ASM posiwire User manual

Please read carefully before operation!
POSIWIRE®
Position Sensors
Installation and operation manual

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Contents
Contents Safety instructions 3
Intended use / unintended use 5
Product description
Operating principle 6
Measurement signal and range 6
Delivery / shipment 7
Mating connectors 7
Installation
Precautions 8
Female connector 90° CONN-DIN-8F-W 19
Female connector CONN-M12-8F-G 20
Female connector CONN-CONIN-12F-G 21
Connection 22
Cable dust wiper SAB5 23
Calibration 24
Electromagnetic compatibility (EMC) 24
Repair and disposal 24
Output specifications 25
Analog Output 25
with Potentiometer 25
with Magnetic Absolute Encoder 29
Incrementel Output 31
with Optical Incremental Encoder 31
SSI Interface 33
with Potentiometer 33
with Magnetic Absolute Encoder 34
with Optical Absolute Encoder 35
CAN-Bus 38
with Magnetic Absolute Encoder 38
with Optical Absolute Encoder 55
DeviceNet 55
Profibus DP 56
Interbus 57
Appendix
Output Information 58
Reliability Characteristics 62
Declaration of Conformity 63

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Safety
instructions
If total failure or malfunction of the sensor can cause danger or
injury to the operator or damage to the machinery or equipment
it is recommended that additional safety measures should be
incorporated into the system.
Any alteration, reconstruction or extension of the sensor is not
allowed.
Sensor must be operated only within values specied in the
datasheet.
Connection to power supply must be performed in accordance
with safety instructions for electrical facilities and performed
only by trained staff.
Disregard of this advice can lead to malfunctions, damage to
property or personal injury and releases the manufacturer from
product liability.
Crossing the dew point must be avoided.
POSIWIRE®
Instruction Manual
Explanation of used
safety signs and
signal words
WARNING, Risk of Injury:
Indicates a potentially hazardous situation, which,
if not avoided, could result in serious injury or
property damage.
WARNING, Risk of Personal Injury or Death:
Indicates a situation that can result in serious personal
injury or death if not properly avoided.
DANGER
WARNING, Risk of Personal Injury or Death:
Indicates a situation that can result in moderate
personal injury or death if not properly avoided.
WARNING
WARNING, Risk of Personal Injury:
Indicates a situation that can result in minor personal
injury if not properly avoided.
CAUTION
WARNING, Risk of Property Damage:
Indicates a situation that can result in minor to major
property damage if not properly avoided.
NOTICE

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Do not open sensor
• Release of spring under tension can result in injury!
Do not snap cable
• Uncontrolledcableretractioncanbreakoffcablexing(cablecliporM4
connection).Brokenxingandcablecanresultininjury.Alsosensor
will be damaged!
Do not travel over range
• Uncontrolled cable retraction can result in injury. Also sensor will be
damaged!
Special attention during mounting and operation of metal cable
sensors
• Risk of injury by the measuring cable!
Sensors without cover / housing (OEM sensors)
• Risk of injury by moving parts. Mounting and operation of the sensor
only with appropriate safety equipment that an injury is impossible!
Do not exceed maximum operating voltage listed in the catalog
• Risk of injury. Sensor will be damaged!
Avoid shock and vibration to the sensor
• Sensor will be damaged!
Safety
instructions
(continued)

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Intended use
Unintended use
The position sensor was intended for linear position measurement,
when properly mounted and used in the properly rated ambient
atmospheric and technical conditions for which the sensor is
designated.
Theunintendeduseiswhenthesensorisusedoutsideitsspecied
technical and ambient atmospheric conditions or when improperly
mounted.
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Instruction Manual
Product
description
The purpose of position sensors is to transform position of a linear and
guided movement into an electrical signal. Specications of measuring
range,environment,handlingandconnectionsasspeciedinthecatalog,
must be followed.
The catalog is part of this instruction manual. If the catalog is not available
it may be requested by stating the respective model number.
The Operating Principle
Linearmotionofthemeasuringcable(exiblestainlesssteel)isconverted
into rotation by means of a precision cable drum. A spring motor provides
torque for the cable retraction. Special design assures precise and repro-
ducible winding of the measuring cable.
Cable extraction or retraction is transformed into an electrical signal.
Depending on application different sensing elements are used.
Optional: Subsequent signal conditioners convert the signal of the sen-
sing element into voltage, current, or digital pulses suitable for standard
interfaces.
Measurement Signal and Range
Measurement signal:
Analog, not adjusted
Potentiometer
Sensitivity not adjustable
Analog, adjusted
Integrated signal conditioner
Sensitivity adjusted
Digital incremental
Incremental encoder
Sensitivity not adjustable
Resistance range is used from about
3% to 98%. 0% or 100% are not pos-
sible.Individual sensitivity isspecied
on the label.
Measuring range corresponds to the
electrical measuring range
(e.g.4...20mA).
Inividualsensitivityisspeciedonlabel
in pulses or increments per millimeter.
Measurement range
Output
Potentiometer    approx.3% approx.30%    approx.98%
(e.g.1kΩ)
Integrated signal conditioner 0 % 30 % 100 %
(e.g.4...20mA)     4mA   8,8mA       20mA
Incremental encoder 0 % 30 % 100 %
(e.g.10pulses/mm)    0   3000       10000
Actual 0 % 30 % 100 %
position 0 mm 300 mm 1000 mm

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POSIWIRE®
Instruction Manual
Delivery /
shipment
Unpacking Do not unpack sensor by pulling ca-
ble or cable clip.
Shipment damages Check sensor immediately for ship-
ping damage.
Shipment protection loop Do not remove until mounting.
(nottobeconfusedwiththe  (preventscablemovementbefore
mounting loop below!) mounting)
In case of any damage or equipment not operating appropriately, please
contact supplier or ASM GmbH Moosinning. To avoid shipment damages,
use original protection facilities and original packing for further shipment.
Mating connectors
Delivery does not include female connectors for electrical connection. They
are available under the following order code:
90° female 8-pin connector DIN CONN-DIN-8F-W
Female 8-pin connector M12 CONN-M12-8F-G
90° female 12-pin connector DIN CONN-DIN-12F-W
Female 12-pin connector CONN-CONIN-12F-G

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Installation
Mounting
loop
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Do not damage cable!
Cable must not be oiled or lubricated!
Do not snap cable!
Do not travel over range!
Do not crack cable!
Cabletravelshouldbeaxialtothecableoutlet
- no misalignment allowed!
Do not drag cable along objects!
Precautions
Do not let snap the cable
Uncontrolled retraction of cable may damage sensor.
No warranty will be granted for snapped cables.
Mounting hints for unfavourable conditions
Ifpossiblefastencablexingwithcableinretractedposition.
Forexample,tamountingloop(seediagram)andputitaroundyourwrist.
Do not remove the mounting loop before the cable ist fastened.
The cable clip may be opened for easy attachment.
Mounting
To ensure proper operation, install the sensor only as described in this
manual.

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POSIWIRE®
Instruction Manual
Installation Installation position
Cable travel should only be axial to the cable outlet
- no misalignment is allowed.
Cable misalignment shortens service life of sensor and causes error
in measurement. Warranty will not be granted for damage caused by
misalignment.
Ifcabletravelaxialtothecableoutletisnotpossible,thecableguidewheel
SR2(accessories)mustbeusedinordertoturnthecable.
For special applications extension cables with clips on both ends are
available.
Fitting the sensor
Depending upon the sensor model, holes in the base plate, threads or T-
slots in the sensor housing enable attachment of the sensor. Dimensions
required are listed in the catalog.
Cable attachment device
For fastening the cable clip the following solutions are available. For
example:
a)SetscrewM5:   Standardxing.
(Allenscrew)
b)AttachmentheadGK1/GK2: Fastcableattachment,easyto
(accessory)   remove.
c) Magnetic clamp MAG1: An easy way to fasten the cable to
(accessory)   ferromagneticmaterials.
The mounting of the M4 connection is made with a through hole and a M4
nut. Note: Do not screw the M4 connection itself into a stationary object,
otherwise the measuring cable will be twisted!
Cable clip attachment
When fastening the cable clip take notice of the chapter Installation / Pre-
cautions(page8).
This prevents cable from damage,
soiling and manipulation.
Soaking of liquids into the cable out-
let is impossible, concentration of
condensing water will be avoided.
This prevents sensor from bending
and damage.
Covered or shielded travel of cable
is preferred.
Cable outlet is preferred pointing
downwards.
Fit sensor on plain base or use three-
point mounting on uneven surfaces.

M3
M4
M2,5
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Torque
 Thefollwingtorques/screwsandscrewmaterialsarerecommended.
 Useatwashersand/orscrewprotectionifnecessary.
 The user is responsible for the appropriate torque, since ASM does not know the operational
conditions of the application.
Mountthesensorontheatsurface.
Model Screw Material Torque [Nm]
WS31/WS31C M2,5 Mounting brackets A2 0.25
WS31/WS31C M3 Clamping claws A2 0.5
WS31/WS31C M4 Mounting brackets A2 0.65
WS42/WS42C M2,5 Mounting brackets A2 0.25
WS42/WS42C M3 Clamping claws A2 0.5
WS42/WS42C M4 Mounting brackets A2 0.65

M5 (4x)
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Instruction Manual
Installation
Model Screw Material Torque [Nm]
WS10 M5, 8 mm deep A2 2.0
WS10ZG M5, 8 mm deep A2 2.0
WS10SG M5, 8 mm deep A2 2.0

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Model Screw Material Torque [Nm]
WS17KT M5 A2 2.5
WS19KT M5 A2 2.5
WS21 M5 A2 2.5

M4 (4x)
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Installation
Model Screw Material Torque [Nm]
WS58C M4, 5 mm deep A2 1.0

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Model Screw Material Torque [Nm]
WS60 M8 A2 10.0
Installation
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Installation
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Model Screw Material Torque [Nm]
WS7.5 M5 A2 2.5

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Installation
Model Screw Material Torque [Nm]
WS61 M5 A2 2.5
WS85 M6 A2 4.0
WS85 for oval hole M6 for oval hole A2 3.0

M5 (4x)
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Installation
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Model Screw Material Torque [Nm]
WS12 M5, 10 mm deep A2 2.0

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Installation
Model Screw Material Torque [Nm]
WS100M M10 A2 20

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Instruction Manual
Installation 90° female connector CONN-DIN-8F-W
Part no.: Operation:
1to2  AssembleO-rings(lubricate!)onshieldingringandrotating
hull.
3 to 7 Stringing parts and cut off projecting braiding. Note detail
drawingofshielding!(SeechapterElectromagnetic Compa-
tibility / EMC).
8 Thread wires through housing, then assemble shielding ring,
sealingringandpinchring.Turnonpressingscrewtoxthe
cable, solder wires.
9 to 13 Assemble remaining parts according to diagram, fasten
pressing screw.
14  Insertprolesealandxfemaleconnectoratmalesocket.
Shielding connected
Put shielding around shielding ring.
Shielding not connected
Cut off shielding and insulate
with heat shrink tube.
Cover
ShapedOring22x1
Distance hull
Female insert
Rotating hull
Oring13x1,25
Oring9x1,5
Housing
Thread ring
Proleseal
Shielding ring
Sealing ring
Pinch ring
Pressing screw
Cable
Use heat shrink tube if necessary
Heat shrink tube

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Instruction Manual
Installation The sensor protection class (IP) is only valid when the electrical plug is
correctly connected.
To ensure sensor protection class assemble all connector seals carefully.
The connector is suitable for cable diameters of 6 to 8 mm.
Thesealingringhastoenclosethecabletightly(useheatshrinktubeif
necessary).
Note:Fourdifferentdirectionsoftheangledoutletarepossible(4x90°)by
changingthepositionoftherotatinghull(partno.9inthedrawingprevious
page).
Female connector CONN-M12-8F-G
1. Stringing parts.
2.Dismantle,expandshieldandturnovertheshieldingring.
3. Push isolating hull into the housing. Thread wires through housing, the
assemble shielding ring, sealing ring and pinch ring. Turn on pressing
screwtoxthecable.Screwwires.
4. Screw insert into housing and fasten pressing screw.
The sensor protection class (IP) is only valid when the electrical plug is
correctly connected.
To ensure sensor protection class assemble all connector seals carefully.
The connector is suitable for cable diameters of 6 to 8 mm.
Thesealingringhastoenclosethecabletightly(useheatshrinktubeif
necessary).
shorten shield
remove insulation
35+1 dismantle
Isolating hull