Pepperl+Fuchs WCS User manual

WCS position encoding
system
Mechanics
Manual

With regard to the supply of products, the current issue of the following document is applicable: The
General Terms of Delivery for Products and Services of the Electrical ndustry, published by the Central
Association of the Electrical ndustry (Zentralverband Elektrotechnik und Elektroindustrie (ZVE ) e.V.)
in its most recent version as well as the supplementary clause: "Expanded reservation of proprietor-
ship"
Worldwide
Pepperl+Fuchs Group
Lilienthalstr. 200
68307 Mannheim
Germany
Phone: [phone] - 0
E-mail: [e-mail]
North American Headquarters
Pepperl+Fuchs nc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [email protected]
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [email protected]-fuchs.com
https://www.pepperl-fuchs.com

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WCS position encoding system
Contents
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1 Introduction................................................................................................................ 5
1.1 Content o this Document............................................................................. 5
1.2 Target Group, Personnel ............................................................................... 5
1.3 Symbols Used ................................................................................................ 6
2 Product Description .................................................................................................. 7
2.1 Functional Description .................................................................................. 7
2.2 Areas o Use ................................................................................................. 10
3 Read Head ................................................................................................................ 13
3.1 Introduction.................................................................................................. 13
3.2 Overview....................................................................................................... 13
3.3 Tolerances .................................................................................................... 15
4 Mounting the Read Head ........................................................................................ 17
4.1 Attaching the Mounting Base ..................................................................... 17
4.2 Replacing Plastic Lenses............................................................................ 19
4.3 Retro itting the Outdoor Protective Enclosure ......................................... 20
4.4 Mounting the Outdoor Protective Enclosure ............................................ 24
5 Code Rail .................................................................................................................. 26
5.1 Introduction.................................................................................................. 26
5.2 Overview....................................................................................................... 26
5.3 Identi ication via ID-Pads............................................................................ 28
6 Mounting the Code Rail........................................................................................... 29
6.1 Introduction.................................................................................................. 29
6.2 Installation Notes......................................................................................... 30
6.2.1 Mounting the Code Rail on a Straight Route .................................... 31
6.2.2 Mounting in Horizontal Curves ......................................................... 32
6.2.3 Mounting in Vertical Curves ............................................................. 34
6.2.4 nterruptions in the Profile Rail ......................................................... 35
6.3 Mounting the Code Rail with Mounting Brackets ..................................... 36
6.3.1 ntroduction...................................................................................... 36
6.3.2 System Overview............................................................................. 37
6.3.3 Attaching the Tensioning Device ...................................................... 41

WCS position encoding system
Contents
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6.4 Mounting the WCS3 Code Rail with the Aluminum Pro ile System.........42
6.4.1 ntroduction ...................................................................................... 42
6.4.2 System Overview ............................................................................. 43
6.4.3 Rail Holder ....................................................................................... 45
6.4.4 Butt Connectors for Profile Rails....................................................... 46
6.4.5 Mounting the Code Rail.................................................................... 48
6.4.6 Fixed Points...................................................................................... 50
6.4.7 Suspended Mounting with Stainless Steel Code Rail....................... 52
6.4.8 Grounding the Aluminum Profile System .......................................... 53
6.4.9 ntegration of the WCS Code Rail in Conductor Lines ...................... 54
6.5 Mounting the WCS2 Code Rail with the Aluminum Pro ile System.........55
6.5.1 ntroduction ...................................................................................... 55
6.5.2 System Description .......................................................................... 56
6.5.3 Rail Holder ....................................................................................... 59
6.5.4 Butt Connectors for Profile Rails....................................................... 60
6.5.5 Mounting the Code Rail.................................................................... 63
6.5.6 Fixed Points...................................................................................... 65
6.5.7 Guide Trolley..................................................................................... 67
6.5.8 Grounding the Aluminum Profile System .......................................... 70
6.6 WCS3 Code Rail Extender or "Extended" Read Heads ..........................71
6.6.1 ntroduction ...................................................................................... 71
6.6.2 System Overview ............................................................................. 71
6.6.3 Mounting the WCS3 Code Rail Extender.......................................... 72
7 Maintenance .............................................................................................................75
7.1 Maintenance .................................................................................................75
7.2 Cleaning........................................................................................................75
7.3 Repairs ..........................................................................................................76
7.3.1 WCS Stainless Steel Code Rail (Aluminum Profile).......................... 76
7.3.2 WCS Stainless Steel Code Rail (Mounting Bracket System) ............ 78
7.3.3 WCS Laminate Code Rail (Aluminum Profile) .................................. 79
7.3.4 WCS Laminate Code Rail (Mounting Bracket System)..................... 81
8 Model Overview or WCS Read Heads...................................................................83
9 Disposal ....................................................................................................................85
10 Appendix...................................................................................................................86
10.1 Cable Overview ............................................................................................86

WCS position encoding system
ntroduction
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1 Introduction
1.1 Content o this Document
This document contains information required to use the product in the relevant phases of the
product life cycle. This may include information on the following:
•Product identification
•Delivery, transport, and storage
•Mounting and installation
•Commissioning and operation
•Maintenance and repair
•Troubleshooting
•Dismounting
•Disposal
The documentation comprises the following parts:
•This document
•Datasheet
n addition, the documentation may comprise the following parts, if applicable:
•EU-type examination certificate
•EU declaration of conformity
•Attestation of conformity
•Certificates
•Control drawings
•nstruction manual
•Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and dismount-
ing lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation, com-
missioning, operation, maintenance, and dismounting of the product. The personnel must have
read and understood the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
Note
For full information on the product, refer to the further documentation on the nternet at
www.pepperl-fuchs.com.

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WCS position encoding system
ntroduction
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
Warning Messages
You will find warning messages, whenever dangers may arise from your actions. t is mandatory
that you observe these warning messages for your personal safety and in order to avoid prop-
erty damage.
Depending on the risk level, the warning messages are displayed in descending order as fol-
lows:
In ormative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
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 the device and any connected systems and plants, or result in
their complete failure.
Note
This symbol brings important information to your attention.

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Product Description
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2 Product Description
2.1 Functional Description
The WCS position encoding system consists of two main components:
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 thus assigns a unique position to every point on
the track. t is possible to route the code rail at points only where positioning is required. The
system allows the code rail to be routed along curves and allows branches to be created. The
code rail is built to order and delivered in a bundle. Unless otherwise ordered, the code rail
always starts with position value 0 and ends with a maximum position according to the ordered
length in meters. The length of a code rail segment ranges from 0 to a maximum total length of
314.573 m (WCS3) or from 0 to a maximum total length of 327 m (WCS2).
Spacers can also be ordered for repair purposes or specific applications, stating the start or
end position of the desired section and the desired length in meters.
For identification applications D-pads are available as short code rail sections, with a length of
between 250 mm and 264 mm and a unique identification number.
Read Head
The U-shaped read head scans the code rail photoelectronically without touching it. The read
head detects a new position value every 0.8 mm (WCS3) or 0.833 mm (WCS2).
This results in the following data:
After insertion into the code rail, the read head determines a highly accurate position value
without reference or delay. The code rail can be scanned at very high speeds. The scanning
can be reproduced, is reliable, and is independent of temperature fluctuations.
The position value, movement speed, and error codes such as the contamination detection or
the "OUT" message can be transmitted directly from the read head to the control panel via a
communication interface. There are a number of types of interfaces available in the WCS3 read
head to achieve this, such as RS-485, SS , CANopen, PROF NET, and EtherNet/ P.
There is a wide range of interface modules available for connecting to other interfaces:
•PROF NET
•PROF BUS DP
•EtherNet/ P
•EtherCAT
•DeviceNet
•CANopen
Each interface module can simultaneously accommodate up to four read heads with an RS-
485 interface and address each separately. This makes it easy to extend your plant at a later
stage.
n addition to automatic contamination detection, there are other optional extensions for the
WCS read head. The options are indicated in the type code with the corresponding letter:
WCS2B WCS3B
Resolution ± 0.42 mm
1200 pos./m
± 0.40 mm
1250 pos./m
Movement speed [v
max
] 12.5 m/s 12.5 m/s
Y axis (tolerance) ± 5 mm ± 15.5 mm
X axis (tolerance) ± 5 mm ± 14 mm

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WCS position encoding system
Product Description
The variants available can be found in the product selector at https://www.pepperl-fuchs.com,
as well as in the model overview for read heads, see chapter 8.
Mounting System
There are three different mounting systems available for mounting the code rail. The bracket
system, the WCS3 aluminum profile system, and the WCS2 aluminum profile system with fix-
ture for a guide trolley. The three mounting systems can be screwed directly to the surface or
mounted on standard C profiles.
The bracket system is the easiest to mount as it features mounting brackets for straight section
elements and curved sections (vertical, horizontal). The brackets are screwed directly to the
code rail and to the surface and C profile.
As an alternative to the mounting brackets, the WCS3 aluminum profile system provides better
stabilization of the code rail and simplified mounting for long, straight sections. n this case, the
code rail is inserted into an extruded aluminum profile developed for the WCS and fixed in
place with a fixing cord. The aluminum profile rail is clipped to plastic brackets and attached to
the surface with a C profile.
The WCS2 aluminum profile rail system with guide trolley is intended for applications with high
running tolerances. The aluminum profile accommodates the code rail and the guide trolley.
The guide trolley is connected to the vehicle via a free-running tappet and guarantees that the
read head is always in the optimal position in relation to the code rail. At the same time, the
read head is decoupled from vehicle vibrations. Use of the guide trolley is generally recom-
mended with the WCS2 read head due to the low read head gap. For the WCS3 read head with
outdoor protective enclosure, an optional guide trolley can be used in combination with the
WCS2 profile rail.
WCS2B and WCS3B
Hntegrated heating element for an extended outside temperature range as
low as -40 °C.
WCS3B
Dntegrated display with a seven-segment display for position and diagnostic
information.
ERead head with Extended option for long distances of up to 629.146
meters.
OOutdoor protective enclosure with degree of protection P69 for outdoor
use.
SSwitching output for signaling when a limit speed is exceeded

WCS position encoding system
Product Description
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Properties o the WCS
•Absolute position encoding system
•Photoelectric principle (infrared range)
•Proven and robust
•Easy 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:
•Up to 327 m (WCS2)
•Up to 314.573 m (WCS3)
•Up to 629.146 m (WCS Extended)
•The coding system is also suitable for curves with a radius of up to 0.5 m (does not apply
to systems with guide trolleys)
•A wide range of areas of application, e.g., automated storage and retrieval systems, mov-
ing carriages, monorail conveyors, galvanic plants, automatic and slewing cranes, eleva-
tors, as well as outdoors such as in harbors, offshore installations, and ships
•Various mounting systems available for installing the code rail
•Connection to any control panel possible, either directly or via interface module
•Connectivity to many fieldbus systems available
•Support during commissioning and maintenance due to extensive system diagnostics
options
•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)
•The WCS3-Outdoor has an P69-compliant protective enclosure

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WCS position encoding system
Product Description
2.2 Areas o Use
The WCS can be used anywhere where material handling equipment has to be positioned pre-
cisely. The operating principle of the WCS enables it to be used in a diverse range of applica-
tions, including:
•nterruptions in the code rail
•Applications with curves and circular paths
•Use of multiple vehicles in a row
Due to the large tolerance between the read head and code rail, the WCS can be used for most
applications. n some cases, however, it is advantageous to use the WCS with a special protec-
tive enclosure or a guide trolley in conjunction with the aluminum profile system. Here are some
examples from the variety of application options:
Automated Storage and Retrieval Systems (High-Bay Warehouses)
Moving carriages, lifting gear, and transversing carriages are each positioned with one read
head. The positioning is independent of the length of the code rail and always absolutely repro-
ducible. 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 sys-
tem:
•Easy to retrofit
•High mechanical tolerances between the measuring system and moving carriages possi-
ble
•Decoupling of vehicle vibrations
Figure 2.1 Automated storage and retrieval system (high-bay warehouse)

WCS position encoding system
Product Description
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Automatic Cranes
Automatic cranes are a typical application for the WCS2 in conjunction with the aluminum pro-
file system. The crane is positioned using one read head each for the crane and the trolley
movement. At each point, the guide trolley ensures the optimal position of the read head 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 WCS can be
used in a very dusty environment, such as in cement works or foundries. f the cranes are used
outdoors, the WCS3 is used with a special protective enclosure.
Figure 2.2 Automatic crane
Galvanic Plants
One or more vehicles in succession moving along a straight route. The vehicles automatically
bring the material to be galvanized into the corresponding bath. The high and adaptable light
output of the read heads has enabled the WCS position encoding system to perform extremely
well even under these difficult conditions. The WCS3 with protective enclosure is ideal for gal-
vanic plants. n addition to degree of protection P69, the enclosure is resistant to acids and
alkalis.
Figure 2.3 Galvanic plant

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WCS position encoding system
Product Description
Overhead Conveyors
Many vehicles have to be positioned on a circular track—the WCS offers the optimal solution
for this. Branches (track switches) and curves can be created. The WCS3 is particularly well-
suited for this task. After a power failure, the current position of the vehicle is transferred to the
control panel immediately; the vehicle does not have to be moved. The WCS can also be used
for distances longer than 314.573 m.
Figure 2.4 Overhead conveyor
Harbor Applications
The WCS with protective enclosure is used for material handling plants in particularly demand-
ing areas such as harbors, offshore installations, and ships. To meet the requirements of these
areas, the WCS includes an P69-compliant protective enclosure that, in addition to protecting
against dust and humidity, has been specifically designed for resistance to aggressive sub-
stances such as salt water, salty air, acids, and alkalis. t offers increased impact resistance
compared to typical outdoor sources of interference such as falling branches and hailstorms. n
combination with built-in heating, the WCS can even be used in snow and temperatures as low
as -40 °C. The indicator LEDs and the display are always visible through the translucent enclo-
sure material.
Figure 2.5 Power rail of a gantry crane

WCS position encoding system
Read Head
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3 Read Head
3.1 Introduction
The enclosure of the read head is made from robust plastic and has degree of protection P54.
The mounting base for securing the read head is included in the scope of delivery. On the
inside of the read head there are easily removable, transparent plastic lenses that protect the
reading area against dirt and damage. dentification notches can be found on these lenses.
The notches are used for adjustment of the zero point for the vertical play of the read head (= Z
axis). The reference point is the top edge of the code rail. Within specified tolerances, the read
head may move around this reference point: if the vertical play on the Z axis is exceeded, the
read head reports "OUT" to the control panel (read head outside the code rail). The tolerances
for the lateral play on the Y axis result from the gap width of the read head. The positions are
reliably determined up to a minimum of 500 mm for both an inclined position in the vertical
direction and in the horizontal direction, as well as in curves. f the position value cannot be
determined, for example due to contamination of the optical system, the read head reports a
unique error code.
From a technological point of view, the WCS2B and WCS3B read heads are very similar. The
resolution and the signals to the interface are almost identical. However, there are differences
in the mechanical systems and in the accessories.
3.2 Overview
WCS2B
WCS2B read heads have a gap width of 10 mm. This results in a distance between the emitter
and receiver that offers high reserves. This makes the WCS2B read head suitable for very dirty
environments such as galvanizing plants, foundries, and steel mills. An optional guide trolley
and the WCS2B rail system are specially designed for operation with imprecise mechanical
connections and where vibrations occur, for example, with automatic cranes.
Figure 3.1 WCS2B dimensional drawing
WCS2B WCS3B
Resolution ± 0.42 mm
1200 pos./m
± 0.40 mm
1250 pos./m
Movement speed [v
max
] 12.5 m/s 12.5 m/s
129
10
75
40
38
33
75 115
57
M12 x 1

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WCS position encoding system
Read Head
WCS3B
WCS3B read heads have a gap width of 31 mm. This allows a greater tolerance when mount-
ing the read head and aligning it in relation to the code rail. WCS3B systems are ideal for mon-
itoring conveyor belts and automated warehouse and lifting systems.
Special features of the WCS3B read head include the status LEDs for the alignment and per-
formance display, an optional "overspeed" output, and an optional 7-segment display for posi-
tion and diagnostic data.
Figure 3.2 WCS3B dimensional drawing
WCS3-Outdoor
WCS3-Outdoor is a WCS3B read head in a special outdoor protective enclosure.
Special features of the WCS3-Outdoor include an P69-compliant protective enclosure that, in
addition to protecting against dust and humidity, has been specifically designed for resistance
to aggressive substances such as salt water, salty air, acids, and alkalis. t offers increased
impact resistance compared to typical outdoor sources of interference such as falling branches
and hailstorms. ntegrated heating even allows the WCS3-Outdoor to be operated in snow and
temperatures as low as -40 °C. The indicator LEDs and the display are always visible through
the translucent enclosure material. The protective enclosure can be used with the WCS3B-
LS2**H, WCS3B-LS3**H, WCS3B-LS5**, and WCS3B-LS6** read heads. The protective
enclosure has three cable outlets. Depending on the mounting position, you can route the con-
nector plug through one of the three outlets.
Figure 3.3 WCS3-Outdoor dimensional drawing
53
40.5
99
78.5
55
90
128
115
31
M12 x 1
B
42.5
239.3
110
119
117
215
28.2
104
115
43 12.5

WCS position encoding system
Read Head
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3.3 Tolerances
Tolerance or Y and Z Axis
Figure 3.4 Tolerance for Y and Z axis
Tolerance or Inclined Position 
Figure 3.5 Tolerance for inclined position 
WCS2B WCS3B WCS3-Outdoor
Y axis ± 5 mm ± 15.5 mm ± 12 mm
Z axis ± 5 mm ± 14 mm ± 12 mm
WCS2B WCS3B WCS3-Outdoor
±10° ±10° ±8°
Y
Z
Y
Z
α

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WCS position encoding system
Read Head
Tolerance or Inclined Position 
Figure 3.6 Tolerance for inclined position 
WCS2B WCS3B WCS3-Outdoor
±5° ±5° ±4°
X
Z
β
B

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Mounting the Read Head
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4 Mounting the Read Head
4.1 Attaching the Mounting Base
As a rule, the read head is mounted on the vehicle. However, the read head can also be
mounted stationary. A code rail piece can also be mounted on the carriage (vehicle identifica-
tion).
A special mounting base is supplied with the read head. This is mounted on the carriage. f the
WCS2 is used with an aluminum profile system and guide trolley, the mounting base is already
installed in the guide trolley. On three sides of the read head enclosure, dovetail grooves are
integrated with a quick-action lock. f required, the read head is pushed onto the base module
of the mounting base via one of these grooves and engaged with a spring tongue. This quick-
action lock makes it easy to mount and quickly replace the read head when necessary without
any adjustment work. The mounting position of the read head is arbitrary. The read head is not
sensitive to extraneous light.
Figure 4.1 Overview
1. Read head
2. Quick-action lock
3. Dovetail groove
4. Mounting base
5. Base module with spring tongue
Warning!
mproper mounting
Risk of injury if mounted improperly
•Ensure you have sufficient space before starting work.
•Take care when using sharp-edged components and always wear safety gloves.
•Ensure that suspended components cannot fall before mounting.
1
2
3
4
5
Note
Mounting Direction
Mount the read head so that the electrical connector plug points in the direction of the
ascending position values on the code rail.

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WCS position encoding system
Mounting the Read Head
Mounting and Dismounting the Mounting Base
1. Secure the mounting base to the guide trolley with size M4 screws.
2. Slide the dovetail groove on the read head onto the base module of the mounting base. n the
end position, the spring tongue engages audibly in the quick-action lock.
The read head is mounted.
3. For dismounting, unlock the spring tongue with a screwdriver.
4. Push the read head off the base module of the mounting base.
Figure 4.2 WCS-MP1 mounting base
Tip
Securing the Mounting Base
Plan elongated holes in the design of the fixture on the carriage. These allow you to correct the
position of the mounting base and thus the read head during mounting.
Caution!
nterference from strong sunlight
f strong sunlight shines directly into the read head gap, this can lead to measurement errors.
When planning the plant, avoid a configuration that allows strong sunlight to shine directly into
the read head gap.
Caution!
nterference from contamination
f dirt or vapors enter the read head gap, this can lead to malfunctions.
When installing the read head, make sure that the read head gap is protected against dirt and
any vapors.
Note
The mounting base is identical for all read heads.
12.5 40 40
105
40
58
3
6
9.5
ø 4.5
3
6
9.5
ø 8

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Mounting the Read Head
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4.2 Replacing Plastic Lenses
n the event of damage or contamination, you can replace the plastic lenses on the inside of the
read head gap.
Replacing Plastic Lenses
1. Loosen two screws on each lens.
2. Remove the lens.
3. Slide the new lens into the intended position on the inside of the read head gap.
4. Secure the lens with the screws. The maximum torque is 0.8 Nm.
The plastic lenses are available in pairs as spare parts.
Figure 4.3 Plastic lenses
Note
WCS2 read head: Phillips screws
WCS3 read head: Torx screws (T10)
Tip
Always replace lenses in pairs.
WCS2B WCS3B
Model number for two lenses
with seals
WCS2-PL2 WCS3B-PL2

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WCS position encoding system
Mounting the Read Head
4.3 Retro itting the Outdoor Protective Enclosure
WCS3B-read heads using RS-485, SS , and CANopen interfaces can be retrofitted with the
enclosure. Read heads with EtherNet/ P and PROF NET interfaces can only be used as pre-
assembled devices.
Figure 4.4 Overview of mounting parts
Assembling the Protective Enclosure
1. Loosen two screws on each lens.
2. Remove the lens.
3. Slide the mounting base over the dovetail groove of the read head. n the end position, the
spring tongue engages audibly in the quick-action lock.
Note
When retrofitting your plant, make sure that you differentiate the mechanical outer dimensions
and the fixture for the outdoor protection enclosure from the standard read head.
1Protective cover
2Protective lid
3Mounting base
4Special tool
5Stopping plugs, pressure relief plugs
6Fastening screws
7Five-pin connection cable for RS-485 or CANopen
8Eight-pin connection cable for SS
51 23
4
6
7
8
Note
WCS2 read head: Phillips screws
WCS3 read head: Torx screws (T10)