ABB
Wireless automation for your factory
This is where you start, …
… release potential … … and increase availability
The benefits of such wireless sensor/actuator tech- Downtimes in operation due to cable breaks, contact
nology are enormous. Capacities are released in wear and troubleshooting are minimised, costs for
engineering, assembly and commissioning which can cables and connection equipment disappear. In
then be used for a new, flexible machine design. short, wireless automation leads to uninterrupted,
even more reliable and, above all, more economic
production.
With WISA, you benefit from …
When using the wireless proximity switches and The WISA product range is supplemented by wire-
sensor pads based on the WISA concept, cable less I/O (input/output) pads which also communicate
movement no longer has to be taken into account. with WISA COM but use a conventional power sup-
Completely new opportunities open up which would ply. In this way the benefits of WISA can also be used
not in the past have been feasible with cables. Ro- for conventional sensors and actuators.
bots have unprecedented freedom of movement,
cable-related restrictions on moving machine parts
no longer apply.
Benefits only offered by WISA:
The freedom to take what’s needed…
… with wireless input/output pads Actuators and conventional position sensors such as
l cylinder switches
Signal cables which cause a nuisance or wear during l pressure switches
operation are commonplace in industry and machine l temperature monitors
building. With WISA COM, elaborate cabling for signal l position switches
transmission is no longer necessary, including with l sensors (inductive, capacitive, optical, ultrasound)
regard to conventional sensors and actuators. For can be connected to the WIOP100 (wireless I/O
this is where the wireless WIOP100 I/O pad comes pad).
into its own, transmitting the signals from the con-
nected sensors and actuators by radio communica- While the wireless I/O pad in a machine/system is
tion to the central WDIO100 input/output module. attached as closely as possible to the connected
field device, the WDIO100 input/output module is
normally positioned together with the machine con-
trols in the control cabinet. A pair of antennas estab-
lishes the radio connection to the wireless I/O pad.
The connection between the input/output module
and the control system (PLC) takes place by field bus
as usual.
WIOP100
wireless I/O pad
24 V DC
Benefits at a glance
The freedom to work wirelessly,
no cables involved at all, …
… with wireless proximity switches … with wireless sensor pads
The WISA concept wireless proximity switches are A great number of inductive sensors and cylinder
inductive sensors which transmit their information by switches are often located within a tight space. In such
radio (WISA COM) and are wirelessly supplied with cases the wireless WSP100 sensor pad is used. The
power (WISA POWER) by means of a magnetic field. WSP100 is a logical development of the communica-
tion module for up to eight WISA sensor heads or dry
These completely wireless sensors comprise an induc- contacts which are connected using short cables. Like
tive sensor head (WSIN…, WSIF…) and a WSIX100 the wireless proximity switches, the sensor pad also
communication module which is the same for all communicates by radio and is wirelessly supplied with
types. The communication module contains both the power via a magnetic field.
radio technology and the power receiver which pro-
vides the operating power for the wireless proximity
switch from the surrounding magnetic field. The power
consumption of the WSIA sensor heads was specially
optimised for this technology. They work with a signifi-
cantly lower supply voltage than conventional position
sensors.
WSP100
wireless sensor pad
Benefits at a glance
At a glance: the WISA concept
WISA POWER, the wireless
energy supply
Reliable energy supply The arguments for WISA POWER
Not by battery but, like the communication, the Unique wireless solution
l
power for the wireless proximity switches and sensor Continuous, maintenance-free power supply
l
pads is also, quasi supplied by radio. A WPU100 No battery changes
l
power supply generates a 120 kHz sinus-shaped
signal which carries no information whatsoever. Using
a pair of primary loops, which are attached around
the outside of the machine or system like bands, the Simple engineering
120 kHz signal is distributed in the machine as a
weak magnetic field. The wireless proximity switches The absence of cables and cable guides makes plan-
and sensor pads are equipped with ferrite antennas ning faster and considerably simpler. Conventional
which are used to collect the operating power from connection equipment is not required, significantly
the magnetic field. simplifying the engineering. Independently of cable
routes, wireless proximity switches and sensor pads
Each primary loop has a dimension of 1m x 1m can be positioned anywhere within the magnetic
up to 3m x 6m. This provides a supplied volume of field. This means that changes even to complex
1m x 1m x 1m up to 3m x 3m x 6m. Using pointed assembly machines can be implemented without
and linear arrangements of the primary loop, even complication.
very localised applications (e.g. on a conveyor) can
be efficiently operated. The number of the WISA
components which can be supplied is, to all intents High availability
and purposes, unlimited.
Where no cables are used, they cannot wear either.
This means, above all, a minimum of downtime. The
absence of cables also removes a source of faults
which otherwise arise particularly in rough environ-
ments, e.g. through aggressive media such as oils,
fats, metal splinters and drilling emulsions, or simply
through high humidity. The commissioning of a new
sensor or pad could not be simpler, requiring no
more than the push of a button.
power supply
Wireless
Primary loop
WISA field devices for wireless
communication and power supply
Diverse application possibilities Arguments in favour of using wireless proximity switches
and WSP100 sensor pads
Machine building and many other industries are able
to utilise the benefits offered by wireless automation, No cables
l
e.g. to monitor and control of: Wireless connection of inductive sensors and dry reed contacts
l
l Turntables for robots and handling applications Fast tool changes without plug-in connections
l
l Robot cells Zero-wear power and data transmission
l
l Modular assembly systems Flexible positioning independent of cable routes
l
l Assembly machines with frequent tool and device
change (e.g. presses)
l Complex movements (e.g. cage stranders, material
handling, robot grippers)
Existing machines and systems can easily be
wirelessly automated as part of retrofit measures.
F
C
A Control cabinet
D Conveyor
WISA field devices for wireless
communication
Diverse application possibilities Arguments in favour of using wireless
WIOP100 I/O pads
The benefits offered by wireless automation are used
in a great variety of industries and applications. For l Integration of actuators
example in the monitoring and control of: l Connection of valve islands
l Turntables for robots and handling applications l Connection of all position sensors, other binary sensors and
l Robot cells and gardens additional contacts and switches
l Modular assembly systems l Integration of offset I/O nodes by radio communication
l Assembly machines with frequent tool and device l Utilisation of conventional IP67 pads
change l Flexible communication independently of bus structures
In existing machine parks, too, WISA can contribute to
optimum future proofing. Thus systems can easily be
converted as part of retrofit measures. Conventional
IP67 pads can easily be replaced by wireless I/O pads.
l 1 input/output module
with FieldBusPlug (FBP)
l 1 pair of antennas with antenna cables
l 1 to 13 I/O pads
24 V DC
10
WISA COM, the wireless
communication
Proven in industrial use Arguments in favour of WISA COM
WISA COM was specifically developed for factory auto- Speed: 2msec cycle time
l
mation. Communication takes place in the 2.4 GHz Reliability: 1-10-9
l
band in accordance with standards ETS 300 328 as Performance: up to 360 devices
l
well as IEEE 802.15.1. The frequency range thus lies Time response: independent of number of devices involved
l
above the electromagnetic interference spectrum
which is created in a typical industrial environment,
such as through welding processes, switching
processes or frequency converters. Simple connection to control system
communication
Wireless
11
WISA: a convincing concept …
… with the best conditions … Wireless I/O pads have proved their worth for inte-
grating conventional sensors and actuators into a
Simple engineering, greater freedom of movement, WISA system. They can, of course, also be used
great reliability – those are just a few of the charac independently of wireless proximity switches.
teristics which make WISA components from ABB
convincing in daily use.
Because of their wireless technology, the proximity The benefits both to the machine builder
switches are perfectly suited to smaller machines and and end user are plain to see:
manufacturing cells, e.g. 3 x 3 x 3 m3. But they are
also suitable for a larger machine volume if several Simple installation requiring no cables
l
individual manufacturing cells are fitted in a modular Ideal for rapid, cable- and contact-free tool changes
l
manner. Zero-wear power and data transmission
l
Particularly flexible for extensions and modifications
l
12
… and in many key positions The WISA concept which communicates on the
2.4 GHz band offers the very best conditions for
Many well-known companies, such as Unilever trouble-free and reliable usage, even in welding
Deutschland or Johann A. Krause in Germany, have applications or near other typical sources of inter-
already gained experience in using this concept of ference in industrial environments.
wireless communication from ABB.
13
Wireless communication
60
33,5
23
WIOP100-8DI8DC wireless I/O pad M12x1 M12x1
39
11
33 60 18
13
33,5
23
Number of inputs 8, digital (type 3 in accordance with IEC 61131) p switching M12x1 M12x1
39
33 18
Number of selectable inputs/outputs 8, digital; 0.5 A
5
11 13
WIOP100
22,5
33,5
Module/actuator supply Separate, 24 V each in 7/8“ mini plug, connectable through to next pad M12x1
5
60 M12x1
4
23
39
4
WIOP100
22,5
18
33
Communication band (GHz) 2.4 ISM band in accordance with ETSI standard ETS 300 328 and FCC
61,5
4
11 13
4
61,5
60
17
WIOP100 17
22,5
60
4
17
61,530
60
17
17
179
213
203
5
- M12 standard Y-splitter SZC1-YU0 for 2 sensors/actuators on a single connection
39,5
36 11
WSP100
22,5
29,8
5
39,5 60
36 39 WSP100
22,5
WIOP100
61,5
33
61,5
29,8
5
39,5
36
Configuration Choice of: WSP100
22,5
61,5 30
- 120 wireless sensors or
30
11,9
- 56 wireless sensors + 7 WIOP100 wireless sensor/actuator pads or
183
11,9
119,5
183
93,5 5 - 13 WIOP100 wireless sensor/actuator pads
30
119,5
93,5 5 25 Number of WDIO100 per machine 1 … 3 without significant loss of performance
11,9
183
WDIO 100
25 unit/manufacturing cell
4,5
119,5
Communication band (GHz) 2.4 ISM band in accordance with ETSI standard ETS 300 328 and FCC
ANT1 ANT2
93,5 WDIO5100 19,5
4,5
24,5
ANT1 ANT2 29,5
25
Range of radio communication 5 m (industrial environment; typically 15 m) 19,5
24,5
84,2
119,5
29,5
Connection to machine control system FieldBusPlug (FBP: PROFIBUS, DeviceNet, Modbus, …)
WDIO 100 84,2
4,5
119,5
ANT1 ANT2
L+
L+
M
M
0 1 2 3 4
X1 15W
0 1 2 3 4
X1
24V DC
+
-
ESC OK
Depth
79,5 Protection category in accordance IP20 15,5
57,5
- 0 1 2 3 4 15,5
X1 45,5
1SAF900100R3000
16
57,5
24V DC
+
1SAF900100R3000
15,5
16
-
45,5
58
Total latency period 20 ms until the signal is available on the connected field bus (or device)
1SAF900100R3000
16
46
95 31,5
(for 99.9% of signals) (max. 34 ms in individual cases)
58
95 31,5 20 52
Wireless delay (air interface) Wireless delay typ. 4 ms (max. 15 ms, with error bound 10-9)
46
31
20 52
Accessories For connection to the control system (PLC): ABB FieldBusPlug, available for 31
30
95 31,5
4,5 20 52
26
101,5
31
9,5
4,5
Antennas
26
30
9,5
4,5 16,8
26
6,3
16,8
16,8
10
404
40430
Front Back
30
Front Back
30
Front Back
14
Wireless communication and power
M12x1 M12x1
M12x1 M12x1
4
M12x1 M12x1
60
17
5
5
4
60
17
5
17
60
17
4
17
4
60
17
17
60
Reduction factor rV2A/rAl/rCu
39
33 (flush) 0.75 / 0.4 / 0.4 0.75 / 0.3 / 0.25 0.75 / 0.35 / 0.3 0.75 / 0.45 / 0.25
11
Sensor heads (non-flush) 0.75 / 0.4 / 0.4 0.8 / 0.45 / 0.4 0.75 / 0.45 / 0.4 0.7 / 0.45 / 0.35
5
WSP100
60
39
60
33
Nominal signal transmission rate [1/s] 5 (min.; signal change per second, higher in individual cases, see below)
61,5
1139
33
Ambient temperature [°C] -25 ... +70 (0 ... +55 for wireless modules)
5
11
WSP100
22,5 22,5
5
60
Protection category in accordance IP67
11,961,5 30
WSP100
39
33
11
with IEC 60529
183
61,5
5
WSP100
22,5
Number of inputs 8 for WISA sensor heads and terminal 1 for WISA sensor heads
4,5
19,5
30
24,5
29,5
switches (potential-free contacts)
84,2
11,9
≥5
4,5
(signal change per second per input; (signal change per second)
4,5
19,5
24,5
29,5
19,5
24,5
84,2 up to 40/s for individual sensor head)
29,5
84,2
also higher, dependent on available power/field strength of magnetic field
4,5
19,5
24,5 57,5
Range of radio communication 5 m (industrial environment; typ. 10 m)
29,5
WSP100
15,5 84,2
45,5 Switching status indicator LED, yellow per input LED, yellow
Operating indicator LED, green
Addressing/Diagnostics By membrane pushbutton and WDIO100-CON-FBP; captive storage
1SAF900100R3000
16
57,5
15,5
WSIX100
57,545,5
Operating temperature range [°C] 0 ... +55
58
15,5
53
45,5
46
57,5
with IEC605299
1SAF900100R3000
16
WSIX100
15,5
45,5
Connections 4 M12 device sockets, 2 inputs each 1 M12 device socket
58
WSIX100
53
20 52
46
58
31
Sensor signals on contacts 4 and 1 (!)
53
46
1SAF900100R3000
16
20 52
46
31
20 52
173
404
50 41 45 45 56
Bottom 313
30 30
34
262
M8 382,5
(4x)
Primary loop size [m2] 1 x 1 to 3 x 6
50 41 45 45 56 30
173 Bottom 313
262
M8 (4x) Expandability with several WPU100-24M up to 6 x 6 x 6 m, modular cells
10
Frequency of power transmission [kHz] 120
30
34
50 41 45 45 56 30
40430 Bottom 313
262
M8 382,5
(4x) Protection category in accordance with IEC 60529 IP65
Front Back
404 382,5
Ambient temperature [°C] 0 ... +45
WPU100
Distance of heart pacemaker wearers 0.8 – 2.5 m depending on cell size or electricity
40430
Front Back
382,5
Mounting Screw mounting
30
Front Back
30
WPC100-Nxx primary loop conductor
Front Back Length [m] 10 to 28 in steps of 1
Connection type Lug for direct connection to WPU100
WPC100
15
Wireless automation with the WISA* concept
communication
4
Wireless
2 3
5
24 V DC
Subject to modification
power supply
Wireless
1 6
(11/06 • 3 • GVD)
1
ABB
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