DD0203 - Detector IFM - Free user manual and instructions

Product type	Speed controller (pulse evaluator)
Brand	IFM
Model	DD0203
Dimensions (L x H x D)	35.5 x 116 x 93 mm (approx.)
Weight	Approx. 150 g (estimate)
AC supply	110...240 V AC, 50...60 Hz, max. 6 W
Alternative DC supply	24 V DC (typ.), tolerance -20/+10 %, max. 4 W
Sensor supply	18.5...30 V DC SELV, ≤ 100 mA
Pulse input type	PNP (type 2 according to IEC 61131-2), max. frequency 5000 Hz
Relay output	Switching capacity 4 A (resistive load 240 V AC or 24 V DC), reinforced insulation
Transistor output	Voltage 10...30 V DC SELV, current ≤ 100 mA
SP threshold setting range	0.1...10 Hz or 10...1000 Hz (depending on model)
Hysteresis	1...100 %, adjustable
Start-up delay	0.1...15 s, adjustable
Switching functions	I (min. speed), II (under-speed), III (speed reached), IV (over-speed)
Protection	IP 20 (housing and terminals)
Ambient temperature	-25...+60 °C
Storage temperature	-25...+70 °C
Max. relative humidity	80 % (31 °C), linear decrease to 50 % (40 °C), non-condensing
Max. operating altitude	2000 m above sea level
Connection	4-pole terminal blocks pitch 5.0 mm, screw connector supplied (Phoenix Contact)
Mounting	DIN rail 35 mm
Maintenance	Maintenance-free; clean housing with a soft, dry cloth after switching off
Repairability	Repair only by manufacturer; unauthorized interventions void warranty
Safety	SELV, installation in enclosure IP 54 min.; not approved for personnel protection

Frequently Asked Questions - DD0203 IFM

What is the main function of the DD0203?

The DD0203 is a speed controller that evaluates pulses from an external sensor to monitor rotations, linear, pendulum or oscillating movements. It compares the measured frequency to set thresholds and switches the relay or transistor outputs accordingly.

How to power the device?

The power supply can be AC (110...240 V, 50/60 Hz on terminals 21/22 and 23/24) or DC (24 V typ. on terminals 1/2 and 3/4). Use only one source. External protection is required: 315 mA slow-blow fuse for DC.

What to do if the Power LED flashes?

The Power LED flashes if the Function potentiometer is in an invalid adjustment zone (between SPx1 and SPx100 positions). Turn the potentiometer to a valid position (gray area on the label).

How to connect a 3-wire PNP sensor?

Connect the brown wire (BN) to the +24 V terminal (5), the black wire (BK) to the pulse input (6), and the blue wire (BU) to 0 V (7). Terminals 5 and 7 provide the sensor supply (18.5...30 V DC, ≤ 100 mA).

What is the Enable input used for?

The Enable input (terminal 8) is used to start the start-up delay. Apply +24 V DC (internal terminal 5 or external) via a NO contact. When the contact opens, the delay starts. A permanent signal disables monitoring.

How to set the switching threshold and hysteresis?

Use the SP potentiometer to set the frequency threshold (Hz). The hysteresis (Hysteresis potentiometer) avoids rapid switching: set a percentage (1...100 %) of the SP value. Use a suitable screwdriver.

What switching functions are available?

Four functions: I (min. speed reached/stop), II (under-speed/blockage), III (rotation speed reached), IV (over-speed). Select via the Function potentiometer in position I, II, III or IV.

Can I use the device for safety applications?

No. The device is not approved for personnel protection. Its use is limited to machine monitoring without safety function.

How to clean the housing?

Switch off the device. Clean dirt with a soft, dry, chemically untreated cloth. Prefer a microfibre cloth without additives.

What to do in case of internal fault or short circuit?

If the Power LED is off and Output is on, there is a short circuit on the transistor output: eliminate it. If Power flashes and Input is off, there is over-speed or sensor short circuit. For an internal error, contact IFM after-sales service. Repairs must only be carried out by the manufacturer.

USER MANUAL DD0203 IFM

Operating instructions

Speed monitors

DD0203

DD0296

Contents

1 Preliminary note.... 3

1.1 Symbols used.... 3
1.2 Warnings.... 3
1.3 Safety symbol on the device 3

2 Safety instructions 4

2.1 Cybersecurity.... 4

3 Transport, handling and storage 5
4 Intended use 6
5 Installation.... 7

5.1 Removing the unit 8
5.2 Installation of the sensors 8

6 Electrical connection 9

6.1 Overview 9
6.2 General wiring information.... 9
6.3 Notes on wiring 10
6.4 Pluggable cage clamps 10
6.5 Voltage supply (power).... 11

6.5.1 AC voltage supply 11
6.5.2 DC voltage supply 11
6.5.3 External DC power supply for inputs and transistor output.... 11

6.6 Inputs.... 12

6.6.1 Connection of the sensor 12
6.6.2 Enable input.... 12

6.7 Outputs.... 12

6.7.1 Relay output.... 12
6.7.2 Transistor output 13

7 Operating and display elements.... 14

7.1 Potentiometer.... 14
7.2 LEDs 14

8 Settings.... 16

8.1 Frequency range and switching function.... 16

8.1.1 Frequency range (SPx1/SPx100) 16
8.1.2 Switching function I... IV 16

8.2 Switch point (SP).... 17
8.3 Hysteresis 17
8.4 Start-up delay.... 17
8.5 Switching diagram.... 18

8.5.1 With start-up delay and coupled voltage supplies 18
8.5.2 With start-up delay and Enable signal coupled to the motor 19

9 Troubleshooting.... 20

10 Maintenance, repair and disposal 21

10.1 Maintenance 21
10.2 Cleaning the housing surface 21
10.3 Repair 21
10.4 Disposal 21

1 Preliminary note

You will find instructions, technical data, approvals and further information using the QR code on the unit / packaging or at documentation.ifm.com.

1.1 Symbols used

Requirement
Instruction
Reaction, result

bold Designation of keys, buttons or indications

→ Cross-reference without link

→ Cross-reference with link

Important note

Non-compliance may result in malfunction or interference

Information

Supplementary note

1.2 Warnings

Warnings indicate the possibility of personal injury and damage to property. This enables safe product handling. Warnings are graded as follows:

WARNING

Warning of serious personal injury

▷ If the warning is not observed, fatal and serious injuries are possible.

CAUTION

Warning of minor to moderate personal injury

▷ If the warning is not observed, minor to moderate injuries are possible.

ATTENTION

Warning of damage to property

▷ If the warning is not observed, damage to property is possible.

1.3 Safety symbol on the device

Safety symbol on the device:

▶ Adhere to the operating instructions for the safe operation of the unit.

2 Safety instructions

- The unit described is a subcomponent for integration into a system.

• The system architect is responsible for the safety of the system.

• The system architect undertakes to perform a risk assessment and to create documentation in accordance with legal and normative requirements to be provided to the operator and user of the system. This documentation must contain all necessary information and safety instructions for the operator, the user and, if applicable, for any service personnel authorised by the architect of the system.

• Read this document before setting up the product and keep it during the entire service life.

• The product must be suitable for the corresponding applications and environmental conditions without any restrictions.
• Only use the product for its intended purpose (→ Intended use).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with the product or incorrect use by the operator.
• Installation, electrical connection, set-up, programming, configuration, operation and maintenance of the product must be carried out by personnel qualified and authorised for the respective activity.
• Protect units and cables against damage.
• Replace damaged units, otherwise the technical data and safety will be impaired.
• Observe applicable documents.

2.1 Cybersecurity

Installation

The device is suitable for operation in a secure environment according to IEC 62443-1-1.

▶ Carry out a risk assessment of the system according to IEC 62443-1-1.
▶ Take measures to ensure physical security. The device has no built-in protection against unauthorised access.

3 Transport, handling and storage

▶ Store the device in its original packaging.
▶ When the device is to be stored again, use the original packaging or pack the device in suitable packaging.
▶ Observe the permissible ambient conditions for the device during storage (→ Technical data).

WARNING

Storage without sufficient protection for pollution degree 2

▷ Risk of electric shock when connecting the device
▶ Store the device in its original packaging.
▶ Otherwise, ensure pollution degree 2 for the device during storage.

4 Intended use

This document applies to the devices DD0203 and DD0296. The devices differ in the setting range of the switch point SP [Hz] (see Switch point (SP) 17).

• DD0203: 0.1...1000 Hz
• DD0296: 0.2...2000 Hz

The device is a pulse evaluation system for monitoring rotating, linear, vibrating or oscillating movements.

Can be used in the control cabinet in an industrial environment (indoors) as a permanently installed device with supply from SELV or AC voltage according to the technical data.

The device receives the pulses from external sensors, measures the pulse interval and calculates the input frequency. This value is compared with the set switch points. The outputs are switched in accordance with the set parameters.

The output (relay) is used for direct control of contactors, smaller drives, valves, etc.

Operation by trained, authorised specialist personnel due to protection rating IP20.

The device is not suited for environments with particular requirements on mechanical stability (e.g. shock/vibration).

▶ Observe the operating conditions (→ Technical data at www.ifm.com).

Fig. 1: Example: speed monitoring of a drive shaft on a conveyor belt

1: Conveyor belt

3: DD0203 / DD0296

5: Transistor output

2: Pulse pick-up on the drive shaft

4: Relay output

6: Signals depending on the selected switching function

5 Installation

▶ Disconnect power.

To ensure correct operation, install the device in a housing that can only be opened using a tool or in a locked control cabinet (both protection rating IP 54 or higher) as an enclosure in accordance with EN61010-1.

Always comply with pollution degree 2 for the device.

▶ Install the device vertically on a 35 mm DIN rail.

Leave enough space ( ≥ 50 mm) between the device and the top and bottom of the control cabinet to enable air circulation and to avoid excessive heating.

ATTENTION

If units are mounted side by side, inadmissible heating may occur between the units.

▷ Malfunction / damage is possible.
▶ Take into account the internal heating of all devices when mounting different devices side by side and observe the environmental conditions for each device.

5.1 Removing the unit

5.2 Installation of the sensors

▶ Follow the manufacturer's installation instructions.

6 Electrical connection

6.1 Overview

Fig. 2: Wiring

Fig. 3: Terminal overview

All GND connections are internally connected with each other.

The terminals 1 and 2 are internally interconnected. The terminals 3 and 4 are internally interconnected. The terminals 21 and 22 are internally interconnected. The terminals 23 and 24 are internally interconnected.

6.2 General wiring information

The unit must be connected by a qualified electrician.

▶ Observe the national and international regulations for the installation of electrical equipment.

WARNING

Use of unconnected terminals

▷ Electric shock possible.
▶ Do not use unconnected terminals (n.c.) which are not shown in the drawing as support point terminals.
▷ Protection guaranteed.

Accessible surfaces of the device are insulated from the circuits with basic insulation according to IEC 61010-1 (mains circuit of overvoltage category II up to 300 V nominal mains voltage).

This does not apply to connection areas and cooling openings (IP20).

The AC voltage supply and relay circuit are insulated from the DC voltage supply and from each other with reinforced insulation according to IEC 61010-1 (mains circuit of overvoltage category II up to 300 V nominal mains voltage).

The external wiring has to be carried out in a way that ensures the required separation from other circuits.

6.3 Notes on wiring

Maximum length of the connection cables:

• 30 m at each terminal

It is recommended to lay all cables in the control cabinet in cable ducts.

Alternatively:

Provide all outgoing cables with suitable strain relief after a maximum of 400 mm. Observe the minimum bending radius of the cables (information from the cable manufacturer).

6.4 Pluggable cage clamps

ATTENTION

No IP 20 protection without connector.

▶ Cover unused connectors with terminals.
▷ Observe IP 20.

Stripping length for the supplied cage clamps: 9-10 mm

Connections that may carry mains voltage are colour-coded red on the pluggable cage clamps. This prevents them from being accidentally plugged on the SELV terminals.

Network terminals:

• AC supply (21...24)
• Out relay (17...20)

SELV terminals:

• DC supply (1...4)
• In/Enable (5...8)
  • Out transistor (13...16)

WARNING

Use of non-coded cage clamps for AC supply (21...24) and out relay (17...20)

▷ Cage clamps carrying mains voltage may be accidentally plugged onto SELV-terminals of the device.
▷ Electric shock possible.
▶ Only use the supplied coded cage clamps for network terminals.
▷ Protection guaranteed.

6.5 Voltage supply (power)

▶ Voltage supply see type label.
▶ Connect the device only to one of the possible voltage connections, either to terminals 21-22 and 23-24 (AC) or to terminals 1-2 and 3-4 (24 V DC).
▶ Lay all supply and signal cables separately. Use a screened cable if required in the application.

6.5.1 AC voltage supply

The device features an internal power supply that powers both the device and the connected sensors. There are two terminals each for L and N. The 2. terminal can be used to supply other devices with AC voltage. These terminals are bridged in the device, so unplugging will interrupt the supply to other devices.

The maximum current rating of the bridged terminals 21-22, 23-24 is 8 A.

WARNING

No internal protection of the bridged terminals 21-22, 23-24

▷ Risk of fire / electric shock due to overload / short circuit
▶ The system architect must provide external protection/limitation to 8 A in accordance with the applicable regulations
▷ Protection guaranteed

If the device is operated on an AC supply, the extra-low voltage provided for the sensor supply meets the SELV criteria according to IEC 61010-2-201.

6.5.2 DC voltage supply

▶ Comply with the SELV criteria for a DC power supply.
▶ The DC supply cable + (terminals 1/2) must be protected externally with a 315 mA time-lag fuse (5 x 20 mm or similar).
▶ The supply of the subsequent devices is not intended.

The DC supply terminals are directly connected to the sensor supply terminals.

6.5.3 External DC power supply for inputs and transistor output

The inputs and the transistor output can optionally be operated via an external +24 V DC power supply.

WARNING

No internal protection of inputs and transistor output

▷ Potential fire hazard
▶ The system architect must provide external protection/limitation to 315 mA in accordance with the applicable regulations
A common fuse for inputs and outputs is permitted.
▷ Protection guaranteed

▶ Connect the reference point (GND) of the external power supply with terminal 15 or 3/4 of the device. Otherwise no switching operation is possible.
▶ The SELV criteria must be observed for external voltage supply.

6.6 Inputs

6.6.1 Connection of the sensor

3-wire DC PNP

2-wire DC quadronorm

2-wire AC/DC

2-wire AC/DC

BN: brown

BU: blue

BK: black

WH: white

The connection of mechanical switch contacts is not recommended since they tend to bounce and produce faulty pulses.

The terminals 5 and 7 can be used for the sensor supply or for the enable input.

6.6.2 Enable input

Using the enable input (terminal 8) the start-up delay can be started.

▶ The internal +24 V DC voltage (terminal 5) or an external +24 V DC voltage is connected to terminal 8 via a closing contact.

When the contact is open (+24 V DC no longer applied) and the set start-up delay has elapsed monitoring starts.

A +24 V DC continuous signal results in a permanent deactivation of the monitoring.

6.7 Outputs

The relay and transistor output have the same switching status.

6.7.1 Relay output

Relay for general use according to IEC 61010-2-201.

WARNING

No internal protection of the relay output

▷ Risk of fire / electric shock due to overload / short circuit
▶ The system architect must provide external protection/limitation to 6 A in accordance with the applicable regulations
▷ Protection guaranteed

▶ To prevent excessive wear and to comply with the EMC standards, interference suppression of the contacts is required for switching inductive loads.

WARNING

Connection of different AC phase conductors to the AC power supply and relays

▷ Electric shock possible
▶ Connect the same phase conductor to the AC voltage supply and the relay.
▷ Protection guaranteed

If the relay output is used to switch very small currents (e.g. PLC inputs), considerable contact resistance can arise. In this case use the transistor outputs for DC.

6.7.2 Transistor output

The transistor output needs an external +24 V DC supply on terminal 13 (see External DC power supply for inputs and transistor output ➞ 11).

The transistor output is only intended for resistive loads. Do not connect any inductive loads.

7 Operating and display elements

Fig. 4: Example: DD0203 with switch point range 0.1...10 Hz and 10...1000 Hz

1: LEDs
2: Potentiometer
3: Panel for labelling

7.1 Potentiometer

Potentiometer	Setting
Function	Frequency range [SPx1/SPx100](Frequency range (SPx1/SPx100) ➕ 16)
	Switching function [I... IV](Switching function I... IV ➕ 16)
SP	Switch point [Hz] The adjustable frequency value depends on the potentiometer position Function.(Switch point (SP) ➕ 17)
Hysteresis	Hysteresis [%](Hysteresis ➕ 17)
Delay	Start-up delay [s](Start-up delay ➕ 17)

7.2 LEDs

LED	Colour	State	Description
Power	green	On	Voltage supply OK
		Flashing	Potentiometer Function in invalid setting range (see Frequency range and switching function 16) or short circuit/overload on sensor supply
Input	yellow	Flashing	Input pulses
Output	green	On	Relay energised Transistor switched
Enable	yellow	On	Enable input switched (+24 V DC is applied to the Enable input)Start-up delay is active

Error signals and diagnostics under Troubleshooting ➞ 20

8 Settings

▶ Set the continuously adjustable potentiometers using a suitable screwdriver.

8.1 Frequency range and switching function

Fig. 5: Potentiometer "Function"

□ Valid setting zone

- Invalid setting zone

▶ Make sure that the setting of the potentiometer is within a valid zone.
▷ If the setting is outside a valid zone, [POWER] flashes.

8.1.1 Frequency range (SPx1/SPx100)

SPx1: corresponds to the device label

SPx100: corresponds to the device label x 100

8.1.2 Switching function I IV

I	Signalled state: minimum rotational speed reached / standstill
	Relay energises (transistor output switched) when the current value is below the switch point.
	If the input frequency increases again, the relay switches back when the current value is above the switch point + hysteresis (SP+HY). The relay is de-energised during the start-up delay and as long as the input frequency is greater than the set switch point.
II	Error signal: underspeed / blocked
	Relay de-energises (transistor output blocked) when the current value is below the switch point.
	If the input frequency increases again, the relay switches back when the current value is above the switch point + hysteresis (SP+HY). The relay is energised during the start-up delay and as long as the input frequency is greater than the set switch point.
III	Signalled state: rotational speed reached
	Relay energises (transistor output conductive) when the current value is above the switch point.
	If the input frequency decreases again, the relay switches back when the current value is below the switch point - hysteresis (SP-HY). The relay is de-energised during the start-up delay and as long as the input frequency is smaller than the set switch point.
V	Error signal: overspeed
	Relay de-energises (transistor output blocked) when the current value is above the switch point.
	If the input frequency decreases again, the relay switches back when the current value is below the switch point - hysteresis (SP-HY). The relay is energised during the start-up delay and as long as the input frequency is smaller than the set switch point.

Switching function in combination with switch point, hysteresis and start-up delay: Switching diagram 18

8.2 Switch point (SP)

Value at which the output changes its switching status according to the switching function.

Value DD0203: 0.1...10 Hz or 10...1000 Hz (depending on potentiometer position SPx1/SPx100)

Value DD0296: 0.2...20 Hz or 20...2000 Hz (depending on potentiometer position SPx1/SPx100)

8.3 Hysteresis

The hysteresis value determines the difference between the switch-off point and the switch point. If the distance between cams is not the same, different pulse sequence times are measured. They may be alternately above or below the switch point so that the output changes its switching status continuously and rapidly. This behaviour can be prevented by increasing the hysteresis factor.

Value: 1...100 %

8.4 Start-up delay

Enables the suppression of error signals when a plant is started. After power on the start-up delay is active only once.

If the drive is frequently switched on and off, it is advisable to couple the voltage supplies of the drive and the speed monitor. By doing so, the start-up delay is active every time the motor is turned on.

If a coupled connection of the voltage supplies is not possible, use the Enable input: Enable input ➞ 12.

Value: 0.1...15 s

8.5 Switching diagram

8.5.1 With start-up delay and coupled voltage supplies

1: Speed monitor supply voltage (coupled to the motor)
2: Start-up delay
3: Switching functions (see Switching function I... IV 16)
A: Input frequency as an indication of (rotational) speed
B: Time

Relay energised, i.e. switched (transistor output switched)

8.5.2 With start-up delay and Enable signal coupled to the motor

1: Voltage supply speed monitor

2: +24 V DC signal at the Enable input (coupled to the motor)

3: Start-up delay

4: Switching functions (see Switching function I... IV 16)

A: Input frequency as an indication of (rotational) speed

B: Time

Relay energised, i.e. switched (transistor output switched)

9 Troubleshooting

LED				Error	Troubleshooting
Power	Input	Output	Enable
	--	○	--	Rotary switch Function in invalid setting zone	Correct the rotary switch position.(Frequency range and switching function 16)
				Short circuit at sensor supply	Remove the short circuit.
				Overspeed	Check whether the input frequency is outside the permissible frequency range.
	--	●	--	Short circuit at transistor output	Remove the short circuit.
○	--	○	●	Internal device error	Contact service

Legend:

○ Off

- On

Flashing

-- any

10 Maintenance, repair and disposal

10.1 Maintenance

The unit is maintenance-free.

10.2 Cleaning the housing surface

▶ Disconnect the device from the voltage supply.
▶ Clean the device from dirt using a soft, chemically untreated and dry micro-fibre cloth.

10.3 Repair

▶ The device must only be repaired by the manufacturer. Observe the safety instructions ( → 2 Safety instructions).

10.4 Disposal

▶ After use, dispose of the unit in an environmentally friendly way in accordance with the applicable national regulations.