MICRO-EPSILON WPS Series User manual

WPS-2300-K100
WPS-5000-K100
Operating Instructions
wireSENSOR, WPS series

Declaration of Incorporation
Declaration of incorporation according to 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 requi-
rements
- 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, 22 May 2019 Dr. Thomas Wisspeintner
Managing Director
Tel. [phone] / 168-0 email [email protected]
Fax [phone] / 168-90 www.micro-epsilon.com

wireSENSOR, WPS K100 series

wireSENSOR, WPS K100 series
Contents
1. Safety ........................................................................................................................................ 7
1.1 Symbols Used ................................................................................................................................................. 7
1.2 Warnings.......................................................................................................................................................... 7
1.3 Notes on CE Marking ...................................................................................................................................... 8
1.4 Intended Use ................................................................................................................................................... 9
1.5 Proper Environment......................................................................................................................................... 9
1.6 Foreseeable Misuse......................................................................................................................................... 9
2. Functional Principle, Technical Data ..................................................................................... 10
2.1 Measuring Principle ....................................................................................................................................... 10
2.2 Structure ........................................................................................................................................................ 10
2.3 Technical Data .............................................................................................................................................. 11
3. Delivery .................................................................................................................................. 12
3.1 Unpacking/Included in Delivery .................................................................................................................... 12
3.2 Storage .......................................................................................................................................................... 12
4. Installation and Assembly...................................................................................................... 13
4.1 Precautions.................................................................................................................................................... 13
4.2 Sensor Mounting ........................................................................................................................................... 14
4.3 Dimensional Drawings................................................................................................................................... 15
4.4 Guiding and Attaching the Wire .................................................................................................................... 17
4.5 Potentiometer Output .................................................................................................................................... 18
4.6 Voltage Output ............................................................................................................................................... 19
4.7 Current Output............................................................................................................................................... 20
5. Operation and Maintenance .................................................................................................. 21
6. Liability for Material Defects.................................................................................................. 21
7. Service, Repair ....................................................................................................................... 22
8. Decommissioning, Disposal .................................................................................................. 22
Appendix

wireSENSOR, WPS K100 series

Page 7
Safety
wireSENSOR, WPS K100 series
1. Safety
Sensor 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 modera-
te 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 due to pre-tensioned spring motor
Do not let the measuring wire snap.
> Risk of injury due to whiplash of the wire with mounting bolts/hooks
> Destruction of the wire and/or the sensor
Do not pull or loop the measuring wire around unprotected body parts.
> Risk of injury
Connect the power supply according to the safety regulations for electrical equipment.
> Risk of injury
> Damage to or destruction of the sensor

Page 8
Safety
wireSENSOR, WPS K100 series
Do not pull out the measuring wire beyond the measuring range listed.
> 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 Notes on CE Marking
For WPS draw-wire displacement sensors with voltage, current, digital or encoder outputs, the EU Directives
2014/30/EU, 2011/65/EU shall apply. In addition, the Machinery Directive is taken into consideration
(2006/42/EC.).
These sensors carry the CE mark and satisfy the requirements of the EU Directives cited and the European
harmonized standards (EN) listed therein.
The EU Declaration of Conformity is available to the responsible authorities at:
MICRO-EPSILON MESSTECHNIK
GmbH & Co. KG
Königbacher Straße 15
94496 Ortenburg / Germany
Draw-wire displacement sensors with potentiometer output are devices (components) which cannot be ope-
rated autonomously and do not carry a CE mark. For WPS draw-wire displacement sensors with potentiome-
ter output, the directives 2006/42/EC and 2011/65/EU shall apply. Therefore, an EU Declaration of Conformity
is not issued according to EMC law and the Machinery Directive. The Declaration of Incorporation shall apply.
Sources: EMVG (Electromagnetic Compatibility of Equipment law), guidelines on the application of Directive
2014/35/EU, Directive 2006/42/EC.

Page 9
Safety
wireSENSOR, WPS K100 series
1.4 Intended Use
- Draw-wire displacement sensors are designed for use in industrial applications. It is used for
displacement and movement measurements,
measuring the position of parts or maneuverable machine components.
- Sensors must only be operated within the limits specified in the technical data, see 2.3.
- Draw-wire displacement sensors must be used only 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.
1.5 Proper Environment
- Sensor protection class: IP 69K
- 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
1.6 Foreseeable Misuse
Do not pull out the measuring wire beyond the measuring range listed. This causes the wire to break and
thus uncontrolled snapping of the measuring wire. Risk of injury.
Do not have sensor held by a second person while the measuring wire is pulled out. Risk of snapping and
thus injury.

Page 10
Functional Principle, Technical Data
wireSENSOR, WPS K100 series
2. Functional Principle, Technical Data
2.1 Measuring Principle
The draw-wire principle transforms a linear movement into a change in resistance.
A measuring wire made of highly flexible stainless-steel cores is wound onto a drum by using a durable
spring motor.
The winding drum is coupled axially with a potentiometer.
Fig. 1 Draw-wire displacement sensor with potentiometer
2.2 Structure
The draw-wire principle is applied in the housing design K100 with different measuring ranges from 2300 to
5000 mm.
The electrical connection is the potentiometer output (resistance divider).

Page 11
Functional Principle, Technical Data
wireSENSOR, WPS K100 series
2.3 Technical Data
Model WPS-2300-K100 WPS-5000-K100
Analog output P / U / I
Measuring range 2300 mm 5000 mm
Resolution Towards infinity
Linearity ≤ ± 5.75 mm ≤ ± 12.5 mm
≤ ± 0.25 % FSO
Sensor element Potentiometer
Wire extension force (max) 8 N
Wire retraction force (min.) 2 N
Wire acceleration (max.) 5 g
Material Housing Glass-fiber reinforced plastic
Measuring wire Polyamide-coated stainless steel (Ø 0.61 mm)
Wire mounting Wire clip
Mounting Through bores Ø 6.4 mm and mounting nuts (for M6) on
the sensor housing
Temperature range Operation -40 … +85 °C (-40 °F ... +185 °F)
Storage -40 … +85 °C (-40 °F ... +185 °F)
Connection Integrated cable, radial, 1 m long
Shock (DIN-EN 60068-2-29) 50 g, 20 ms
Vibration (DIN-EN 60068-2-26) 20 g, 20 Hz – 2 kHz
Protection class (ISO 20653) IP 69K
FSO = Full Scale Output
Free return of measu-
ring wire not permitted!
> Risk of injury due to
whiplash of the wire
with mounting bolts/
hooks.
> Destruction of the
wire and/or the
sensor.

Page 12
Delivery
wireSENSOR, WPS K100 series
3. Delivery
3.1 Unpacking/Included in Delivery
1 Sensor
4 Slot nuts
1 Assembly instruction
Do not remove draw-wire displacement sensors from packaging using the wire, wire clip.
Transport them in such a way that they cannot be damaged.
Check the delivery for completeness and shipping damage immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or your supplier.
iThe transport lock of the measuring wire must only be removed immediately prior to installation and only by technical staff.
Optional accessories are listed in the chapter Appendix.
3.2 Storage
Store sensors solely with the transport lock installed. This prevents the measuring wire from ever being pulled
out and unintentional snapping.
> Risk of injury due to whiplash of the wire with wire clip
- Temperature range for storage: -40 °C - +85 °C (-40 °F ... +185 °F)
- Humidity: 5 - 95 % (non-condensing)
- Atmospheric pressure

Page 13
Installation and Assembly
wireSENSOR, WPS K100 series
4. Installation and Assembly
4.1 Precautions
Do not pull out the measuring wire beyond the measuring range listed.
> Damage to or destruction of the sensor
Do not damage the measuring wire.
Do not oil or grease the measuring wire.
Do not kink the measuring wire.
Do not pull the measuring wire diagonally.
Do not let the measuring wire drag around objects.
Attach the measuring wire to the measured object while the wire is retracted.
Do not wrap the measuring wire around body parts.
Free return of measu-
ring wire not permitted!
> Risk of injury due to
whiplash of the wire
with mounting bolts/
hooks.
> Destruction of the
wire and/or the
sensor.
Secure the measuring
wire during installation
work.

Page 14
Installation and Assembly
wireSENSOR, WPS K100 series
4.2 Sensor Mounting
Mount the sensor either with M6 screws (through-hole) or with slot nuts (mounting grooves) according
to the specifications in the following table and according to the following figures, see Fig. 2, see Fig. 3.
Model Screws for
through-hole
Slot nuts for
mounting grooves
WPS-2300-K100 3 x M6 M6 x 3.2 mm
WPS-5000-K100 3 x M6 M6 x 3.2 mm
The slot nuts can be mounted on each sensor side into the mounting grooves.
Make sure that the thread length of the screws, which you use for the slot nuts, protrude from the sensor
edge between 5 mm and 7 mm into the mounting groove.
> Damage of the sensor housing due to the screw being too long
The sensor does not have to be oriented in a special way.
Select the installation position in such a way that damage to or contamination of the measuring wire is
avoided.
iIf possible, prefer an installation position in which the measuring wire exits downward. This prevents liquids from entering the measuring wire outlet.
iDo not let the measuring wire snap! There is no liability for material defects in case of damage due to snapping.

Page 15
Installation and Assembly
wireSENSOR, WPS K100 series
4.3 Dimensional Drawings
26
(1.02)
38
(1.50)
52.2
(2.06)
82.5
(3.25)
15
(.60)
16.4
(.65)
100 (3.94)
80 (3.15)
50 (1.97)
104.1 (4.10)
162 (6.38)
50 (1.97)
43
(1.69)
80 (3.15)
100 (3.94)
3x ø6.4
Mounting grooves
for M6
Mounting
holes
12
(.47)
Fig. 2 Dimensional drawing WPS-2300-K100, dimensions in mm, not to scale
If a measuring wire is
stretched in the area
where operating
personnel is located,
injuries may occur.
> Risk of dama-
ge for wire and
sensor
Do not twist the
measuring wire!

Page 16
Installation and Assembly
wireSENSOR, WPS K100 series
154.1 (6.07)
212 (8.35)
43
(1.69)
3x ø6.4
Mounting
grooves for M6
15
(.60)
16.4
(.65)
82.5
(3.25)
52.2
(2.06)
38
(1.50)
26
(1.02)
Mounting holes
12
(.47)
100 (3.94)
80 (3.15)
50 (1.97)
50 (1.97)
80 (3.15)
100 (3.94)
Fig. 3 Dimensional drawing WPS-5000-K100, dimensions in mm, not to scale
If a measuring wire is
stretched in the area
where operating
personnel is located,
injuries may occur.
> Risk of dama-
ge for wire and
sensor
Do not twist the
measuring wire!

Page 17
Installation and Assembly
wireSENSOR, WPS K100 series
4.4 Guiding and Attaching the Wire
If the measuring wire must be pulled out of the sensor
to guide the wire or attach it to the measured object:
- the sensor must not be held by a second person
during that process,
- the measuring wire must not be pulled out beyond
the measuring range listed,
- the area around the sensor must be protected
against snapping of the measuring wire.
Incorrect
Correct
Fix the measuring wire to the target using a wire
clip.
Guide the measuring wire vertically out of the sen-
sor housing.
Diagonal pull is only permitted up to 3 degrees.
If you drag the measuring wire over the insertion hole or
other objects, the measuring wire will be damaged and/
or tear.
iIf the measuring wire cannot be fed vertically out of the housing, it is essential to use a guide pulley
(accessory TR1-WDS or TR3-WDS, see chapter
Appendix).
Guide the measuring wire in a protected area so
that it cannot get caught or otherwise be dama-
ged.
max. 3 °
Wire outlet 0 °
±3 ° tolerancy
If a measuring wire
is stretched in the
area where operating
personnel is located,
injuries may occur.
Do not twist the measu-
ring wire!

Page 18
Installation and Assembly
wireSENSOR, WPS K100 series
4.5 Potentiometer Output
Draw-wire displacement sensors with potentiometer output are connected according to the table, see Fig. 4.
Potentiometer output (P) Integrated cable -CA / -CR
Input voltage max. 32 VDC with
1 kOhm / max. 1 W
White = Input +
Brown = Ground
Green = Signal
Resistance 1 kOhm ±10 %
(resistance divider)
Temperature coefficient ±0.0025 % FSO/°C
Contact current ≤ 10 μA
Sensitivity dependent on measuring range
Fig. 4 Table of potentiometer output
FSO = Full Scale Output
Use any potentiometer only when switched to voltage divider. Using it as a variable resistor destroys the com-
ponent. Observe maximum contact currents.
iUse potentiometers only as voltage dividers, not as variable series resistors!

Page 19
Installation and Assembly
wireSENSOR, WPS K100 series
4.6 Voltage Output
Voltage output (U) Integrated cable -CA / -CR
Operating voltage 14 ... 27 VDC (non-stabilized 1)
White = Supply
Brown = Ground
Green = Signal
Yellow = Ground
Current consumption max. 30 mA
Output voltage 0 ... 10 VDC
Options 0 ... 5 / ±5 V
Output current 2 mA max.
Load resistance > 5 kOhm
Output noise 0.5 mVeff
Temperature coefficient ±0.005 % FSO/°C
Fig. 5 Table for voltage output
FSO = Full Scale Output
1) Non-stabilized, measured on the input terminals of the sensor

Page 20
Installation and Assembly
wireSENSOR, WPS K100 series
4.7 Current Output
Current output (I) Integrated cable -CA / -CR
Operating voltage 9 ... 32 VDC (non-stabilized 1)
White = Supply
Brown = Ground
Output current 4 ... 20 mA
Load < 600 Ohm
Output noise 1.6 μAeff
Temperature coefficient ±0.005 % FSO/°C
Fig. 6 Table for current output
FSO = Full Scale Output
1) Non-stabilized, measured on the input terminals of the sensor