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Knick P168 2 Series User Manual

Universal speed signal doubler
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P168*2
Universal Speed Signal Doubler
www.knick-international.com

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Summary of Contents for Knick P168 2 Series

  • Page 1 P168*2 User Manual incl. Safety Manual Universal Speed Signal Doubler Read before installation. www.knick-international.com Keep for future use.

  • Page 2: Supplemental Directives

    P168*2 Supplemental Directives READ AND SAVE THIS DOCUMENT FOR FUTURE REFERENCE. BEFORE ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN THE PRODUCT, PLEASE ENSURE A COMPLETE UNDERSTANDING OF THE INSTRUC- TIONS AND RISKS DESCRIBED HEREIN. ALWAYS OBSERVE ALL SAFETY INFORMATION. FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS DOCUMENT COULD RESULT IN SERIOUS INJURY AND/OR PROPERTY DAMAGE.

  • Page 3: Table Of Contents

    P168*2 Table of Contents 1 Safety............................. 1.1 Intended Use ................................. 1.2 Personnel Requirements ........................... 1.3 Isolation ................................... 1.4 Installation and Operation..........................1.5 Residual Risks ................................ 2 Product ............................2.1 Package Contents ..............................2.2 Product Identification............................2.2.1 Example Design ............................2.2.2 Product Code ............................2.2.3 Nameplate ..............................
  • Page 4 P168*2 7 Decommissioning......................... 38 7.1 Removal................................... 38 7.2 Return Delivery ..............................40 7.3 Disposal ................................... 40 8 Accessories ............................ 41 9 Dimension Drawings ........................42 10 Specifications..........................43 10.1 Limit Values ................................43 10.2 Recommended Operating Conditions ......................43 10.3 Input ..................................44 10.3.1 Reference Voltage ..........................
  • Page 5 P168*2 12 Safety Manual ..........................55 12.1 General Description ............................55 12.2 Safety and Safety Integrity Level Requirements..................56 12.2.1 Functional Safety Requirements....................... 56 12.2.2 Safety Integrity Requirements......................56 12.3 SRACs for System Project Planning and Structure, as well as Operation, Maintenance and Safety Monitoring ..............................

  • Page 6: Safety

    This document contains important instructions for the use of the product. Always follow all instruc- tions and operate the product with caution. If you have any questions, please contact Knick Elektronische Messgeräte GmbH & Co. KG (hereinafter sometimes referred to as “Knick”) using the information provided on the back page of this document.

  • Page 7: Personnel Requirements

    • The product must be installed by qualified electrical engineering personnel. • The product may not be opened, modified, or independently repaired. Replace it with an equiva- lent product. Repairs may only be carried out by Knick. • The operating company must ensure compliance with the specified interface parameters and ambient conditions.

  • Page 8: Product

    ◦ For 1-channel device: 3 units ◦ For 2-channel device: 6 units • Test Report 2.2 according to EN 10204 • Installation Guide with safety instructions Note: The user manual (this document) is published electronically. knick-international.com ➜ 2.2 Product Identification 2.2.1 Example Design Speed Signal Doubler Input pulses/output pulses 2 inputs →...

  • Page 9: Product Code

    P168*2 2.2.2 Product Code P16800 Product Family P 1 6 _ _ _ P _ _ / _ _ _ _ _ _ _ Input pulses/output pulses 1 input → 1 output 2 inputs → 2 outputs 2 inputs → 2 outputs, configurable as DOT (direction of travel), frequency division 1:1 or 2:1 or 4:1 with retention of 90°...

  • Page 10: Nameplate

    P168*2 2.2.3 Nameplate The P168*2 is identified by nameplates on the side and front of its housing. The information on the nameplates varies depending on the version of the product. Product Code, p. 9 ➜ 1-Channel Speed Signal Doubler P16812 Example: P16800 Series Universal Speed Signal Doubler...
  • Page 11 P168*2 2-Channel Speed Signal Doubler P16822 Example: 1 Nameplate, device front 18 DIP switch output 1 2 Nameplate, device side 19 DIP switch input 1 3 Manufacturer 20 Two-tier terminal 4 4 LED (2×) channel 1 21 Connection diagram input 1 and 2 from sensor 5 Meaning of LED display 22 Two-tier terminal 5 6 LED (2×) channel 2...

  • Page 12: Symbols And Markings

    European Union. UL Listed: Combined UL mark for Canada and the United States The symbol on Knick products means that waste devices must be disposed of separately from unsorted municipal waste. Square-wave signal, high level...

  • Page 13: Design

    P168*2 2.4 Design 1 Metal foot catch 7 LED (2×) channel 2 (if present) 2 Side (with nameplate) 8 LED (2×) channel 1 3 Two-tier terminal 1 9 Two-tier terminal 4 4 Two-tier terminal 2 10 Two-tier terminal 5 5 Two-tier terminal 3 11 Two-tier terminal 6 6 Device front (with nameplate) 12 DIP switch...

  • Page 14: Functional Description

    P168*2 2.5 Functional Description The P168*2 universal speed signal doubler multiplies speed sensor signals or binary status signals by non-interacting decoupling. It records the pulses and transmits them to the output after electrical iso- lation, thus fulfilling SIL 2 specifications. The inputs process the sensor signals in a non-interacting manner and thus fulfill SIL 4 specifications.

  • Page 15: Input/Output

    P168*2 2.6 Input/Output Speed sensors with voltage output and current output can be connected to inputs U or I of the P168*2. Speed Sensor with Voltage Output For speed sensors with voltage output, the P168*2 with its voltage reference input U is connected with the sensor power supply (4).
  • Page 16 P168*2 Speed Sensor with Current Output For speed sensors with current output (1), each of the two sensor outputs is connected with one input each (I ) (3), of the P168*2. The GND of the P168*2 is connected with the negative connec- tion of the sensor power supply (4).
  • Page 17 P168*2 Output Circuit of a Channel of P168*2 1 Internal voltage converter 3 Switch output for status signaling 2 Output driver for current and voltage P168*2 is supplied with power through the V connection and GND (supply not shown in the figure). The output of the P168*2 has two supply connections: V and U .

  • Page 18: Voltage Supply

    P168*2 2.7 Voltage Supply The P168*2 is supplied by channel via the output circuit. The output circuits and, with them, the asso- ciated galvanically isolated input circuits are supplied via terminal V or U . The power supplies of channels 1 and 2 are galvanically isolated. P168*2 can be supplied with a downstream controller or an additional power supply unit.
  • Page 19 P168*2 Supply via the Controller at Connections V and U If a high level is required at the inputs of the controller, U must be connected. Current output Current input Voltage output Voltage input...
  • Page 20 P168*2 Additional Power Supply via External Power Supply Unit at Connection V For supply via controller, the available currents are usually limited. If the permitted current is ex- ceeded, the controller can display an error message. To prevent this, an additional power supply can be used to supply V Current output Current input...
  • Page 21 P168*2 Additional Power Supply via External Power Supply Unit at Connection U (Output Driver) For supply via controller, the available currents are usually limited. If the permitted current is ex- ceeded, the controller can display an error message. To prevent this, an additional power supply can be used to supply U The output stage of P168*2 is supplied via the U operating voltage connection.

  • Page 22: Shielding Concept

    P168*2 2.8 Shielding Concept The P168*2 is used to multiply speed sensor signals and voltage-/current-generating speed sensors, particularly for rolling stock. Here, speed signals are decoupled in a non-interacting manner from a pri- mary signal circuit and supplied to the P168*2. The primary signal circuit is retained and the speed sensor remains galvanically connected to the primary control unit (Control Unit 1).

  • Page 23: Decoupling The Signals Of A Speed Sensor With Current Output

    P168*2 2.8.1 Decoupling the Signals of a Speed Sensor with Current Output The figure shows the principle wiring for the serial decoupling of signals from a primary speed signal circuit with current-generating speed sensors. Junction box Control cabinet Speed sensor Controller 1 Current output Terminal...

  • Page 24: General Information On Shielding P168*2

    P168*2 2.8.3 General Information on Shielding P168*2 The P168*2 has a double shield design for input and outputs that can be adapted to different applica- tions. Each input and each electrically isolated output is equipped with two nested shields: • Inner shield: Firmly connected to the GND terminal •...

  • Page 25: Fundamentals Of Shielded Cables And Signal Routing

    P168*2 2.8.4 Fundamentals of Shielded Cables and Signal Routing Shielded cables are required for: • Connecting speed sensors to the inputs of P168*2 • Connecting the outputs of P168*2 to controllers • A separate power supply unit, if necessary Signal Cables at the P168*2 Output, p. P168*2 Power Supply, p.
  • Page 26 P168*2 Measures for Avoiding Problems with Potential Note: Observe additional safety Instructions (e.g., SIL levels), if any. Safety Manual, p. 55 ➜ 1. Use of P168*2 between speed sensor and signal load • Reduces signal problems and interference current on cable shields. •...

  • Page 27: Signal Cables At The P168*2 Output

    P168*2 2.8.5 Signal Cables at the P168*2 Output Signals should be transmitted to the secondary control unit and power supply of P168*2 with only one shielded cable and along the shortest possible route. Both ends of the cable shield must be de- signed for a low-interference potential.

  • Page 28: Configuration

    P168*2 3 Configuration 3.1 Terminals The various wiring options make it possible to adjust the load of the controller such that it equals the load of a speed sensor. Voltage Supply, p. 18 ➜ 3.2 DIP Switches The individual input and output functions of P168*2 are set via the DIP switches on the product. The assignment of the functions to the DIP switch positions is listed on the nameplate.
  • Page 29 P168*2 DIP Switch at Output The outputs Output 1 and Output 2 can be configured differently. Overview of DIP switch functions at the output: DIP switches Output 1 and Output 2 • Select current or voltage output • For current output: Choose high level 14 mA or 20 mA •...

  • Page 30: Installation And Commissioning

    P168*2 4 Installation and Commissioning 4.1 Mounting The following conditions must be complied with: • The product is approved for installation in closed electrical operating areas like underfloor contain- ers, roof boxes, and the engine rooms of rolling stock. • Inside rolling stock, the product many only be installed and operated in closed control cabinet that can be locked.
  • Page 31 P168*2 Mounting on Level Surfaces with Accessory ZU1472 Wall-Mount Adapter (order separately) Note: The miniature illustration (3) on the wall-mount adapter also represents the correct installation orientation of P168*2 (1) in the ZU1472 Wall-mount adapter (2). Required aids: Two M6 screws and suitable washers. Click P168*2 (1) into accessory ZU1472 (2).

  • Page 32: Terminal Assignment

    P168*2 4.2 Terminal Assignment 1 Terminal 1 (1.1...1.4) 4 Terminal 4 (4.1...4.4) 2 Terminal 2 (2.1...2.4) 5 Terminal 5 (5.1...5.4) 3 Terminal 3 (3.1...3.4) 6 Terminal 6 (6.1...6.4) Terminal Label Input/Output Channel Function Output Power supply Output Power supply (output driver) Output Output signal (current or voltage) Output...

  • Page 33: Block Diagram

    P168*2 Block Diagram Input 1 Output 1 4.1 U 4.2 I Signal 4.3 U Out 3.3 4.4 GND SW 3.4 5.4 GND GND 2.1 Power 5.3 Screen Screen 2.2 6.1 U 6.2 I Signal Out 1.3 6.3 U SW 1.4 6.4 GND GND 2.4 5.1 GND...

  • Page 34: Electrical Installation

    P168*2 4.3 Electrical Installation WARNING! Voltages dangerous to touch. Do not install the product when it is carrying voltage. Disconnect the electrical system from the mains. Secure the electrical system against reconnection. Verify that the electrical system is dead. Ground and short-circuit the electrical system. Cover neighboring, live parts with insulating materials or place barriers around them.

  • Page 35: Insertable Jumpers

    P168*2 4.4 Insertable Jumpers The cables and jumpers are connected to the two-tier terminals (push-in version). Terminal Assignment, p. 32 ➜ 2-pin and 3-pin jumpers are available: • 2-pin jumper: ◦ To connect connection U with connection V ◦ Connection of the GND and Screen terminals, depending on selected shield design •...

  • Page 36: Operation

    The devices are maintenance-free. They are not to be opened. Repair The product cannot be repaired by the user. The local contact persons and information on the repair procedure can be found at www.knick-international.com. Storage Familiarize yourself with the information on storage temperatures and relative humidity in the Specifi-...

  • Page 37: Troubleshooting

    Connect load resistance correctly. signal input. put) Faulty configuration Check configuration. Disconnection Check cable and connections. Further support for troubleshooting is available at support@knick.de. ➜ See also DIP Switches, p. 28 ➜ LED Signaling, p. 36 ➜ Specifications, p. 43...

  • Page 38: Decommissioning

    P168*2 7 Decommissioning The product must be shut down and secured against starting up again if the following occurs: • Visible damage to the product • Failure of electrical function • Storage at temperatures outside the specified temperature range The product may only be started up again after a professional routine test by the manufacturer. 7.1 Removal WARNING! Voltages dangerous to touch.
  • Page 39 P168*2 Removal from 35 mm DIN Rail 1. Pull down the metal foot catch (1). 2. Lift the product off the DIN rail. Removal with Wall-Mount Adapter 1. Loosen the M6 screws (1). 2. Slightly bend up the wall-mount adapter on one side to separate it from the product.

  • Page 40: Return Delivery

    For details on how to return and dispose of electrical and electronic devices in an environmentally friendly manner, please refer to the manufacturer's declaration on our website. If you have any queries, suggestions, or questions about how Knick recycles electrical and electronic waste devices, please send us an email: support@knick.de...

  • Page 41: Accessories

    P168*2 8 Accessories ZU1472 Wall-mount adapter, optional Accessory ZU1472 enables the installation of the P168*2 on a level surface. Use two M6 screws (EN 912/ISO 4762) with washers (EN 125/ISO 7089) to mount the wall-mount adapter. (Screws and washers not included in the package con- tents.)

  • Page 42: Dimension Drawings

    P168*2 9 Dimension Drawings Note: All dimensions are listed in millimeters [inches]. The accessory ZU1472, “Wall-mount adapter, ” is available as an option and not included in the P168*2 package contents. The hole spacing for accessory ZU1472, “Wall-mount adapter, ” is 124 mm [4.88ʺ]. 1 ZU1472 wall-mount adapter...

  • Page 43: Specifications

    P168*2 10 Specifications 10.1 Limit Values The specifications listed here must be complied with. Deviations can lead to destruction of the product. Unless otherwise indicated, all voltage vales refer to the associated GND. Operating temperature, enclosure Max. 95 °C (203 °F) Voltage reference for level Min.

  • Page 44: Input

    P168*2 10.3 Input Input signal Voltage U or current I Waveform Square Input frequency f 0 … 25 kHz Sensor Speed encoder, speed sensor, position encoder, or pulse generator Reference potential 10.3.1 Reference Voltage Reference voltage U 10 … 33.6 V Error detection open cable U < 8 … 10 V;...

  • Page 45: Output

    P168*2 10.4 Output Output signal Voltage U or current I Waveform Square Reference potential Signal conversion options Current → current Voltage → voltage Current → voltage Voltage → current 10.4.1 Voltage Output Voltage level Low: < 1 V (at max. 20 mA) High: U  … U  – 2 V (at max.

  • Page 46: Transfer Characteristics

    P168*2 10.5 Transfer Characteristics Frequency division P168*2P31/2*: 1:1 or 2:1, switchable P168*2P31/4*: 1:1 or 4:1, switchable P168*2P31/8*: 1:1 or 8:1, switchable Functional characteristics The output level follows the input level. Flow time t ≤ 10 µs Difference of the flow times of both channels < 5 µs Duty cycle distortion without frequency division Max.

  • Page 47: Reaction To Input Signals

    P168*2 10.6 Reaction to Input Signals Condition Voltage output OUT Current output OUT Switch output SW Voltage input Closed High High High Closed f < 1 Hz (for activated Middle voltage Invalid configuration Closed standstill detection) Middle voltage (for Low or High, Low or High, Closed deactivated standstill dependent on input...

  • Page 48: Auxiliary Power

    P168*2 10.7 Auxiliary Power P168*2 is designed for direct connection to a railway control unit for odometry. For proper function- ing, the supply of P168*2 must be provided at a specific source in accordance with EN 50155:2022 Sec- tion 5.1.1. For direct connection to a battery, burst immunity is restricted to evaluation criterion B. The influence on galvanic isolation must be considered.

  • Page 49: Isolation

    P168*2 10.8 Isolation Galvanic isolation Input circuits against output circuits, Input circuit channel In 1 against input circuit channel In 2 Details on Isolation, Isolating Distances, Contamination, and Overvoltage, p. 54 ➜ Type test voltage Input against output: 8.8 kV AC/5 s 5 kV AC/1 min Channel 1 against channel 2: 3 kV AC/1 min Output against outer shield of the output (screen): 710 V AC/5 s...

  • Page 50: Device

    P168*2 10.10 Device Weight Approx. 170 g Connection type Mechanical coded two-tier terminals in push-in version, pluggable Cable cross-section 0.2 … 1.5 mm (AWG 24 … 16) Cable Flexible (stranded) with ferrule or solid (single-wire) Use shielded copper wires only. The cables must be temperature-resistance to no lower than 75 °C (167 °F) unless the application demands more stringent requirements.

  • Page 51: Appendix

    Regulation (EC) No. 1907/2006 (REACH) The current standards and directives may differ from those specified here. The applied standards are documented in the Declaration of Conformity and the corresponding certificates. You can find these at www.knick-international.com under the corresponding product. ➜...

  • Page 52: Compliance With Standards

    P168*2 11.2 Compliance with Standards In this section, all relevant specifications are grouped by standard. EN 50155 Installation location Installation location 1, Table C.1 Operating temperature class Temperature change class for fast temperature changes Increase operating temperature class upon switching on ST1, ST2 Power supply range in accordance with Section 5.3 : 10 … 33.6 V...

  • Page 53: Industrial Applications

    P168*2 EN 50121-3-2, EN 50121-1 EMC immunity Note: The device is designed for direct connection to a railway control unit for odometry. All connections, including supply voltage V and U , are assigned to the groups of signal and communication cables, process, measurement, and control cables in accordance with EN 50121-3-2.

  • Page 54: Details On Isolation, Isolating Distances, Contamination, And Overvoltage

    P168*2 11.3 Details on Isolation, Isolating Distances, Contamination, and Overvoltage Rated Insulation Voltages (Excerpt) Section Actual value [mm] ≤ Altitude [km] Rated insulation voltage [V] Clearance Creepage EN 50124-1, EN 60664-1, EN 61010-1, distance UL 61010-1 1000 1000 1) 2) 1) 2) 1) 2) Key:...

  • Page 55: Safety Manual

    P168*2 12 Safety Manual 12.1 General Description When using a P16812/P16822, it is possible to extract vehicle speed information that is transmitted as electrical rectangle signals from a sensor to a primary control unit and route it to a secondary control unit (signal doubling).

  • Page 56: Safety And Safety Integrity Level Requirements

    P168*2 12.2 Safety and Safety Integrity Level Requirements 12.2.1 Functional Safety Requirements The functional safety requirements underlying the development were defined on the basis of a market study and are as follows: 1. The speed information received by the primary control unit must match the speed information transmitted by the sensor at all times, even after the integration of a P16812/P16822, and must not experience any significant delay as the result of the integration of a P16812/P16822.

  • Page 57: Sracs For System Project Planning And Structure, As Well As Operation, Maintenance And Safety Monitoring

    P168*2 12.3 SRACs for System Project Planning and Structure, as well as Operation, Maintenance and Safety Monitoring All of the safety-related application conditions (SRACs) listed below must be fulfilled to be able to jus- tify using a P16812/P16822 for a safety-related application. For reasons of expediency, we do not differentiate between SRACs for system project planning and structure and SRACs for operation, maintenance and safety monitoring here.

  • Page 58: Srac E: Wiring (Input And Output Side)

    P168*2 12.3.5 SRAC E: Wiring (Input and Output Side) Name P168*2-SRAC_E Title Wiring (Input and Output Side) Text For the P16812/P16822 wiring, the integrator must implement a sufficient number of quality assur- ance measures. Here, the integrator must particularly ensure that connecting a P16812/P16822 leads to compliance with the following conditions: - The information transmitted to the primary control unit is not corrupted and (in the case of a P16822) there is no negative impact on the required independence of the sensor signals, if any.

  • Page 59: Srac H: Do Not Use Standstill Detection (Middle Voltage) For Safety-Related Applications

    The integrator must coordinate with the railway operator to determine if safety testing (in the meaning of EN 50129) is considered necessary and implement it accordingly. The results must be integrated into the higher-level safety instructions. If necessary, Knick will support the integrator as part of the safety testing of a universal speed signal doubler.

  • Page 60: List Of Recommendations

    P168*2 12.4 List of Recommendations Note: Unlike the listed SRACs, the implementation of recommendations is not mandatory. SRACs for ➜ System Project Planning and Structure, as well as Operation, Maintenance and Safety Monitoring, p. 57 If neither Recommendation 1 nor Recommendation 2 are implemented, a higher failure rate must be used.

  • Page 61: List Of Function-Specific, Safety-Related Error Rates

    P168*2 12.5 List of Function-Specific, Safety-Related Error Rates The error rate of the output of a P16812 or a single channel of a P16822 depends on the intended application. The following table shows the associated error rates for two cases: Case 1, that the integrator does not implement any of the recommendations and Case 2, that the integrator implements Recommendation 1 or Recommendation 2.

  • Page 62: Abbreviations

    P168*2 13 Abbreviations American Wire Gauge Conformité Européenne (European conformity) Channel Digital Input Dual Inline Package (slide switch with positions ON and OFF) Functional Failure Rate (failure rate of a product) Frequency of the input signal Failures in time (failures in 10 hours) Frequency of the output signal Ground...
  • Page 63 P168*2 Notes...
  • Page 64 Knick Elektronische Messgeräte GmbH & Co. KG Beuckestraße 22 14163 Berlin Germany Phone: +49 30 80191-0 Fax: +49 30 80191-200 info@knick.de www.knick-international.com Translation of the original instructions Copyright 2025 • Subject to change Version 1 • This document was published on April 15, 2025.

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