ABB Wireless Proximity Switches Instruction sheet

Wireless
Proximity Switches
Technical Description
V6
Planning and
Installation Guidelines

The documentation has been prepared with care. The products described are, however, constantly under
development. For that reason the documentation is not in every case checked for consistency with performance
data, standards or other characteristics, and does not represent an assurance of characteristics in the sense of
§ 459, Para. 2 of the German Civil Code. In the event that it contains technical or editorial errors, we retain the right
to make alterations at any time and without warning.
No claims for the modification of products that have already been supplied may be made on the basis of the data,
diagrams and descriptions in this documentation.
©This manual is copyrighted. Any reproduction or third party use of this protected publication, whether in whole or
in part, without the written permission of ABB STOTZ-KONTAKT GmbH, is forbidden.
Please note the following
Target group
This description is intended for the use of trained specialists in electrical installation and control and
automation engineering, who are familiar with the applicable national standards.
Safety requirements
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Planning and Installation Guidelines 3
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 09.2004
V 6
Contents Page
1 Primary loops ............................................................................................. 5
1.1 Geometry of the primary loops .................................................................. 5
1.2 Arrangement variants for the primary loops .............................................. 6
1.3 Distances to primary loops, safety aspects .............................................. 8
1.4 Distances of primary loops to metal constructions ................................ 10
1.5 Installation of the primary loop cables .................................................... 11
1.6 Installation of the primary loop supply line ............................................. 12
1.7 Electrically conductive ring construction inside the machine ................ 13
2 Wireless proximity switches .................................................................... 14
2.1 Sensor head properties ........................................................................... 14
2.2 Functional principle of the sensor heads ............................................... 14
2.3 Switching distance of the sensor heads ................................................ 14
2.4 Flush mounting and non flush mounting ................................................ 17
2.5 Mutual influence ....................................................................................... 17
2.6 Communication module .......................................................................... 18
2.7 Configuration of wireless proximity switches ......................................... 19
2.8 Deleting the configuration of wireless proximity switches ..................... 19
2.9 Installation of the communication module ............................................. 20
2.10 Switching Frequency and Latency ........................................................... 21
3 Input module ............................................................................................. 22
3.1 Functions of the input module ................................................................. 22
3.2 Ready status of the input module ............................................................ 23
3.3 Switching of the input module ................................................................. 23
3.4 RUN Mode
Operation of the input module ................................................................. 24
3.5 Password inquiry ...................................................................................... 25
3.6 CFG Mode
Configuration of wireless proximity switches ......................................... 26
3.7 DEL Mode
Delete configured wireless proximity switches ...................................... 28
3.8 SET Mode
System settings at the input module ....................................................... 28
continuation ...

4 Planning and Installation Guidelines
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 09.2004
V 6
Contents ( ... continuation)
Page
3.9 Antenna ..................................................................................................... 35
3.10 Field Bus Integration and Data Mapping ................................................ 36
3.11 WDI100 data structure at the PLC ........................................................... 37
3.11.1 Input data from the input module WDI100 .............................................. 37
3.11.2 Parameter to be downloaded to the input module WDI100 ................... 39
3.12 Commissioning of Communication ........................................................ 39
4 Power supply ............................................................................................ 40
4.1 Electrical connections .............................................................................. 41
4.2 Primary loop sizes and current values .................................................... 43
4.3 Power supply LED signals ...................................................................... 45
4.4 Comissioning ........................................................................................... 46
Appenix
A Checklist ................................................................................................... A1

Planning and Installation Guidelines 5
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
1 Primary loops
Primary loops are used to generate the electromagnetic field which supplies energy for all
wireless proximity switches of a machine or a manufacturing cell.
Below, the fundamental things are described which have to be observed for the installation
of the primary loops.
1.1 Geometry of the primary loops
The top view to the primary loops represented on the left-hand side of figure 1.2 shows the edge
length saand the edge length sc.
Maximum permitted sizes of the primary loops:
- Edge length sabetween 1 m and 3 m
- Edge length scbetween 1 m and 6 m
The following constraint has to be observed:
-s
c≥sa
Procedure:
●Set up 4 two-dimensional primary loops (2 pairs) around the part of the machine containing
wireless proximity switches in a way that always the two opposite primary loops roughly have the
same size and geometry.
●Set up the primary loops rectangular to each other.
- Max. tolerance: ± 8°.
●Set up the lop pairs symmetrically.
●Permitted distance of the two primary loops of one pair to each other:
- 2/3 of the shortest edge length of one primary loop (± 10%).
●The individual primary loops must cross each other with 1/6 (tolerance max. ± 20%) of their
length (refer to fig. 1.3).
This way, a square outline is evenly supplied with energy.
Important:
Position the primary loops in a way that their electromagnetic field is not shielded by
large metal surfaces or short cicuit loops, in e. g. the support structure (refer to fig. 1.6).

6 Planning and Installation Guidelines
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
sa
sa
Sa6/
Sa6/
Sa6/Sa6/
sa
sa
sc
d
as
c
s>
d
a
1.2 Arrangement variants for the primary loops
Fig. 1.2: Arrangement of primary loops for machines with nearly square outline the height of which is greater than
the length of one of the edges.
Machine volume
Primary loops
sa
sc
da
m2m3
scs> a
Design constraint valid for each of
the two coil pairs
The smallest side sa of one loop determines the distance dato the next parallel loop: da~ 2/3 x sa
Fig. 1.1: Dimensioning principle for loop pairs
Example:
Top view 3D representation
1.) The smallest side sa of one loop determines the distance dato the next parallel loop: da~ 2/3 x sa
2.) The following constraint is valid: Overlapping “distance” of a coil from cell border: sa/6
2CDC352057F0004..EPS
2CDC352058F0004..EPS

Planning and Installation Guidelines 7
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
Fig. 1.4: Arrows on the outer insulation of the primary loop cables:
If the arrows point towards the same direction, the primary loop pairs and further primary loops arranged in
parallel are installed correctly.
●The primary loop cables are marked in regular spacings with arrows on the outer insulation.
These arrows all have to point towards the same direction when installing a pair of primary loops
and further primary loops arranged in parallel (refer to fig. 1.6).
Fig. 1.3: Arrangement of primary loops for machines with rectangular outline
Top view 3D representation
s
b
s
a
s
c
d
a
d
a
d
c
s
a
z
c
z
c
z
a
z
a
d
a
d
a
d
c
s
b
1.) The smallest side sa, scof one loop determines the distance da, dcto the next parallel loop:
da~ (4-) 5/6 x sa(sa< sc< sbis assumed)
2.) The following constraint is valid:
Overlapping “distance” of a coil from cell border za, zcapproximately 1/6 of the smallest side sa, scof this loop
Machine volume
Primary loops
2CDC352015F0003.EPS
Power
supply
(Principle representation: For reasons
of clarity only one pair of primary loops
is represented).
2CDC352059F0004..EPS

8 Planning and Installation Guidelines
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
1.3 Distances to primary loops, safety aspects
●Persons with cardiac pacemakers have to observe minimum clearances to the primary loops.
Refer to the explanations below and fig. 1.5.
●Cardiac pacemakers are particularly sensitive to electromagnetic fields.
●The primary loops generate an electromagnetic field the field strength of which depends on the
set current. The strongest electromagnetic field is right next to the primary loop cable.
●The required current depends on the edge length of a primary loop. For rectangular primary loops
the short edge is the relevant length.
Measures
●Marking for Pace Maker Carriers:
If the machine/installation does not have a fence around it to determine this distance (for
minimum distances please refer to the following table and fig. 1.5), a black-yellow line has to
be attached to the floor in order to make the distance clear. In this case, suitable labelings have
to be installed in the line of the distance.
The Engineering Package WEP100.0101 (1SAF900091R0101.ZIP) contains an example for this.
●The values given in the following table are theoretical values intended for the planning of a
machine/installation with wireless proximity switches. During commissioning and acceptance
these values have to be verified by corresponding measurements and, if necessary, the
distances have to be corrected.
●For more detailed information please refer to chapter "Regulations for the Erection of
Installations and Safety-Related Regulations" in Volume 7 (certificates, standards, regulations)
and to the expert’s report of the "Berufsgenossenschaft der Feinmechanik und Eletrotechnik
BGFE".

Planning and Installation Guidelines 9
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
1)Distance for cardiac pacemakers = Minimum clearance from the primary loop area to be
observed by persons wearing cardiac pacemakers.
2)This value is also valid for smaller primary loops with two windings.
Fig. 1.5: Minimum clearances to primary loops for persons wearing cardiac pacemakers (principle representation)
Marking for the
minimum clearance
Top view 3D representation
2CDC352016F0003.EPS
1000 - 1200 8.0 2) 800
1200 - 1400 10.0 1000
1400 - 1600 12.0 1300
1600 - 1800 13.0 1400
1800 - 2000 15.0 1600
2000 - 2200 16.0 1700
2200 - 2400 18.0 1900
2400 - 2600 20.0 2100
2600 - 2800 22.0 2300
2800 - 3000 24.0 2500
Short edge of the
primary loop [mm]
Current [A] Distance for cardiac
pacemakers [mm] 1)
Long edge of the primary loop (one winding):
1200 – 6000 mm
Minimum clearance to
the primary loops for
persons wearing cardiac
pacemakers

10 Planning and Installation Guidelines
Planning and
Installation Guidelines
Technical Description
Wireless Proximity Switches / Issue: 03.2005
V 6
1.4 Distances of primary loops to metal constructions
a Distance of primary loops to metal surfaces or metal gratings min.. 30 mm. Consequently, the
same distance is valid for primary loops standing vertically on metal platforms, steel-reinforced
industrial floors, etc. Especially for large steel objects a distance of > 100 mm is recommended.
b Large metal surfaces (e.g. larger than approx. 50 % of the primary loop area) surrounding the
primary loop arrangement (including machine fencings made of metal) should have a minimum
clearance of 200 mm (for small primary loops) up to 500 mm (for large primary loops) to the
entire primary loop area in order not to burden the power supply too much. This distance is the
overlapping in fig. 1.2.
c Inside of ring constructions with continuous electric connections the electromagnetic field
induces currents which can attenuate the energy field of the primary loops. In order to avoid an
attenuation of the electromagnetic field, the electric conductivity of those ring constructions has to
be interrupted, e.g. by inserting an isolating plastic part, unless the distance to the loops or
potentional sensor positions is large enough (see b and fig. 1.9)
d In order to avoid inadmissible contact voltages at those interrupted ring constructions in the
immediate neighborhood of a primary loop, the area of the ring construction must have a
minimum clearance of 30 mm to the nearest primary loop area, if the relevant area is not larger
than 9 m² (see fig. 1.5). For larger primary loops up to 18 m² this distance has to be increased
linearly up to 120 mm.
Fig. 1.6: Minimum clearance of the primary loops to metal ring constructions
(e.g. aluminum contour frame with plexiglas pane)
Metal ring construction
(e.g. aluminum contour frame
with plexiglas pane)
2CDC352018F0003.EPS
Minimum clearance
Primary loop
Supply line for
the primary loop
Insulator
(at any place in the metal
ring construction)