Professional Documents
Culture Documents
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.
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
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
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
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
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
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
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
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
When you want to extend the cable length to longer than 7 meters, see page 48(3.4.2).
Accessories
PJ-V90 (Main controller)
PJ-V91 (Sub-controller)
No accessories included.
PJ-V20/V21/V22/V40/V41/V42
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.
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.
*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.
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.
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.
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.
x
Contents
Introduction ....................................................................................................... i
Symbols ............................................................................................................. i
Label ................................................................................................................. ii
Part Names ...................................................................................................... iv
Accessories ...................................................................................................... v
Features ........................................................................................................... vi
Important Safety Message ............................................................................ viii
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 5 Troubleshooting 73
5.1 Troubleshooting ................................................................................... 74
xii
Chapter 6 Information 77
6.1 Reference information ......................................................................... 78
xiii
Chapter 1
Outline and Specifications
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.
Receiver
Base unit
(PJ-V20, PJ-V40)
Transmitter cable
PJ-VCxT
Receiver cable
PJ-VCxR
Main controller
PJ-V90
Fig.1-1
2
Chapter 1 Outline and Specifications
Transmitter Receiver
Fig. 1-2
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
4
Chapter 1 Outline and Specifications
Base unit
Fig.1-3
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
PJ-V90 PJ-V91
Power Output
supply
Fig. 1-5
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
Screw
Slotted screwdriver
Cap
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
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
1
470 30* 470 30*1
33 Dead
50 40 zone
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
33 Dead
50 40 zone
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
22
7.2
77
172 183
77
160
22 77
29
12
Chapter 1 Outline and Specifications
34
28.5
82 28
1
8.5 26
90
(93)
70 10
15.5
*4 x slot (55)
(Mounting hole)
35.4
18.3
4 5 12.1
14.6
5.3
7
*Detail of slot
13
Chapter 1 Outline and Specifications
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
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
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
PJ-V90 PJ-V91
16
Chapter 2 System Outline
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
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.
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
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
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.
19
Chapter 2 System Outline
3
2 Key 4
PJ-V90
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
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
When the MPCE monitoring function is not selected, the MPCE OFF indicator is
illuminated.
For mode setting procedures, refer to page 51 (3.5).
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).
21
Chapter 2 System Outline
100%
0%
Fig.2-6
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 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.
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
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.
23
Chapter 2 System Outline
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.
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.
24
Chapter 2 System Outline
LOCKOUT input
LOCK REL. input
FSD OFF 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.
25
Chapter 2 System Outline
26
Chapter 3
System Installation and Startup
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.
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
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.
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.
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
30
Chapter 3 System Installation and Startup
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.
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.
Direction of
Approach
S
Fig. 3-1
Parallel Approach
Direction of
Approach
Fig. 3-2
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
Direction of
Approach
Fig. 3-4
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.
Normal Approach
C = 8 (d-14) where d <
= 40 mm
d = Minimum object sensitivity
PJ-V20: d = 28mm
PJ-V40: d = 48mm
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
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
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
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.
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:
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.
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.
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
S = K x Ts
Example
Assume that an object approaches vertically to the detecting surface and the
operator is 14 years old or older.
Direction of
Approach
Calculation (When using the PJ-V20, PJ-V40)
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.
37
Chapter 3 System Installation and Startup
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
Perimeter of danger
A A A A area
Object to be Object to be
detected detected
A A A A
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
600
500
300
200
(185)
100
0
0 1 2 3 4 5 6 7 8 9 10
3
Operating range Y (m)
Fig. 3-7
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
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.
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
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
Fig. 3-11
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
Fig. 3-12
42
Chapter 3 System Installation and Startup
Dead
zone
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
43
Chapter 3 System Installation and Startup
Base unit
Fig. 3-14
Sensor head
Mounting bracket
Fig. 3-15
Fig. 3-16
Fig. 3-17
44
Chapter 3 System Installation and Startup
M4 screws
3
Fig. 3-18
PJ-V22/42
8 PJ-V21/41
End cap
PJ-V22/42
7 PJ-V21/41 End cap
5 PJ-V21/41 PJ-V22/42
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
PJ-V
3
Base unit
Fig. 3-21
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.
46
Chapter 3 System Installation and Startup
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
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.
Spring washer
M4 screws
47
Chapter 3 System Installation and Startup
1) Have ready the required length of transmitter and receiver connector cables.
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
Fig. 3-27
Receiver Cable(black)
PJ-VCxR
PJ-V90
Fig. 3-28
49
Chapter 3 System Installation and Startup
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.
ClawsB
Fig. 3-29
Claw A
Claw B
DIN rail
Hook claw A to the DIN rail.
Snap
Fig. 3-30
50
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.
Fig. 3-31
51
Chapter 3 System Installation and Startup
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.
52
Chapter 3 System Installation and Startup
Mode switches
2. RESTART INTERLOCK
1 2 3 4 5
1 2 3 4 5
1. START INTERLOCK
1 2 3 4 5
1 2 3 4 5
Fig. 3-32
53
Chapter 3 System Installation and Startup
Block diagram
Control
circuit FSD1
FSD2
SSD
AUX
(Auxiliary
Signal monitor)
input
3 Indicators
24 VDC
Ground
Fig. 3-33
Before starting any wiring job, be sure to shut off all power. Failure to do this
WARNING may result in an electrical shock.
54
Chapter 3 System Installation and Startup
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.
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
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.
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
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.
56
Chapter 3 System Installation and Startup
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
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.
57
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.
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.
58
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.
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 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.
59
Chapter 3 System Installation and Startup
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.
60
Chapter 3 System Installation and Startup
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.
Adjustable angle ()
Rear mounting Side mounting
Not using intermediate support 25 15
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.
61
Chapter 3 System Installation and Startup
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
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.
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.
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.
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.
4
Transmitter Receiver
Test piece
Fig. 4-1
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.
1) Supply power
Disable operation of the guarded machine. Supply power to the PJ-V. Bring the
PJ-V into Run status.
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.
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.
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
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
2) Preventive maintenance
Clean the transmitting and receiving surfaces according to the procedures
described in 4.5 Preventive Maintenance. See page 72.
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
AUX
(Auxiliary monitoring)
FSD1
FSD2
4 SSD
Fig. 4-3
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.
Section A
(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.
Controller (PJ-V90)
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
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.
72
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
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 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).
Confirm that the LOCKOUT input is closed (terminals 1 and 2 closed). This can
be checked using the Lockout indicator on the controller.
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.
74
Chapter 5 Troubleshooting
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
USA
UL (Underwriters Laboratories, Inc.)
Address: 333 Pfingsten Road,
Northbrook, IL 60062-2096, USA
Phone: 847-272-8800
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
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
FSD2
SSD
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
Standard type
2-4.5
17
32
40
4 2
38 17.5 25
46
29 35
7
4 2 Fig. 7-3
81
Chapter 7 Optional Items
Model: OP-31786
Model: OP-31787
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.
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
NOTICE
Do not attempt to operate or service this machine until you have read
and understand the instructions written in this manual.
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