FACTORY AUTOMATION

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

With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the Electrical Indus-
try, published by the Central Association of the Electrical Industry (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

1 Introduction................................................................................. 4

2 Declaration of conformity .......................................................... 5

3 Safety ........................................................................................... 6
3.1 Symbols relevant to safety.................................................................. 6
3.2 Intended use......................................................................................... 6
3.3 General safety instructions ................................................................. 6

4 Product Description ................................................................... 7

4.1 Device description ............................................................................... 7

5 Operation..................................................................................... 9
5.1 Operating mode ................................................................................... 9
5.2 Setup mode ........................................................................................ 10
5.3 Timer functions, reversing the detection direction of the output
relay ..................................................................................................... 11

6 Service and Maintenance ........................................................ 14

7 Appendix ................................................................................... 15
7.1 Technical data..................................................................................... 15
7.2 Terminal assignment ......................................................................... 17
7.3 Dimensions, operating and display devices ................................... 17
7.4 Connection diagram .......................................................................... 18
7.5 Functional description....................................................................... 19

3
 KFU8-DW-1.D
Introduction

1 Introduction
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.

Symbols used
The following symbols are used in this manual:

Note!
This symbol brings important information to your attention.

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: +49 621 776-4411
Fax: +49 621 776-274411
E-Mail: fa-info@pepperl-fuchs.com
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 KFU8-DW-1.D
Declaration of conformity

2 Declaration of conformity
This product was developed and manufactured under observance of the applicable European
standards and guidelines.

Note!
A Declaration of Conformity can be requested from the manufacturer.

The product manufacturer, Pepperl+Fuchs GmbH, D-68307 Mannheim, has a certified quality
assurance system that conforms to ISO 9001.

ISO9001
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 KFU8-DW-1.D
Safety

3 Safety
3.1 Symbols relevant to safety
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or 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 possible fault.
Non-observance could interrupt devices and any connected facilities or systems, or result in
their complete failure.

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.
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.
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 KFU8-DW-1.D
Product Description

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.

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.

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.
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 V DC power supply.
When an alternating voltage is connected, a 24 V DC source is available for the sensor.

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 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
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.

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 KFU8-DW-1.D
Operation

5 Operation
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.

Note!
Select a wider measurement range.

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.

Error message

Note!

If, when switching on again, the error message appears, then the factory presets were
loaded.

1. Enter the parameters again.

2. Switch the device off and back on again.
The normal function of the output relay is restored.
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 KFU8-DW-1.D
Operation

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 value and displayed. Specify the hysteresis limits of
the switching point in Hz as well.
2. Rotational speed measurement in rpm (factory preset)
The signal frequency calculated from the cycle duration is multiplied 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:

450 rpm x 10 pulses/revolution
= 75 Hz
60 s/min

A rate of rotation of 450 rpm x 10 pulses/revolution = 4500 rpm would be displayed in the
rotational speed measuring function.

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:

Display in parameter Frequency range in Number of decimal

editor Hz Speed range in rpm 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

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
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recommended that the second measuring range be used.

10
 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.
Example:
On exceeding the maximum permissible rotational speed of 600.5 rpm signal should be
activated in the control room. The alarm message should then extinguish when the speed
drops below 500 rpm.
Set the upper hysteresis limit to 600.5 rpm and the lower hysteresis limit to 500 rpm.

Message or
The message GrU? appears if an attempt is made to set a value for the upper hysteresis limit
which is lower than the lower hysteresis limit. The message GrO? appears if an attempt is
made to display a value for the lower hysteresis value which is greater than the upper
hysteresis limit.

5.3 Timer functions, reversing the detection direction of the output relay

Time base for the timer functions

(factory preset: 1.0 s)
A time between 0.1 s and 999.9 s can be set for the timer function of the output relay.

Timer function and reversing the detection direction

(factory preset: 0)
The KFU8-DW-1.D rotational speed monitor in combination with a reversal of the direction of
action can be adjusted to any one of 10 different settings in order to modify the switching
behavior of the output relay. In functions 0 to 4, the output relay is active according to the
selected time function when the upper hysteresis value is exceeded. In functions 5 to 9, the
detection direction is inverted, i.e. the relay is active below the lower hysteresis limit.

No. Function No. Function

0 No timer function 5 No timer function, inverted
1 ON delay 6 ON delay, inverted
2 OFF delay 7 OFF delay, inverted
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3 Defined ON time 8 Defined ON time, inverted

4 Pulse extension 9 Pulse extension, inverted

11
 KFU8-DW-1.D
Operation

The ON delay causes the timer to start when the upper hysteresis limit is exceeded and the
relay to trigger (retriggerable) only when the timer has run out.
The OFF delay causes the relay to operate immediately after the upper limiting value is
exceeded. Each time the measured parameter falls below the lower limit, the timer is started
and as soon as the timer runs out the relay switches off (retriggerable).
defined ON time implies that the relay operates when the upper hysteresis limit is exceeded
and switches off again after the preset time (not retriggerable) independently of further
variations in rpm.
Pulse extension ensures that the relay operates when the upper limit is exceeded and
switches off again as soon as the preset time (not retriggerable) elapses. see Figure 5.1 on
page 13

Startup override
(factory preset: 1.5 s)
A startup override time between 0.1 s and 999.9 s can be programmed in order to avoid false
signals on the start-up of a drive that is being monitored for underspeed. During this time the
device and the output relay behave as if the machine had already exceeded the upper
hysteresis limit.
The startup override time is started by a positive signal on terminal 2; the positive signal must
be at least as long as the override time. The start signal can originate from a higher order
control, or be generated by the connection of the power supply to the rotational speed monitor.
In the latter case, terminals 2 and 3 have to be bridged.
Example:
In normal operation, a machine requires a maximum of 50 s to run up to a nominal speed of
500 rpm. Set the startup override time to a value greater than 50 s. When the period of 50 s has
elapsed, the underspeed monitoring function (relay function 5) is active. If the startup runs
according to plan within this time, the relay will not have actuated.
If the startup takes longer than anticipated, then the relay will switch 50 s after commencement
of the startup override, until the upper hysteresis limit has been reached.

Display rate
(factory preset: 0.33 s)
In order to ensure good readability of the display, the time taken to indicate the current
measured value in the display can be selected between 0.01 s and 2.5 s.

Note!
The display rate influences neither the time required to calculate the measured value nor the
switching characteristics of the output relay.

Software version number

Note!
You can only read out the version number of the software.
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 KFU8-DW-1.D
Operation

t Start-up

0
0

1
0
t Relais t Relais
1

2
0
t Relais t Relais
1

3
0
t Relais t Relais
1

4
0
t Relais t Relais
1

5
0

6
0
t Relais t Relais
1

7
0
t Relais t Relais
1

8
0
t Relais t Relais
1

9
0
t Relais t Relais
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Figure 5.1 Timer functions, reversal of direction of action of the output relay

13
 KFU8-DW-1.D
Service and Maintenance

6 Service and Maintenance

The device is designed and constructed to function stable over long periods of time. For this
reason, regular cleaning or maintenance is unnecessary.

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 KFU8-DW-1.D
Appendix

7 Appendix
7.1 Technical data
Power supply
Rated voltage 196 ... 250 VAC, 47 ... 63 Hz, (Term. 16, 18)
98 ... 127 VAC, 47 ... 63 Hz, (Term. 17, 18)
20,4 ... 28 V DC, Uss =10 %, (Term. 4, 5)
Fusing external fusing 4 A
Power consumption < 5 VA (Term. 16, 18)
< 5 VA (Term. 17, 18)
< 5 W (Term. 4, 5)

Display/controls
Type 4-digit 7-segment display, red, 7 mm digit height
Display area: 0,002 ... 9999 Hz or 0.01... 9999 rpm
Parameter assignment Keypad menu guidance

Switching state LED yellow, 3 mm

Input 1
Connection Terminals 8-, 9+
Connectable sensor types NAMUR sensors in accordance with DIN EN 60947-5-6
Open loop voltage 8.2 V DC
Short-circuit current 6.5 mA
Switching point 1,2 ... 2.1 mA, switching hysteresis about 0.2 mA
Impedance 1.2 k

Input frequency 0,002 ... 10000 Hz, pulse pause/duration:  20 s

Input 2
Connection Terminals 7+, 13- sensor supply
Terminals 14, 15 npn/pnp input (galvanically isolated)
Connectable sensor types Two, three or four-wire proximity switches, incremental rotary
encoders or externally generated pulses 16 ... 30 V
Sensor supply voltage 19 ... 28 V DC not stabilized; 30 mA short-circuit proof
Switching point high: 16 ... 30 V DC; max. 10 mA by way of an integral voltage
current sink; R i  3 k
low: 0 ... 6 VDC

Input frequency 0,002 ... 40000 Hz, puls pause/duration:  12 s

Input 3
Startup override Triggered by an external signal 16 ... 30 V (Term. 1-, Term. 2+)
or by switching on bridge terminal 2/3
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or by switching on the supply voltage (Term. 2 and Term. 3

continuously bridged)
Bridging delay 0,1 ... 999.9 s (external triggering signal)

15
 KFU8-DW-1.D
Appendix

Output
Relay 1 changeover contact NO (Term. 10), NC (Term. 11), COM
(Term. 12)
Contact loading 250 VAC / 2 A / cos?  0.7
40 V DC / 2 A
Delay  20 ms (inc. computing time)
Mechanical service life  30,000,000 switching cycles
Timer function ON delay, OFF delay, defined ON time, pulse expansion
Time 0 ... 999.9 s direction detection reversible

Transfer characteristics
Measuring error
Changing interval
Time delay before availability
0 ... 40000 Hz:  ±0.1%
Display: ±1 digit
5 ms (internal processing time)
 400 ms

Ambient conditions
Ambient temperature
Storage temperature
Relative humidity
Altitude
Operating conditions
-25 ... 50 °C (248 ... 323 K)
-40 ... 85 °C (233 ... 358 K)
5 - 95%, non-condensing
0 - 2000 m
The device is for indoor use only

Conformity
Electromagnetic compatibility EN 50081-2, EN 50082-2

Mechanical data
Degree of protection IP20
Connection Coded, removable terminals, core cross-section:  0.34 ... 2.5
mm 2
Design Modular terminal housing in Makrolon, system KF
Mounting Snap-on to 35 mm DIN mounting rail according to DIN
EN50022 or screw fixing by means of extendable latches in 90
mm grid
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 KFU8-DW-1.D
Appendix

7.2 Terminal assignment

Term. 1: Sensor power supply Term. 10: Relay, normally open contact
GND NO
Term. 2: Trigger input for startup Term. 11: Relay, normally closed contact
override NC
Term. 3: Sensor power supply Term. 12: Relay root
+24 V DC COM
Term. 4: Power supply Term. 13: Sensor power supply
+ 24 V DC GND
Term. 5: Power supply Term. 14: NPN input
GND - (cathode)
Term. 6: Not connected Term. 15: PNP input
+ (anode)
Term. 7: Sensor power supply Term. 16: Power supply
+ 24 V DC L1, 230 VAC
Term. 8: NAMUR input Term. 17: Power supply
L- L1, 115 VAC
Term. 9: NAMUR input Term. 18: Power supply
L+ N, AC

7.3 Dimensions, operating and display devices

115

Yellow LED,
Relay switch
state indication

1 2 3 4 5 6
Drehzahlwächter
Output Speed monitor

7-segment-display

Mode +

107
93

Control keys Enter –

PEPPERL+FUCHS GERMANY
7 8 9 10 11 12
13 14 15 16 17 18

"Mode" and "+": Start parameter editor

"+": Advance to next parameter selection or increase the value of
the flashing digit
"-": Advance to next parameter selection or decrease the value of
the flashing digit
"Mode": Display parameter value (right digit flashes) or shift the
flashing digit to the left
"Enter": Exit parameter value display, the device now operates
temporarily with the altered parameter.
"Enter" and "+": Exit parameter editor, the parameters are now stored in the
EEPROM in a non-volatile manner.
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 KFU8-DW-1.D
Appendix

7.4 Connection diagram

NAMUR NAMUR
Sensor Encoder
L+ L+ 9
9 9 NAMUR L+
8 8 8
L– L– NAMUR L-
DC-3-wire DC-3-wire
Bridge fitted:
sensor, PNP sensor, NPN start-up bypass triggered by
L+ 7 L+ 7 switching on the power supply
15 15 Sensor power
14 14
L– 13 supply 24 V DC 3
L– 13 7 Sensor power
supply 24 V DC External trigger signal
DC-2-wire DC-2-wire
sensor, PNP sensor, NPN 15 Trigger input for
L+ 7 L+ 7 Galvanically isolated start-up bypass 2
15 15 input
14
14 14 Sensor power
L– 13
L– 13 supply GND 1
13 Sensor power
Encoder, Encoder,
push-pull push-pull supply GND
L+ 7 L+ 7
15 15
14 14
13
L– 13 L–
External
rectangular signal
16-30 V L+ 6
15 Not connected
14
0V L–
4
L+ COM 12
Power supply 24 V DC
5
L- NC 11
yellow Relay output
16 10
L1 (230 V) NO
Power supply 230 V AC 18
N
Power supply 115 V AC
17
L1 (115 V)

Figure 7.1 Connection diagram

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 KFU8-DW-1.D
Appendix

7.5 Functional description

Operating mode

X=0: frequency measurement 0.002 Hz ... 40000 Hz

X=1: rotational speed measurement 0.01 rpm ... 9999 rpm
Preset at the factory: X=1

Number of pulses per revolution for rotational speed

measurement (will be ignored for frequency measurement)
1 ≤ XXXX ≤ 1200
Preset at the factory: XXXX=1

Measuring and display range

Frequency measurement: 0 ≤ X ≤ 3
Rotational speed measurement: 0 ≤ X ≤ 2
Preset at the factory: X=1

X Frequency range Rotational speed

in Hz in rpm
0000 0 ... 9999
000.1 0.0 ... 999.9
00.02 0.0 ... 99.99
0.003 0.0 ... 9.999 —

Lower hysteresis limit of switching point

0 ≤ XXXX ≤ 9998 (depending on the measuring range)
Preset at the factory: XXXX=100

Upper hysteresis limit of switching point

0.001 ≤ XXXX ≤ 9999 (depending on the measuring range)
Preset at the factory: XXXX=200

Period for the timer function of switching relay

0.1 s ≤ XXX.X ≤ 999.9 s
Preset at the factory: XXX.X=1.0 s

Timer function of switching relay

Preset at the factory: X=0
X Function
0 No timer function
1 ON delay
2 OFF delay
3 Defined ON time
4 Pulse lengthening
5 No timer function, inverted
6 ON delay, inverted
7 OFF delay, inverted
8 Defined ON time, inverted
9 Pulse lengthening, inverted

Start-up bypass
0.1 s ≤ XXX.X ≤ 999.9 s
Preset at the factory: XXX.X=1.5 s

Display rate
0.01 s ≤ XX.X ≤ 2.5 s
Preset at the factory: XX.X=0.33 s

The number of the software version

can be read only.

Figure 7.2 Graphic function description

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FACTORY AUTOMATION –
SENSING YOUR NEEDS

Worldwide Headquarters
Pepperl+Fuchs GmbH
68307 Mannheim · Germany
Tel. +49 621 776-0
E-mail: info@de.pepperl-fuchs.com

USA Headquarters
Pepperl+Fuchs Inc.
Twinsburg, Ohio 44087 · USA
Tel. +1 330 4253555
E-mail: sales@us.pepperl-fuchs.com

Asia Pacific Headquarters

Pepperl+Fuchs Pte Ltd.
Company Registration No. 199003130E
Singapore 139942
Tel. +65 67799091
E-mail: sales@sg.pepperl-fuchs.com

www.pepperl-fuchs.com
Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany 129506 / TDOCT0610C_ENG
12/2012