DP4122 - Speed controller IFM - Free user manual and instructions

USER MANUAL DP4122 IFM

Operating instructions

Speed monitor

DP4122

Contents

1 Preliminary note 4

1.1 Symbols used 4
1.2 Warnings.... 4
1.3 Safety symbol on the device 4

2 Safety instructions.... 5
3 Intended use.... 6
4 Function 7

4.1 Operating modes 7
4.2 Application as an IO-Link device 7

4.2.1 General information.... 7
4.2.2 Application example 8
4.2.3 IO Device Description (IODD) 8

4.3 Standard IO wiring 8
4.4 Function diagrams.... 9

4.4.1 Single point mode 9
4.4.2 Window mode 9
4.4.3 Two point mode 10
4.4.4 Deactivated mode 11
4.4.5 Standard IO mode.... 11
4.4.6 Switching delays 11
4.4.7 Switch-off delay.... 12

4.5 Start-up delay 12

5 Installation.... 13
6 Electrical connection.... 14

6.1 Input side 14
6.2 Connecting the device.... 14

6.2.1 Mounting the connector.... 15

6.2.1.1 Maximum cable length 15

7 Operating and display elements 16

7.1 LEDs.... 16
7.2 Display 16

8 Menu.... 17

8.1 General.... 17
8.2 Parameters adjustable via IO-Link 17

8.2.1 C.uni - customer-specific unit 17
8.2.2 FLASH_ON – activate flashing of the display 17
8.2.3 FLASH_OFF – deactivate flashing of the display 17
8.2.4 SSC counter – switching counter 17
8.2.5 internal_temperature – operating temperature microcontroller 17
8.2.6 operation hours – operating hours 17
8.2.7 Application-specific tag 17
8.2.8 Location tag 17
8.2.9 Function tag 18
8.2.10 ModE — switch point mode ..... 18
8.2.11 LoGc - switch point logic 18
8.2.12 SP1 — switch point 1.... 18
8.2.13 SP2 — switch point 2.... 18
8.2.14 HyS - switch points hysteresis 18
8.2.15 dS — switching delay.... 18
8.2.16 dr — switch-off delay 19
8.2.17 P-n - output configuration.... 19
8.2.18 Lo/Hi - min/max measured input values 19
8.2.19 dSt — start-up delay time.... 19
8.2.20 ScAL - set decimal point 19
8.2.21 C. FEP — custom user endpoint for frequency 19
8.2.22 PrSC – prescaler 20

8.2.23 coLr - display colours and colour changes 20
8.2.24 cFH/cFL — upper/lower value for colour change 21
8.2.25 diS.b - display power on. 21
8.2.26 diS. U — refresh rate of the displayed measured value.... 21
9 Operation 22
10 Troubleshooting 23
11 Maintenance, repair and disposal 24

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
Instructions
Reaction, result

[...] Designation of keys, buttons or indications

→ Cross-reference

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.

3 Intended use

The device is a pulse evaluation system. It monitors rotating, linear, vibrating or oscillating movements.

It 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.

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

1: Conveyor belt

3: DP4122

5: Transistor output / IO-Link

2: Pulse pick-up on the drive shaft

4: Transistor output (e.g. to control a light indicator, horn or relay)

6: Signals depending on the selected switching function

The device is suited for wet environments. Observe instructions in chapters "Installation" and "Electrical connection".

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

The unit is intended for indoor use only.

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

4 Function

Depending on the operating mode, the device displays the current frequency in Hz or the rotational speed in RPM. It generates output signals according to the operating mode and the parameter setting. In addition, it makes the process data available via IO-Link (in Hz or RPM, depending on the operating mode).

The device is designed for half-duplex communication. So the following options are possible:

• Remote display: reading and displaying the current frequency/speed
• Remote parameter setting: reading and changing the current parameter setting
• IO-Link parameter setting: IO Device Description (IODD) (→ 8)

4.1 Operating modes

The following operating modes are available:

Operating mode 1: HZ_M (default)
Description	Displays the frequency in Hz
Application	Standard applications with frequency measurement in Hz
IODD designation	DP4122 Factory setting / (CMPT=HZ_M)
IO-Link device ID	1167 d / 00 04 8f h
IO-Link parameter CMPT	HZ_M (default)

Operating mode 2: rpnM
Description	Displays the frequency in revolutions per minute (RPM)
Application	Converted values in RPM
IODD designation	DP4122_Status_B / (CMPT=rpnM)
IO-Link device ID	1294 d / 00 05 0e h
IO-Link parameter CMPT	rpnM

In operating mode 2, the display of the device always shows kRPM.

Selection of the operating mode via IO-Link interface:

▷ see document "Addition to the operating instructions: Selecting the operating mode using an IO-Link interface" at www.ifm.com

If the operating mode is changed, the parameters of the device are reset to the factory settings with the exception of CMPT.

4.2 Application as an IO-Link device

4.2.1 General information

The unit has an IO-Link communication interface which requires an IO-Link capable module (IO-Link master).

The IO-Link interface allows direct access to the process and diagnostic data and enables setting of the parameters of the unit during operation.

You will find further information about IO-Link and all the necessary information about the required IO-Link hardware and software at:

www.io-link.ifm

4.2.2 Application example

Fig. 2: Application example with IO-Link master

1: Conveyor belt and pulse pick-up 2: DP4122

3: Fully bidirectional IO-Link communication 4: IO-Link master - Remote parameter setting: reading and changing the parameter setting

5: Fieldbus (e.g. Profibus, Profinet etc.) 6: PLC

4.2.3 IO Device Description (IODD)

You will find the IODDs required for configuration of the IO-Link device as well as detailed information about the process data structure, diagnostic information and parameter addresses at documentation.ifm.com

4.3 Standard IO wiring

Switch points (standard IO mode) can also be used in combination with the standard inputs of a PLC. OUT1 and OUT2 can be switched to digital inputs (e.g. standard input modules). OUT1 and OUT2 can be evaluated via two digital inputs and implement a window function.

Voltage supply (pin 1 and 3) can be done via the input modules. With standard input modules, pins 1 and 3 are used for voltage supply ( → Electrical connection).

Fig. 3: Application example with a fieldbus system (e.g. AS-i)

1: Conveyor belt and pulse pick-up 2: DP4122

3: Digital outputs 4: Digital fieldbus module

5: Fieldbus (e.g. Profibus, Profinet etc.) 6: PLC

4.4 Function diagrams

4.4.1 Single point mode

Fig. 4: NO (IO-Link parameter LoGc: no / high active)

SP1: Overspeed: Reset point / underspeed: Switch point

SP1+H: Overspeed: Switch point / underspeed: Reset point

If a set rotational speed is not reached, this is signalled by the switching signal as open.

Fig. 5: NC (IO-Link parameter LoGc: nc / low active)

SP1: Overspeed: Reset point / underspeed: Switch point

SP1+H: Overspeed: Switch point / underspeed: Reset point

If a set rotational speed is not reached, this is signalled by the switching signal as closed.

1: Power-on delay time
3: normally open
2: Start-up delay
4: normally closed

4.4.2 Window mode

Fig. 6: NO (IO-Link parameter LoGc: no / high active)

SP1: Switch-on point window

SP1+H: Switch-off point

SP2: Switch-on point window

SP2-H: Switch-off point

If the set speed range is left, the switching signal will signal this as open.

Fig. 7: NC (IO-Link parameter LoGc: nc / low active)

SP1: Switch-off point window

SP1+H: Switch-on point

SP2: Switch-off point window

SP2-H: Switch-on point

If the set speed range is left, the switching signal will signal this as closed.

1: Power-on delay time
3: Normally open

2: Start-up delay

4: Normally closed

4.4.3 Two point mode

Fig. 8: NO (IO-Link parameter LoGc: no / high active)

SP1: Overspeed: Switch point / underspeed: Reset point
SP2: Overspeed: Reset point / underspeed: Switch point

If a set rotational speed is not reached, this is signalled by the switching signal as open.

Fig. 9: NC (IO-Link parameter LoGc: nc / low active)

SP1: Overspeed: Switch point / underspeed: Reset point
SP2: Overspeed: Reset point / underspeed: Switch point

If a set rotational speed is not reached, this is signalled by the switching signal as closed.

4.4.4 Deactivated mode

NO (IO-Link parameter LoGc: no / high active)

The switching signal is always signalled as open.

NC (IO-Link parameter LoGc: nc / low active)

The switching signal is always signalled as closed.

4.4.5 Standard IO mode

The yellow LEDs indicate the switching status of the unit.

Switching function NO:

transistor output	LED yellow	Description
Closed	on	Rotational speed > SP1 and during start-up delay
Open	off	Rotational speed < SP2

Switching function NC:

transistor output	LED yellow	Description
Closed	on	Rotational speed < SP2
Open	off	Rotational speed > SP1 and during start-up delay

4.4.6 Switching delays

The switching delay enables filtering of input signals. The switching delay is activated or restarted by a positive switching edge of the input signal. Only if the input signal is still active after the delay time has elapsed, the output will be set to the active switching state. Pulses that are shorter than the switching delay will be filtered.

4.4.7 Switch-off delay

The switch-off delay enables filtering of input signals. The switch-off delay is activated or restarted by a negative switching edge of the input signal. Only if the input signal is still inactive after the delay time has elapsed, the output will be set to the inactive switching state. Pulse pauses that are shorter than the switch-off delay will be filtered.

4.5 Start-up delay

The start-up delay enables the suppression of error signals when a plant is started. It is effective after the power supply is applied and is dependent on a low speed.

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, a start trigger point can be set in the process date or in SIO via ENABLE (Pin 2) via IO-Link. The positive switching edge of the corresponding signal serves as the start trigger point. In addition, the system can start up by itself; after detection of the first pulses the delay timer is started (value: 0...999.9 s in steps of 0.1 seconds).

5 Installation

ATTENTION

Higher shock ≥ IK06

▷ Damage possible
▷ Protection rating and, in wet environments, electrical protection might be impaired
▶ If necessary, the system creator must take external measures to protect the device depending on the requirements of the corresponding application.
▶ Replace damaged devices, otherwise the technical data and safety will be impaired.

The IP rating of the overall system depends on the protection ratings of the individual devices, the applied connection elements and the corresponding protective caps.

ATTENTION

No protection rating / no protection of the contacts without mounted connectors / protective caps.

▷ Inadmissible soiling / moisture possible.
▷ Disconnection of circuits / safety possibly impaired.
▷ Before installation / when replacing the device, maintain pollution degree 2.
▶ Disconnection / safety guaranteed.

▶ Connect the M12 connectors of the device ( → Electrical connection).
▶ Install the device so that the M12 connection parts and the device are protected from mechanical stress such as shock and vibration.
▶ If necessary, fix the device with cable ties.

The following applies to all types of mounting:

The responsibility for the compliance with the requirements concerning mounting of the device in the application with regard to shock, vibration, acceleration and weight lies with the system architect.

6 Electrical connection

The unit must be connected by a qualified electrician.

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

CAUTION

Use in wet environments

▷ Electric shock possible.
▶ Voltage derating required ( → Technical data).

The input and output circuits are insulated from each other and from device surfaces that could be touched with basic insulation according to IEC 61010-1 (secondary circuit with max. 32 V DC, supplied from the mains circuit up to 300 V of overvoltage category II).

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

6.1 Input side

Operating voltage (SELV/PELV)

CAUTION

The input current of the operating voltage is not limited.

▷ No fire protection.
▶ Protect the circuit.
▶ Protect the sensor supply via the same fuse.

Potential	M12 connector 1	Fuse
L+ / supply voltage	Pin 1	≤ 2 A

Required tripping characteristic of the fuse:

T_fuse ≤ 120 s at max. 6.25 A (fire protection)

▶ Alternatively supply the device via a limited energy circuit according to IEC 61010-1 or class 2 according to UL1310.

Output reaction to overload or short circuit:

For self-protection of the output in case of excessive thermal load (due to short circuit or overload), the output driver starts clocking. If a short circuit / overload continues for several hours, the driver may be damaged!

6.2 Connecting the device

▶ Disconnect power.
▶ Connect the unit as follows:

Fig. 10: Electrical connection

1: 4-pole M12 connector

• Pin 1: L+ / supply voltage
• Pin 2: OUT2 / digital output 2
• Pin 3: L- / supply voltage
• Pin 4: OUT1 / IO-Link (C/Q)

2: 5-pole M12 socket

• Pin 1: L+
  • Pin 2: ENABLE for start-up delay in SIO mode
• Pin 3: L-
  • Pin 4: IN1 / digital input 1
• Pin 5: not connected

The device must not be externally supplied via the 5-pole M12 socket ②.

Always use the provided connection cables to connect other devices.

See also application examples ( → Intended use)

6.2.1 Mounting the connector

The threaded connections in the device correspond to the M12 standard. To ensure compliance with the specified protection rating, only cables that comply with this standard may be used. In the case of self-assembled cables, the system manufacturer is responsible for the protection rating.

▶ Use connectors with gold-plated contacts.
▶ During installation, place the connectors vertically so that the coupling nut will not damage the thread.
▶ Observe the coding of the connectors during installation.

If connector in the device:

▶ Tighten the cable sockets according to the torque specifications indicated by the cable vendor. Maximum permissible tightening torque: 1.8 Nm

If sockets in the device:

▶ Tighten the cable plug using 1.3 ± 0.1 Nm.
▶ Provide all outgoing cables with suitable strain relief after a maximum of 200 mm. Observe the minimum bending radius of the cables ( → information from the cable manufacturer).

6.2.1.1 Maximum cable length

• Without IO-Link communication: 30 m on each side
• With IO-Link communication: 20 m on the master side

7 Operating and display elements

1: LED I
2: LED Power
3: LED II
4: Display

7.1 LEDs

LED		Colour	Status	Designation
I	OUT1	yellow	on	Output 1 switched.
Power		green	on	Voltage supply OK. Device in operating mode.
			off	No voltage supply. Device switched off.
II	OUT2	yellow	on	Output 2 switched.

Error signals and diagnostics: Troubleshooting

7.2 Display

Colour	Designation
Red/green	7-segment LED display, 4 digits, with colour change

Error signals and diagnosis: Troubleshooting

In the operating mode the input frequency is displayed. The display value is scaled automatically in the basic setting.

Operating mode 1:

Manual scaling via parameter [C. FEP] is activated by parameter [ScAL].

Manual scaling:

Display constraint to a step increment of 1 Hz.

Operating mode 2:

Process or parameter values with more than 4 digits cannot be fully displayed.

8 Menu

8.1 General

Irrespective of the operating mode (standard IO mode or IO-Link device), the device can be configured via an IO-Link tool.

Parameter cloning and parameter setting backup is possible with an IO-Link tool.

8.2 Parameters adjustable via IO-Link

The following functions or parameters are only available via IO-Link tools.

8.2.1 C.uni – customer-specific unit

Customer-specific unit with max. 4 characters.

8.2.2 FLASH_ON – activate flashing of the display

Used to identify a unit. Display flashes and shows [dEVC].

8.2.3 FLASH_OFF – deactivate flashing of the display

Deactivates the flashing of the display.

8.2.4 SSC counter – switching counter

Counts the state changes from low to high of the internal detection. Counter values are not saved permanently.

8.2.5 internal_temperature – operating temperature microcontroller

Reads the data from the internal temperature sensor of the microcontroller.

8.2.6 operation_hours – operating hours

Only counts full operating hours. Operating times of less than one full hour are not saved. Counter readings are saved permanently.

8.2.7 Application-specific tag

Customer-specific application description, max. 32 characters long.

Default value: “ *** ” / can be freely defined by the customer

8.2.8 Location tag

Customer-specific location tag of the unit, max. 32 characters long.

Default value: “ *** ” / can be freely defined by the customer

8.2.9 Function tag

Customer-specific function tag of the unit, max. 32 characters long.

Default value: “ *** ” / can be freely defined by the customer

8.2.10 ModE – switch point mode

Setting of the switch point mode.

• Single point mode ( → 9)
• Window mode (→ 9)
- Two point mode (→ 10)
• Deactivated mode ( → ☐ 11)

8.2.11 LoGc — switch point logic

Setting of the switch point logic: Function diagrams ( → ☐ 9).

• [High active] = switch is closed when activated.
• [Low active] = switch is opened when activated.

8.2.12 SP1 – switch point 1

Threshold for the upper switch point.

In "Single point mode" SP1 is adjustable over its entire value range. In "Two point mode" and "Window mode" the lower limit is restricted by SP2. It always applies: SP1 > SP2.

8.2.13 SP2 — switch point 2

Threshold for the lower switch point.

Only active in the switch point modes "Two point mode" and "Window mode".

In "Single point mode" the existing setting of SP2 is ignored. When changing to "Two point mode" or "Window mode", SP2 is automatically adjusted. It always applies: SP2 < SP1.

SP1 limits the maximum setting value of SP2. It always applies: SP2 < SP1.

8.2.14 HyS – switch points hysteresis

Setting of the hysteresis with respect to switch points SP1 and SP2: Function diagrams ( → ☐ 9).

Only active in the switch point modes "Single point mode" and "Window mode".

Setting range: 0.5...100 %

Resolution: 0.1 %

8.2.15 dS — switching delay

Delay when the output changes to the active switching status.

Setting range: 0...99.99 s

Resolution: 0.01 s

8.2.16 dr — switch-off delay

Delay when the output changes to the idle state.

Setting range: 0...99.99 s

Resolution: 0.01 s

8.2.17 P-n — output configuration

• [PnP] = load connected to ground
• [nPn] = load connected to VBB

8.2.18 Lo/Hi — min/max measured input values

[Lo] = lowest measured value

[Hi] = highest measured value

8.2.19 dSt — start-up delay time

Setting of the delay time between switch-on/reset of the unit and start of speed evaluation.

8.2.20 ScAL — set decimal point

Operating mode 1: Operating modes

• [OFF] = indication in Hz with automatic decimal point setting.
• [cccc] = indication without decimal place.
• [ccc.c] = indication with 1 decimal place.
• [cc.cc] = indication with 2 decimal places.
• [c.ccc] = indication with 3 decimal places.

With a fixed display screen ( [ScAL] ≠ OFF ) only the decimal point is set. No automatic scaling takes place.

C. FEP – custom user endpoint for frequency ( → 19)

If [ScAL] is set to [cccc], [ccc.c], [cc.cc] or [c.ccc], decimal places of the frequency-dependent process and parameter values cannot be displayed.

8.2.21 C. FEP — custom user endpoint for frequency

Settings for scaled display values.

The parameters are only displayed in operating mode 1 and when [ScAL] is set to [cccc], [ccc.c], [cc.cc] or [c.ccc].

All displayed frequency/speed values are interpolated based on a 2-point approximation. IO-Link process data and parameters are not influenced by scaling.

U(f) corresponds to the scaled value f corresponds to the value in Hz

1: Scaling factor 2
2: Scaling factor 1
3: Scaling factor 0.5

8.2.22 PrSC — prescaler

Setting of the number of targets. The number of targets is automatically included in the measured values.

Only active in operating mode 2.

8.2.23 coLr – display colours and colour changes

Assignment of the display colours "red" and "green" within the measuring range.

Fig. 11: Hysteresis function with [r1ou]

Fig. 12: Hysteresis function with [G1ou]

For b/w printouts: gn = green, rd = red

• [rEd] = continuously red (independent of the measured value).
- [GrEn] = continuously green (independent of the measured value).
• [r1ou] = red when OUT1 switches.
• [G1ou] = green when OUT1 switches.

Fig. 13: Window function with [r1ou]

Fig. 14: Window function with [G1ou]

For b/w printouts: gn = green, rd = red

[r-cF] = red when the measured value is between the values [cFL] and [cFH].

[G-cF] = green when the measured value is between the values [cFL] and [cFH].

8.2.24 cFH/cFL — upper/lower value for colour change

If [coLr] is set to [r-cF] or [G-cF]

▶ Select [cFH] and set the upper limit.
Setting range corresponds to the measured values. The lowest setting value is [cFL].

▶ Select [cFL] and set the lower limit.

Setting range corresponds to the measured values. The highest setting value is [cFH].

Fig. 15: Function [r-cF]

Fig. 16: Function [G-cF]

For b/w printouts: gn = green, rd = red

8.2.25 diS.b — display power on

• [OFF] = the measured value display is switched off in the operating mode.
- [On] = the measured value display is switched on in the operating mode.

8.2.26 diS. U — refresh rate of the displayed measured value

• [d1] = update of the measured values every 50 ms.
• [d2] = update of the measured values every 200 ms.
• [d3] = update of the measured values every 600 ms.

i

Even with an unsteady frequency, [d1] provides optimum readability.

9 Operation

After power on, the device is in the operating mode (SIO). It carries out its measurement and evaluation functions and provides output signals according to the set parameters.

10 Troubleshooting

Display	LED			Error	Troubleshooting
	I	Power	II
OFF	off	off	off	Supply voltage too low.	Check/correct the supply voltage: Electrical connection
SC	flashes	can differ	flashes	Excessive current at the switching output OUTx (see LED I/II).	Check switching output for short circuit or excessive current. Remove the fault.
OL	can differ	on	can differ	Process value too high (measured frequency > 5000 Hz / > 300000 RPM).	Check connected sensor and value range.
Rotating segment	can differ	can differ	can differ	Temperature in housing exceeds limit value.	Check the device temperature.

11 Maintenance, repair and disposal

The unit is maintenance-free.

▶ Carry out cleaning considering the technical data (protection rating) and the connection technology used.
▶ Cleaning agents must be checked by the system manufacturer / operator for their suitability for the device materials ( → Technical data) and the connection technology used.
▶ The cleaning agents must not damage the device materials.
▶ It is not possible to repair the unit.
▶ After use, dispose of the unit in an environmentally friendly way in accordance with the applicable national regulations.