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Reliable wireless automation

Reach for freedom!

Wireless automation with the WISA concept

ABB
Wireless automation for your factory
This is where you start, …

Modern factory floors are characterised by a high … act logically, …


degree of automation. Robots and assembly ma-
chines work automatically in the production lines, e.g. What then, makes more sense than to minimise
in the automotive industry. Sensors are responsible these risk factors or to avoid them completely? With
for reliability and precision and it is not unusual to use a concept for wireless automation which avoids the
several hundred in one manufacturing cell. high expenses for wiring sensors while at the same
time increasing the mobility and flexibility of the
In the past, each individual sensor had to be con- sensors.
nected to the machine control system via cables,
terminals and I/O modules, requiring a great amount
of time for planning, assembly, installation and com-
missioning as well as creating high wiring costs. This
amount of wiring also involves many risks – from
limited movement to cable wear and the conse-
quences of production downtimes.


… 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 …

WISA stands for Wireless Interface for Sensors … greater reliability …


and Actuators and has today become an ABB
standard which was developed specially for factory The effects of this innovative connection principle on
automation. safety and reliability are worth a second look. Wrong
cabling, cable wear and cable breakages are a thing
Corresponding to the high requirements of an indus- of the past. The wireless proximity switches and
trial environment, field devices with WISA, such as sensor pads can be clearly identified during assembly
sensors and actuators, can be used completely and in operation through signalling locally and at the
without wired connection. Only WISA offers this input/output module. In contrast to conventional
wireless solution which includes both sensors, continuous presence checks, in which every
l wireless communication (WISA COM) field device reports its functional efficiency to the
and central input/output module, ensure that errors are
l wireless power supply (WISA POWER). identified in good time.

…greater mobility, … … and many more possibilities.

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:

l Developed for industrial use


l Real-time capability
l Special reliability
l High field device density
l Solution for wireless energy supply
l Minimal use of frequency band

WISA: especially for factory automation


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

l Wireless connection of sensors and actuators to the machine


control system
l Data transmission in the 2.4 GHz band: unaffected by typical
sources of interference in an industrial environment
l Fast and simple tool change since no data/signal connections
need to be disconnected
l Configurable at the push of a button
l Flexible with regard to upgrades and retrofitting
l Zero-wear data communication
l Reliable communication without costly plug-in connections,
slip rings or dynamic cable carriers


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

l Independent of cables for more flexibility and absolute freedom


Wireless proximity switch Wireless proximity switch with
consisting of communication offset sensor head of movement
module and sensor head l Data transmission in the 2.4 GHz band: unaffected by typical
sources of interference in an industrial environment
l Fast and simple tool change since no sensor cables need to be
disconnected
l Configurable at the push of a button
l Flexible with regard to upgrades and retrofitting
l Reliable communication without costly plug-in connections,
slip rings or dynamic cable carriers
l Zero-wear energy and data communication


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.

Das spricht für den Einsatz drahtfreier Arguments


And this is how you entry to wireless automation with wireless
WISA field devices might look:
(A) 1 input/output module with FieldBusPlug (FBP)
(B) 1 pair of antennas with antenna cables
B
(D + E) 2 power supplies with 1 pair of primary loops each
E
(C) 1 to 120 wireless proximity switches or
(F) 1 to 13 wireless sensor pads or
(C + F) 1 to 56 proximity switches and 1 to 7 sensor pads
F

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.

And this is how your entry to wireless automation


with I/O pads might look:

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

The connection to the control system (PLC) uses a


Reliability in every-day production field bus. The WDIO100 input/output module can be
connected to the respective field bus using the ABB
Data transmission between the wireless field devices FieldBusPlug (FBP). A corresponding selection of
and the WDIO100 input/output module always field bus plugs for the various field bus systems
works reliable. This is assured by frequency hopping (PROFIBUS DP, DeviceNet, Modbus, …) is available.
with various frequency sequences, antenna switching
and automatic repetition in the absence of acknowl-
edgment. The WDIO100 expects a function message
from each field device allocated to it every 500ms. In
this way the module monitors the proper function of
the devices. If a function signal is absent, the opera-
tional error is noticed immediately.

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.

Typical examples of scenarios in which wireless


proximity switches can be used to particular effect
due to their technical properties are:
l Manufacturing cells and revolving machines
l Assembly lines, e.g. transmission or engine
assembly in the automotive industry
l Material handling, e.g. palletiser
l Robot applications
l Packaging machines
l Machines for foodstuffs and luxury items,
e.g. metering systems

or special applications such as:


l Cage stranders for underwater cables
l Presses for motor vehicle parts

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

Range of radio communication 5m (industrial environment; typically 15m)


5

60
17
WIOP100 17
22,5

Diagnostics block by block for sensors, actuators; continuous radio monitoring 17

60

4
17
61,530

Status LEDs Status of inputs/outputs, input/output diagnostics, voltages, communication


30
179
213
203

Addressing By pushbutton and WDIO100-CON-FBP

60
17
17
179
213
203

Protection category in accordance IP67


30

with IEC 60529


179
213
203

Ambient temperature [°C] 0 ... +55


Data transmission WISA COM radio system, real-time capable ABB radio standard (cf. WDIO100)6039
33
Accessories - Plug, socket 7/8“ (“Mini”) 5-pole for power supply 11
60
39
29,8 33

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

WDIO100-CON-FBP input/output module 11

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

Operator display - LCD display, two lines with 16 characters each


19,5
Depth 24,5
ESC OK 79,5 29,5
84,2
- 4 membrane pushbuttons
DC-IN 15W
24V 0V Depth
ESC OK 79,5
PE
119,5

L+
L+
M
M

0 1 2 3 4
X1 15W

Supply voltage 24 V DC; 15 W max.


DC-IN
24V 0V
PE
L+
L+
M
M

0 1 2 3 4
X1

24V DC
+
-
ESC OK
Depth
79,5 Protection category in accordance IP20 15,5
57,5

DC-IN 15W 45,5


with IEC 60529
24V 0V 57,5
+
24V DC
PE
L+
L+
M
M

- 0 1 2 3 4 15,5
X1 45,5

Ambient temperature [°C] 0 ... +50

1SAF900100R3000
16
57,5
24V DC
+

WDIO100 Mounting On 35 mm DIN rail in accordance with EN 60715 or screw mounting

1SAF900100R3000
15,5

16
-
45,5
58

Dimensions (H x W x D) [mm] 140 x 120 x 85 (casing: 120 x 120 x 80)


46
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

PROFIBUS, DeviceNet, Modbus, …


101,5
30

4,5 20 52
26

101,5

31
9,5

4,5

Antennas
26
30
9,5

WAT100-x Panel antenna, 70 degree beam width


6,3101,5

4,5 16,8
26

x = R, L (right, left-handed circular polarisation)


9,5

6,3

16,8

Dimensions (H x W x D) [mm] 101 x 95 x 32


WAC100-N0x Antenna cable in lengths x = 3 m, 5 m 173
6,3

16,8
10

WAT100 Accessories WAM100 antenna mounting for mast mounting 173


30
34
10
50 41 45 45 56 30 30
Bottom 313 34 262
50 41 45 45 56 30
173 313
Bottom 262
10
30
34
50 41 45 45 56 30
404 Bottom 313
262

404

40430
Front Back
30
Front Back

30
Front Back

14
Wireless communication and power
M12x1 M12x1

M12x1 M12x1
4

Sensor heads for wireless sensor pads and communication module


4

M12x1 M12x1

Type M8x1 M12x1 M18x1 M30x1,5


60

60

17
5

Designation (inductive, flush) WSIF015-M8N WSIF020-M12N WSIF050-M18N WSIF100-M30N


17
M12x1 M12x1
4

5
4

Designation (inductive, non-flush) WSIN020-M8N WSIN040-M12N WSIN080-M18N WSIN150-M30N


4

Nominal operating distance Sn


60

60

17
5

17

(flush /non-flush) [mm] 1.5 / 2 2 / 4 5 / 8 10 / 15


60

60

17
4

17
4

Assured operating distance Sa


flush/non-flush) [mm] 0...1.21 / 0...1.62 0...1.62 / 0...3.24 0...4.05 / 0...6.5 0...8.1 / 0...12.15
60

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

Overall length/thread [mm] 50 / 30 60 / 50 60 / 50 60 / 50


22,5

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

Wireless sensor pad and communication module


30 30
11,9 11,961,5

WSP100-8i sensor pad WSIX100 communication module


183 183

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

Nominal signal transmission rate 1/s ≥5


183

≥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

Protection category in accordance IP67


1SAF900100R3000
16

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

Weight 550 g 125 g


WSIX100
58

Sensor head supply Pin 2; 2.8 V (1 mW max.)


53

20 52
46

31
20 52

31 Power supply WISA POWER (120 kHz magnetic field)


WSIX100 Data transmission WISA-COM radio system, real-time capable ABB radio standard (cf. WDIO100)
20 52

31 Accessories M12 WISA Y-splitter WSC1-YU0 WSC100 extension cable, mounting


for 2 sensors on a single connection between WSIX communication module
and WSI/WSIF sensor head:
173
10
30
0.3 / 0.6 / 0.75 / 1m
34
50 41 45 45 56 30
313 M8 (4x)
WPU100-24, WPU100-24M power supply
Bottom 262

173

Volume supplied by one pair WPU100 [m3] 1 x 1 x 1 to 3 x 3 x 3 or 2.5 x 2.5 x 5


10
173 30
34
10

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

Printed in the Federal Republic of Germany


*WISA = Wireless Interface for Sensors and Actuators

1 Wireless proximity switch (consisting of The quickest way to further information:


communication module and sensor head)
2 Wireless sensor pad Application and installation examples, downloads as well as
3 Wireless I/O pad technical information on the subject of wireless automation
4 Antenna can be found on the Internet.
5 Input/output module Simply go to our web page
6 Power supply

Brochure No. 2CDC 171 019 B0201


7 Primary loop cable http://www.abb.de/stotzkontakt

and click on the


wireless automation button.

ABB
ABB STOTZ-KONTAKT GmbH ABB Global Contact Directory
P. O. Box 10 16 80
D-69006 Heidelberg The ABB Contact Directory (http://www.abb.com/contacts/)
Telephone: ++49 62 21 / 701-0 helps you find local contacts for ABB products in your country.
Telefax: ++49 62 21 / 701-729
Please select the relevant product group from the dropdown
http://www.abb.de/stotzkontakt
menu to the right or from the page.

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