MICRO-EPSILON turboSPEED DZ140 User manual

DS05(03)
DS05(04)
DS05(07)
DS05(14)
DS05(15)
DS1
DS1(04)
DS1/T
Operating Instructions
turboSPEED DZ140

MICRO-EPSILON
MESSTECHNIK
GmbH & Co. KG
Königbacher Strasse 15
94496 Ortenburg / Germany
Tel. [phone] / 168-0
Fax [phone] / 168-90
e-mail [email protected]
www.micro-epsilon.com
Speed measuring system for turbo chargers

turboSPEED DZ140
Contents
1. Safety ........................................................................................................................................................ 5
1.1 Symbols Used ................................................................................................................................................. 5
1.2 Warnings.......................................................................................................................................................... 5
1.3 Notes on CE Marking ...................................................................................................................................... 6
1.4 Intended Use ................................................................................................................................................... 6
1.5 Proper Environment......................................................................................................................................... 7
2. Functional Principle, Technical Data ....................................................................................................... 8
2.1 Applications ..................................................................................................................................................... 8
2.2 Functional Principle ......................................................................................................................................... 8
2.3 Structure of the Complete Measuring System................................................................................................ 8
2.4 Technical Data ................................................................................................................................................. 9
3. Delivery ................................................................................................................................................... 11
3.1 Unpacking, Included in Delivery.................................................................................................................... 11
3.2 Storage .......................................................................................................................................................... 11
4. Installation .............................................................................................................................................. 12
4.1 Sensor............................................................................................................................................................ 12
4.2 Sensor Cable ................................................................................................................................................. 15
4.3 Supply and Signal Cable............................................................................................................................... 15
4.4 Controller DZ140............................................................................................................................................ 16
4.5 Electrical Connections................................................................................................................................... 17
4.5.1 Supply, Outputs............................................................................................................................ 17
4.5.2 Power Supply ............................................................................................................................... 18
4.5.3 RAW SIGNAL ................................................................................................................................ 20
4.5.4 Ground Concept........................................................................................................................... 20

turboSPEED DZ140
5. Operation ................................................................................................................................................ 22
5.1 Connecting the Measuring System............................................................................................................... 22
5.2 LEDs on the Controller .................................................................................................................................. 23
5.3 Positioning of the Sensor .............................................................................................................................. 24
5.3.1 Open Compressor Housing ......................................................................................................... 24
5.3.2 Closed Compressor Housing....................................................................................................... 24
5.4 Test Signal...................................................................................................................................................... 25
5.5 Settings .......................................................................................................................................................... 26
5.5.1 Mode (Turbo Charger Speed, Sensitivity, Test Signal) ............................................................... 26
5.5.2 Number of Blades......................................................................................................................... 27
5.6 Analog Output ............................................................................................................................................... 28
6. Troubleshooting...................................................................................................................................... 29
7. Liability for Material Defects .................................................................................................................. 31
8. Service, Repair ....................................................................................................................................... 31
9. Decommissioning, Disposal ................................................................................................................. 31
Appendix
A 1 Optional Accessories ............................................................................................................................. 32
A 2 Labels on Rear Side of Controller for Printing...................................................................................... 33

Page 5
Safety
turboSPEED DZ140
1. Safety
System operation assumes knowledge of the operating instructions.
1.1 Symbols Used
The following symbols are used in these operating instructions:
CAUTION Indicates a hazardous situation which, if not avoided, may result in minor or moder-
ate injury.
NOTICE
Indicates a situation that may result in property damage if not avoided.
Indicates a user action.
iIndicates a tip for users.
Measure Indicates hardware or a software button/menu.
1.2 Warnings
Connect the power supply and the display/output device according to the safety regulations for electrical
equipment.
> Risk of injury
> Damage to or destruction of the sensor and / or controller
The supply voltage must not exceed the specified limits.
> Risk of injury
> Damage to or destruction of the sensor and / or controller
Avoid shocks and impacts to the sensor and controller.
> Damage to or destruction of the sensor and controller
Protect the sensor cable against damage
> Failure of the measuring device
CAUTION
NOTICE

Page 6
Safety
turboSPEED DZ140
1.3 Notes on CE Marking
The following apply to the turboSPEED DZ140:
- EU directive 2014/30/EU
- EU directive 2011/65/EU, “RoHS” category 9
Products which carry the CE mark satisfy the requirements of the EU directives cited and the European
harmonized standards (EN) listed therein. The EU Declaration of Conformity is available to the responsible
authorities according to EU Directive, article 10, at:
MICRO-EPSILON MESSTECHNIK GmbH & Co. KG
Königbacher Str. 15
94496 Ortenburg / Germany
The measuring system is designed for use in industrial environments and meets the requirements.
1.4 Intended Use
- The system is designed for use in industrial and laboratory applications.
- It is used for speed measurement on turbo chargers.
- The system must only be operated within the limits specified in the Technical Data, see Chap. 2.4.
- The system must be used in such a way that no persons are endangered or machines and other material
goods are damaged in the event of malfunction or total failure of the controller.
- Take additional precautions for safety and damage prevention in case of safety-related applications.

Page 7
Safety
turboSPEED DZ140
1.5 Proper Environment
- Protection class controller: IP 65
- Operating temperature
Sensor:
• Models DS05(03), DS05(04), DS05(07), DS05(14), DS05(15): -40 ... +200 °C (-40 ... +392 °F)
• Models DS1, DS1(04): -40 ... +235 °C (-40 ... +455 °F)
• Model DS1/T: -40 ... +235 °C (-40 ... +455 °F),
(short-term +285 °C, +545 °F)
Sensor cable: -40 ... +200 °C (-40 ... +392 °F)
Controller: -40 ... +125 °C (-40 ... +257 °F) (at max. 15 VDC power supply) 1)
- Storage temperature
Sensor, sensor cable: -40 ... +200 °C (-40 ... +392 °F)
Controller: -40 ... +125 °C (-40 ... +257 °F)
- Humidity: 5 - 95 % (non-condensing)
- Ambient pressure: Atmospheric pressure
- Supply: 9 ... 30 VDC / briefly 36 VDC / max. 50 mA
1) If power supply is higher, the max. acceptable ambient temperature decreases, see Fig. 14.

Page 8
Functional Principle, Technical Data
turboSPEED DZ140
2. Functional Principle, Technical Data
2.1 Applications
The non-contacting compact revolution counter is designed for industrial application for turbo charger moni-
toring on test benches and for measurements during driving tests.
2.2 Functional Principle
A very fast proximity sensor responds to turbo charger blades (depending on initial state) made of electrically
conducting materials passing by. The eddy current loss principle effects impedance changes in a measuring
coil (sensor). This change of impedance gives rise to an electric signal.
2.3 Structure of the Complete Measuring System
The non-contacting single-channel measuring system consists of:
- Sensor and sensor cable
- Controller (installed in a compact aluminum housing)
- Power supply and signal cable, see Chap. 4.3
Individual components of the measuring system can be changed without limiting the functionality.
turboSPEED
Remote
Status
SENSOR
SUPPLY /
OUTPUT
Mode
RAW SIGNAL
Blades
Sensor Controller
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fig. 1 Components for speed measurement

Page 9
Functional Principle, Technical Data
turboSPEED DZ140
2.4 Technical Data
Model DZ140 (Controller)
Sensors DS05(03) DS05(04) DS05(07) DS05(14) DS05(15) DS1 DS1(04) DS1/T
Measuring principle /
Target (blade material) eddy current principle / aluminum or titanium
Maximum speed range
(measuring range) 200 ... 400,000 RPM
Operating
temperature
Controller -40 ... +125 °C, -40 ... +257 °F (at a maximum of 15 VDC supply voltage)1)
Sensor -40 ... +200 °C,
-40 ... +392 °F
-40 ... +235 °C,
-40 ... +455 °F
-40 ... +235 °C,
-40 ... +455 °F
(short-term
+285 °C, +545 °F)
Sensor cable -40 ... +200 °C, -40 ... +392 °F
Integral sensor cable 0.5 m ±0.15 m 0.75 m ±0.15 m 0.8 m ±0.15 m
Number of blades rotary switch (accessible from the outside) for 1 up to 16 blades
Digital output 1 pulse / blade (switch Blades on 1, TTL level, variable pulse duration) or
1 pulse / revolution (switch Blades on 2...16, TTL level with 100 µs pulse duration)
Analog output
Mode 1, 3, 5: 0 ... 5 V (200 ... 200,000 rpm)
Mode 0, 2, 4: 0 ... 5 V (200 ... 400,000 rpm)
mode rotary switch, adjustable, accessible from outside
RAW signal
Analog measurement signal to control distance between sensor and blade by means of an oscilloscope,
see Fig. 20;
load resistance > 5 kOhm, load capacity max. 1 nF
Output sensor temperature 0 ... 5 V (-50 ... +300 °C, -58 ... +572 °F)
Power supply 9 V ... 30 VDC / max. 50 mA (short-term up to 36 VDC)
1) If power supply is higher, the max. acceptable ambient temperature decreases, see Fig. 17.

Page 10
Functional Principle, Technical Data
turboSPEED DZ140
Model DZ140 (Controller)
DS05(03) DS05(04) DS05(07) DS05(14) DS05(15) DS1 DS1(04) DS1/T
Storage tem-
perature
Sensor,
sensor cable -40 ... +200 °C, -40 ... +392 °F
Controller -40 ... +125 °C, -40 ... +257 °F
Cable
PC140-3 supply and output cable 3 m
PC140-6 supply and output cable 6 m
PC140-8 supply and output cable 8 m
Weight Controller DZ140: appr. 92 g
Protection class Controller DZ140: IP 65
FSO = Full Scale Output

Page 11
Delivery
turboSPEED DZ140
3. Delivery
3.1 Unpacking, Included in Delivery
1 Controller DZ140
1 Protection cover for the RAW SIGNAL output
1 Operating Instructions
1 Multi corrugated spring
Separately available:
Sensor DSx or Sensor DSx/T including integrated sensor cable
Power supply and signal cable PC140-x, see Chap. 4.3.
Carefully remove the components of the measuring system from the packaging and ensure that the
goods are forwarded in such a way that no damage can occur.
Check the delivery for completeness and shipping damages immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or supplier.
You will find further optional accessories in appendix, see Chap. A 1.
3.2 Storage
- Storage temperature:
Sensor and sensor cable: -40 ... +200 °C (-40 ... +392 °F)
Controller: -40 ... +125 °C (-40 ... +257 °F)
- Humidity: 5 - 95 % (non-condensing)

Page 12
Installation
turboSPEED DZ140
4. Installation
4.1 Sensor
35 (1.38)
18 (0.71)
45°±3°
ø 3
(0.12 dia)
WS4
appr. 9,5
(0.37)
Sensor cable
ø approx. 3.5 mm
Length 0.5 m (±0.15 m)
with BNC connector
Fig. 2 Dimensional drawing DS05(03)
66
(2.60)
ø 3
(0.12 dia.)
WS4
appr. 9,5
(0.37)
Sensor cable
ø approx. 3.5 mm
Length 0.5 m (±0.15 m)
with BNC connector
Fig. 3 Dimensional drawing DS05(04)
Measuring
direction

Page 13
Installation
turboSPEED DZ140
ø 3
(0.12)
46
(1.81)
66
(2.60)
1 (0.04)
M5
WS4
appr. 9,5
(0.37)
ø 3 (0.12 dia.)
Sensor cable
ø approx. 3.5 mm
Length 0.5 m (±0.15 m)
with BNC connector
Fig. 4 Dimensional drawing DS05(07)
M5
28
(1.10)
appr. 9,5
(0.37)
WS4 Sensor cable
ø approx. 3.5 mm
Length 0.5 m (±0.15 m)
with BNC connector
Fig. 5 Dimensional drawing DS05(14
45
(1.77)
M5
WS4
appr. 9,5
(0.37)
Sensor cable
ø approx. 3.5 mm
Length 0.5 m (±0.15 m)
with BNC connector
Fig. 6 Dimensional drawing DS05(15)

Page 14
Installation
turboSPEED DZ140
M5x0.5
40
(1.57)
WS4
appr. 9,5
(0.37)
Sensor cable
ø approx. 3.5 mm
Length 0.75 m (±0.15 m)
with BNC connector
Fig. 7 Dimensional drawing DS1
M5x0.5
approx. 9.5
(.37)
40 (1.57) Sensor cable ø approx. 4.5 mm
Kabellänge 0.8 m (± 0.15 m)
with triax-BNC-connector
ø approx. 19 (.75)
Sensor cable with 2 shields
(triax cable)
ø approx. 5 mm
Length 0.8 m (±0.15 m)
with triax cable socket
Fig. 8 Dimensional drawing DS1/T
M5x0.5
42
(1.65)
WS6
Sensor cable with metal protec-
tion hose
stainless steel IP 40
ø appr. 6.0; cable length 0.8 m
(± 0.15 m)
with BNC-connector
Fig. 9 Dimensional drawing DS1(04)
Dimensions in mm (inches), not to scale
Measuring
direction

Page 15
Installation
turboSPEED DZ140
4.2 Sensor Cable
Mount the sensor cable in such a way that the cable sheath is not exposed to any sharp-edged or heavy
objects. Do not kink the cable.
iNever come below the proper bending radius of the sensor cable: 10 x diameter in the case of dynamic application,
5 x diameter in the case of static application.
Make sure that the plug connectors at the sensor and at the controller fit tightly.
iAs the capacity and the adjustment of the measuring system change, please do not shorten the matched sensor cables.
4.3 Supply and Signal Cable
iNever come below the proper bending radius of the supply and signal cable: 7.5 x cable outer diameter.
Fig. 10 Supply and signal cable, 3, 6 or 8 m long

Page 16
Installation
turboSPEED DZ140
4.4 Controller DZ140
The controller DZ140 is installed in an aluminum housing. The controller demodulates and amplifies the
speed-dependent measuring signal.
62
(2.44)
33.3
(1.31)
41.3
(1.63)
83.8
(3.3)
19.5
(0.77)
18
(0.71)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Fig. 11 Dimensions controller, dimensions in mm (inches), not to scale

Page 17
Installation
turboSPEED DZ140
4.5 Electrical Connections
4.5.1 Supply, Outputs
Supply/Output Labeling and color
PC140-x 1
2
5
3
7
4
6
8
9
10
View on solder cup side,
10-pole cable connector
SUPPLY /
OUTPUT
RAW SIGNAL
Blades
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Pin Assignment
1 Analog output speed 0 ... +5 V Uablue
2 Reserved, do not connect! yellow
5 GND GND black
3 TTL-Impulse, digital TTL green
5 GND GND black
Housing PE black
4, 6 Reserved, do not connect!
7 Supply - SUPPLY- white
8 Power supply + 9 ... 30 VDC SUPPLY+ brown
Fig. 12 Pin assignment female connector SUPPLY/OUTPUT and PC140-x
The connector housing / electronics housing is connected with the housing electronics and connector “PE”.
Connect the PE connector (outer shielding braid) and the electronic housing with motor housing, test
stand ground or protective earth.
An interior shielding braid (Pin 5) meshs the signals Pin 1 and the signal on Pin 3. PC140-x is a 3, 6 or 8 m
long, pre-assembled 8-wired power and signal cable. It must be ordered as the sensor separately. The out-
puts are temporary short-circuit proof.
Pin 9 and 10 are not assigned.

Page 18
Installation
turboSPEED DZ140
4.5.2 Power Supply
Power supply UV: +9 ... 30 VDC (temporarily up to 36 VDC)
Current consumption: I max < 50 mA
The controller is protected against voltage reversal and overvoltage.
iOnly use the power supply for measuring devices and not simultaneously for drives or similar pulse
interference. MICRO-EPSILON recommends the power supply unit PS2020, see Chap. A 1. 12 V on-
board power supply is possible.
PS2020
230 VAC
PE
N L
PS2020
PC140-x
turboSPEED
Remote
SUPPLY /
OUTPUT
Mode
RAW SIGNAL
Blades
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0
0 V 100 110 125
9 V
15 V
24 V
30 V
U /V
V
T/°C
Fig. 13 Connection Power Supply Fig. 14 Derating curve
Wire color PC140-x Assignment The power supply UVhas to be limited at 100 °C am-
bient temperature and it must not exceed 15 VDC at
125 °C, see Fig. 14.
SUPPLY + brown +9 … 30 VDC
SUPPLY - white Supply -

Page 19
Installation
turboSPEED DZ140
S
RWire
ILast
UR Wire
upply +
Supply -
GND
BNC
DZ140 Controller
PE
L
GND
RWire
M
V
UR Leitung
e.g. Ua, UTemp
from DZ140
Further
measuring
instruments
Fig. 15 Thermal overheating possible by measuring loop - avoid
If the GND line is connected to the negative pole of the power supply (e.g. due to connected measuring
instruments), avoid connecting the controller to loads with high currents, e.g. starter.
S
RWire
ILast
UR Wire
upply +
Supply -
GND
BNC
DZ140 Controller
PE
L
GND
RWire
M
V
e.g. Ua, UTemp
from DZ140
Further
measuring
instruments
Fig. 16 Short connection leads directly to the supply - recommendation
iAlso consider the possible ground loops, which can result from the use of the multi corrugated spring (connection between GND and PE), see Chap. 6.

Page 20
Installation
turboSPEED DZ140
4.5.3 RAW SIGNAL
Via a BNC socket RAW SIGNAL the controller provides an analog voltage of 2.8 ... 5 V to align the sensor,
see Fig. 20, see Chap. 5.3.2. Load resistance > 5 kOhm.
Disconnect the connected measuring devices after alignment of the sensor distance and close the
female connector with the delivered protection cap.
4.5.4 Ground Concept
Supply +
Supply -
GND
Shield
BNC
Triax
DZ140 Controller
PEPE PE
L
GND
Sensor
Fig. 17 Ground concept for DSx sensors