Igus IS-EC-W-FIX-2500-BETA Operating instructions
- Type
- Operating instructions
Table of contents
2/18
Manual EC. W.FIX V1.1
Table of contents
1 Introduction ...................................................................................................... 3
2 Safety Notices, Protective Measures and Guidelines ................................... 3
2.1 Important Notes ................................................................................. 3
2.2 Qualified personnel ........................................................................... 3
2.3 Safety ................................................................................................ 4
2.4 Electromagnetic compatibility ............................................................ 5
2.5 Maintenance ...................................................................................... 6
3 Intended use ..................................................................................................... 6
4 Function ............................................................................................................ 6
5 Product ............................................................................................................. 6
5.1 variants .............................................................................................. 6
5.2 Specifications .................................................................................... 7
6 Installation ........................................................................................................ 8
6.1 Mechanical installation ...................................................................... 9
6.2 Electrical installation .........................................................................10
6.3 Assignment of the extension cable / hardware connection ...............10
6.3.1 Connection to i.Cee:plus II ...............................................................10
6.3.2 Connection to customer PLC ...........................................................11
6.3.3 Power supply ....................................................................................11
7 Commissioning ...............................................................................................12
7.1 With i.Cee:plus II (delivered with IS.EC.W.F.P.SU.01.BETA) ..........12
7.2 Directly to PLC (delivered with IS.EC.W.F.SU.01.BETA) .................12
7.3 Example Siemens control .................................................................13
8 Reset ................................................................................................................17
9 Troubleshooting ..............................................................................................17
10 FAQs ................................................................................................................17
11 Accessories/extension cable .........................................................................17
12 Abbreviations ..................................................................................................17
13 Service .............................................................................................................18
Safety Notices, Protective Measures and Guidelines
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Manual EC. W.FIX V1.1
1 Introduction
Thank you very much
for the purchase of the sensor EC.W.F. / EC.W.F.P. The sensor offers the possibility to obtain service life information of igus® e-
chains®. The condition monitoring module described below reduces the risk of unexpected operational failures due to a failure of
igus e-chain systems®.
The product handed over is a BETA product, this means that the product is still in the development stage, the CE marking is not
yet given. On the final product, some technical details may be different.
If you have any further questions, do not hesitate to contact our customer service. The contact details can be found on page 18.
2 Safety Notices, Protective Measures and Guidelines
2.1 Important Notes
Read this manual carefully before commissioning the EC.W.F. / EC.W.F.P. For your own safety and to avoid personal injury and
property damage, all safety instructions mentioned in this manual must be read and understood, and all listed protective measures
must be followed. Device-specific safety instructions including associated protective measures can be found under the respective
subchapters.
This manual has been prepared to the best of our knowledge and belief. It is used for technical documentation and to support the
user during commissioning. The warnings and safety instructions as well as instructions released by igus® regarding the EC.W.F.
/ EC.W.F.P. must be passed on to the end user in any case if the EC.W.F. / EC.W.F.P. is used as part of an overall system.
igus® GmbH exclusively assumes a warranty for products from igus® in accordance with the standards, norms and specifications
in this manual. The warranty extends exclusively to the exchange or repair of a defective EC.W.F. / EC.W.F.P. No liability is
assumed for consequential damages and consequential errors.
igus® GmbH assumes no responsibility for the integration of the EC.W.F. / EC.W.F.P. in the overall system. The responsibility for
this lies with the plant designer or the end user. Please note the information under "Qualified personnel".
igus® GmbH assumes no liability for personal injury or property damage resulting from incorrect use or unauthorized technical
changes to the EC.W.F. / EC.W.F.P.
igus® GmbH reserves the right to make changes and optimizations to the product or technical documentation at any time without
prior notice.
The EC.W.F. / EC.W.F.P. may only be used if:
- All installation instructions and safety instructions mentioned in this manual have been followed.
- The housing has been professionally installed in accordance with valid ESD & EMC regulations.
- No changes at EC.W.F. / EC.W.F.P. and it is in a technically perfect condition.
- The operating limits set out in the technical data (see also: 7) are indicated, are complied with.
2.2 Qualified personnel
Sebastian Probst
The EC.W.F. / EC.W.F.P. may only be operated and maintained by a qualified specialist.
- The staff must have read and understood this manual and any existing additional documentation.
- Personnel must be familiar with all relevant applicable standards, regulations and accident prevention regulations.
- Staff must be able, through their training, to anticipate or identify any hazards which may arise when using the control
system.
- Personnel must be able to ensure the safety of persons and objects when using the sensor unit in the overall system.
- Personnel must be trained in the handling of ESD sensitive equipment and take all necessary precautions.
Safety Notices, Protective Measures and Guidelines
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Manual EC. W.FIX V1.1
2.3 Safety
The following information boards will appear a few times in the manual, they are classified so that the grade and type of hazard
are marked.
Safety instructions marked with DANGER indicate an immediate danger situation.
Failure to comply with the information inevitably leads to a serious or even fatal accident.
DANGER!
Safety instructions marked with WARNING indicate a possible dangerous situation.
Failure to comply with the notice may lead to a serious or even fatal accident or damage to property.
WARNING!
Safety instructions marked with CAUTION indicate any dangerous situation.
Failure to comply with the notice may result in an accident or property damage.
CAUTION!
Safety instructions marked with NOTE indicate a possible dangerous situation.
Failure to comply with the notice may result in property damage.
General information and explanations are also marked in this way.
NOTE!
Safety Notices, Protective Measures and Guidelines
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Manual EC. W.FIX V1.1
2.4 Electromagnetic compatibility
- Risk of injury due to interference of signals and devices
Disturbed signals can cause unforeseen device actions.
Perform wiring according to EMC guidelines. Failure to comply with these precautions may result in death, serious injury
or material damage. Observe the points mentioned in Table 1, while assembling and wiring.
WARNING!
EMC measures
Effects
Device
assembly
use cable clamps or EMC cable glands for
the shield pad, connect metallic parts over
a large area
Good conductivity due to flat contact
Add switching devices such as contactors,
relays or solenoid valves with interference
suppression combination or spark
extinguishing elements (e.g. diodes,
varistors, RC links).
Reduce mutual interference coupling.
Do not install electrical equipment and its
connected sensors in the immediate vicinity
of electromagnetic interference fields
Avoid malfunctions
Install electrical equipment in grounded
metal control cabinet
Reduce interference and emission.
Wiring
Keep cables as short as possible
Avoid capacitive and inductive interference couplings
Do not lay sensor cables and signal lines
together with cables for DC and AC voltage
above 60 V in a cable duct.
Avoidance of mutual interference coupling
Ground shields of digital signal cables on
both sides over a large area via EMC cable
glands or via conductive connector
housings
Avoid interference with lines, reduce emissions, avoid
malfunctions
Ground shields of analog sensor cables on
one side over a large area via EMC cable
glands or conductive connector housings.
Avoid interference with lines, reduce emissions, avoid
malfunctions
Connect shields of connected sensor and
digital signal lines within a control cabinet to
the terminals marked with (Shield).
Avoid interference with lines, reduce emissions, avoid
malfunctions
Table 1: EMC measures and their effects
Product
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Manual EC. W.FIX V1.1
2.5 Maintenance
The service of EC.W.F. / EC.W.F.P. may only be done by qualified specialists. Please refer to Chapter 1.2 (Qualified
Personnel). If hardware problems occur due to unqualified personnel, the warranty expires. If you experience any other
hardware problems, please contact our customer service (see page 18).
NOTE!
If EC.W.F. / EC.W.F.P. does not work properly, it must be checked whether all plug-in and screw connections are still properly
connected. They must be reconnected if this is not given.
If this does not resolve the malfunction, please contact Customer Service (page 18 ).
3 Intended use
The sensor EC.W.F. / EC.W.F.P. monitors the wear of the igus® e-chain® and helps to determine service life information from
which maintenance information is derived. The sensor is used exclusively for this purpose.
The sensor EC.W.F. / EC.W.F.P. is not a safety component within the meaning of the Machinery Directive. The device
is intended exclusively for wear detection on igus® e-chain systems® and is not suitable for the prevention of personal
injury during machine/plant operation. In case of disregard, serious personal injury up to death or serious irreversible
injuries as well as property damage are possible.
DANGER!
Only install sensors that also match the igus® e-chain® you have installed.
Use the device only as intended. The protection of persons is not guaranteed if the device is not used in accordance with its
intended use.
igus® GmbH is not liable for damages caused by improper use.
Read this original instruction manual before commissioning the device. Knowledge of the original operating instructions is part of
the intended use.
Any use other than that specified under 'Intended use' or a use going beyond that shall be deemed not to be in accordance with
the intended purpose.
The use of the device is inadmissible iparticular in the following cases:
- in safety-relevant circuits
- in rooms with an explosive atmosphere
- On machines and systems with extreme vibrations
4 Function
The EC.W.F. / EC.W.F.P. System enables the customer to obtain percentage lifetime information for sliding e-chain systems® for
predictive maintenance planning. The percentage lifetime information determined by the system can be transmitted by means of
a potential-free normally open contact for further processing by a PLC or other measuring technologies (IS.EC.W.F...). In a further
product version, it is possible to read out the service life information via UART and, for example, to the i.Cee:plus II module
(IS.EC.W.F.P..) and to make further calculations on the service life there. This lifetime percentage information gives the customer
the opportunity to create a maintenance plan for the e-chain systems® and predict their service life.
5 Product
5.1 variants
Variants
Description
EC.W.F.
- LOW-cost variant for direct connection to the customer's PLC
- 3 wear levels can be detected
EC.W.F.P.
- Product variant that is connected to i.Cee:plus II for direct lifetime calculation.
- 4 wear levels can be detected
Table 2: Product Overview
Product
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Manual EC. W.FIX V1.1
5.2 Specifications
Mechanical Specifications
D x W x H in millimeters incl. plugs & fasteners
Varies with e-chain®
adapted to opening bridge x 18mm x adapted to internal
height
Weight in grams
Approx. 120 g
Fastening / Assembly
in the last chain link at the fixed point of the e-chain®, wear
block pointing in the direction of the abrasion surface
Colour
Black
Table 3: Mechanical specifications
- Risk of destruction
An operating voltage above the voltage specified in the technical data destroys the EC.W.F. / EC.W.F.P. Always select
only the operating voltage specified in the technical data.
CAUTION!
Electrical Specifications
Power supply
5... 30 V DC (1A max.)
Power supply potential-free contacts / I/O ports
5... 30 V DC (0.15A max.) dependent on operating voltage
Output voltage UART
5V DC (25mA max.)
Abrasion contacts
5 V DC (1.5mA max.), low-active
Table 4: Electrical specifications
Interfaces
UART
5V (0.5A max.) Output, 9600 baud, 8N1, no parity
I/O Ports
Logical states, high active
Table 5: Interfaces
Installation
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Manual EC. W.FIX V1.1
Ambient conditions
- Risk of malfunctions
- Fire
- Danger of explosion
- Risk of electric shock
Operate the EC.W.F. / EC.W.F.P. neither in water nor in humid environments or in aggressive, flammable, or explosive
atmospheres and not in extreme vibrations. Due to the self-heating of the device, it must be ensured that the outside
temperature does not exceed 40°C. If this is not guaranteed, a ventilated or air-conditioned housing must be used.
WARNING!
Temperature range
Operation
-20... 40 °C
Storage
-40... 45 °C
Transport
-40... 45°C
Relative humidity
Suitable for outdoor use, hermetically sealed otherwise
non-condensing
Protection
IP67 DIN EN 60529
Table 6: Environmental conditions
6 Installation
Always lay the connecting cables of the device outside the traffic routes. There is a risk of tripping in the case of loosely
laid cables.
Do not lay or squeeze cables over sharp edges, corners or moving parts. No objects may be hung or attached to pipes.
Electrical equipment must be handled carefully. Movable cables and plugs must be protected against damage caused
by trapping, shock and driving over with vehicles and equipment.
Electrical appliances, wires and plug-in devices may only be used if they meet the operational and local safety
requirements with regard to operating mode and environmental influences.
CAUTION!
Installation
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Manual EC. W.FIX V1.1
6.1 Mechanical installation
Get assembly manual here:
https://igus.widen.net/s/2rdsmcrvd7/sma_i.sense-ec.w-montageanleitung--assembly-instructions
There is a risk of crushing when installing the sensor. Please wear gloves or take other protective measures to eliminate
this danger.
CAUTION!
Make sure that the series of e-chain® embossed on the sensor matches the igus® e-chain® you have installed. Deviating
sensors can be damaged if they are installed incorrectly.
NOTE!
The board is housed in a separate housing, which must be securely attached. You can reset the sensor if you hold a
magnet on the top of that box for 2 seconds.
NOTE!
Figure 2 - Board Chassis for Small e-chain® Series
- In the last chain link at the fixed point
(static area of the chain)
- in the middle between the upper and
lower opening bridge
- Separation bar with wear block in the
direction of the sliding part of the e-
chain®
- to be used as a commercially
available igus® separator
- if necessary, separation bars must be
replaced by special separation bars
- Be sure to use appropriate sensors.
Chain connection
element
last link in the
chain at the fixed
end side
Figure 1 - Sensor installation
Installation
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Manual EC. W.FIX V1.1
6.2 Electrical installation
Immediately switch the device voltage-free in the event of damage or damage to the connection cables and in the event
of interference or unusual phenomena such as arcs, sparks, the smell of fire or noticeable noise. In such a case, the
device must be withdrawn from circulation immediately. Disconnect all electrical energy sources from the device. In any
case, do not try to repair the device yourself. Report defects immediately to your superiors, warn others and contact the
igus® branch responsible for your country.
- Risk of electric shock
- Danger of electric arcs
- Injury driving
- Risk of component destruction
Always turn off the power supply before disconnecting or establishing electrical connections in the system. Secure the
power supply against reactivation.
In the case of electrical connections that are not properly installed, arcs may occur. To EC.W.FIX connected cables
must not have exposed and stripped wire ends. In addition, ensure that all connections are securely seated.
WARNING!
6.3 Assignment of the extension cable / hardware connection
Available at igus® as:
CF240.PUR.03.05
MAT904172110
6.3.1 Connection to i.Cee:plus II
When connected to i.Cee:plus II
Wire of the line (color)
Designation/Function
Brown
+5…30 V DC
yellow
GND (power supply)
green
TX
white
RX
grey
GND (UART)
Table 7: Connection IS.EC.W.F.P.SU.01.BETA to i.Cee:plus II
Figure 3 - Block Diagram Connection of the Sensor
EC.W.F.[inner-height].01.BETA
i.Cee:plus II or
Customers PLC
IS.EC.W.F.SU.01.BETA /
IS.EC.W.F.P.SU..01.BETA
Installation
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Manual EC. W.FIX V1.1
6.3.2 Connection to customer PLC
When connected to customer PLC
Wire of the line (color)
Name
Function
Brown
+5…30 V DC
Power supply
yellow
GND
Power supply
White
I/O Port 1
75 % remaining lifetime
green
I/O Port 2
50 % remaining lifetime
grey
I/O Port 3
25 % remaining lifetime
Table 8: Connection IS.EC.W.F.SU.01.BETA to customer PLC
6.3.3 Power supply
The power supply is ensured via the connected cable.
Wire of the line (color)
Name/Function
brown
+5…30V DC
yellow
GND
Table 9: Power supply
Commissioning
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Manual EC. W.FIX V1.1
7 Commissioning
7.1 With i.Cee:plus II (delivered with IS.EC.W.F.P.SU.01.BETA)
The sensor is connected via UART directly to the connecting line with i.Cee:plus II. Further steps on integrating it into the module
can be found in the instructions for i.Cee:plus II. You can reach them via the QR code on the device.
Here you have 4 wire loops.
7.2
7.3 Directly to PLC (delivered with IS.EC.W.F.SU.01.BETA)
Provide 3 digital PLC inputs (24V DC) and
connect them to 3 digital sensor outputs.
Provide I/O ports as inputs, the contacts on the
sensor are normally open
Extend variable table with state variables of the
three inputs
State logic table:
I/O Port State
Describtion
1
2
3
1
1
1
100 … 76% lifetime
remaining
0
1
1
75 … 51% lifetime remaining
0
0
1
50 … 26% lifetime remaining
0
0
0
< 25% lifetime remaining,
Chain replacement should
be initiated.
Process the state variables, for example, by
displaying three states in the user interface.
Example:
Commissioning
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Manual EC. W.FIX V1.1
7.4 Example Siemens control
The sensor transmits states directly to the controller via so-called I/O ports, for this purpose some settings have to be made in the
PLC.
Open the TIA Portal program by double-clicking on the following desktop icon (see Figure 4).
Figure 4: Desktop icon TIA Portal
Figure 5 - Adding a New Device
Select your controller type that is connected to EC.W.F.SU.01.BETA (see Figure 6 ).
Figure 6 - Selecting a Controller Type
Commissioning
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Manual EC. W.FIX V1.1
Select your CPU type and press the Add button (see Figure 7 )
Figure 7 - CPU Selection
Attention:
To connect the sensor to a CPU, 3 digital inputs are required! (Usually 24V DC inputs are used).
Overall, however, the sensor can generate voltages in the range between 3... Provide 30V DC for digital inputs. The
amount of voltage provided for the digital inputs depends on the level of operating voltage supplied to the digitizer. Here
these is 5V.
For digital inputs outside this voltage range (e.B. 230V AC), e.B three 24V DC relays are also required, which are
controlled via the digitizer. The 230V AC at the digital inputs can then be evaluated via the switching contacts of the
relays.
Click the "Show all variables" button and create all required PLC variables. In the example below, four PLC variables were defined
as inputs for four conductor loops and four PLC variables as outputs to indicate the status of the four conductor loops via light
detectors (see
Figure 8 ).
Figure 8 Creating a Variable Table
Commissioning
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Manual EC. W.FIX V1.1
By clicking next to Network 1, a name can be assigned to the network. In our example, this is called "conductor loop 1". The next
step is to select the location in the network where a bit link is to be inserted. In the example shown, the conductor loop 1 is inserted
for input %I0.0 and output %Q0.0(see Figure 11 ).
Figure 11 - Network1 (Conductor Loop1)
Now two more networks can be created for conductor loop 2 and conductor loop 3 . Figure 12 shows the complete program.
Figure 12: Sample Program
Load program to PLC(see Figure 13).
Figure 13: Icon for loading into PLC
Abbreviations
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Manual EC. W.FIX V1.1
8 Reset
You can reset the sensor by holding a magnet on the top of that box for approx. 2 seconds.
9 Troubleshooting
- Data transfer or I/O ports not available
o Check that all lines are connected correctly and securely.
o If this does not help, please contact our customer service.
- Sensor does not fit the e-chain®
o Contact customer service and ask for a suitable sensor
10 FAQs
- How do I retrieve lifetime information?
o i.Cee:plus II displays lifetimes in the user interface.
o In the PLC, states are transmitted to the controller via I/O ports and the controller processes the information
in its own way.
- Is it possible to download the sensor's data from the user interface?
o No
- Is it possible to replace the wear block?
o yes
11 Accessories/extension cable
Sensors
Article
Cable length [m]
Article
Extension
line
According to data sheet
https://igus.widen.net/s/chw7jgp29z/eu_data_sheet_chainflex_cf240.pur
CF240.PUR.03.05
MAT904172111
Table 10: Accessories
12 Abbreviations
Abbreviation
Description
EMC
Electromagnetic compatibility
ESD
Electrostatic discharge
GUI
Graphical User Interface
PLC
Programmable Logic Controller
Table 11: Abbreviations used
hold magnet
here
Service
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Manual EC. W.FIX V1.1
13 Service
Customer service
de-smartplastics-serv[email protected]
+49 (0) 2203 9649 9806
Technical support for igus® smart plastics
Documentation/FW
https://www.igus.de/info/isense-ec-w-lowcost?_ga=2.188992361.350712485.1653630266-1155834304.1651642878
Download manuals, FW updates and certificates
Website smart Plastics
https://www.igus.de/info/vorausschauende-wartung-smart-plastics
Possibility to order sensors, processing units and other accessories
Contact
www.igus.de
+49 (0) 2203-9649-0F
Imprint
© 2023
All rights at
igus® GmbH
Spicher Str. 1a
51147 Cologne
Sebastian Probst
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Igus IS-EC-W-FIX-2500-BETA Operating instructions
- Type
- Operating instructions
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