MICRO-EPSILON WPS-2300-MK88-M User manual

WPS-2400-MK60-M
WPS-2300-MK88-M
WPS-3500-MK88-M
WPS-5000-MK88-M
Operating Instructions
wireSENSOR,WPS
Draw-wire mechanics

Declaration of Incorporation
Declaration of incorporation according to the EC Machinery Directive 2006/42/EC, Annex II B
The manufacturer and person authorized to compile the relevant technical documents
MICRO-EPSILON MESSTECHNIK
GmbH & Co. KG
Königbacher Straße 15
94496 Ortenburg / Germany
hereby declare that the machine designated below complies with the relevant fundamental health and safety requirements of the EC
Machinery Directive, including modifications to it applicable at the time of this declaration, based on its design and construction and in
the version put on the market by us – to the extent that the scope of supply allows.
Machine design: Draw-wire sensor (mechanics and models with potentiometer output)
Type designation: WDS-xxx, WPS-xxx
The following fundamental health and safety requirements according to Annex I of the directive specified above have been applied
and complied with:
- No. 1.1.2. Principles of safety integration
- No. 1.7.3. Marking of machinery
- No. 1.7.4. Operating instructions

Furthermore, we declare compliance with the following directives and standards including the modifications applicable at the time this
declaration is made:
- Directive 2006/42/EC (machinery)
EN ISO 13857: 2008 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs
EN 60204-1: 2006 + EN 60204-1: 2006/A1: 2009 Safety of machinery - Electrical equipment of machines - Part 1: General re-
quirements
- Directive 2011/65/EU (RoHS)
EN 50581: 2012 Technical documentation for the assessment of electrical and electronic devices with respect to the restriction of
hazardous substances
We also declare that the special technical documentation for this partially completed machine has been created in accordance with
Annex VII, Part B, and commit ourselves to disclose this to the market surveillance authorities upon request.
The commissioning of these partially completed machines is prohibited until the partially completed machine(s) has/have been
installed in a machine that meets the requirements of the EC Machinery Directive and for which an EU Declaration of Conformity ac-
cording to Annex II, Part A exists.
Ortenburg, May 22th 2019 Dr. Thomas Wisspeintner
Managing Director
Tel. [phone] / 168-0 e-mail [email protected]
Fax [phone] / 168-90 www.micro-epsilon.com

wireSENSOR, WPS MK60-M / MK88-M

wireSENSOR, WPS MK60-M / MK88-M
Contents
1. Safety ........................................................................................................................................ 7
1.1 Symbols Used ................................................................................................................................................. 7
1.2 Warnings.......................................................................................................................................................... 7
1.3 Intended Use ................................................................................................................................................... 8
1.4 Proper Environment......................................................................................................................................... 8
1.5 Foreseeable Misuse......................................................................................................................................... 9
2. Functional Principle, Technical Data ..................................................................................... 10
2.1 Measuring Principle ....................................................................................................................................... 10
2.2 Structure ........................................................................................................................................................ 10
2.3 Technical Data .............................................................................................................................................. 11
2.3.1 MK60............................................................................................................................................. 11
2.3.2 MK88............................................................................................................................................. 12
3. Delivery ................................................................................................................................... 13
3.1 Unpacking, Included in Delivery.................................................................................................................... 13
3.2 Storage .......................................................................................................................................................... 13
4. Installation and Assembly...................................................................................................... 14
4.1 Precautionary Measures................................................................................................................................ 14
4.2 Sensor Mounting ........................................................................................................................................... 14
4.3 Installing the Encoder.................................................................................................................................... 17
4.4 Wire Guide and Fastening............................................................................................................................. 19
4.5 Sensitivity Characteristics.............................................................................................................................. 20
5. Operation and Maintenance .................................................................................................. 21
6. Liability for Material Defects.................................................................................................. 21
7. Decommissioning, Disposal .................................................................................................. 21
8. Service, Repair ....................................................................................................................... 22
Appendix

wireSENSOR, WPS MK60-M / MK88-M

Page 7
Safety
wireSENSOR, WPS MK60-M / MK88-M
1. Safety
System operation assumes knowledge of the operating instructions.
1.1 Symbols Used
The following symbols are used in these operating instructions:
Indicates a hazardous situation which, if not avoided, may result in minor or mode-
rate injury.
Indicates a situation that may result in property damage if not avoided.
Indicates a user action.
iIndicates a tip for users.
1.2 Warnings
Do not open the sensor housing.
> Risk of injury from pre-tensioned spring motor
Do not let the measuring wire rewind without control (snap back).
> Risk of injury from whiplash effect of the wire with assembly bolts/clips
> Destruction of wire and/or of sensor
Do not pull or loop the measuring wire around unprotected parts of the body.
> Risk of injury
Connect the power supply in accordance with the safety regulations for electrical equipment.
> Risk of injury
> Damage to or destruction of the sensor

Page 8
Safety
wireSENSOR, WPS MK60-M / MK88-M
Do not pull the measuring wire over the specified measuring range.
> Destruction of the measuring wire and/or the sensor
The supply voltage must not exceed the specified limits.
> Damage to or destruction of the sensor
Avoid shocks and impacts to the sensor
> Damage to or destruction of the sensor
1.3 Intended Use
- Draw-wire sensors are used for
measuring displacement and distance.
measuring the position of parts or moving machine components.
- The sensors must only be operated within the limits specified in the technical data, see Chap. 2.
- Draw-wire sensors must be used in such a way that no persons are endangered or machines and other
material goods are damaged in the event of malfunction or total failure of the sensor.
- Take additional precautions for safety and damage prevention in case of safety-related applications.
1.4 Proper Environment
- Protection class: Depending on the encoder 1
- Temperature range:
Operation: -40 °C ... +85 °C (-40 °F ... +185 °F)
Storage: -40 °C ... +85 °C (-40 °F ... +185 °F)
- Humidity: 5 - 95 % (non-condensing)
- Ambient pressure: Atmospheric pressure
1) Not valid for mechanics!

Page 9
Safety
wireSENSOR, WPS MK60-M / MK88-M
1.5 Foreseeable Misuse
Do not pull the measuring wire over the specified measuring range. This may lead to damage of the measu-
ring wire and also to uncontrollable snapping of the measuring wire. Risk of injury.
Make sure the sensor is not held by another person when the measuring wire is extracted. Risk of snapping
and injury.

Page 10
Functional Principle, Technical Data
wireSENSOR, WPS MK60-M / MK88-M
2. Functional Principle, Technical Data
2.1 Measuring Principle
With the draw-wire principle, a linear motion is transformed into a change in resistance.
A measuring draw-wire made of highly flexible stainless steel wires is wound onto a drum with the aid of a
long life spring motor. The winding drum is coupled axially with an encoder.
Fig. 1 Draw-wire displacement sensor with potentiometer
2.2 Structure
The draw-wire principle is applied in form of MK60 and MK88 housings with different measuring ranges from
2300 mm to 5000 mm. The sensors are designed to ensure simple installation of an incremental or absolute
encoder. Individual selection of the interfaces, resolution and type of connection is thus possible.

Page 11
Functional Principle, Technical Data
wireSENSOR, WPS MK60-M / MK88-M
2.3 Technical Data
2.3.1 MK60
Model WPS-2400-MK60-M
Measuring range 2400 mm
Output type Depending on the encoder
Linearity ±0.1% FSO (±2.4 mm)
Resolution Depending on the encoder
Mean distance per rotation 150.75 mm ±0.4 mm
Typ. repeatability ±1 mm
Temperature range Operation -40 °C ... + 85 °C (-40 °F ... +185 °F)
Storage -40 °C ... + 85 °C (-40 °F ... +185 °F)
Material Housing Plastic, PBT GF 20
Draw-wire Polyamide-coated (ø 0.45 mm)
Wire mounting Wire clip
Sensor mounting Mounting holes
Wire acceleration (max) 5 g
Wire retraction force (min) 1 N
Wire extension force (max) 8 N
Shock (DIN-EN 60068-2-29) 50 g, 5 ms in 2 axes, 1 direction and 1000 shocks each
Vibration (DIN-EN 60068-2-6) 20 g/ 20 Hz ... 2 kHz in 2 axes and 10 cycles each
Suitable encoder Synchro flange ø 58 mm; shaft ø 6 mm
FSO = Full Scale Output

Page 12
Functional Principle, Technical Data
wireSENSOR, WPS MK60-M / MK88-M
2.3.2 MK88
Model WPS-2300-MK88-M WPS-3500-MK88-M WPS-5000-MK88-M
Measuring range 2300 mm 3500 mm 5000 mm
Output type Depending on the encoder
Linearity ±0.1% FSO
(±2.3 mm)
± 0.3 % FSO
(± 10.5 mm)
±0.4% FSO
(±20 mm)
Resolution Depending on the encoder
Mean distance per rotation 238.8 mm ±0.3 mm 239.7 mm ±0.8 mm 240.0 mm ±1 mm
Typ. repeatability ±1 mm ±3 mm ±8 mm
Temperature range Operation -40 °C ... + 85 °C (-40 °F ... +185 °F)
Storage -40 °C ... + 85 °C (-40 °F ... +185 °F)
Material Housing Plastic, PA 6 GF 30
Draw-wire Polyamide-coated stainless steel (ø 0.45 mm)
Wire mounting Wire clip
Sensor mounting Mounting holes or mounting grooves
Wire acceleration (max) 5 g
Wire retraction force (min) 3 N
Wire extension force (max) 9 N
Shock (DIN-EN 60068-2-29) 50 g, 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN-EN 60068-2-6) 20 g/ 20 Hz... 2 kHz in 3 axes and 10 cycles each
Suitable encoder Synchro flange ø 58 mm; shaft ø 6 mm
FSO = Full Scale Output

Page 13
Delivery
wireSENSOR, WPS MK60-M / MK88-M
3. Delivery
3.1 Unpacking, Included in Delivery
1 Sensor
1 Assembly Instructions
Do not unpack the draw-wire sensors by pulling the wire or wire bolt / clip.
Ensure that the goods are forwarded in such a way that no damage can occur.
Check the delivery for completeness and shipping damage immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or supplier.
iThe transport lock for the measuring wire may only be removed directly before installation and only by qualified personnel.
3.2 Storage
Store the sensors only with mounted transport lock. This prevents the measuring wire from being pulled out
as well as accidental wire snapping.
> Risk of injury from whiplash effect of the wire with assembly bolts/clips
- Temperature range storage: -40 °C ... +85 °C (-40 °F ... +185 °F)
- Humidity: 5 - 95 % (non-condensing)
- Atmospheric pressure

Page 14
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
4. Installation and Assembly
4.1 Precautionary Measures
Do not pull the measuring wire over the measuring range.
> Damage to or destruction of the sensor is possible.
Do not damage the measuring wire.
Do not oil or grease the measuring wire.
Do not bend the measuring wire.
Do not pull the measuring wire at an angle.
Do not allow to loop the measuring wire around objects.
Fix the measuring wire to the target when wound up.
Do not loop the measuring wire around parts of the body.
4.2 Sensor Mounting
Mount the sensor according to the following table:
Model Screws Mounting clamp
WPS-2400-MK60 3 x M3 no
WPS-2300-MK88 3 x M4 yes
WPS-3500-MK88 3 x M4 yes
WPS-5000-MK88 3 x M4 yes
The sensor does not have to be oriented in a special way.
Choose the installation position so that damage and soiling of the measuring wire is avoided.
iIf possible, choose an installation position with measuring wire outlet facing downwards. This prevents liquids penetrating the measuring wire outlet.
iDo not let the measuring wire snap! Damage caused by snapping is not covered by the liability for material defects.
Uncontrolled retraction
of the measuring wire is
not permitted!
> Risk of injury from
whiplash effect of
the wire with assem-
bly bolts/clips
> Destruction of wire
and/or of sensor.
Secure the wire during
installation work.

Page 15
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
50 (1.97)
60 (2.36)
89 (3.50)
142 (5.59)
24.2 (.95)
50 (1.97)
60 (2.36)
ø42±0.1 (1.65 dia.) ±.0039
3x ø4.3 (.17 dia.)
after 120°
3x ø3.6
(.14 dia.)
Mounting
holes
16 (.63)
0.5 (.019)
56.8 (2.23)
4+0.1
0
ø50+.05
0
ø35 (1.38 dia.) ø6 H7 (.24 dia. +.12 (.0047)
0
27(1.06)
1.97 dia.
+.002 0
.16 +.004
0
Fig. 2 Dimensional drawing WPS-2400-MK60-M, dimensions in mm (inches), not to scale
A measuring wire under
tension where opera-
tors are standing can
lead to injuries.
> Risk of damage to
wire and sensor.
Do not twist the measu-
ring wire.

Page 16
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
22.2 (.87)
1
(.04)
M3
ø58 (2.28 dia.)
ø56 0
-.05
0.02
ø0.02
ø50 .05
0
10.9
(.43)
0.5 (.02)
27.5 (1.08)
57.8
(2.28)
4+.1
0
38.2 (1.50)
78 (3.07)
88 (3.46)
78 (3.07)
100 (3.94)
88 (3.46)
141.3 (5.56)
89.8 (3.54)
ø8
(.31 dia.)
3xø4.3 after 120°
(.17 dia.)
3xø4.2
(.16 dia.)
ø42±0.1
A
A
ø6 H7 +.012
0
2.04 dia.0
-.02
1.97 dia. .02
0
ø35 (1.38 dia.)
.16 +.004
0
Fig. 3 Dimensional drawing WPS-xxxx-MK88-M, dimensions in mm (inches), not to scale
A measuring wire under
tension where opera-
tors are standing can
lead to injuries.
> Risk of damage to
wire and sensor.
Do not twist the measu-
ring wire.

Page 17
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
4.3 Installing the Encoder
iMake sure that the measuring wire is always tensioned by the spring motor in order to prevent it from jumping off the pulley.
Mount the encoder/adapter flange assembly on the draw-wire mechanism.
Fasten the coupling and the encoder shaft with the supplied hexagon socket screw.
Press the supplied cap into the opening in the adapter flange housing.
i
Make sure that the encoder shaft is not rotated during installation! Follow the installation instructions
issued by the manufacturer of the encoder.
Coupler ROTEX GS ID 6
(+0.012) with grub screw-
elastomer coupler element
3 x 2.5 x 8 EcoSyn screw ISO 4042
3 x M4 screw DIN7985
Serrated lock washer
Servo flange /
Synchro flange
adapter
Rotary encoder with
servo flange /
synchro flange
Fig. 4 Mounting of adapter flange and encoder, WPS-2400-MK60-M

Page 18
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
Coupler ROTEX GS ID 6
(+0.012) with grub screw-
elastomer coupler element
3 x 2.5 x 8 EcoSyn screw ISO 4042
3 x M4 screw DIN7985
serrated lock washer
Servo flange /
synchro flange
adapter
Rotary encoder with servo
flange / synchro flange
Fig. 5 Mounting of adapter flange and encoder, WPS-xxxx-MK88-M

Page 19
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
4.4 Wire Guide and Fastening
If the measuring wire has to be extracted from the sensor to
guide the wire or to fix it to the target,
- the sensor may not be held by another person
- the measuring wire may not be further extracted but only
to the specified measuring range
- the surroundings of the sensor have to be protected
against snapping of the measuring wire
Wrong
Correct
Fix the measuring wire to the target using an wire clip.
Guide the measuring wire vertically out of the sensor
housing.
Misalignment is only permissible up to 3 degrees.
Dragging of the measuring wire on the inlet hole or other
objects leads to damage and/or breakage of the measuring
wire.
iIf the measuring wire cannot be fed vertically out of the housing, it is essential to use a guide pulley (accesso-
ry TR1-WDS or TR3-WDS), see Chapter Accessories.
Keep measuring wire in an area where it cannot be
snagged or otherwise be violated.
Fig. 6 Wire fastening and misalignment
max. 3 °
Wire outlet 0 °
±3 ° tolerance
A measuring wire under
tension where opera-
tors are standing can
lead to injuries.
> Risk of damage to
wire and sensor.
Do not twist the measu-
ring wire!

Page 20
Installation and Assembly
wireSENSOR, WPS MK60-M / MK88-M
4.5 Sensitivity Characteristics
Designed with a single-layered wire wound onto the drum, the WPS-2300-MK88-M draw-wire mechanics pro-
vides high measurement accuracy. The WPS-3500-MK88-M and WPS-5000-MK88-M models have a double-
layered wire which enables a larger measuring range while maintaining the same housing size.
Models with a multi-layer/double-layer winding provide reduced measurement accuracy at the start of the
measuring range which is why they are primarily recommended as wire pre-extension.
The sensitivity curve throughout the entire measuring range is shown in the diagram, see Fig. 7.
Sensitivity
(rotation)
[mm]
Extension[mm]
Pre-extension length
Extension length max.
Highest measurement accuracy
238.8 ±0.3
242.5 ±0.5
5000
MR 2300
MR 5000
2. layer 1. layer
0
2700 ±300
Step to 2. layer
MR 3500
Fig. 7 Sensitivity characteristics draw-wire mechanics WPS-xxxx-MK88-M, dimensions in mm