detection zone above the floor

The height of the detection zone shall be a maximum of 1000 mm, although if
the installation height H, is greater than 300 mm (200 mm for persons under
14 years old), the lowest allowable installation height of the device shall be
calculated using the formula.
H
d<
=( + 40)
15
d = Detection capability
PJ-V20: d = 28mm
PJ-V40: d = 48mm

Example
Safety Distance Calculation (Normal Approach)

An automated machine has a maximum stopping time of 0.06 seconds. The PJ-V
has a response time of 0.015 seconds and a detection resolution of 28 mm (PJ-
V20), 48 mm (PJ-V40). Remember that for K = 2000 mm/sec, S must be greater
than 100 mm and less than 500 mm. The operator must be 14 years old or older.
S

Calculation (When using the PJ-V20) Direction of


Approach

From EN 999,
S=KxT+C
S<
PJ-V
= 500 K = 2000, S > 500 K = 1600
C = 8 x (d - 14) [d = Detection capability (mm) = 28 mm (PJ-V20)]

Accordingly,
S = 2000 x (0.015 + 0.06) + 8 x (28 - 14)
S = 262 mm

Thus, in this example, the transmitter and receiver must be mounted so that the
PJ-V detection zone is located 262 mm or more away from the nearest hazardous
area of the machine.

34
Chapter 3 System Installation and Startup

Calculation (When using the PJ-V40)

From EN 999,
S=KxT+C
40 < d = 48 mm (PJ-V40)
K = 1600 mm/sec
C = 1200 mm - 0.4H (H = top beam height (mm) >
= 900 mm)
Accordingly,
S = 1600 x (0.015 + 0.06) + (1200 - 0.4H)

The top beam height must be 900 mm or more, and the bottom beam height must
be 300 mm or less. When the top beam height is 1000 mm,
S = 1600 x (0.015 + 0.06) + [1200 - (0.4 x 1000)]
= 920 mm

Thus, in this example, the transmitter and receiver must be mounted 920 mm or 3
more away from the nearest hazardous area of the machine.

Using ANSI standards formula


Formula (from ANSI B11.19)

S = K x (Ts + Tc + Tr + Tbm) + Dpf


S = minimum safety distance on a line or surface between the nearest hazardous
area and detection zone (mm)
K = constant obtained from data on approach speed of body or part of body
(mm/sec)
Ts = stopping time of press or machine measured from the final de-energized
control element such as an air valve (sec). It is measured at a position, such
as 90 of crankshaft rotation, to obtain the maximum stopping time. A brake
monitor is used to measure the machine stopping time.
Tr = PJ-Vs maximum response time (= 0.015 sec).
Tc = maximum response time of press or machine control circuit to activate
machines brake.
Tbm = brake monitor set time - (Ts + Tc).
When the machine does not have a brake monitor, add a percentage in-
crease factor to Ts + Tc to allow for braking system wear and regard that
value as the brake monitor set time. (For example, brake monitors usually
add an extra 20% to the measured stopping time.) In your case, contact the
machine manufacturer for guidelines in selecting a percentage increase
factor.
Dpf = added distance due to the depth penetration factor shown in Fig. 3-5. This is
related to the minimum object sensitivity of the PJ-V and how far an object
can move through the detection zone before the PJ-V reacts.
Unit: mm
300
Depth Penetration Factor (Dpf)

250

200

150

100

50

0
0 10 20 30 40 50 60 70 80 90
Minimum Object Sensitivity (d)
Fig. 3-5

35
Chapter 3 System Installation and Startup

Example
Assume that an object approaches vertically to the detecting surface and the
operator is 14 years or over.
In the case of Tr = 0.015 sec, Ts + Tc = 0.06 sec, and brake monitor set time = 0.1
sec:

Calculation (When using the PJ-V20) S

From ANSI B11.19, Direction of


Approach
K = 1600 (mm/sec), Dpf = 71.4 mm
S = 1600 x (0.06 + 0.015 + 0.1 - 0.06) + 71.4
= 255.4 mm PJ-V

Thus, in this example, the PJ-V20 must be mounted so that the detection zone is
located 255.4 mm or more away from the nearest hazardous area of the machine.

Using ANSI/RIA R15.06-1999 standards formula


3 Formula (from ANSI/RIA R15.06-1999)

Ds = [K x (Ts + Tc + Tr)] + Dpf


Ds = minimum safety distance between safeguarding
device and the hazard
K = speed constant: 1.6 m/sec (63 inches/sec) minimum based on the movement
being the hand/arm only and the body being stationary.
Note: A greater value may be required in specific applications and when body
motion must also be considered.
Ts = worst stopping time of the machine/equipment
Tc = worst stopping time of the control system
Tr = response time of the safeguarding device including its interface
Dpf = maximum travel towards the hazard within the presence sensing safeguard-
ing devices (PSSD) field that may occur before a stop is signaled. Depth
penetration factors will change depending on the type of device and applica-
tion. Formula = 3.4 x [(Detection Capability) - 6.875 mm]. See figure B.2 in
ANSI/RIA R15.06 for specific values.

Example
Assume that an object approaches vertically to the detecting surface and the
operator is 14 years old or older.

In the case of machine stopping time = 0.16 sec and in case of control system
stopping time = 0.05 sec.

Calculation (When using the PJ-V20)


From ANSI/RIA R15.06-1999,
K = 1600 (mm/sec)
Ts = 0.16 sec
Tc = 0.05 sec
Tr = 0.015 sec (PJ-V's response time)
Dfp = 3.4 x (28 - 6.875) mm = 71.825 mm

Accordingly,
Ds = [1600 x (0.16 + 0.05 + 0.015)] + 71.825
Ds = 431.825 mm

Thus, in this example, the transmitter and receiver must be mounted 431.825 mm
or more away from the nearest hazardous area of the machine.

36
Chapter 3 System Installation and Startup

Using OSHA standards formula


Formula (from OSHA 1910.217 (C))

S = K x Ts

S = minimum safety distance on a line or surface between nearest hazardous


area and detection zone (mm).

K = constant obtained from data on approach speed of body or part of body


(mm/sec). This value is 1600 (mm/sec).

Ts = maximum stopping time of the press or machine (measured at approximately


90 position of crankshaft rotation). Ts includes the response times of the
clutch, braking system, controls, PJ-V and any other time needed for the
machine to cease hazardous motion. In addition, add a percentage increase
factor to allow for deterioration of the machine stopping performance. In your
case, contact the machine manufacturer for guidelines in selecting a percent- 3
age increase factor.

Example
Assume that an object approaches vertically to the detecting surface and the
operator is 14 years old or older.

In the case of machine stopping time = 0.16 sec: S

Direction of
Approach
Calculation (When using the PJ-V20, PJ-V40)

From OSHA 1910.217 (C), PJ-V

K = 1600 (mm/sec)

Ts= PJ-Vs response time + machines stopping time + additional time to allow
for increase of machine stopping time (Here, 10% of machines stopping
time is added.)
= 0.015 + 0.16 + 0.16 x 0.1 = 0.191

Accordingly,
S = 1600 x 0.191
S = 305.6 mm

Thus, in this example, the transmitter and receiver must be mounted 305.6 mm or
more away from the nearest hazardous area of the machine.

3.2.2 Indirect-reflection interference


A reflective surface adjacent (right and left) to, above and below the detection zone
may cause an obstruction in the detection zone that won't be detected. Reflective
surfaces may be part of the machine, mechanical guard, or workpiece (such as
shiny metal, glossy paint, metallic foil, or other similar material). The test proce-
dures must be used to test for this condition. See page 64.

Prevention against indirect-reflection interference


1) Mount the PJ-V so that no reflective surface is present inside the effective
aperture angle of the transmitter and receiver.
The minimum distance from the detection zone to reflective surface, X, can be
read from Fig. 3-7 or calculated from the formula. This assumes a worst case
condition where the transmitter and receiver are not in optical alignment.
See Fig. 3-6.

37
Chapter 3 System Installation and Startup

Mount the transmitter and receiver in a location with no indirect-reflection


DANGER interference. Indirect-reflection interference may cause an obstruction in the
detection zone that won't be detected, possibly resulting in a serious acci-
dent including serious injury or death.

The minimum distance from the detection zone to the reflective surface, X, is
calculated from the formula.
When Y (operating range) is equal to or greater than 3000 (Y >= 3000)
X = (Y - 3000)/2 x tan 2A + 185, A = 3.5 (effective aperture angle)
Y = operating range (mm)
When Y (operating range) is less than 3000 (Y < 3000)
X = 185 mm

Example
When the operating range, Y, is 4 m, the minimum safety distance required from
3 the detection zone to the reflective surface is calculated as shown below.
When finding X from Fig. 3-7, X = 246 mm.
When finding X from the calculations,
Y = 4000, A = 3.5
X = (4000 -3000) / 2X [tan 2 (3.5)] + 185
= 246 mm
Thus, in this example, the PJ-V must be mounted 246 mm or farther away from the
reflective surface.
2) Prevent the reflective surface from reflecting.
Cover the reflective surface with non-reflective material or roughen the surface.

Safe Unsafe
A= 3.5 1. A= 3.5 1.

Approach direction
Object to be Approach direction Worst case condition
detected Object to be < Y >
detected A A
A A A A
A A A A Trans- Receiver
Transmitter Receiver A A
mitter X
Transmitter Receiver

Mirror-surfaced object Mirror-surfaced object

Perimeter of danger Perimeter of danger Mirror-surfaced


area area object

Perimeter of danger
A A A A area

Object to be Object to be
detected detected

A A A A

Transmitter Receiver Transmitter Receiver


Mirror-surfaced object Mirror-surfaced object

Perimeter of danger Perimeter of danger


area area

Fig. 3-6

1. The PJ-Vs effective aperture angle is 2.5. However, because of possible optical
misalignment during installation of the transmitter and receiver, regard the angle as
3.5.

38
Chapter 3 System Installation and Startup

Minimum Distance for Reflective surface


700

600

500

Minimum distance X. (mm)


400

300

200
(185)

100

0
0 1 2 3 4 5 6 7 8 9 10
3
Operating range Y (m)

Fig. 3-7

3.3 Mounting the Sensor Head (STEP 2)


3.3.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head.


Take proper measures to prevent indirect-reflection interference

(Items to be performed in STEP 2)


Understand the general mounting precautions
Understand the multiple sensor head mounting precautions
Understand the detection zone and mounting space
Mount the sensor head

3.3.2 General mounting precautions


The sensor head must be mounted at the minimum safety distance or farther away
from the hazardous area to ensure safety. Considerations in selecting the mounting
location are shown below.

Mounting location
The sensor head and cabling must be out of the way of components, feedstock,
tools, etc.

Mounting orientation
Mount the PJ-V transmitter and receiver with the transmitting and receiving sur-
faces facing each other and their cable extruded ends oriented in the same direc-
tion. The transmitter and receiver must be mounted parallel and in-line with each
other.
See Fig. 3-8.

39
Chapter 3 System Installation and Startup

Correct mounting orientation

c)
a) b)
a) Both cable ends down. b) Both cable ends up. c) Oriented parallel to floor with
both cable ends pointing in the
same direction.

Incorrect mounting orientation

a) b) c)

a) Cable ends pointing in opposite directions. b), c) Transmitter and receiver not parallel with each other.
Problem: Voids in defined area Problem: Reduced excess gain

Fig. 3-8

The transmitter and receiver must be mounted with their cable extruded ends
DANGER oriented in the same direction as illustrated. Failure to mount these units
correctly as illustrated may result in a severe hazard including serious injury
or death to the operator.

Hard guards
If the PJ-V does not protect all areas of the hazardous zone, the areas unprotected
by the PJ-V must be protected by additional safeguards such as safety barriers or
the like. A machine operator must not be able to stand between the machine and
the PJ-V in any way or detour the PJ-V detection zone to reach the hazardous area
of the machine. Protections such as mechanical guards must be installed in front of
the hazardous area of the machine to prevent personnel from standing between
the PJ-V and machine.

Safe Unsafe

PJ-V PJ-V

PJ-V
PJ-V

PJ-V
PJ-V

Guard

Fig. 3-9

40
Chapter 3 System Installation and Startup

If the PJ-V does not protect all areas of the hazardous zone, the areas unpro-
DANGER tected by the PJ-V must be protected by additional safeguards such as safety
barriers. A machine operator must not be able to stand between the machine
and the PJ-V in any way or detour the PJ-V detection zone to reach the
hazardous area of the machine. Protections such as mechanical guards must
be installed in front of the hazardous area of the machine to prevent person-
nel from standing between the PJ-V and machine. Failure to follow the above
correctly may result in a severe hazard including serious injury or death to
the operator.

Dead zone
The PJ-V detection zone is between the marks on the sensor head. Detection
is not performed in the zone between the mark and the end of the transmitter and
receiver housing. Therefore, additional measures must be taken to detect any
object which attempts to reach the hazardous area through this dead zone, or the
PJ-V must be mounted so that no object reaches the hazardous area through this 3
dead zone.

Dead zone
(= 50 mm)

Detection
zone

Dead zone
(= 50 mm)

Fig. 3-10

Requirements
All cabling must be installed and routed in accordance with national and local
codes and good workmanship practices.

41
Chapter 3 System Installation and Startup

3.3.3 Precautions on mounting multiple PJ-V sensor heads


When two or more PJ-V sensor heads are mounted in close proximity, precautions
must be taken to avoid one sensor head interfering with another. Interference
occurs when the receiver of one sensor head receives the light beam emitted from
the transmitter of another sensor head. At this time, the sensor head indicators will
give an ambient light detected indication status. If interference is not removed, the
Receiver (red) indicator in the Diagnostic frame is illuminated, causing a Lockout
status.

When the transmitter and receiver are mounted back-to-back with each other as
shown in Fig. 3-11, the orientation of the PJ-V must be changed. When two sensor
heads are vertically stacked, mounting as shown in Fig. 3-11 is recommended.

Safe Unsafe
1-T 1-R 2-R 2-T 1-T 1-R 2-T 2-R
3 1-T 1-R 2-T 2-R

1-T 1-R 1-T 1-R 1-T 1-R 1-T 1-R

2-R 2-T 2-T 2-R


1 2

2-R 2-T 2-T 2-R


1. Main controller (PJ-V90)
2. Main controller (PJ-V90)
"T" shows transmitter.
"R" shows receiver.

Fig. 3-11

Interference suppression function


Up to two PJ-V controllers can be connected to prevent interference between the
two sensor heads connected to the controllers. When three PJ-V sensor heads are
mounted in close proximity, the third head may interfere with the first and second
heads even if the first and second do not interfere with each other because of using
the interference suppression function available by connecting the main controller
(PJ-V90) and sub-controller (PJ-V91). Attention must be paid when three or more
sensor heads are used in close proximity. See Fig. 3-12.

Since the interference suppression function automatically works by connecting the


sub-controller (PJ-V91) to the main controller (PJ-V90), no special settings are
required. In addition, this connection does not affect the PJ-V response time.
For controller extension procedures, refer to page 6.

Safe Unsafe
1-T 1-R 2-T 2-R 3-R 3-T 1-T 1-R 2-T 2-R 3-T 3-R

1-T 1-R 2-T 2-R 3-T 3-R

3-R 3-T 3-R 3-T 3-T 3-R 3-T 3-R


2-T 2-R 2-T 2-R
1-T 1-R 1-T 1-R

2-T 2-R 2-T 2-R 1 2 3

1. Main controller (PJ-V90)


2. Sub-controller (PJ-V91)
1-T 1-R 1-T 1-R 3. Main controller (PJ-V90)
"T" shows transmitter.
"R" shows receiver.

Fig. 3-12

42
Chapter 3 System Installation and Startup

3.3.4 Mounting the sensor head


Sensor head mounting space
When considering the mounting space, you must take the dead zone into consid-
eration in addition to the detection zone. The detection zone is between the
marks on the sensor head. Secure the necessary mounting space including the
dead zone. ( See Fig. 3-13.)
In the dead zone, detection is not performed. Therefore, additional measures such
as safety barriers must be taken so that any access to the hazardous area cannot
be made through the dead zone.

Dead
zone

Detection Necessary mounting


area space
3

Dead
zone

Fig. 3-13

In the dead zone, detection is not performed. Use additional measures such
CAUTION as safety barriers so that any access to the hazardous area cannot be made
through the dead zone. Any access to the hazardous area through the dead
zone may result in a serious hazard including operator injury or death.

Mounting procedures
Mount the sensor head onto a securely fixed surface that will not be struck by any
external forces. To increase safety, the PJ-V has the relatively small aperture angle
specification required by the current standards of 2.5 (operating range: 3 m or
more). Take care to correctly select the mounting surface and the mounting hole
locations.
The angles that the mounting bracket can be adjusted to are given below.
Adjustable angle ()
Rear mounting Side mounting
Not using intermediate support 25 15
Using intermediate support 5 5

Mounting procedures according to the number of optical axes


Number of optical axes Mounting procedures
When increasing the number of See Mounting procedures using
optical axes to 36 or more with the the intermediate support on page 45.
PJ-V20 series, and to 18 or more with
the PJ-V40 series.
When, though the number of optical
axes to be used is smaller than that
shown above, mounting the units onto
a place with visible vibration.
In any cases other than the above. See Ordinary mounting procedures
on page 44.
When increasing the number of optical axes to 36 or more with the PJ-V20
WARNING series, and to 18 or more with the PJ-V40 series, be sure to mount the speci-
fied number of the intermediate support (OP-31785) included with the base
unit (PJ-V20, PJ-V40) to the specified position and use the PJ-V.
And, when mounting the units onto a place with visible vibration, use the
intermediate support, regardless of the number of optical axes to be used.

43
Chapter 3 System Installation and Startup

Ordinary mounting procedures


1) Connect the extension unit to the base unit.
See page 5.
Extension connector
Extension unit A

Base unit

End cap/Extension unit B

Fig. 3-14

2) Attach the mounting brackets to the sensor head.


Attach the mounting bracket to the top end of the sensor head using the two
3 screws included with the mounting bracket. Also attach the mounting bracket to
the bottom end in the same way.
At this time, temporarily mount the unit by tightening the two screws firmly within
a limit that still allows the sensor head to rotate. If the screws are tightened too
much, optical adjustment is impossible. If they are too loose, note that optical
misalignment may occur due to firmly retightening the screws after optical
adjustment.The screw tightening torque is 0.922 Nm or less.
Place the end of the
sensor head between the
two brackets, and tighten
the screws to fix the unit.

Sensor head

Mounting bracket

Fig. 3-15

3) Determine the mounting hole locations.


Position the transmitter and receiver face-to-face with each other at the same
height.
Measure the four mounting hole locations each for the transmitter or receiver,
using normal measurement equipment such as levels. For information on the
mounting hole locations, see the outline drawing on pages 10 and 11.
Determine the mounting locations
for the transmitter or receiver.

Fig. 3-16

4) Drill and tap the mounting holes in the mounting surface.


Drill and tap the four mounting holes for M4 screws in the mounting surface to
fix the mounting brackets (both for transmitter and receiver).

Drill and tap the holes for M4 screws.

Fig. 3-17

44
Chapter 3 System Installation and Startup

5) Mount the sensor head to the mounting surface.


Mount the transmitter and receiver each using four M4 screws.
At this time, temporarily mount the unit by tightening the four M4 screws firmly
within a limit that still allows the sensor head to move up and down. If the
screws are tightened too much, the sensor head height cannot be adjusted. If
the screws are too loose, note that optical misalignment may occur due to firmly
retightening the screws after optical alignment.The screw tightening torque is
1.37 Nm or less.

M4 screws

3
Fig. 3-18

Mounting procedures using the intermediate support


1) Confirming the mounting position for the intermediate support.
Mount the intermediate support to any one of the shaded units shown below.
( See page 10, 11.) Note that the position and number of the intermediate
supports to be mounted vary depending on the number of optical axes to be
used. You can mount the support to any position on the shaded unit. Mount the
intermediate support both to the transmitter and receiver.
PJ-V20: 36 to 48 optical axes Mount one intermediate support to mounting
position 1.
52 to 64 optical axes Mount one intermediate support each to
mounting positions 1 and 2 (two supports in total).
PJ-V40: 18 to 24 optical axes Mount one intermediate support to mounting
position 1.
26 to 32 optical axes Mount one intermediate support each to
mounting positions 1 and 2 (two supports in total).
When mounting the units where there is visible vibration: When using one
intermediate support, mount it close to the midpoint of the total length of the
connected units. When using two intermediate supports, mount one of them
close to the one-third point of the total length of the connected units and the
other close to the two-thirds point.
End cap

PJ-V22/42
8 PJ-V21/41
End cap
PJ-V22/42
7 PJ-V21/41 End cap

6 PJ-V21/41 Mounting Mounting Mounting Mounting


PJ-V22/42

position 2 position 2 position 2 position 2 End cap

5 PJ-V21/41 PJ-V22/42

4 PJ-V21/41 Mounting Mounting Mounting Mounting Mounting Mounting Mounting Mounting


position 1 position 1 position 1 position 1 position 1 position 1 position 1 position 1

3 PJ-V21/41

2 PJ-V21/41

1 PJ-V20/40

PJ-V20: 64 axes PJ-V20: 60 axes PJ-V20: 56 axes PJ-V20: 52 axes PJ-V20: 48 axes PJ-V20: 44 axes PJ-V20: 40 axes PJ-V20: 36 axes
PJ-V40: 32 axes PJ-V40: 30 axes PJ-V40: 28 axes PJ-V40: 26 axes PJ-V40: 24 axes PJ-V40: 22 axes PJ-V40: 20 axes PJ-V40: 18 axes
Fig. 3-19

45
Chapter 3 System Installation and Startup

2) Mounting the intermediate support to the unit


Fit the unit side piece of the intermediate support into the grooves on the flat
surface of the unit specified in step 1, and then slide the piece.

PJ-V

Unit side piece of the


intermediate support
Slide the unit side piece of the
intermediate support.
Fig.3-20

3) Connect the extension unit to the base unit.


See page 5.
Extension connector
Extension unit A

3
Base unit

End cap/Extension unit B

Fig. 3-21

4) Attach the mounting brackets to the sensor head.


Attach the mounting bracket to the top end of the sensor head using the two
screws included with the mounting bracket. Also attach the mounting bracket to
the bottom end in the same way.
At this time, temporarily mount the unit by tightening the two screws firmly within
a limit that still allows the sensor head to rotate. If the screws are tightened too
much, optical adjustment is impossible. If they are too loose, note that optical
misalignment may occur due to firmly retightening the screws after optical
adjustment. The screw tightening torque is 0.922 Nm or less.
Place the end of the
sensor head between the
two brackets, and tighten
the screws to fix the unit.

Sensor head

Mounting bracket

Fig. 3-22

5) Determine the mounting hole locations for the transmitter, receiver, and
the fixing side piece of the intermediate support.
Position the transmitter and receiver face-to-face with each other at the same
height.
Measure six mounting hole locations each for the transmitter and receiver,
using normal measurement equipment such as levels. (When using 52 or more
axes with the PJ-V20, and 26 or more axes with the PJ-V40, measure eight
mounting hole locations each for transmitter and receiver.) For information on
mounting hole locations, see the outline drawings on pages 10 and 11.

(Rear mounting) (Side mounting)


Fig. 3-23

46
Chapter 3 System Installation and Startup

6) Drill and tap the mounting holes in the mounting surface.


Drill and tap six mounting holes for M4 screws in the mounting surface (each for
transmitter and receiver). (When using 52 or more axes with the PJ-V20, and 26
or more axes with the PJ-V40, measure eight mounting hole locations each for
transmitter and receiver.)

Drill and tap the holes for M4 screws.

Fig. 3-24

7) Mount the fixing side piece of the intermediate support to the mounting
surface.
The fixing side piece of the intermediate support is available in the piece for rear
mounting and the one for side mounting. Use the intermediate support suited to
your mounting orientation.The screw tightening torque is 0.686 Nm or less.
3
Fixing side piece
of intermediate
support

Direction of optical axes Direction of optical axes


(For rear mounting) (For side mounting)

(Rear mounting) (Side mounting)


Fig. 3-25

The fixing side piece for rear mounting of the intermediate support is available
in standard or wide versions. The standard fixing side piece needs to be
screwed to the mounting surface before step 8. However, the wide type can be
screwed to the mounting surface even after step 8.

8) Mount the sensor head to the mounting surface.


Mount the transmitter and receiver each using four M4 screws.
When mounting the sensor head to the mounting surface, align the center of the
unit side piece of the intermediate support with that of its fixing side piece, and
push the projection on the unit side piece into the fixing side piece. The screw
tightening torque is 1.37 Nm or less.

Spring washer

M4 screws

Push the unit side piece.

(Push the unit side piece into the


fixing side piece)
(Rear mounting) (Side mounting)
Fig. 3-26

47
Chapter 3 System Installation and Startup

3.4 Wiring between the Sensor Head and Controller (STEP 3)


3.4.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head


Take proper measures to prevent indirect-reflection interference
Take proper measures to prevent mutual interference
Install additional safeguards to protect the areas unprotected by the PJ-V
Mount the sensor head

Items to be performed in STEP 3


The controller will be mounted and the wiring between the sensor head and con-
3 troller installed.
The power supply, outputs, and other inputs must be wired to the controller in
accordance with national and local electrical codes. Before wiring to the controller,
cable wiring locations must be precisely checked to correctly install the wiring.

3.4.2 Connection between the sensor head and connector cable


Follow the procedures described below to connect the connector cables to the
sensor head.

1) Have ready the required length of transmitter and receiver connector cables.

[Transmitter cable (gray):] [Receiver cable (black):]


2-m cable: Model PJ-VC2T 2-m cable: Model PJ-VC2R
5-m cable: Model PJ-VC5T 5-m cable: Model PJ-VC5R
7-m cable: Model PJ-VC7T 7-m cable: Model PJ-VC7R

Cable length extension


The transmitter and receiver connector cable lengths can each be extended up
to 21 meters. The cable length can be adjusted as required by properly combin-
ing the cables, provided that the transmitter and receiver cable lengths are each
within 21 meters. You may connect any number of cables, provided that the
length is within 21 meters. However, do not combine a transmitter connector
cable with a receiver connector cable.

Cable extension example


Model Cable length Model Cable length
PJ-VC2T 2m PJ-VC5R 5m
PJ-VC5T 5m PJ-VC7R 7m
7 m total 12 m total

The transmitter cable length is 7 meters, and the receiver cable length is 12 me-
ters.

2) Connect the transmitter connector cable (color: gray) to the transmitter, and
the receiver connector cable (color: black) to the receiver.
See Fig. 3-27.

3) When using two or more connector cables, connect the connector cables
together.

48
Chapter 3 System Installation and Startup

Gray Gray (When using two or


more connector cables)

Transmitter Transmitter Transmitter


connector cable connector cable
PJ-VC2T PJ-VC2T
PJ-VC5T PJ-VC5T
PJ-VC7T PJ-VC7T

Black Black (When using two or


more connector cables)

Receiver Receiver Receiver


connector cable connector cable
PJ-VC2R PJ-VC2R
PJ-VC5R PJ-VC5R
PJ-VC7R PJ-VC7R

Insert the connector.


3
Rotate the connector end
until you cannot rotate it anymore.

Fig. 3-27

The transmitter connector cable length can be extended up to 21 meters.


DANGER The receiver connector cable length can also be extended up to 21
meters. Do not extend either of the cables longer than 21 meters. Using a
cable longer than 21 meters causes the PJ-V to operate unstably and
could result in a severe hazard including serious injury or death.

Do not combine a transmitter connector cable with a receiver connector


cable to extend the cable length. To extend the transmitter cable length,
be sure to use the PJ-VC2T, PJ-VC5T, or PJ-VC7T cables only. To extend
the receiver cable length, be sure to use the PJ-VC2R, PJ-VC5R, or PJ-
VC7R cables only. Failure to do so will cause the PJ-V to operate unstably
and could result in a severe hazard including serious injury or death.

3.4.3 Connection between the controller and connector cable


Connect the transmitter and receiver connector cables to the controller. Connect
the transmitter connector cable with a gray cable to the gray connector on the
controller, and the receiver connector cable with a black cable to the black connec-
tor. The connection procedures are the same as those for connecting the sensor
head and connector cable. ( See Fig. 3-28.)
Transmitter Cable(gray)
PJ-VCxT

Receiver Cable(black)
PJ-VCxR

Transmitter connector (gray)


Receiver connector (black)

PJ-V90

Fig. 3-28

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Chapter 3 System Installation and Startup

3.4.4 Mounting the controller


The controller must be mounted inside a control panel with IP-54 or higher level
enclosure rating. Mount the controller to a 35mm standard DIN rail inside the
control panel. ( See Fig. 3-30.) Or, mount the controller directly to the inside wall of
the panel with IP-54 or higher level enclosure rating. ( See Fig. 3-31.)
Do not mount any noise source such as an inverter in close proximity to the PJ-
V90. Place any noise source at least 2 cm away from the PJ-V90.

Mounting the controller to a DIN rail


1) After confirming that claws B are in locked status, hook claw A located on
the rear of the controller onto the DIN rail, as shown in Fig. 3-29.

2) As shown in Fig. 3-30, push the controller against the DIN rail to hook claws
B onto the DIN rail.
Before dismounting the controller from the DIN rail, release claws B from
3 locked status. ( See Fig. 3-29.)

* When using the PJ-V91, be sure to first connect it to the PJ-V90 and then
mount the connected controllers to the DIN rail. The PJ-V91 has no claw for
mounting to a DIN rail.

(Rear view of the PJ-V90)


Claw A

ClawsB

Locking status Released from locking status

Fig. 3-29

Claw A

Claw B
DIN rail
Hook claw A to the DIN rail.

Snap

Push the controller


to hook claw B.

Fig. 3-30

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Chapter 3 System Installation and Startup

When mounting the controller directly to the inside wall of the control
panel
1) Determine the mounting hole locations for the controller. For information on
the mounting hole dimensions, see the outline drawings on pages 13 and 14.
2) Drill the mounting holes for the controller, and if necessary, tap the holes.
3) Mount the controller to the inside wall of the control panel using four M5
screws. If necessary, use M5 nuts. The screw tightening torque is 1.42Nm.

* The PJ-V91 has no mounting holes. It is mounted by screwing it to the PJ-V90.

Washer for M5 screw


Spring washer
M5 screw
3

Fig. 3-31

3.5 Setting the Mode (Setting the Dip SW) (STEP 4)


3.5.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head


Take proper measures to prevent indirect-reflection interference
Take proper measures to prevent mutual interference
Install additional safeguards to protect the areas unprotected by the PJ-V
Mount the sensor head
Mount the controller

Items to be performed in STEP 4


The PJ-V mode will be set.
The controller contains two sets of MODE SWITCHES. These switches are used to
set two operating modes and turn the MPCE Monitoring function on or off. The
operation modes can be used in combination with each other. If the mode switch
setting is changed during PJ-V operation, the PJ-V enters a Lockout status.

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Chapter 3 System Installation and Startup

3.5.2 Operation mode


There are two operation modes and the MPCE monitoring function. These opera-
tion mode(s)/function can be used in combination with each other. For example,
Restart Interlock mode and Start Interlock mode can be both selected.

When the sub-controller (PJ-V91) is used, it operates with the same operation
mode(s)/function as set for the main controller (PJ-V90).

Start Interlock
In this mode, the PJ-V enters Lockout status when power is supplied to the PJ-V.
By rotating the LOCK REL. key or closing (terminals 3 and 4 are short-curcuited)
the LOCK REL. input, the PJ-V can restart. KEYENCE recommends that you use
the Start Interlock mode. Even if power is supplied in error, the PJ-V enters Lock-
out status, preventing the machine from unexpectedly starting up.

3 Restart Interlock
In this mode, the PJ-V enters Lockout status when an object is placed into the
detection zone and blocks one or more optical axes. To restart the PJ-V, you need
to remove the detected object from the detection zone, and then rotate the LOCK
REL. key or close (terminals 3 and 4 are short-curcuited) the LOCK REL. input.
When this mode is inactive, Run status is automatically resumed as soon as a
detected object is removed from the detection zone.

MPCE monitoring
When this mode is selected, the MPCE monitoring input, a signal input, is effective.
The MPCE monitoring input is used to monitor whether the MPCE is operating
correctly. This input is utilized when the MPCE is a safety relay.

Mode switch setting


The mode switches are shown in Fig. 3-32. Two operation modes and the MPCE
Monitoring function can be set depending on how to the mode switches are set.

To set the mode, follow the instructions below:


1) Loosen the screw shown in Fig. 3-32.
2) Pull the projection forward and open the lid.
3) Set the MODE 1 dip switches.
When MODE 1 dip switches (1 to 3) are set to the ON position, the corre-
sponding mode is set.
4) Set the MODE 2 dip switches to the same positions as those for MODE 1. If
any MODE 2 dip switches are set to positions different than those for MODE
1, a Lockout status will occur when power is supplied to the controller. At this
time, turn the power off and correct the switch settings.
5) Tighten the screw shown in Fig. 3-32. The screw tightening torque is
0.0745Nm or less.

52
Chapter 3 System Installation and Startup

Mode switches

2. Pull the projection forward


and open the lid.

1. Loosen the screw.

Example: When setting


Start Interlock mode
1. START INTERLOCK 3
ON
ON

2. RESTART INTERLOCK

1 2 3 4 5
1 2 3 4 5

MODE 1 3. MPCE (Monitoring)


SWITCHES 4. NOT USED
5. NOT USED
ON
ON

1. START INTERLOCK
1 2 3 4 5
1 2 3 4 5

MODE 2 2. RESTART INTERLOCK


SWITCHES 3. MPCE (Monitoring)
4. NOT USED
5. NOT USED

Fig. 3-32

3.6 Electrical Connections (STEP 5)


3.6.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head


Take proper measures to prevent indirect-reflection interference
Take proper measures to prevent mutual interference
Install additional safeguards to protect the areas unprotected by the PJ-V
Mount the sensor head
Mount the controller
Set the modes

Items to be performed in STEP 5


The PJ-V will be electrically connected to the machine and external input equip-
ment.

53
Chapter 3 System Installation and Startup

Block diagram

Transmitter Receiver Transmitter Receiver

Main controller Sub-controller


PJ-V90 PJ-V91

Control
circuit FSD1

FSD2

SSD

AUX
(Auxiliary
Signal monitor)
input
3 Indicators
24 VDC

Ground

Fig. 3-33

All electrical connections must be made by qualified person (as defined on


WARNING page viii) only in accordance with national and local electrical codes, regula-
tions, and laws. Be sure to shut off all power to the machine and the PJ-V
before starting connection. Never allow any metal filings or chips to enter the
controller and impair the proper operation of the PJ-V.

3.6.2 Power supply wiring


The PJ-V power supply is 24 VDC. It is recommended that you use a separate DC
power supply exclusively for the PJ-V. When using the PJ-V in Europe, use a
power supply conforming to the EMC directives and low-voltage directives. And,
use the power supply whose primary and secondary circuits are double insulated
or intensively insulated.

Precautions on supplying power to the PJ-V


Connect the positive and negative terminals of a 24 VDC power supply to the
specified terminals on the terminal block.

The polarity must be correct, or the PJ-V will not function.


Use a power supply whose supply voltage is 24 VDC 10% and ripple (p-p) of
5% or less.
Correct grounding is essential to maintain electromagnetic compatibility.
Do not supply AC power to the controller. This will damage the PJ-V.

Before starting any wiring job, be sure to shut off all power. Failure to do this
WARNING may result in an electrical shock.

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Chapter 3 System Installation and Startup

3.6.3 Connecting to the controller


The connection outline and required considerations are described below.

Understanding the precautions on mounting the PJ-V to the machine control


circuit
Understanding the perimeter guarding special requirements (as applicable)
What is the MPCE?
What is the MSCE?
Wiring example
What is the MPCE Monitoring function?
What is the auxiliary monitoring output (AUX)?
What are the LOCKOUT input and LOCK REL. input?
What is the FSD OFF input?

Precautions on mounting the PJ-V to the machine control circuit


The machine control circuit varies in configurations depending on the machine
3
type. The PJ-V can be connected to various machine control circuits. When consid-
ering which method is best for your application, keep in mind the following precau-
tions:

The PJ-V must be wired to your machine control circuit so that a stop signal
from the PJ-V can immediately halt the machine at any point in its operating
cycle or stroke. If the machine is a mechanical power press, do not connect the
PJ-V to it. This is because that machine is unable to stop at any point in its
stroke.
The PJ-V is general purpose electro-sensitive protective equipment, and is not
designed for any specific type of machine.
All safety-related control circuit elements including pneumatic, electrical, and
hydraulic controls must be designed so that a control logic fault, or a failure of or
damage to the control circuit cannot lead to a hazardous situation.
Both control output relays FSD1 and FSD2 must always be used to connect the
PJ-V to the machine. If a fault occurs in one relay, the other relay is used to
stop the machine.
For advice on connecting any safety device to your machine, contact the ma-
chine manufacturer.
Before starting to wire the controller, be sure to shut off all power. Failure to do
this may result in an electrical shock.
The PJ-V is not subjected to Type Testing as executed under Article 44.2 of
the Industrial Safety and Health Law. Therefore, if used in Japan, the PJ-V
cannot be used as a safety device for a press or shear as stipulated by Article
42 of the Law.
Before selecting the best method for your machine and application, read through
the following connection methods.

Failure to follow the above precautions may result in a severe hazard


DANGER including serious injury or death to the operator.

For advice on where to wire the PJ-V to your machine control circuit,
contact the manufacturer of the machine protected by the PJ-V. If the PJ-V
is not properly wired to the machine or does not provide maximum protec-
tion to machine operators, a severe hazard including serious injury or
death to the operator may occur. The connection to the machine control
circuit is the responsibility of the employer.

55
Chapter 3 System Installation and Startup

Special requirements when used as perimeter guarding


When using the PJ-V for machine or robot perimeter safeguarding, perform wiring
so that the machine or robot can immediately stop the hazardous motion when an
obstruction in the detection zone blocks the optical axis. To prevent the machine or
robot from automatically restarting after a detected obstruction is removed from the
detection zone, set the Restart Interlock (RESTART I/L) mode. When using the
LOCK REL. key to release Lockout status, locate the controller outside the hazard-
ous area. If this is not possible, use the LOCK REL. input to allow Lockout status to
be released outside the hazardous area.

When using the PJ-V for machine or robot perimeter safeguarding, set the
WARNING Restart Interlock (RESTART I/L) mode so that the machine or robot cannot
automatically restart after a detected obstruction is removed from the detec-
tion zone. When using the LOCK REL. key to release Lockout status, locate
the controller outside the hazardous area. If this is not possible, use the
LOCK REL. input to allow Lockout status to be released outside the hazard-
3 ous area. If Lockout status can be released or the machine can be automati-
cally reset within the hazardous area, a severe hazard including serious
injury or death to the user may result.

MPCE (Machine Primary Control Element)


Two MPCEs (machine primary control elements) must be used for machine control
circuits. These directly control the machine as the last elements to start or stop the
machines normal operating motion. Control methods include pneumatic, hydraulic,
clutch, and mechanical braking systems. An MPCE may consist of relays, contac-
tors, solenoids, or electromechanical valves.

Two MPCEs are normally controlled by the FSD1 and FSD2 relays.

KEYENCE strongly recommends that you use safety relays for the MPCEs and
activate the MPCE Monitoring function to ensure safety. Activating the MPCE
Monitoring function allows an MPCE fault to be detected.
Refer to MPCE Monitoring on page 58 [MPCE monitoring (When using the MPCE
Monitoring function)].

Safety relay
Contact A Contact B

One A and B contact are


interconnected by a joint and
mechanically forced to move together.

Interconnected

Fig. 3-34

KEYENCE strongly recommends that you use safety relays for the MPCEs and
IMPORTANT activate the MPCE Monitoring function. Activating the MPCE Monitoring function
allows an MPCE fault to be detected.

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Chapter 3 System Installation and Startup

MSCE (Machine Secondary Control Element)


The MSCE is a machine control element independent of the machine primary
control elements (MPCE), and can disconnect the power source from the related
hazardous section.

The MSCE is normally controlled by the SSD relay.

Standard connection method (Complies with EN 61496-1)


The following connection method uses the FSD1, FSD2, and SSD relays to control
the machine. This wiring method can be recommended for any application.The
tightening torque for the controller (PJ-V90) terminals is 0.4 Nm or less.
The applicable cable is either a single core wire or twisted wire having a nominal
cross-sectional area of 0.5 to 2.5 mm2 or AWG#20 to 14.

The method to arrest hazardous machine motion will vary depending on the type of
machine. Methods of controlling the motion include hydraulic, pneumatic, clutch, 3
and mechanical braking systems. Thus, there are several variations of MPCEs and
MSCE, including relays, contactors, solenoids, and electromechanical valves.

Wiring example
External input
circuit diagram
24 V
PLC
Terminal No. 510 IN OUT
1 3 5 11
WARNING
1.8 K See instruction manual
2 4 6 12 for installation, test and N (V ac)
0V control.
STATUS or L (V ac)
CLEAR CAUTION common or
BLOCKED
Electric shock hazard (V dc) + (V dc)
LOCKOUT may exist.
OPERATION MODE MPCE1
START I/L
1 RESTART I/L 13 MPCE2
LOCKOUT* MPCE OFF
AUX
2 14 Arc supression
SIGNAL INPUT

LOCK REL. 3 LOCKOUT


15 MPCE1
LOCK REL.
(Lockout release) FSD1
4 FSD OFF 16 Arc supression
DIAGNOSTICS OUTPUT
5 TRANSMITTER
17 MPCE2
FSD OFF 6 RECEIVER
FSD2 M
18 Arc supression
CONTROLLER
7 FSD 1 19 MSCE
FSD 2 SSD
8 SSD 20
MPCE
9 21

MPCE1 MPCE2 10 24 V 22
11 LOCKOUT RELEASE POWER 23
0V
12 24
WARNING
An arc suppression device should only
PJ-V90 be installed across the coils of the
MPCE. Never install an arc suppres-
sion device directly across the control
output contacts of the PJ-V. An arc
supression device may fail with a
short-circuit and, if installed across the
contacts, will disable the MPCE from
operating, possibly resulting in a
severe hazard including serious injury
or death to the operator.

Fig. 3-35

* LOCKOUT input terminals 1 and 2 are short-circuited with a shorting bar. When using
the LOCKOUT input, remove this shorting bar.

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Chapter 3 System Installation and Startup

KEYENCE strongly recommends that you use safety relays for the MPCEs and
activate the MPCE Monitoring function. The wiring example of using safety relays
for the MPCEs and MSCE is given below.

1) Have ready three safety relays for the MPCE1, MPCE2, and MSCE.
2) Wire the relay coil of MPCE 1 to the FSD1 (terminals 15 and 16).
3) Wire the relay coil of MPCE 2 to the FSD2 (terminals 17 and 18).
4) Wire the relay coil of the MSCE to the SSD (terminals 19 and 20).
5) To use the MPCE Monitoring function, wire the N.C. contact of the MPCE1
and the N.C. contact of the MPCE2 to the MPCE monitoring input (terminals
11 and 12), as shown in Fig. 3-35 on page 57.
When the LOCKOUT input is opened (terminals 1 and 2 are open-circuited), the
PJ-V enters LOCKOUT status.
Therefore, when not necessary, close (terminals 1 and 2 are short-circuited) this
3 input. (When the PJ-V is shipped, these input terminals are short circuited with a
short bar to be held closed. When not using this input, use the PJ-V with these
terminals connected with the short bar.)

Before starting any wiring job, be sure to shut off all power. Failure to do this
WARNING may result in an electrical shock.

Control methods include pneumatic, hydraulic, clutch, and mechanical braking


IMPORTANT systems, and the MPCE may consist of relays, contactors, solenoids, or electrome-
chanical valves. When the proper connection method for your machine control
system is unknown, contact the machine manufacturer.

MPCE monitoring (When using the MPCE Monitoring function)


The MPCE Monitoring function monitors the action of the MPCE1 and MPCE2 and
detects a control circuit fault which prevents a stop signal sent from the PJ-V from
reaching the machine. When the MPCE Monitoring function is used, the MPCEs
must use safety relays, and these relays should have a response time of 250 ms or
less.
See page 56 [MPCE (Machine Primary Control Element)].

Setting the MPCE Monitoring function


MODE 1 and 2 SWITCHES are used to set the MPCE Monitoring function.
See page 51 (3.5).

Wiring for the MPCE Monitoring function


The N.C. contact of the safety relay used for the MPCE is used for the MPCE
Monitoring input. When using the MPCE Monitoring function, wire the N.C. contacts
of the MPCEs directly to the MPCE monitoring input (terminals 11 and 12).
The necessary wiring to use the MPCE Monitoring function is shown on the con-
nection diagram (Fig. 3-35).

MPCE Monitoring function


If either of the following conditions occurs while the MPCE Monitoring function is
active, the controller judges the condition as a fault and enters Lockout status. To
restart the machine, you must turn off the power supply one time, correct the
MPCE, and then resupply the power.

1) The N.C. contact of the MPCE does not close within 250 ms after one or
more optical axes are blocked and the BLOCKED (red) indicator on the
controller is illuminated.

2) The N.C. contact of the MPCE does not open within 250 ms after all optical
axes return to being clear and the CLEAR (green) indicator is illuminated.

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Chapter 3 System Installation and Startup

KEYENCE strongly recommends that you use safety relays for the MPCEs and
IMPORTANT activate the MPCE Monitoring function to ensure safety. Activating the MPCE
Monitoring function allows MPCE faults to be detected.

AUX relay (When using the auxiliary monitoring relay)


The auxiliary monitoring relay is used to transmit the status of the FSD1 and FSD2
relays to the PLC, etc.

Wiring
The AUX (auxiliary monitoring) relay is wired as shown in Fig. 3-35 on page 57.

Function
The AUX (auxiliary monitoring) relay operates in the same way as an FSD
relay, that is, it closes when the PJ-V is in Run status, and opens when the PJ-
V is in Stop status or Lockout status.
3
Never use the AUX (auxiliary monitoring) relay as part of the machine safety
DANGER control circuit. This relay is strictly a non-safety output for monitoring only.
Using the AUX (auxiliary monitoring) relay to send a stop signal to the ma-
chine may result in a failure to stop the machine, causing a serious accident,
including serious injury or death.

LOCKOUT and LOCK REL. (Lockout Release) input


LOCK REL. input
The LOCK REL. input is used to restart the controller from Lockout status. The
LOCK REL. input functions when this input is closed (terminals 3 and 4 are short-
circuited). The function of this input is equivalent to that of the LOCK REL. key on
the controller. In Lockout status by detection of control device fault (see page 19),
the Lockout status cannot be released until the fault is corrected and power is re-
supplied.
When the PJ-V with the Restart Interlock mode active is used for safeguarding the
machine perimeter, we strongly recommend that you release the Lockout status
using the LOCK REL. input from outside of the hazardous area.
When the optical axis is blocked or recognizes a Lockout status, the LOCK REL.
key and the LOCK REL. input do not function and the controller remains in the
appropriate status, either a Lockout status or Stop status. However, when the
LOCK REL. input is activated, the LOCK REL. indicator remains illuminated during
activation of the LOCK REL. input even if this input does not function.

LOCKOUT input
The LOCKOUT input is used to force the PJ-V into Lockout status. This input
functions when opened (terminals 1 and 2 are open-circuited). The input terminals
are numbered 1 and 2, and these terminals are short-circuited with a shorting bar
when the PJ-V is shipped. When using this input, remove this shorting bar. When
the LOCKOUT input and LOCK REL. input and LOCK REL. key are activated
simultaneously, activating priority is given to the LOCKOUT, forcing the PJ-V into
Lockout status.

Wiring
The wiring for the LOCKOUT and LOCK REL inputs are shown in Fig. 3-35 on
page 57.

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Chapter 3 System Installation and Startup

FSD OFF input


Machines with cyclic operations such as a power press have both safe and unsafe
cycles of operation.

By using the FSD OFF input, you can test whether the FSD1 and FSD2 relays are
operating properly during a safe cycle.

Wiring
This input is activated by wiring the input as shown in Fig. 3-35. These wire
connections are connected to a relay, pushbutton switch, etc. The switch must
be held open (terminals 5 and 6 are open-circuited.) during the unsafe cycle.

Function
When the FSD OFF input is closed (terminals 5 and 6 are short-circuited.), the
FSD is opened and the controller sends a stop signal to the machine.

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Chapter 3 System Installation and Startup

3.7 Supplying Power and Final Optical Alignment (STEP 6)


3.7.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head


Take proper measures to prevent indirect-reflection interference
Take proper measures to prevent mutual interference
Install additional safeguards to protect the areas unprotected by the PJ-V
Mount the sensor head
Mount the controller
Set the modes
Power supply wiring
3
Items to be performed in STEP 6
Supply power to the PJ-V and align the final optical axes.

Each bracket attached to the top and bottom of the transmitter and receiver has
two screws. Final fine adjustment of the optical axis angle can be performed by
loosening these screws so that the sensor head can still rotate. If these screws are
too loose at this time, note that optical misalignment may occur due to retightening
the screws after alignment.

3.7.2 Final optical alignment


In the final step of the optical alignment, the angle of the transmitter and receiver is
adjusted so that both optical axes are finely aligned.

Rotation angle that can be adjusted with the mounting bracket

Adjustable angle ()
Rear mounting Side mounting
Not using intermediate support 25 15

Using intermediate support 5 5

1) Supply power to the controller.

2) If the sensor head indicator LEDs are illuminated in red, adjust the angle of
the transmitter and receiver until all LEDs are illuminated in green. If the
LEDs flash in green, the received light quantity is still insufficient. Continue to
adjust the angle until all LEDs are illuminated in green.

3) When all the sensor head indicator LEDs are illuminated in green, adjust the
angle of the transmitter and receiver to the center of the angle range that
allows all LEDs to be illuminated in green.

After final optical alignment has been completed, firmly retighten any screws that
have loosened to such an extent that the sensor head can rotate.

The screw tightening torque for attaching the mounting bracket to the PJ-V is 0.922
Nm, for attaching the bracket to the mounting surface is 1.37 Nm, and for attach-
ing the fixing side piece on the intermediate support to the mounting surface is
0.686 Nm.

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Chapter 3 System Installation and Startup

3.8 Operation Test (STEP 7)


3.8.1 Checking the present situation
Check whether the following items have been completed.

Calculate the minimum safety distance to mount the sensor head


Take proper measures to prevent indirect-reflection interference
Take proper measures to prevent mutual interference
Install additional safeguards to protect the areas unprotected by the PJ-V
Mount the sensor head
Mount the controller
Set the modes
Power supply wiring
3 Final optical alignment

Items to be performed in STEP 7


The operation test will be performed to check whether the PJ-V is functioning
properly.

3.8.2 Test procedures after installation


Perform the test according to the 4.1 Test Procedures after Installation and at
Periodic Inspections, on page 64.

Always perform the test according to the test procedures after maintenance,
DANGER adjustment, or modification to the machine or the PJ-V, and before machine
operation startup. Testing is very important to verify safe operation of the PJ-
V. Failure to test correctly may result in a severe hazard including serious
injury or death to the operator.

62
Chapter 4
Test Procedures and Maintenance

4.1 Test Procedures after Installation


and during Periodic Inspections ....................................... 64

4.2 Test Procedures after Machine Adjustment,


Modification or Maintenance, and before Startup ........... 66

4.3 Periodic Inspection Procedures ........................................ 69


4.3.1 Inspecting and replacing the relay board unit ........................ 70
4.3.2 Mounting the relay board unit for replacement ...................... 70
4.4 Preventive Maintenance ..................................................... 72
4.4.1 Cleaning the PJ-V .................................................................. 72
4.5 Testing the Sensor Head Indicators ................................. 72
Chapter 4 Test Procedures and Maintenance

This chapter explains the PJ-V operation test procedures and maintenance meth-
ods. The operation of the PJ-V must periodically be tested and maintained to keep
the machine safe.

Test Procedures after Installation


Test Procedures after Machine Adjustment, Modification or Maintenance, and
before Startup
Periodic Inspection Procedures
Preventive Maintenance
Testing the Sensor Head Indicators

4.1 Test Procedures after Installation


The following test procedures must be performed after installation and during
periodic inspections by qualified person (as defined on page viii). A copy of the
test results needs to be kept with the maintenance and inspection results. A test
piece with the appropriate diameter is required to test the PJ-V. The test piece
diameter required for the respective models is shown in the table below. Separately
have ready a test piece with the diameter specified in the table below.
4 Use the proper size test piece as indicated below.
Model PJ-V20 Series PJ-V40 Series
Test piece diameter 28 mm* 48 mm
* A test piece 28 mm in diameter is included with the PJ-V20. Separately have
ready test pieces with the other diameters.

1) Check that the PJ-V can be used with the machine to be guarded.
For information on machines with which the PJ-V cannot be used, refer to page
ix.

2) Check the minimum safety distance


Verify that the mounting distance of the PJ-V is equal to or greater than the
minimum safety distance from the hazardous area. see page 31.

3) Check for additional protection to the areas unprotected by the PJ-V


Verify that all accesses to the hazardous area unprotected by the PJ-V are
guarded by other means, such as gates, fences, or wire screens. Confirm that
all additional safety devices and safety barriers are installed properly and
operating properly.

4) Check the safety in the area between the detection zone and hazardous
area
Verify that no person can stand between the PJ-V detection zone and hazard-
ous area of the machine. Confirm that the PJ-V can only be restarted from a
position outside the hazardous area.

5) Check the wiring


Check the electrical connections between the machine control circuit and the
PJ-V. Verify that they are properly and securely wired to the machine so that a
stop signal from the PJ-V can immediately halt the machine during any point in
the machines operation cycle. See page 57 (Fig. 3-35).

64
Chapter 4 Test Procedures and Maintenance

6) Operation test
To verify that the PJ-V is operating properly, choose the proper size test piece
for the PJ-V model, and place it in the detection zone to block the optical axis.
Move the test piece as shown in Fig. 4-1. Confirm that the sensor head indica-
tors remain illuminated in red while the test piece is placed in the detection zone
as illustrated.
When the Restart Interlock mode is inactive, confirm that the BLOCKED (red)
indicator on the controller is on and the CLEAR (green) indicator and LOCK-
OUT (yellow) indicator on the controller is off while the test piece is present
anywhere in the detection zone. When the Restart Interlock mode is active,
confirm that the BLOCKED (red) indicator and LOCKOUT (yellow) indicator on
the controller are on and the CLEAR (green) indicator on the controller is off to
indicate that the PJ-V is in a Lockout status.

Use a proper size test piece as shown below.


Model PJ-V20 Series PJ-V40 Series
Test piece diameter 28 mm* 48 mm
* A test piece 28 mm in diameter is included with the PJ-V20. Separately have
ready test pieces with the other diameters.

4
Transmitter Receiver

Test piece
Fig. 4-1

7) Check for machine stoppage


Start the machine operation. Place the test piece in the detection zone to block
the optical axis while the machine is in operation. The machine must stop
immediately. Never insert the test piece into the hazardous area of the machine.
With the machine at rest, place the test piece in the detection zone. Verify that
the machine does not restart while the test piece is present in the detection
zone.

8) Check the braking system


Verify that the braking system is working properly. If the machine does not stop
fast enough, adjust the braking system or increase the distance from the detec-
tion zone to the hazardous area.

9) Check the test results


If the safety device or machine fails any of these tests, do not operate the
machine. Immediately forbid use of the machine and notify the employer.

10) Remove the key from the keyswitch.

11) Record the test results.

65
Chapter 4 Test Procedures and Maintenance

If the PJ-V and machine do not function exactly as described in the test
DANGER procedures, do not operate the machine. If the safety device, braking
system, and control system do not operate properly, they cannot stop
hazardous machine motions. A severe hazard may result, including seri-
ous injury or death to the operator.

While performing the procedure in step 6, the employer must ensure that
the PJ-V detection ability is not adversely affected by any reflected sur-
face or working object on the machine. This situation will cause a fault
status where the BLOCKED (red) indicator on the controller is not illumi-
nated and a stop signal is not sent to the machine, even when the test
piece is placed in the detection zone. This lack of response by the PJ-V
may occur because the light emitted from the transmitter reflects off an
adjacent reflective surface and returns via an alternate path to the re-
ceiver, as described on page 37 (3.2.2). Failure to correct this lack of
response by the PJ-V may result in a severe hazard including serious
injury or death to the operator. Either relocate the detection zone farther
away from the reflective surface or reduce the reflection of the surface by
masking or painting the surface. After resolving the above problem on the
machine, repeat the above test procedures.

4
4.2 Test Procedures after Machine Adjustment, Modification
or Maintenance, and before Startup
The following test procedures must always be performed after machine adjustment,
modification or maintenance, and before daily machine startup by qualified per-
son (as defined on page viii). KEYENCE recommends that you perform these test
procedures once a day or at every shift change, as part of an operators safety
performance inspection procedures. A copy of the test results needs to be kept
with machine maintenance and inspection results. A test piece with the appropriate
diameter is required to test the PJ-V. The test piece diameter required for the
respective models is shown in the table below. Separately have ready a test piece
with the diameter specified in the table below.

Use a proper size test piece as shown below.


Model PJ-V20 Series PJ-V40 Series
Test piece diameter 28 mm* 48 mm
* A test piece 28 mm in diameter is included with the PJ-V20. Separately have
ready test pieces with the other diameters.

1) Supply power
Disable operation of the guarded machine. Supply power to the PJ-V. Bring the
PJ-V into Run status.

2) Check for additional protection to the areas unprotected by the PJ-V


Confirm that no person can enter the hazardous area by detouring from the PJ-
V detection zone. If any person can do this, add any other guarding neccessary
such as safety barriers. Verify that all additional safety devices are installed and
operating properly.

3) Check the minimum safety distance


Verify that the mounting distance of the PJ-V is equal to or greater than the
calculated minimum safety distance from the hazardous area.
see page 31 (3.2.1).

66
Chapter 4 Test Procedures and Maintenance

4) Check safety in the area between the detection zone and hazardous area
Make sure that the machine operator is not able to stand between the PJ-V
detection zone and hazardous area.

The operator must perform the test procedures according to the regular
DANGER inspection program after maintenance, adjustment, or modification to the
machine or the PJ-V. Testing is performed to ensure that the PJ-V and the
machine control systems work properly to stop the machine without fail.
Failure to test correctly may result in a severe hazard including serious injury
or death to the operator.

5) Check for signs of external damage to wiring


Check for signs of external damage to the PJ-V, cables, and wiring. If any
damage is found, forbid use of the machine and notify the employer.

6) Check that the control panel is locked


Verify that the control panel to which the PJ-V90, PJ-V91 is mounted is closed
and locked. The key must be kept in custody by the employer.

7) Operation test
Place the proper size test piece in the detection zone to block the optical axis, in
order to confirm that the PJ-V is operating properly. Move the test piece as
4
shown in Fig. 4-2. Confirm that the sensor head indicators remain illuminated in
red while the test piece is placed in the detection zone as illustrated. When the
Restart Interlock mode is inactive, confirm that the BLOCKED (red) indicator on
the controller is on and the CLEAR (green) indicator and LOCKOUT (yellow)
indicator on the controller is off while the test piece is present anywhere in the
detection zone. When the Restart Interlock mode is active, confirm that the
BLOCKED (red) indicator and LOCKOUT (yellow) indicator on the controller are
on and the CLEAR (green) indicator on the controller is off to indicate that the
PJ-V is in Lockout status.

Test piece to use


Model PJ-V20 Series PJ-V40 Series
Test piece diameter 28 mm* 48 mm
* A test piece 28 mm in diameter is included with the PJ-V20. Separately have
ready test pieces with the other diameters.

Transmitter Receiver

Test piece
Fig. 4-2

If the PJ-V and machine do not function exactly as described in the test
DANGER procedures, do not operate the machine. If the safety device, braking system,
or control system do not operate properly, they cannot stop hazardous
machine motions. A severe hazard including serious injury or death may
result to the operator.

67
Chapter 4 Test Procedures and Maintenance

8) Check for machine stoppage


Start the machine operation. Place the test piece in the detection zone to block
the optical axis while the machine is in operation. The machine must stop
immediately. Never insert the test piece into the hazardous area of the machine.
With the machine at rest, place the test piece in the detection zone. Verify that
the machine does not restart while the test piece is present in the detection
zone.

9) Check the braking system


Verify that the braking system is working properly. If the machine does not stop
fast enough, adjust the braking system or increase the distance from the detec-
tion zone to the hazardous area.

10) Check the test results


If the safety device or machine fails in any of these tests, do not operate the
machine. Immediately forbid use of the machine and notify the employer.

11) Remove the key from the keyswitch.

While performing the procedure in step 7, the employer must ensure that the
4 DANGER PJ-V detection ability is not adversely affected by any reflected surface or
working object on the machine. This situation will cause a fault status where
the BLOCKED (red) indicator on the controller is not illuminated and a stop
signal is not sent to the machine, even when the test piece is placed in the
detection zone. This lack of response by the PJ-V may occur because the
light emitted from the transmitter reflects off an adjacent reflective surface
and returns via an alternate path to receiver, as described on page 37 (3.2.2).
Failure to correct this lack of response by the PJ-V may result in a severe
hazard including serious injury or death to the operator. Either relocate the
detection zone farther away from the reflective surface or reduce the reflec-
tion of the surface by masking or painting the surface. After resolving the
above problem on the machine, repeat the above test procedures.

68
Chapter 4 Test Procedures and Maintenance

4.3 Periodic Inspection Procedures


It is recommended that the following procedures be performed at least once every
six months or more frequently depending on machine usage. Only qualified
person (as defined on page viii) must perform the inspection procedures. The
inspection results must be kept with the machine records.

1) Check the machine stopping time


Using a brake monitor or other device recommended by the machine manufac-
turer, check the stopping time of the machine. Compare this with the previously
calculated result used to find the minimum safety distance. If the stopping time
has increased, repair or adjust the braking system as required, and re-measure
the stopping time. If the stopping time has not reduced, the safety distance must
be recalculated and the PJ-V must be reinstalled according to the resulting
distance.

2) Preventive maintenance
Clean the transmitting and receiving surfaces according to the procedures
described in 4.5 Preventive Maintenance. See page 72.

3) Inspect the output relays


Inspect the PJ-V relays described on page 70 (4.3.1). Also inspect and test 4
whether the MPCEs and MSCE are functioning properly. Replace any worn or
faulty relays with a Keyence-supplied relay board unit (OP-31788).

4) Final optical alignment


Perform the Final Optical Alignment procedures. ( 3.7.2, page 61. ) Perform
the Test Procedures after Installation and at Periodic Inspections. ( 4.1, page
64.)

5) Test
Perform the 4.2 Test Procedures after Machine Adjustment, Modification or
Maintenance, and before Startup. ( See 4.2, page 66.)

Unless all of the above test procedures are verified, the machine must not be
operated. If problems were found, do not use the machine until they are corrected.

69
Chapter 4 Test Procedures and Maintenance

4.3.1 Inspecting and replacing the relay board unit


Relays are the only mechanical parts in the PJ-V. Periodically inspect the relay
contacts for welding. For dismounting and mounting procedures for the relay board
unit, refer to section 4.3.2. The relay board unit is available from KEYENCE. Four
output relays (FSD1, FSD2, SSD, and AUX) are mounted onto the relay board unit.
To replace the relays, use the relay board unit designed exclusively for the PJ-V.

Because a dangerous voltage is applied to the controller, be sure to turn the


WARNING power switch off before working on the PJ-V.

AUX
(Auxiliary monitoring)

FSD1

FSD2

4 SSD

Fig. 4-3

4.3.2 Mounting the relay board unit for replacement


To replace the relay board unit, follow the instructions below:

Dismounting procedures
1) Loosen the two screws shown in Fig. 4-4 until they turn without effect.
2) Pull out the relay board unit horizontally by holding sections A and B, shown
in Fig. 4-4.

(Dismounting the relay board unit)


Controller
(PJ-V90)

Section A
(finger catch)

Relay board unit


(OP-31788)

Draw the relay board unit


out horizontally.

Section B (finger catch)

Screw

Fig. 4-4

70
Chapter 4 Test Procedures and Maintenance

Mounting procedures
1) Have a relay board unit ready. Then, fit the relay board unit into the top and
bottom guides, and reinsert the relay unit. See Fig. 4-5.
2) Tighten the screws until they cannot turn anymore.
The screw tightening torque is 0.294 Nm or less.

(Mounting the relay board unit)

Controller (PJ-V90)

Relay board unit (OP-31788)


Fit the relay board unit into the top and
bottom guides and then insert it.

4
Fig. 4-5

The output relays are selected to activate the relay monitoring circuit. Do not
DANGER mount any relays other than the relay board unit available from KEYENCE. If
any relay other than the relay board unit available from KEYENCE is used,
the PJ-V will not operate normally, resulting in dangerous accidents that may
result in serious injury or death to the operator.

Be sure to turn off the power supply before replacing the relay board unit.
WARNING Otherwise, electrical shock may occur.

71
Chapter 4 Test Procedures and Maintenance

4.4 Preventive Maintenance


4.4.1 Cleaning the PJ-V
Oil, dirt, or dust can accumulate on the transmitting and receiving surfaces. This
accumulation affects operation of the PJ-V. Periodic cleaning of the transmitting
and receiving surfaces will prevent problems from occurring due to accumulation of
these substances.

Clean the transmitting and receiving surfaces with ethyl alcohol or isopropanol.
Never use a solvent such as gasoline, paint, varnish, or acetone. Using such
solvents may obscure, discolor, or dissolve the surface. Use a clean cloth. Do not
scrub but wipe the surface when cleaning. Scrubbing the surface will streak the
surface or generate static electricity, gathering even more dust or dirt.

4.5 Testing the Sensor Head Indicators


The sensor head indicators can be inspected by passing the test piece through the
detection zone.
4
The sensor head indicators are used to help your optical alignment. When the
number of red-illuminated LEDs on the indicator with eight LEDs changes accord-
ing to the ratio of clear optical axes to the total of all axes, the indicator is regarded
as functioning properly.

72
Chapter 5
Troubleshooting

5.1 Troubleshooting ................................................................. 74


Chapter 5 Troubleshooting

5.1 Troubleshooting
STATUS

All indicators (both sensor head and controller) are off, and no operation
CLEAR
BLOCKED
LOCKOUT
OPERATION MODE

is available.
START I/L
RESTART I/L
MPCE OFF
SIGNAL INPUT
LOCKOUT
LOCK REL.
FSD OFF
DIAGNOSTICS
Main power is not supplied properly. Check power supply connections and
TRANSMITTER
RECEIVER
CONTROLLER
FSD 1
supply voltage.
FSD 2
SSD
MPCE

ON OFF Internal circuit fault. Replace the controller.

Controler The BLOCKED (red) indicator is on.


STATUS
CLEAR (When Start Interlock and Restart Interlock modes are not selected)
BLOCKED
LOCKOUT One or more optical axes are blocked. Confirm that no objects are present in
ON OFF
the detection zone. Check that no dust, dirt, or other obstructions are on the
transmitting and receiving surfaces.

The transmitter and receiver are in optical misalignment. Readjust the transmit-
ter and receiver according to the Final Optical Alignment procedures de-
scribed in this manual. See 3.7.2 on page 61.

When the FSD OFF input is used, open (terminals 5 and 6 are open-circuited)
the FSD OFF input. This can be checked using the FSD OFF indicator on the
controller.

The operating range is set out of the specifications.


5 Controler The BLOCKED (red) and LOCKOUT (yellow) indicators are both on.
STATUS
CLEAR
BLOCKED
The Start Interlock mode is active and operating. Either rotate the LOCK REL.
LOCKOUT
ON OFF
key or use the LOCK REL. input to enter Run status.

The Restart Interlock mode is active and operating. Lockout status occurs each
time one or more optical axes are blocked or the FSD OFF input is closed
(terminals 5 and 6 are short-circuited).

System fault. Refer to the Diagnostic indicators.

Confirm that the LOCKOUT input is closed (terminals 1 and 2 closed). This can
be checked using the Lockout indicator on the controller.

Controler The Receiver/Transmitter Diagnostic indicator is on, and the BLOCKED


STATUS
CLEAR (red) and LOCKOUT (yellow) indicators are both on. Other Diagnostic
BLOCKED
LOCKOUT indicators are on/off.
DIAGNOSTICS There is a problem in the receiver/transmitter or in the receiver/transmitter
One of these indicators TRANSMITTER
is illuminated. RECEIVER cable. Some receiver/transmitter problems cause the BLOCKED (red) indicator,
CONTROLLER
FSD 1
LOCKOUT (yellow) indicator, and Receiver/Transmitter Diagnostic indicator to
FSD 2 be illuminated.
SSD
MPCE

ON OFF Check the receiver/transmitter cable connections to the controller. Confirm that
all cable connections are properly connected to the connector. For the connec-
tions, refer to page 48 (3.4).

Check the cable between the controller and receiver/transmitter. Look for wear
and stress on the cable. Disconnect the power supply, and if the cable is not
connected to the receiver/transmitter connector, connect it.

Receiver/Transmitter fault. Replace the receiver/transmitter.

If none of the above resolves the problem, contact KEYENCE.

74
Chapter 5 Troubleshooting

Controler The FSD1/FSD2/SSD Diagnostic indicator is on.


STATUS
CLEAR
BLOCKED
Confirm that the relay board unit is properly installed. Observe relay operation.
LOCKOUT The SSD relay must be closed in Run status and in Stop status, while in Lock-
DIAGNOSTICS
TRANSMITTER
out status it must be open. The FSD1 and FSD2 relays must be closed in Run
RECEIVER status, while in Lockout status and in Stop status they must be open.
CONTROLLER
FSD 1
One of these indicators
is illuminated.
FSD 2
SSD
Inspect the output relays (FSD1, FSD2, and SSD) according to 4.3.1 Inspect-
MPCE ing and replacing the relay board unit on page 70.
ON OFF

If none of the above resolves the problem, replace the controller and contact
KEYENCE.
Controler
STATUS
The Controller Diagnostic indicator is on.
CLEAR
BLOCKED If the Controller Diagnostic indicator and Transmitter Diagnostic indicator or
LOCKOUT
Receiver Diagnostic indicator are illuminated, look for a fault on the transmitter
DIAGNOSTICS
TRANSMITTER
or receiver cable.
RECEIVER
CONTROLLER
FSD 1 Confirm that MODE 1 SWITCHES and MODE 2 SWITCHES are properly set.
FSD 2
SSD
MPCE
If none of the above resolves the problem, contact KEYENCE.
ON OFF

Controler
STATUS
The MPCE Diagnostic indicator is on. (When using the MPCE monitoring)
CLEAR
BLOCKED Verify the wiring between the MPCEs and FSDs.
LOCKOUT

DIAGNOSTICS
The relay contacts do not respond within 250 ms after the FSD operates. The
TRANSMITTER
RECEIVER
CONTROLLER
relay contact may be welded or the relay response time may be deteriorated. 5
FSD 1 Check the relays and replace the relays if necessary.
FSD 2
SSD
MPCE
ON OFF The Clear (green) indicator is on with an obstruction in the detection zone.
Controler When a reflective surface is present near the detection zone, install the PJ-V
STATUS
CLEAR away from any reflective surface a distance calculated from the formula or the
BLOCKED
LOCKOUT
distance read from the figure.
ON OFF Refer to page 37 (3.2.2).

75
Chapter 5 Troubleshooting

76
Chapter 6
Information

6.1 Reference information ........................................................ 78


Chapter 6 Information

6.1 Reference information


Many organizations provide materials concerning the proper usage of safety
devices for automatic machines or presses. The following information is provided
for user reference only. KEYENCE is not responsible for the accuracy, complete-
ness, or effectiveness of the information for a specific application by any company.

USA
UL (Underwriters Laboratories, Inc.)
Address: 333 Pfingsten Road,
Northbrook, IL 60062-2096, USA

Phone: 847-272-8800

OSHA (Occupational Safety and Health Administration)


Address: Superintendent of Documents
Government Printing Office
Washington, D.C. 20402-9371, USA
Phone: 202-783-3238

ANSI (American National Standards Institute, Inc.)


Address: 11 West 42nd Street
New York, NY 10036, USA

Phone: 212-642-4900

6 EUROPE
CEN (European Committee for Standardization)
Address: Central Secretariat
Rue de Stassart 36
B-1050 Brussels, Belgium

78
Chapter 7
Optional Items

7.1 Connector cable .................................................................. 80

7.2 Relay board unit .................................................................. 81

7.3 Mounting bracket ................................................................ 81

7.4 Intermediate support .......................................................... 81

7.5 Release tool ......................................................................... 82

7.6 End cap ................................................................................ 82

7.7 LOCK REL. (Lockout Release) key ................................... 82

7.8 Test piece ............................................................................ 82


Chapter 7 Optional Items

7.1 Connector cable


Product name Model Weight
2m transmitter cable for the PJ-V PJ-VC2T 150 g
5m transmitter cable for the PJ-V PJ-VC5T 340 g
7m transmitter cable for the PJ-V PJ-VC7T 460 g
2m receiver cable for the PJ-V PJ-VC2R 160 g
5m receiver cable for the PJ-V PJ-VC5R 360 g
7m receiver cable for the PJ-V PJ-VC7R 490 g

The cable length can be extended by properly combining the connector cables
above. The transmitter cable length can be extended up to 21 meters (using three
PJ-VC7T cables), and the receiver cable length can also be extended up to 21
meters (using three PJ-VC7R cables). Cable length extension is only allowed
within this range. The transmitter cable length may be different from the receiver
cable length. Do not combine a transmitter cable with a receiver cable to extend
the transmitter or receiver cable length. Be sure to only use the PJ-VC2T/PJ-VC5T/
PJ-VC7T cables to extend the transmitter cable, and the PJ-VC2R/PJ-VC5R/PJ-
VC7R cables to extend the receiver cable.

14 14
7
45 43

2000/5000/7000

Fig. 7-1

80
Chapter 7 Optional Items

7.2 Relay board unit


AUX
(Auxiliary monitoring)

FSD1 Model: OP-31788


For replacement procedure, see page 70 (4.3.2).

FSD2

SSD

7.3 Mounting bracket


Two mounting brackets make up a single set. Two sets of brackets are also in-
cluded with the base unit (PJ-V20, PJ-V40).

Model: OP-31784
For mounting procedures to the sensor head or mounting surface on the machinery, see
page 43 (3.3.4).

11
18
28

*2 x slot
18 4

4
27.5
17.5
5
*Detail of slot
29

Fig. 7-2

7.4 Intermediate support


A single set of intermediate supports is made up of four fixing side pieces for rear
mounting (two standard pieces and two wide ones) , four fixing side pieces for side
mounting, and two unit side pieces. 7
Two sets of supports are included with the base unit (PJ-V20, PJ-V40).
Model: OP-31785
For mounting procedures to the sensor head or mounting surface on the machinery, see
page 43 (3.3.4).
fixing side piece for side mounting fixing side piece for rear mounting unit side piece

For rear mounting 3 For side mounting

Standard type
2-4.5

17

32
40

4 2

Wide type 2-4.5


2-5
12.5
17 9

38 17.5 25
46
29 35
7

4 2 Fig. 7-3

81
Chapter 7 Optional Items

7.5 Release tool


One release tool is included with the base and the extension unit (PJ-V20/V21/V22,
PJ-V40/V41/V42).

Model: OP-31609 (one piece included)


For usage, see page 5 (Fig. 1-4).

7.6 End cap


Two end caps make up a single set (one for the transmitter and one for the re-
ceiver). A single set of end caps are included with the base unit (PJ-V20, PJ-V40).

Model: OP-31786

7.7 LOCK REL. (Lockout Release) key


Two LOCK REL. keys are included with the main controller (PJ-V90).

Model: OP-31787

7.8 Test piece


A test piece is included with the base unit (PJ-V20).
Separately have ready test pieces with the other diameters.
Item name Model
Test piece
7 (diameter: 28 mm, length: 280 mm)
OP-31608

82
PJ-V Glossary
LOCKOUT
Lockout status is one of the non-hazardous statuses, a status where all of the
three control outputs (FSD1, FSD2, and SSD) are open and the machine is
stopped. In addition to Lockout status, the PJ-V provides another status in
which the machine is stopped, which is called Stop status. In Stop status, the
FSD1 and FSD2 relays are open and the SSD relay is closed.

MPCE (Machine Primary Control Element)


The MPCE is the last element to directly control the machine. There are multiple
variations of components that can be MPCEs, such as relays and solenoid
valves. The MPCE is directly controlled by control output relay FSD.

FSD (Final Switching Device)


The FSD is a control output relay of the PJ-V, which is connected to the MPCE
and used to send a machine stop signal to the MPCE when an obstruction is
detected. The PJ-V controller is equipped with two FSD relays. When an ob-
struction in the detection zone blocks the optical axis, the FSD is opened.

MSCE (Machine Secondary Control Element)


The MSCE is an element to stop supplying power to the related hazardous
section on the machine controlled by the MPCE. The MSCE is controlled by the
SSD control output relay.

SSD (Secondary Switching Device)


The SSD is a control output relay of the PJ-V, which is connected to the MSCE
and used to send a signal to stop supplying power to the related hazardous
section, and send a signal to the MSCE when a Lockout status occurs. The PJ-
V90 is equipped with one SSD relay. When Lockout status occurs, the SSD is
opened.

AUX (Auxiliary Monitoring Relay)


The auxiliary monitoring relay operates in the same way as the PJ-V's FSD1
and FSD2 control output relays. Its main purpose is to signal the control system
status (whether the machine is stopped or running) to a PLC. The PJ-V90 is
equipped with one AUX relay.

Safety relay
Safety relays are used for the FSD1 , FSD2, and SSD relays. These are special
relays in which one a- and b-contact are interconnected by a joint and forced to
move together. If one relay becomes immobilized by a welded contact, the
welded contact can be detected based on the contact gap of the other relay.

MPCE monitoring
MPCE monitoring input is used to detect a failure of the MPCE. This input can
be utilized when safety relays are used for the MPCEs. Connect the MPCEs b-
contact to the MPCE monitoring input on the controller. The MPCEs b-contact
must operate opposite that of the FSD. Accordingly, if operation of the FSD is
not opposite the operation of the MPCEs b-contact, the PJ-V judges this as a
fault and invokes Lockout status.

START Interlock
Start Interlock is one of the PJ-Vs operation modes, and causes Lockout status
when power is supplied to the PJ-V. The Start Interlock mode is set using the
mode switches on the PJ-V90.

83
RESTART Interlock
Restart Interlock is one of the PJ-Vs operation modes, and causes Lockout
status when an obstruction in the detection zone blocks the optical axis. The
Restart Interlock mode is set using the mode switches on the PJ-V90.

84
Warranty
Warranty period
The warranty period shall be for one year from date of delivery.
One year from date of delivery herein means one year from the date when
we have delivered the PJ-V Series to the purchaser.

Warranty scope
KEYENCE PJ-V Series products are strictly factory-inspected. However, if the
PJ-V Series becomes unable to comply with the specifications due to im-
proper manufacturing within the warranty period, we will replace or repair the
PJ-V Series, free of charge. However, the following cases shall be excluded
from the warranty scope.

The PJ-V Series becomes unable to comply with the specifications due to
improper handling or wrong use
Any factor other than a defect of the delivered product
Improper modifications or repairs
Opening the transmitter, receiver, or controller housing
Acts of God or disaster
Any cause that cannot be foreseen on the scientific/technical level at the
time when the PJ-V Series has been shipped from KEYENCE

The warranty herein means the warranty with respect to the delivered prod-
uct alone. We shall not be liable for any damages resulting from a failure of
the delivered product. Only the purchaser of the PJ-V Series shall be saved
by application of this warranty. Any other warranty cannot be applied. And,
any person must not stretch the terms used in this warranty in his/her favor.

Disclaimer
KEYENCE does not make any other warranty of any kind, whether expressed
or implied, with respect to the product, except for the foregoing warranty.
And, KEYENCE specifically disclaims the implied warranties of merchantabil-
ity and fitness for a particular purpose.
Except for the obligations specifically set forth in this warranty, in no event
shall KEYENCE be liable for any direct, special, incidental or consequential
damages, whether based on contract, tort, or any other legal theory, and
whether advised of the possibility of such damages.

85
Index
B MPCE monitoring ........................................................ 52, 58
MPCE Monitoring input ..................................................... 25
Blocked ............................................................................. 18
MSCE (Machine Secondary Control Element) .................. 57

C
O
Cable length extension ..................................................... 48
Operation Mode indicators ................................................ 21
Clear .................................................................................. 18
Compliance with international standards ........................... vii
Connected indicator .......................................................... 21 P
Connecting extension unit (s) .............................................. 5 Pulsed light emission method ............................................. 3
Connector cable ................................................................... v
Controller ......................................................................... iv, 8
Q
Controller extension procedure ........................................... 6
Qualified person ................................................................ viii
Controller indicators .......................................................... 18

D R
Relay board unit ................................................................ 70
Dead zone ......................................................................... 41
Relay fault monitoring circuit ....................................... 23, 24
Diagnostics indicators ....................................................... 21
Restart Interlock .......................................................... 18, 52
Dimensions ......................................................................... 9
Run status ......................................................................... 18
Disconnecting extension unit (s) ......................................... 5

F S
Safety relay ................................................................. 23, 56
Final optical alignment ...................................................... 61
Self-diagnostic circuit .......................................................... 3
FSD OFF input ............................................................ 25, 60
Sensor head .................................................................... iv, 7
FSD (Final Switching Device) relay ................................... 23
Sensor head indicators ..................................................... 22
Sensor head indicators: Alarm and fault indicators ........... 22
I Sensor head indicators: Normal status indicators ............. 22
Indirect-reflection interference ........................................... 37 Sensor head mounting location ........................................ 39
Interference suppression function ..................................... 42 Sensor head mounting orientation .................................... 39
Intermediate support ......................................................... 45 Signal input ....................................................................... 25
Signal Input indicators ....................................................... 21
L Specifications ...................................................................... 7
SSD (Secondary Switching Device) relay ......................... 24
Label: Controller ................................................................... ii
Start Interlock .............................................................. 17, 52
Label: Sensor head ............................................................. iii
Status indicators ................................................................ 18
Lockout . ............................................................................ 19
Stop status ........................................................................ 19
Lockout input ............................................................... 25, 59
LOCK REL. (Lockout Release) input .................... 20, 25, 59
LOCK REL. (Lockout Release) key ................................... 20 T
Lockout status ................................................................... 19 Transmitter/receiver extension ............................................ 4

M W
Minimum safety distance ................................................... 31 Wiring method ................................................................... 57
Minimum safety distance formulas .................................... 33
Mode switches .................................................................. 51
Mounting the controller ...................................................... 50
Mounting the sensor head ................................................ 39
MPCE (Machine Primary Control Element) ....................... 56

86
MEMO

87
MEMO

88
0123
96M0810

PJ-V Series Instruction Manual


Instruction
Manual
Extendable Safety Light Curtain

PJ-V Series
NOTICE
Do not attempt to operate or service this machine until you have read
and understand the instructions written in this manual.

Specifications are subject to change without notice.


AFFILIATED COMPANIES
KEYENCE CORPORATION OF AMERICA KEYENCE SINGAPORE PTE LTD KEYENCE (HONG KONG) CO., LTD
Phone: 201-930-0100 Fax: 201-930-0099 Phone: 6392-1011 Fax: 6392-5055 Phone: 3104-1010 Fax: 3104-1080

KEYENCE DEUTSCHLAND GmbH KEYENCE (MALAYSIA) SDN BHD KEYENCE INTERNATIONAL TRADING
KEYENCE CORPORATION Phone: 06102-36 89-0 Fax: 06102-36 89-100 Phone: 03-2092-2211 Fax: 03-2092-2131 (SHANGHAI) CO., LTD.
1-3-14, Higashi-Nakajima, Phone: 021-68757500 Fax: 021-68757550
Higashi-Yodogawa-ku, Osaka, KEYENCE (UK) LIMITED KEYENCE (THAILAND) CO., LTD
Phone: 01908-696900 Fax: 01908-696777 Phone: 02-369-2777 Fax: 02-369-2775 KEYENCE KOREA CORPORATION
533-8555, Japan
Phone: 02-563-1270 Fax: 02-563-1271
Phone: 81-6-6379-2211 KEYENCE FRANCE S.A. KEYENCE TAIWAN CO., LTD
Fax: 81-6-6379-2131 Phone: 01 47 92 76 76 Fax: 01 47 92 76 77 Phone: 02-2627-3100 Fax: 02-2798-8925

KEYENCE CORPORATION, 1999 0010-8 96M0810 Printed in Japan