Pepperl+Fuchs KFU8-DW-1.D User manual

KFU8-DW-1.D
Rotational speed monitor
FACTORY AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following
document is applicable: The General Terms of Delivery for Products and
Services of the Electrical Industry, published by the Central Association of
the ElectricalIndustry (Zentralverband Elektrotechnik und Elektroindustrie
(ZVEI) e.V.) in its most recent version as well as the supplementary
clause: "Expanded reservation of proprietorship"
KFU8-DW-1.D

KFU8-DW-1.D
Contents
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1 Introduction....................................................5
2 Declaration of conformity .............................7
3 Safety ..............................................................8
3.1 Symbols relevant to safety ................................................8
3.2 Intended use.....................................................................9
3.3 General safety instructions................................................9
4 Product Description ....................................11
4.1 Device description ..........................................................11
5 Operation......................................................15
5.1 Operating mode..............................................................15
5.2 Setup mode ....................................................................17
5.3 Timer functions, reversing the detection direction of the
output relay .....................................................................21
6 Service and Maintenance ...........................27

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Contents
7 Appendix ......................................................28
7.1 Technical data.................................................................28
7.2 Terminal assignment.......................................................33
7.3 Dimensions, operating and display devices ....................34
7.4 Connection diagram .......................................................35
7.5 Functional description.....................................................36

KFU8-DW-1.D
Introduction
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1Introduction
Congratulations
You have chosen a device manufactured by Pepperl+Fuchs.
Pepperl+Fuchs develops, produces and distributes electronic
sensors and interface modules for the market of automation
technology on a worldwide scale.
Before you install this device and put it into operation, please read the
operating instructions thoroughly. The instructions and notes
contained in this operating manual will guide you step-by-step
through the installation and commissioning to ensure the trouble-free
usage of this product. This is useful to you, because with this you:
■support the safe operation of the device
■can utilize the device’s entire range of functions
■reduce faulty operation and the associated errors
■reduce costs from downtime and incidental repairs
■increase the effectiveness and operating efficiency of your
plant.
Store this operating manual somewhere safe in order to have it
available for future work on the device.
Directly after opening the packaging, please ensure that the device is
intact and that the package is complete.

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KFU8-DW-1.D
Introduction
Symbols used
The following symbols are used in this manual:
Handling instructions
This symbol denotes handling instructions.
Contact
If you have any questions about the device, its functions, or
accessories, please contact us at:
Pepperl+Fuchs GmbH
Lilienthalstraße 200
68307 Mannheim
Telephone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Note!
This symbol brings important information to your attention.

KFU8-DW-1.D
Declaration of conformity
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2 Declaration of conformity
This product was developed and manufactured under observance of
the applicable European standards and guidelines.
The product manufacturer, Pepperl+Fuchs GmbH, D-68307
Mannheim, has a certified quality assurance system that conforms to
ISO 9001.
Note!
A Declaration of Conformity can be requested from the manufacturer.
ISO9001

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KFU8-DW-1.D
Safety
3Safety
3.1 Symbols relevant to safety
Danger!
This symbol indicates a warning about an immediate possible danger.
In case of ignoring the consequences may range from personal injury
to death.
Warning!
This symbol indicates a warning about a possible fault or danger.
In the event the warning is ignored, the consequences may course
personal injury or heaviest property damage.
Do not proceed beyond a warning notice until the indicated
conditions are fully understood and met. Refer to this manual for
specific Warning or Caution information.
Caution!
This symbol indicates a warning about a possible fault.
In case of ignoring the devices and any connected facilities or
systems may be interrupted or fail completely.

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Safety
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3.2 Intended use
The KFU8* series comprises a range of devices used to display and
monitor periodic signals. The devices can be used as a control
cabinet module or for field applications. Use wiring designed
specially for the devices.
3.3 General safety instructions
Installation and commissioning of all devices must be performed by a
trained professional only.
Always operate the device as described in these instructions to
ensure that the device and connected systems function correctly. The
protection of operating personnel and plant is only guaranteed if the
device is operated in accordance with its intended use.
The devices fulfill a degree of protection IP 20 according to IEC/EN
60529.
When packing the device for storage or transport, use materials that
will protect the device from bumps and impacts and protect against
moisture. The original packaging provides the best protection. Also
take into account the permitted ambient conditions.
The operating company bears responsibility for observing locally
applicable safety regulations.

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KFU8-DW-1.D
Safety
User modification and or repair are dangerous and will void the
warranty and exclude the manufacturer from any liability. If serious
faults occur, stop using the device. Secure the device against
inadvertent operation. In the event of repairs, return the device to your
local Pepperl+Fuchs representative or sales office.

KFU8-DW-1.D
Product Description
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4 Product Description
4.1 Device description
The rotational speed monitor KFU8-DW-1.D is a device for displaying
and monitoring periodical signals which occur in almost all areas of
process automation, i.e. from general frequencies to specific speeds.
The input signals are evaluated and converted into a frequency or
speed by a powerful -controller in accordance with the cycle
method.
Furthermore, in applications involving slow processes, where sensors
deliver multiple pulses per revolution, it is possible to automatically
operate with the actual speed of the drive by specifying the number of
pulses per revolution.
The measured value is displayed on a 7-segment LED display on the
front of the device. The display has 4 digits and up to 3 decimal
places. The parameterization is performed using the 4 buttons below
the display.
Note!
Close attention was paid to the special case of speed measurement
during the development of the device. The indicators and inputs can
therefore occur in Hz or in rpm.

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KFU8-DW-1.D
Product Description
The monitoring function is actuated by a limiting value, whose upper
and lower hysteresis values can be selected within the relevant
measurement and indicating range.
The output signal is generated by a changeover relay when the value
exceeds or falls below the hysteresis limits. Due to its high switching
capability, the relay output can be used to directly drive an actuator, or
as an input signal to a higher level control.
In addition, the switching state of the relay is indicated by a yellow
LED on the front of the device.
A function block is connected in line with the output relay, which
enables 10 different timer functions to be employed; thus there is no
need to connect a separate timer relay in series. In addition to ON
delay, OFF delay, defined ON time and pulse expansion, the direction
of operation of the relay can also be selected, i.e. to monitor
underspeed or overspeed.
The integral startup override is triggered when the supply voltage is
switched on or by an external signal and prevents false signals from
occurring when the monitored system starts up.
The rotational speed monitor can be operated with a 115 VAC,
230 VAC or 24 VDC power supply. When an alternating voltage is
connected, a 24 VDC source is available for the sensor.

KFU8-DW-1.D
Product Description
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The device comprises 3 galvanically isolated circuits:
■230 V, 115 V voltage supply circuit, connections 16, 17, 18
■Signal circuit
■24 V voltage supply, connections 4, 5
■Sensor/signal, connections 1, 2, 3, 7, 8, 9, 13, 14, 15
■Relay output circuit, connections 10, 11, 12
Note!
All currently available two, three or four-wire proximity switches and
incremental rotary encoders are acceptable as sensors. Moreover,
two terminals are reserved for the connection of proximity switches as
per DIN 19234 (NAMUR).
Caution!
Insulation co-ordinates for specifying data on galvanic/electrical
isolation are in accordance with DIN EN 50178:
The KFU8-DW-1.D device is intended for use in enclosed electrical
operating areas, to which only competent electrical personnel or
properly instructed electrotechnical personnel have access or entry.
The device is designed for use in degree of pollution 2 and surge
category II as per EN 50178.

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KFU8-DW-1.D
Product Description
The circuits in this component device are separated from mains by
reinforced/double insulation (basic + supplementary).
There is no isolation between the signal circuit connections and the
exposed/contactable surfaces.

KFU8-DW-1.D
Operation
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5Operation
5.1 Operating mode
Signal frequency
The rotational speed monitor processes input signals from 0.002 Hz
... 40 kHz, over 4 measurement ranges. Cycle durations of 25 µs to
500 s are evaluated. Signals not having a duty rate of 1:1 must have a
minimum pulse pause or pulse duration of 12 s in order to be
detected with certainty behind the input filter.
Measurement underrange, message
This message appears either when no input signal is detected, or if
the displayed value would be zero due to the selection of an
excessively high measurement range.
Example: The device receives a signal of 0.1 Hz in the 0 Hz ... 9999
Hz measurement and display range. This implies that the display
would indicate zero and an observer might presume that the machine
had stopped.
Measurement overrange, message
The preset display and measurement range was exceeded.

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Operation
Very low signal frequencies, displayed value is not valid,
message
During the measurement of very low signal frequencies, the
measuring system has detected that the signal has fallen below the
last computed frequency. The time between the last two signal edges
has already elapsed. The device is now waiting for the next positive
signal edge in order to compute the next measured value. Here, 'XXX'
represents the positions of the first three digits of the last measured
value.
Self test, message
When the power supply is switched on, the device performs a self
test. The message appears when it is established that there is an
error, for example during the check summation of the EEPROM data;
in this state, the output relay behaves as if there has been a power
failure. The error message can be cleared by switching the supply
voltage off and on again.
Note!
Select a wider measurement range.

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Operation
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Error message
1. Enter the parameters again.
2. Switch the device off and back on again.
The normal function of the output relay is restored.
5.2 Setup mode
See chapter 7.5
Function selection
2 measurement functions are available:
1. Frequency measurement in Hz
The established cycle duration of the input signal is converted
into a frequency in Hz through the formation of a reciprocal val-
ue and displayed. Specify the hysteresis limits of the switching
point in Hz as well.
2. Rotational speed measurement in rpm (factory preset)
Note!
If, when switching on again, the error message appears,
then the factory presets were loaded.

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KFU8-DW-1.D
Operation
The signal frequency calculated from the cycle duration is mul-
tiplied by 60 and displayed in rpm. Specify the hysteresis limits
of the switching point in rpm.
Pulse divider
(factory preset: 1 pulse/revolution)
Applications involving slow processes are frequently equipped with
sensors which provide several pulses per revolution. In the rotational
speed measuring function, the device undertakes the conversion to
the actual value of rpm by inputting the numerical value (of
pulses/revolution), i.e. both the indication and the input of the
hysteresis limits are obtained from the actual rate of rotation of the
drive.
Example:
In normal operation, a machine rotates at 450 rpm. An incremental
rotary encoder providing 10 pulses per revolution is used as the rate
of rotation sensing element.
The input frequency is:
A rate of rotation of
450 rpm x 10 pulses/revolution = 4500 rpmwould be displayed in the
rotational speed measuring function.
450 rpm x 10 pulses/revolution
60 s/min = 75 Hz

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Operation
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By programming the pulse divider to 10 pulses/revolution, the display
would indicate the actual drive speed of 450 rpm.
Display and measurement range
(factory preset: 0 ... 999,9)
Four measuring and display ranges are available for frequency
measurement and three measuring and display ranges are available
for speed measurement:
Example:
The maximum permissible rotational speed of the drive is 600.5 rpm.
The first two measuring ranges can be selected. However, in order to
fully utilize the accuracy of the display, it is recommended that the
second measuring range be used.
Display in
parameter
editor
Frequency
range in Hz
Speed range in
rpm
Number of
decimal places
0000 0 ... 9999 0
000.1 0,0 ... 999,9 1
00.02 0,0 ... 99,99 2
0.003 0,0 ... 9,999 ---- 3

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KFU8-DW-1.D
Operation
Message
This message appears when an attempt has been made to change
the range in such a way that previously input limiting values lie outside
the display and measuring range, or the respective places following
the decimal point would be cut off.
Example:
You have already entered the maximum permitted speed of
600.5 rpm as the upper hysteresis limit and are attempting to change
to the range 0.0 rpm ... 99.99 rpm (limit value outside of display and
measurement range).
Or:
You are attempting to change to the range 0 rpm ... 9999 rpm
(decimal point was removed).
Switching points of the output relay or
(factory preset: 100 or 200)
The output relay switching points are defined by the upper and lower
hysteresis limit. When the upper hysteresis limit O_Gr is exceeded, a
switching operation is triggered and on falling below the lower
hysteresis limit U_Gr, a switch back operation occurs. If a hysteresis
limit is not desired, enter the same value for both parameters. The
output relay then switches both on and off at a defined speed.