MICRO-EPSILON WPS Series User manual

MICRO-EPSILON MESSTECHNIK GmbH & Co. KG
Koenigbacher Str. 15 · 94496 Ortenburg / Germany
Tel. [phone] / 168-0 · Fax [phone] / 168-90
[email protected] · www.micro-epsilon.com
Your local contact: www.micro-epsilon.com/contact/worldwide/
WPS - x - MK30
WPS - x - MK46
WPS - x - MK60
WPS - x - MK77
WPS - x - MK88
WPS - x - MK120
Operating Instructions
wireSENSOR, WPS

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 require-
ments 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 13857:2019 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and
lower limbs
EN 60204-1:2018 Safety of machinery - Electrical equipment of machines - Part 1: General requirements
- Directive 2011/65/EU (RoHS)
EN IEC 63000:2018 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 accor-
dance 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 Decla-
ration of Conformity according to Annex II, Part A exists.
Ortenburg, Germany Dipl.-Ing.(FH) Eduard Huber, MBA
July 1, 2021 Quality Manager
Tel. [phone] / 168-0 e-mail [email protected]
Fax [phone] / 168-90 www.micro-epsilon.com

wireSENSOR, WPS

wireSENSOR, WPS
Contents
1. Safety ........................................................................................................................................ 7
1.1 Symbols Used ................................................................................................................................................. 7
1.2 Warnings.......................................................................................................................................................... 7
1.3 Notes on Product Marking............................................................................................................................... 9
1.4 Intended Use ................................................................................................................................................. 10
1.5 Proper Environment....................................................................................................................................... 10
1.6 Foreseeable Misuse....................................................................................................................................... 10
2. Functional Principle, Technical Data ..................................................................................... 11
2.1 Functional Principle ....................................................................................................................................... 11
2.2 Structure ........................................................................................................................................................ 11
2.3 Technical Data MK30 Analog......................................................................................................................... 12
2.4 Technical Data MK46 Analog......................................................................................................................... 13
2.5 Technical Data MK77 Analog......................................................................................................................... 14
2.6 Technical Data MK60 Analog......................................................................................................................... 15
2.7 Technical Data MK88 Analog......................................................................................................................... 16
2.8 Technical Data MK120 Analog....................................................................................................................... 17
2.9 Technical Data MK30 Digital.......................................................................................................................... 18
2.10 Technical Data MK46 Digital.......................................................................................................................... 19
2.11 Technical Data MK77 Digital.......................................................................................................................... 20
2.12 Technical Data MK60 Digital.......................................................................................................................... 21
2.13 Technical Data MK88 Digital.......................................................................................................................... 22
3. Delivery ................................................................................................................................... 23
3.1 Unpacking, Included in Delivery.................................................................................................................... 23
3.2 Storage .......................................................................................................................................................... 23
4. Installation and Assembly...................................................................................................... 24
4.1 Precautions.................................................................................................................................................... 24
4.2 Sensor Mounting ........................................................................................................................................... 25
4.3 Dimensional Drawings................................................................................................................................... 26
4.3.1 wireSENSOR WPS MK30 Analog................................................................................................. 26
4.3.2 wireSENSOR WPS MK30 Digital.................................................................................................. 28
4.3.3 wireSENSOR WPS MK46 Analog................................................................................................. 29
4.3.4 wireSENSOR WPS MK46 Digital.................................................................................................. 31
4.3.5 wireSENSOR WPS MK77 Analog................................................................................................. 32

wireSENSOR, WPS
4.3.6 wireSENSOR WPS MK77 Digital.................................................................................................. 34
4.3.7 wireSENSOR WPS MK60 Analog................................................................................................. 35
4.3.8 wireSENSOR WPS MK60 Digital.................................................................................................. 36
4.3.9 wireSENSOR WPS MK88 Analog................................................................................................. 37
4.3.10 wireSENSOR WPS MK88 Digital.................................................................................................. 38
4.3.11 wireSENSOR WPS MK120 Analog............................................................................................... 39
4.4 Wire Guide and Fastening............................................................................................................................. 41
4.5 Pin Assignment Analog ................................................................................................................................. 42
4.5.1 Potentiometer Output ................................................................................................................... 42
4.5.2 Voltage Output.............................................................................................................................. 43
4.5.3 Current Output.............................................................................................................................. 44
4.6 Pin Assignment Digital................................................................................................................................... 45
4.6.1 CANopen ..................................................................................................................................... 45
4.6.1.1 CANopen Pin Assignment .......................................................................................... 45
4.6.1.2 CANopen Features...................................................................................................... 46
4.6.1.3 CANopen Setting the Baud Rate and the Subscriber Address (Node ID)................. 46
4.6.2 Incremental Encoder .................................................................................................................... 47
4.6.2.1 Signal Output .............................................................................................................. 47
4.6.2.2 Pin Assignment ........................................................................................................... 49
5. Operation ................................................................................................................................ 51
6. Operation and Maintenance .................................................................................................. 51
7. Disclaimer............................................................................................................................... 52
8. Service, Repair ....................................................................................................................... 53
9. Decommissioning, Disposal .................................................................................................. 54
Appendix

Page 7
Safety
wireSENSOR, WPS
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 moder-
ate 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
The supply voltage must not exceed the specified limits.
> Risk of injury
> Damage to or destruction of the sensor
Do not open the sensor housing.
> Risk of injury from pre-tensioned spring motor
Do not pull or loop the measuring wire around unprotected parts of the body.
> Risk of injury
Do not let the measuring wire rewind without control (snap back).
> Risk of injury from whiplash effect of the wire with wire clip / eyelet
> Destruction of the measuring wire and/or the sensor
Do not pull the measuring wire over measuring range.
> Risk of injury
> Destruction of the measuring wire and/or the sensor

Page 8
Safety
wireSENSOR, WPS
Connect the power supply and the display/output device according to the safety regulations for electrical
equipment.
> Damage to or destruction of the sensor
Avoid shocks and impacts to the sensor.
> Damage to or destruction of the sensor

Page 9
Safety
wireSENSOR, WPS
1.3 Notes on Product Marking
For WPS draw-wire displacement sensors with voltage, current, digital or encoder outputs, the EU Directives
2014/30/EU and 2011/65/EU shall apply for CE, or SI 2016 No. 1091 and SI 2012 No. 3032 shall apply for
UKCA. In addition, the Machinery Directive is taken into consideration (2006/42/EC or SI 2008 No. 1597).
These sensors carry the CE / UKCA marking and satisfy the requirements of the EU Directives / UK regula-
tions cited and the European harmonized standards (EN) listed therein.
The Declaration of Conformity is available to the responsible authorities at:
MICRO-EPSILON MESSTECHNIK GmbH & Co. KG
Koenigbacher Straße 15
94496 Ortenburg / Germany
Draw-wire displacement sensors with potentiometer output are devices (components) which cannot be oper-
ated autonomously and do not carry a CE / UKCA marking. For WPS draw-wire displacement sensors with
potentiometer output, the Directives 2006/42/EC and 2011/65/EU shall apply for CE, or SI 2008 No. 1597 and
SI 2012 No. 3032 shall apply for UKCA. Therefore, an EU Declaration of Conformity is not issued. The Decla-
ration of Incorporation shall apply.

Page 10
Safety
wireSENSOR, WPS
1.4 Intended Use
- Draw wire sensors are used for
distance or displacement measuring
position determination of components or moving machine parts.
- The sensors must only be operated within the limits specified in the technical data, see 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.
1.5 Proper Environment
- Protection class: IP20 1
IP65 (MK60, MK88, MK120)
- Temperature range:
Operation: -20 ... +80 °C (-4 ... +176 °F)
Storage: -40 ... +80 °C (-40 ... +176 °F)
- Humidity: 5 ... 95 % RH (non-condensing)
- Ambient pressure: Atmospheric pressure
iNote the slight power dissipation of the potentiometer above +40°C (+104 °F)! (-0.15 W/10 K)!
1.6 Foreseeable Misuse
Do not pull the measuring wire beyond the measuring range listed. This causes then 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
injury.
1) For models with potentiometer. For models with encoder depends on encoder type.

Page 11
Functional Principle, Technical Data
wireSENSOR, WPS
2. Functional Principle, Technical Data
2.1 Functional Principle
With the wire principle, a linear motion is transformed into a change in resistance by a rotation.
A measuring 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 a
• multi-turn potentiometer (Type WPS-...-MKxx-...-P/U/I) respectively with an
• encoder (Type WPS-...-MKxx-E).
Fig. 1 Draw-wire sensor with potentiometer
2.2 Structure
The draw wire principle is used in the housing design MK30, MK46, MK77, MK60 , MK88 and MK120 with dif-
ferent measuring lengths from 50 to 7500 mm (1.69 to 295.2 in).
Two versions of the electrical connection are possible:
- Potentiometer output (resistance divider)
- Voltage output (with integrated electronics)
- Current output (with integrated electronics)
- Incremental encoder (with integral electronics, HTL or TTL output)
- CANopen output (with integrated electronics)

Page 12
Functional Principle, Technical Data
wireSENSOR, WPS
2.3 Technical Data MK30 Analog
Model WPS-50-MK30 WPS-150-
MK30
WPS-250-
MK30
WPS-500-
MK30
WPS-750-
MK30
Measuring range 50 mm 150 mm 250 mm 500 mm 750 mm
Analog output Potentiometer
Resolution Conductive plastic potentiometer towards infinity - - - -
Wire potentiometer - - - 0.15 mm 0.2 mm
Hybrid potentiometer - towards infinity
Linearity Conductive plastic
potentiometer P50
≤ ±0.5 % FSO ≤ ±0.25 mm - - - -
Wire potentiometer P25 ≤ ±0.25 % FSO - - - ≤ ±1.25 mm ≤ ±1.87 mm
Hybrid potentiometer P25 ≤ ±0.25 % FSO -≤ ±0.375 mm ≤ ±0.625 mm - -
Hybrid potentiometer P10 ≤ ±0.1 % FSO - - ≤ ±0.25 mm ≤ ±0.5 mm ≤ ±0.75 mm
Sensor element Conductive plas-
tic potentiometer Hybrid potentiometer Wire/hybrid potentiometer
Wire extension force (max.) ca. 2.5 N
Wire retraction force (max.) ca. 1 N
Wire acceleration (max.) ca. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (Ø 0.36 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves on the sensor housing
Tempera-
ture range
Storage -20 … +80 °C
Operation -20 … +80 °C
Connection Soldering tags
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP20
Weight approx. 45 g
FSO = Full Scale Output

Page 13
Functional Principle, Technical Data
wireSENSOR, WPS
2.4 Technical Data MK46 Analog
Model WPS-1000-MK46 WPS-1250-MK46
Measuring range 1000 mm 1250 mm
Analog output Potentiometer Potentiometer, current,
voltage
Resolution Wire potentiometer P25 0.3 mm 0.4 mm
Hybrid potentiometer P10/U10/I10 towards infinity
Linearity Wire potentiometer P25 ≤ ±0.25 % FSO ≤ ±2.5 mm ≤ ±3.12 mm
Hybrid potentiometer
P10/U10/I10
≤ ±0.1 % FSO ≤ ±1 mm ≤ ±1.2 mm
Sensor element Wire/hybrid potentiometer
Wire extension force (max.) approx. 1.6 N approx. 1.5 N
Wire retraction force (min.) approx. approx. 1 N
Wire acceleration (max.) approx. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (ø 0.36 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves
on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection P10/P25 Soldering tags
CR-P10/CR-P25/CR-U10/CR-I10 integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and
1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP20
Weight approx. 80 g
FSO = Full Scale Output

Page 14
Functional Principle, Technical Data
wireSENSOR, WPS
2.5 Technical Data MK77 Analog
Model WPS-2100-MK77
Measuring range 2100 mm
Analog output Potentiometer
Resolution Wire potentiometer P25 0.55 mm
Linearity Wire
potentiometer P25
≤ ±0.25 % FSO ≤ ±5.25 mm
Sensor element Wire potentiometer
Wire extension force (max.) approx. 5 N
Wire retraction force (max.) approx. 3.5 N
Maximale Seilbeschleunigung approx. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (ø 0.45 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves
on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection P25 Soldering tags
CR-P25 integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP20
Weight P25 approx. 220 g
CR-P25 approx. 275 g (incl. cable)
FSO = Full Scale Output

Page 15
Functional Principle, Technical Data
wireSENSOR, WPS
2.6 Technical Data MK60 Analog
Model WPS-1500-MK60
Measuring range 1500 mm
Analog output Potentiometer, current, voltage
Resolution Hybrid potentiometer P10 towards infinity
Linearity Hybrid potenti-
ometer P10
≤ ±0.15 % d.M. ≤ ±2.25 mm
Sensor element Hybrid potentiometer
Wire extension force (max.) approx. 8 N
Wire retraction force (max.) approx. 1 N
Wire acceleration (max.) approx. 5 g
Material Housing Glass-fiber reinforced plastic (PBT GF20)
Measuring wire Polyamide-coated stainless steel (ø 0.45 mm)
Wire mounting Wire clip
Mounting Mounting holes
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and
1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP65
Weight approx. 290 g (incl. cable)
FSO = Full Scale Output

Page 16
Functional Principle, Technical Data
wireSENSOR, WPS
2.7 Technical Data MK88 Analog
Model WPS-2300-MK88 WPS-3500-MK88 WPS-5000-MK88
Measuring range 2300 mm 3500 mm 5000 mm
Analog output Potentiometer, current, voltage
Resolution Hybrid potentiometer P10 towards infinity
Linearity Hybrid potentiometer P10 ≤ ±0.15 % d.M. ≤ ±3.45 mm - -
Hybrid potentiometer P10 ≤ ±0.3 % d.M. -≤ ±10.5 mm -
Hybrid potentiometer P10 ≤ ±0.4 % d.M. - - ≤ ±20 mm
Sensor element Hybrid potentiometer
Wire extension force (max.) approx. 9 N
Wire retraction force (min.) approx. 3 N
Wire acceleration (max.) approx. 7 g
Material Housing Glass-fiber reinforced plastic (PA 6 GF30)
Protection cap Glass-fiber reinforced plastic (PBT GF20)
Measuring wire Polyamide-coated stainless steel (ø 0.45 mm)
Wire mounting Wire clip
Mounting Mounting holes or mounting grooves on the sensor housing
Tempera-
ture range
Storage -20 … +80 °C
Operation 20 … +80 °C (on request -40 … +85 °C)
Connection integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 10 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP65 (on request IP67)
Weight approx. 400 ... 430 g (incl. cable)
FSO = Full Scale Output

Page 17
Functional Principle, Technical Data
wireSENSOR, WPS
2.8 Technical Data MK120 Analog
Model WPS-3000-MK120 WPS-5000-MK120 WPS-7500-MK120
Measuring range 3000 mm 5000 mm 7500 mm
Analog output Potentiometer, current, voltage
Resolution Hybrid potentiometer P10 towards infinity
Linearity Hybrid potenti-
ometer P10
≤ ±0.15 % FSO ≤ ±4.5 mm ≤ ±7.5 mm ≤ ±11.25 mm
Sensor element Hybrid potentiometer
Wire extension force (max.) approx. 10 N
Wire retraction force (min.) approx. 4 N
Wire acceleration (max.) approx. 6 g
Material Housing Plastics (PA 6)
Measuring wire Polyamide-coated stainless steel (Ø 0.45 mm)
Wire mounting Wire clip
Mounting Mounting holes or mounting grooves on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 40 g / 6 ms in 3 axes, 2 directions and 3000 shocks each
Vibration (DIN EN 60068-2-6) 3 g / 10 … 5000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP65
Weight approx. 850 g (incl. cable)
FSO = Full Scale Output

Page 18
Functional Principle, Technical Data
wireSENSOR, WPS
2.9 Technical Data MK30 Digital
Model WPS-500-MK30 WPS-750-MK30
Measuring range 500 mm 750 mm
Digital output Encoder: E (5 ... 24 VDC) / Encoder E830 (8 ... 30 VDC)
Resolution 10 Pulse / mm 6.7 Pulse / mm
0.1 mm 0.15 mm
Linearity ≤ ±0.5 % FSO ≤ ±0.25 mm ≤ ±0.375 mm
Sensor element Incremental encoder
Wire extension force (max.) approx. 2.5 N
Wire retraction force (min.) approx. 1 N
Wire acceleration (max.) approx. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (ø 0.36 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP54
Weight approx. 80 g (incl. cable)
FSO = Full Scale Output

Page 19
Functional Principle, Technical Data
wireSENSOR, WPS
2.10 Technical Data MK46 Digital
Model WPS-1250-MK46
Measuring range 1250 mm
Digital output Encoder: E (5 ... 24 VDC) / Encoder E830 (8 ... 30 VDC)
Resolution 4 Pulse / mm
0.25 mm
Linearity ≤ ±0.05 % FSO ≤ ±0.625 mm
Sensor element Incremental encoder
Wire extension force (max.) approx. 1.5 N
Wire retraction force (min.) approx. 1 N
Wire acceleration (max.) approx. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (ø 0.36 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection integrated cable, radial, length 1 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP54
Weight ca. 120 g (incl. cable)
FSO = Full Scale Output

Page 20
Functional Principle, Technical Data
wireSENSOR, WPS
2.11 Technical Data MK77 Digital
Model WPS-2100-MK77
Measuring range 2100 mm
Digital output Encoder: E (5 ... 24 VDC) / Encoder E830 (8 ... 30 VDC)
Resolution 2.32 Pulse / mm
0.43 mm
Linearity ≤ ±0.05 % FSO ≤ ±1.05 mm
Sensor element Incremental encoder
Wire extension force (max.) approx. 5 N
Wire retraction force (min.) approx. 3.5 N
Wire acceleration (max.) approx. 5 g
Material Housing Plastics
Measuring wire Polyamide-coated stainless steel (ø 0.45 mm)
Wire mounting Eyelet (Ø 4.5 mm)
Mounting Mounting holes or mounting grooves on the sensor housing
Temperature range Storage -20 … +80 °C
Operation -20 … +80 °C
Connection integrated cable, radial, length 2 m
Shock (DIN EN 60068-2-27) 50 g / 5 ms in 3 axes, 2 directions and 1000 shocks each
Vibration (DIN EN 60068-2-6) 20 g / 20 … 2000 Hz in 3 axes and 10 cycles each
Protection class (DIN EN 60529) IP54
Weight ca. 275 g (incl. cable)
FSO = Full Scale Output