Pepperl+Fuchs WCS Series Manual
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Pepperl+Fuchs WCS Series Manual

Position encoding system
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FACTORY AUTOMATION
MANUAL
WCS
position encoding system
Mechanics

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Summary of Contents for Pepperl+Fuchs WCS Series

  • Page 1 FACTORY AUTOMATION MANUAL position encoding system Mechanics...
  • Page 2 WCS position encoding system 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 Electrical Indus- try, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the supplementary clause: "Expanded reservation of proprietorship"...

  • Page 3: Table Of Contents

    WCS position encoding system Introduction................. 5 Declaration of conformity ............6 CE conformity..................6 Safety ................... 7 Symbols relevant to safety..............7 General safety instructions ..............7 Product Description ..............8 Functional Description ................ 8 Application areas ................10 Readers ..................13 Mounting .....................
  • Page 4 WCS position encoding system Mounting WCS3 Code Rail with the Aluminum 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...

  • Page 5: Introduction

    WCS position encoding system Introduction Introduction Congratulations 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 used The following symbols are used in this manual: Note! This symbol draws your attention to important information.

  • Page 6: Declaration Of Conformity

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

  • Page 7: Safety

    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. Note! Disposal Electronic waste is hazardous waste.

  • Page 8: Product Description

    WCS position encoding system Product Description Product Description 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.
  • Page 9 WCS position encoding system Product Description 1. Interface module 2. Code rail 3. Reader Properties of 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...

  • Page 10: Application Areas

    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) Application areas The WCS can be used anywhere where material handling equipment has to be positioned precisely.
  • Page 11 WCS position encoding system Product Description Figure 4.2 Automatic crane Galvanic plants One or more vehicles moving in a line along a straight route. The vehicles bring the material to be galvanized into the corresponding bath automatically. The high and adaptable light output of the readers has enabled the WCS position encoding system to perform extremely well even under these difficult conditions.
  • Page 12 WCS position encoding system Product Description Figure 4.4 Overhead conveyor...

  • Page 13: Readers

    WCS position encoding system Readers Readers The reader housing is made from a robust plastic and has IP54 protection. The product contents include the mounting bracket for mounting the reader. On the inside of the reader there are easily removable, transparent plastic lenses that protect the reading area against dirt and damage.
  • Page 14 WCS position encoding system Readers M12 x 1 Figure 5.2 WCS3B dimensional drawing Tolerance for Y- and Z-axis WCS2B WCS3B Y-axis ± 5 mm ± 15.5 mm Z-axis ± 5 mm ± 14 mm...
  • Page 15 WCS position encoding system Readers Tolerance for inclined position α α WCS2B WCS3B ±10° ±10° α...

  • Page 16: Mounting

    WCS position encoding system Readers Tolerance for inclined position β β WCS2B WCS3B ±5° ±5° β Mounting As a rule, the reader is mounted on the vehicle. However, the reader can also be mounted stationary. A code rail unit can also be mounted on the carriage (vehicle identification). A special mounting bracket is supplied with the reader.
  • Page 17 WCS position encoding system Readers 1. Reader 2. Quick-action lock 3. Groove 4. Mounting base 5. Base module with spring tongue Note! Mounting Direction Mount the reader so that the electrical connecting plug points in the direction of the ascending position values on the code rail.

  • Page 18: Plastic Lenses

    WCS position encoding system Readers Note! The mounting bracket is identical for all readers. 12.5 ø 8 ø 4.5 Figure 5.3 WCS-MP1 mounting bracket Plastic Lenses In the event of damage or contamination, you can replace the reader's plastic lenses. Replacing the Plastic Lenses 1.
  • Page 19 WCS position encoding system Readers WCS2B WCS3B Model number for two lenses WCS2-PL2 WCS3B-PL2 with seals...

  • Page 20: Code Rail

    WCS position encoding system Code Rail Code Rail The absolute code rail is different for the WCS2 system and WCS3 system Therefore, the code rails are not interchangeable. For WCS3, the height of the code rail is always 70 mm; for WCS2, the rail can be supplied at a height of 55 mm or 70 mm.

  • Page 21: Grounding The Code Rail

    WCS position encoding system Code Rail WCS2B code rail 1. 6-digit position identifier Dimensions [mm] Code rail 55 x 0.5 Code rail 70 x 0.5 WCS3B code rail 1. 6-digit position identifier Grounding the Code Rail When installing the WCS code rail made from laminate or stainless steel, make sure that the code rail is connected with the plant potential every 30 m with low resistance.

  • Page 22: Identification

    WCS position encoding system Code Rail WCS-MT1 clamping fixture Stainless steel code rail Tightening torque WCS2B, 55 mm 6 Nm WCS2B, 70 mm 9 Nm WCS3B, 70 mm 7 Nm Identification In applications where the vehicle number is recognized in the plant, special code rail units known as ID pads are available for the WCS3 system.
  • Page 23 WCS position encoding system Code Rail ID pad WCS3-ID70-M1 XXXX 19.2 19.2 240 ... 264 Figure 6.1 XXXX = 0001 - 1260 Designation Part number Material 184073 Stainless steel WCS3-ID70-M1 184761 Laminate WCS3-ID70-L1 Table 6.1 : When ordering, please specify the desired ID pad number...

  • Page 24: Mounting The Code Rail

    WCS position encoding system Mounting the Code Rail Mounting the Code Rail With continuous position measurement for a route, you have to mount the code rail in one piece. Depending on the usage conditions, there are various options for securing the code rail: Mounting bracket Aluminum profile rails Installation position...
  • Page 25 WCS position encoding system Mounting the Code Rail Figure 7.2 Vertical installation...

  • Page 26: Mounting The Code Rail With Mounting Brackets

    WCS position encoding system Mounting the Code Rail Figure 7.3 Installation on a wall Figure 7.4 Installation on a ceiling Mounting the Code Rail with Mounting Brackets The bracket system is an easy way to mount laminate or stainless steel code rails. It consists of brackets for routing the code rail in straight sections, as well as brackets for routing the code rail on curves and circular paths.
  • Page 27 WCS position encoding system Mounting the Code Rail Mounting brackets without fastening screws M4 x 12 3.5 x 6.5 M6 x 12 WCS-MB/WCS-MB-C WCS-MB-B Designation Part number Function/use Support distance WCS-MB 184236 Bracket for straight 1.25 m sections WCS-MB-C 184099 Bracket for straight 1.25 m sections,...
  • Page 28 WCS position encoding system Mounting the Code Rail Mounting bracket with fastening screws M6 x 12 M6 x 12 WCS-MB1 Designation Part number Function/use Support distance WCS-MB1 184098 Bracket for straight 1.25 m sections WCS-MB1-B 184100 Bracket for curve 0.5 m – 0.7 m...

  • Page 29: Mounting The Code Rail On A Straight Route

    WCS position encoding system Mounting the Code Rail Mounting bracket with fastening screws for mounting in C profile rails 30 mm x 32 mm M6 x 20 M6 x 12 M4 x 12 3.5 x 6.2 M6 x 12 WCS-MB2/WCS-MB2-C WCS-MB2-B Designation Part number...

  • Page 30: Mounting The Code Rail On Curves

    WCS position encoding system Mounting the Code Rail In addition to clamping, you can screw the code rail to the bracket. To do so, use the top two free holes (M6) of the bracket. Screwing the rail to the bracket creates a fixed point between the code rail and the substructure.

  • Page 31: Mounting Wcs2 Code Rail With The Aluminum Profile System

    WCS position encoding system Mounting the Code Rail Note! Circular Path Note the following special features of a closed route (circular path, oval, etc.): due to the operating mode of the WCS, you cannot route the code rail continuously along the entire circuit.
  • Page 32 WCS position encoding system Mounting the Code Rail Fixing cord Reader Guide trolley Aluminum profile rail Rail holder Code rail Mounting the Profile Rail Rail holders are available for mounting the aluminum profile rail quickly. The profile rail snaps into the rail holders. The rail holder is available in three different versions: Without fastening screws With fastening screws With fastening technology for mounting in C profile rails...
  • Page 33 WCS position encoding system Mounting the Code Rail Figure 7.7 WCS2 profile system with rail holder mounted on C profile rail, with reader in the guide trolley Rail Holder without Fastening Screws Figure 7.8 WCS2-MH...
  • Page 34 WCS position encoding system Mounting the Code Rail Designation Part number Function/use Support distance WCS2-MH 184641 Rail holder Perpendicular/suspended mounting: 1.5 m Lateral mounting: 1.25 m Rail Holder with Fastening Screws Figure 7.9 WCS2-MH1 Designation Part number Function/use Support distance WCS2-MH1 184052 Rail holder with screw...

  • Page 35: Rail Holders

    WCS position encoding system Mounting the Code Rail Rail holder with fastening screws for mounting in C profile rails 30 mm x 32 mm Figure 7.10 WCS2-MH2 Designation Part number Function/use Support distance WCS2-MH2 184053 Rail holder with screw Perpendicular/suspended connection for C mounting: 1.5 m profile rails...

  • Page 36: Adapter Plates For Profile Rails

    WCS position encoding system Mounting the Code Rail Figure 7.11 Aligning the rail holders (example for WCS2-MH2) 3. Snap the profile rail into the rail holder by pressing lightly. 7.2.2 Adapter Plates for Profile Rails Adapter plates are required for connecting aluminum profile rails. The WCS2-MC* adapter plate consists of two flat pieces and four self-tapping screws.
  • Page 37 WCS position encoding system Mounting the Code Rail Designation Part number Function/use Material/mounting WCS2-MC1 184050 Adapter plate for Aluminum/steel self-tapping aluminum profile rails screws M3 x 4.5 mm WCS2-MC2 184051 Adapter plate for Stainless steel/stainless steel powder-coated self-tapping screws M3 x 4.5 aluminum profile rails Assembling the Adapter Plate 1.
  • Page 38 WCS position encoding system Mounting the Code Rail The tips of the screws press into the aluminum profile and fix the adapter plate in place. 3. Slide the profile rails together with the adapter plates.

  • Page 39: Mounting The Code Rail

    WCS position encoding system Mounting the Code Rail Note! When you slide the aluminum profile rails together with the butt connectors, make sure there is a gap to compensate for thermal expansion. A gap is necessary if the maximum possible operating temperature is greater than the temperature during the assembly.
  • Page 40 WCS position encoding system Mounting the Code Rail 2. Fix the code rail in place by pressing the plastic fixing cord into the groove of the profile rail and simultaneously pressing on the code rail. Caution! Operational safety Pressing the cord in correctly is important for the operational safety of the aluminum profile system, particularly if it is mounted suspended.

  • Page 41: Fixed Points

    WCS position encoding system Mounting the Code Rail This ensures that the fixing cord sits correctly in the groove. The contact pressure of the fixing cord is so great that the code rail cannot slip out of the profile rail even when it is mounted suspended. Note! As part of regular plant maintenance, check that the fixing cord and code rail are securely in place, especially if the profile rail is mounted suspended.

  • Page 42: The Guide Trolley

    WCS position encoding system Mounting the Code Rail For vertical mounting, secure the aluminum profile with a suitable support bracket (on site). To ensure that the code rail does not slip in the aluminum profile rail, you can fix the code rail in place by using a spring dowel pin or a self-tapping screw in the middle of the section.
  • Page 43 WCS position encoding system Mounting the Code Rail Designation Part number Function/use Material Max. speed WCS2-GT09-P1 184046 Guide trolley for reader Plastic rollers 8 m/s for aluminum profile Sheet steel, rails galvanized WCS2-GT09-P1- 184047 Guide trolley for reader Plastic rollers 8 m/s for powder-coated Sheet steel,...

  • Page 44: Grounding The Aluminum Profile System

    WCS position encoding system Mounting the Code Rail ø 8 mm Figure 7.14 WCS2 guide trolley and tappet Caution! When mounting and using the tappet, make sure that the guide trolley is not subjected to any forces. There must be no rigid connection between the vehicle and the guide trolley. Note! Slide the guide trolley with the reader into the profile rail such that the electrical connector points in the direction of the ascending position values.

  • Page 45: Mounting Wcs3 Code Rail With The Aluminum Profile System

    WCS position encoding system Mounting the Code Rail Figure 7.15 Grounding Mounting the WCS3 Code Rail with the Aluminum Profile System A special aluminum profile system has been developed for quick mounting of the 70 mm WCS3 code rail made from plastic laminate or stainless steel. The aluminum profile is designed to support the code rail and the guide trolley.
  • Page 46 WCS position encoding system Mounting the Code Rail Fixing cord Rail holder Aluminum profile rail Reader Mounting base End stop to the vehicle Code rail Mounting the Profile Rail Rail holders are available for mounting the aluminum profile rail quickly. The profile rail snaps into the rail holders.
  • Page 47 WCS position encoding system Mounting the Code Rail Figure 7.16 WCS3 profile system with rail holder mounted on C profile rail, with reader Rail Holder without Fastening Screws Figure 7.17 WCS3-MH Designation Part number Function/use Support distance WCS3-MH 184711 Rail holder Perpendicular/suspended mounting: 2.5 m Lateral mounting: 2 m...

  • Page 48: Rail Holders

    WCS position encoding system Mounting the Code Rail Rail Holder with Fastening Screws Figure 7.18 WCS3-MH1 Designation Part number Function/use Support distance WCS3-MH1 184075 Rail holder with screw Perpendicular/suspended connection mounting: 2.5 m Lateral mounting: 2 m Rail holder with fastening screws for mounting in C profile rails 30 mm x 32 mm Figure 7.19 WCS3-MH2...

  • Page 49: Adapter Plates For Profile Rails

    WCS position encoding system Mounting the Code Rail Figure 7.20 Aligning the rail holders (example for WCS3-MH2) 3. Snap the profile rail into the rail holder by pressing lightly. 7.3.2 Adapter Plates for Profile Rails Adapter plates are required for connecting aluminum profile rails. The WCS3-MC1 connector consists of a 170 mm long extruded aluminum profile and two self-tapping screws.
  • Page 50 WCS position encoding system Mounting the Code Rail 2. Screw the self-tapping screws into the 1.8 mm diameter holes in the flat pieces. The tips of the screws press into the aluminum profile and fix the adapter plate in place. 3.

  • Page 51: Mounting The Code Rail

    WCS position encoding system Mounting the Code Rail Note! When you slide the aluminum profile rails together with the adapter plates, make sure there is a gap to compensate for thermal expansion. A gap is necessary if the maximum possible operating temperature is greater than the temperature during the assembly.

  • Page 52: Fixed Points

    WCS position encoding system Mounting the Code Rail 2. Fix the code rail in place by pressing the plastic fixing cord into the groove of the profile rail and simultaneously pressing on the code rail. Caution! Operational safety Pressing the cord in correctly is important for the operational safety of the aluminum profile system, particularly if it is mounted suspended.
  • Page 53 WCS position encoding system Mounting the Code Rail Figure 7.21 3. Drill two 3 x 6 mm self-tapping screws into these holes. The self-tapping screws are not included in the product contents. The screws press into the aluminum profile, establishing a tight-fitting connection between the rail holder and the aluminum profile.

  • Page 54: Vertical Curves

    WCS position encoding system Mounting the Code Rail 7.3.5 Vertical Curves In addition to horizontal curves, vertical curves are required to create inclines/declines. Figure 7.23 Vertical curves up to a minimum radius of 4 m can be created with the aluminum profile in conjunction with the laminate code rail.

  • Page 55: Interruptions In The Profile Rail

    WCS position encoding system Mounting the Code Rail 7.3.6 Interruptions in the Profile Rail In some applications, it is necessary to interrupt the course of the code rail, e.g., for crane crossings, for fire protection gates, or for large expansion joints in buildings. Caution! Make sure that interruptions in the code rail are at least 85 mm and the two code rail parts are aligned.

  • Page 56: Grounding The Aluminum Profile System

    Integration of the WCS Code Rail in Conductor Lines In many applications, electrical energy is transferred to the carriage via conductor lines. Pepperl+Fuchs offers an integrated solution of power transmission and position measurement. This requirement was taken into account in the development of the new Vahle VKS 10 conductor line.
  • Page 57 WCS position encoding system Mounting the Code Rail WCS3-CS70-L2 WCS3B-Lesekopf Figure 7.25 Integration of the WCS3-CS70-L2 code rail in the Vahle VKS 10 power rail To mount the WCS3 code rail in the VKS 10 system, a special mounting hole and a special code rail are required.
  • Page 58 Twinsburg, Ohio 44087 · USA Tel. +1 330 4253555 E-mail: sales@us.pepperl-fuchs.com Asia Pacific Headquarters Pepperl+Fuchs Pte Ltd. Company Registration No. 199003130E Singapore 139942 Tel. +65 67799091 E-mail: sales@sg.pepperl-fuchs.com www.pepperl-fuchs.com Subject to modifications / DOCT3785 Copyright PEPPERL+FUCHS • Printed in Germany 10/2014...

This manual is also suitable for:

Wcs2-pl2Wcs3b-pl2Wcs2Wcs3Wcs3bWcs2b

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