Pepperl+Fuchs WCS Series User manual

WCS
position encoding system
Mechanics
FACTORY AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the lectrical Indus-
try, published by the Central Association of the lectrical Industry (Zentralverband
lektrotechnik und lektroindustrie (ZV I) e.V.) in its most recent version as well as the
supplementary clause: " xpanded reservation of proprietorship"
WCS position encoding system

WCS position encoding system
3
1 Introd ction................................................................................. 5
2 Declaration of conformity .......................................................... 6
2.1 CE conformity....................................................................................... 6
3 Safety ........................................................................................... 7
3.1 Symbols relevant to safety.................................................................. 7
3.2 General safety instr ctions ................................................................. 7
4 Prod ct Description ................................................................... 8
4.1 F nctional Description ........................................................................ 8
4.2 Application areas ............................................................................... 10
5 Readers ..................................................................................... 13
5.1 Mo nting ............................................................................................. 16
5.2 Plastic Lenses .................................................................................... 18
6 Code Rail ................................................................................... 20
6.1 Gro nding the Code Rail................................................................... 21
6.2 Clamping Fixt re for the Stainless Steel Code Rail ........................ 21
6.3 Identification....................................................................................... 22
7 Mo nting the Code Rail............................................................ 24
7.1 Mo nting the Code Rail with Mo nting Brackets............................ 26
7.1.1 Mounting the Code Rail on a Straight Route .................................... 29
7.1.2 Mounting the Code Rail on Curves .................................................. 30
7.2 Mo nting WCS2 Code Rail with the Al min m Profile System ..... 31
7.3 Rail Holders ........................................................................................ 35
7.3.1 Adapter Plates for Profile Rails......................................................... 36
7.3.2 Mounting the Code Rail ................................................................... 39
7.3.3 Fixed Points ..................................................................................... 41
7.3.4 The Guide Trolley............................................................................. 42
7.3.5 Grounding the Aluminum Profile System.......................................... 44

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WCS position encoding system
7.4 Mo nting WCS3 Code Rail with the Al min m Profile System .....45
7.4.1 Rail Holders...................................................................................... 48
7.4.2 Adapter Plates for Profile Rails ......................................................... 49
7.4.3 Mounting the Code Rail....................................................................51
7.4.4 Fixed Points...................................................................................... 52
7.4.5 Vertical Curves .................................................................................54
7.4.6 Interruptions in the Profile Rail ..........................................................55
7.4.7 Suspended Mounting with Stainless Steel Code Rail ....................... 55
7.4.8 Grounding the Aluminum Profile System .......................................... 56
7.4.9 Integration of the WCS Code Rail in Conductor Lines ...................... 56

WCS position encoding system
Introduction
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1 Introduction
Congrat lations
You have chosen a device manufactured by Pepperl+Fuchs. Pepperl+Fuchs develops,
produces and distributes electronic sensors and interface modules for the market of
automation technology on a worldwide scale.
Symbols sed
The following symbols are used in this manual:
Handling instructions
You will find handling instructions beside this symbol
Contact
If you have any questions about the device, its functions, or accessories, please contact us at:
Pepperl+Fuchs GmbH
Lilienthalstraße 200
68307 Mannheim
Telephone: [phone]
Fax: [phone]
-Mail: [e-mail]
Note!
This symbol draws your attention to important information.

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WCS position encoding system
Declaration of conformity
2 Declaration of conformity
2.1 C conformity
This product was developed and manufactured under observance of the applicable uropean
standards and guidelines.
Note!
A declaration of conformity can be requested from the manufacturer.

WCS position encoding system
Safety
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3 Safety
3.1 Symbols relevant to safety
3.2 General safety instructions
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the system operator.
Installation and commissioning of all devices must be performed by a trained professional only.
User modification and or repair are dangerous and will void the warranty and exclude the
manufacturer from any liability. If serious faults occur, stop using the device. Secure the device
against inadvertent operation. In the event of repairs, return the device to your local
Pepperl+Fuchs representative or sales office.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt devices and any connected facilities or systems, or result in
their complete failure.
Note!
Disposal
lectronic waste is hazardous waste. When disposing of the equipment, observe the current
statutory requirements in the respective country of use, as well as local regulations.

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WCS position encoding system
Product Description
4 Product Description
4.1 Functional Description
The WCS position encoding system consists of two main components:
1. The code rail
The code rail carries information for the absolute code. The code rail is routed parallel to
the track for the material handling equipment and assigns a unique position to every point
on the track. It is possible to route the code rail only at points where positioning is required.
The system allows the code rail to be routed along curves and allows branches to be cre-
ated. The code rail is built to order and delivered in a bundle. Unless otherwise ordered,
the code rail always starts with the position value 0. The maximum length of the code rail
is 327 m (WCS2) or 314.5 m (WCS3). Brackets are available for mounting the code rail.
2. The reader
The U-shaped reader scans the code rail photoelectronically without touching it. very
0.833 mm (WCS2) or 0.8 mm (WCS3), the reader detects a new position value. After in-
sertion into the code rail, the reader determines the position value without reference or de-
lay. The code rail can be scanned at very high speeds. The scanning is reproducible,
reliable, and independent of temperature fluctuations. The position value can be trans-
ferred directly from the reader to the controller via a serial RS485 interface. For connection
to standard interfaces, there is a wide range of interface modules available:
• Parallel
• SSI
• PROFIBUS DP
• DeviceNet
• CANopen
• thernet
• InterBus-S
• PROFIN T
• MODBUS RTU
Up to four readers can be connected simultaneously to all interface modules with the ex-
ception of the SSI interface module.

WCS position encoding system
Product Description
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1. Interface module
2. Code rail
3. Reader
Properties of the WCS
■ Absolute position encoding system
■ Photoelectric principle (infrared range)
■ Proven and robust
■ asy to maintain
■ No reference points required
■ No calibration and adjustment work necessary
■ Resistant to power failure
■ Millimeter-precise positioning with absolute repeat accuracy
■ Determination of position value in real time and regardless of temperature fluctuations
■ Guaranteed reading up to a speed of 12.5 m/s
■ High resolution = ±0.4 mm
■ Variable route length: 0.1 m to 327 m
■ Coding system also suitable for curves with up to 0.5 m radius
■ A wide variety of applications, such as stock feeders, trolleys, monorail conveyors,
galvanic plants, automatic and slewing cranes, as well as elevators
■ Various mounting systems available for installing the code rail
■ Connection to any controller possible, either directly or via interface module
■ Connectivity to many fieldbus systems available
■ Support during commissioning and maintenance with extensive system diagnostics
options
1
2
3

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WCS position encoding system
Product Description
■ High functional reliability as a result of permanent self-diagnostics
■ Contamination warning
■ Optional heating for ambient temperatures down to -40 °C
■ Digital output of an adjustable limit speed (optional)
4.2 Application areas
The WCS can be used anywhere where material handling equipment has to be positioned
precisely. The functional principle of the WCS enables it to be used in a diverse range of
applications, such as:
■ Interruptions in the code rail (lane changes, track switches)
■ Applications with curves and circular paths
■ Use of multiple vehicles in a row
Due to the larger tolerances of the reader in relation to the code rail, in most applications the
WCS3 system can be used. In some circumstances, however, it is advantageous to use the
WCS2 in conjunction with the aluminum profile system. Here are some examples from the
variety of application options:
Stock Feeders (High-Bay Wareho se)
Trolleys, lifting gear, and transversing carriages are each positioned with one reader. The
positioning is independent of the length of the code rail and always absolutely reproducible. For
new high-bay warehouses we recommend the WCS3 system. For retrofits in older warehouses,
it may be beneficial to use the WCS2 in conjunction with the aluminum profile system:
■ asy to retrofit
■ High mechanical tolerances between the measuring system and moving carriages
possible
■ Decoupling of vehicle vibrations
Figure 4.1 Stock feeder (high-bay warehouse)
A tomatic Cranes
Automatic cranes are a typical application for the WCS2 in conjunction with the aluminum
profile system. The crane is positioned using one reader each for the crane and the trolley
movement. At each point, the guide trolley ensures the optimum position of the reader in
relation to the code rail and decouples any vibrations from the crane track. Optional cleaning
brushes for the code rail can be attached to the guide trolley. This means that the WCS2 can be
used in a very dusty environment, such as in cement works or foundries.