iwis CCM-S Series User manual

iwis.com/ccm-s
CCM-S Chain Condition Monitoring
Operating Instructions
ORIGINAL OPERATING INSTRUCTIONS
READ CAREFULLY BEFORE USE
RETAIN THIS DOCUMENT FOR LATER REFERENCE

Operating Instructions
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Table of contents
1Introduction ______________________________________________________________ 5
1.1 Using these Operating Instruction _________________________________________________ 5
1.2 Change without notice __________________________________________________________ 5
1.3 Presentation of the information __________________________________________________ 5
1.3.1 Symbols used _______________________________________________________________________ 6
1.3.2 Trademarks _________________________________________________________________________ 7
1.3.3 Notational conventions _______________________________________________________________ 7
1.3.1 Printing ____________________________________________________________________________ 7
1.4 Copyright_____________________________________________________________________ 7
1.5 Liability ______________________________________________________________________ 7
2Use, obligations on the operator, basic safety instructions ___________________8
2.1 Intended purpose ______________________________________________________________ 8
2.2 Use for a purpose other than the intended purpose __________________________________ 9
2.3 General notes on use __________________________________________________________ 10
2.3.1 Qualified personnel _________________________________________________________________ 10
2.3.2 Changes to the programme ___________________________________________________________ 10
2.3.3 Replacement parts __________________________________________________________________ 10
2.3.4 Technical condition __________________________________________________________________ 10
2.3.5 Compliance with regulations __________________________________________________________ 10
2.4 General hazard warnings _______________________________________________________ 11
2.4.1 Risks / sources of risk ________________________________________________________________ 11
2.4.2 General accident prevention regulations_________________________________________________ 11
2.4.3 Power down systems before working on them ____________________________________________ 11
2.4.4 Hazard locations ____________________________________________________________________ 12
2.5 General obligations on the operator ______________________________________________ 13
2.5.1 Monitoring behaviour________________________________________________________________ 13
2.5.2 Selection and qualifications of staff, basic obligations ______________________________________ 13
2.6 General safety instructions _____________________________________________________ 13
2.7 Safety instructions relevant to the specific product or technology ______________________ 14
2.7.1 Housing: Upper part and lower part (sliding shoe), SLS Material ______________________________ 14
3Transport / storage_______________________________________________________ 17
3.1 Storage conditions ____________________________________________________________ 17
3.2 Transport inspection __________________________________________________________ 17
3.3 Packaging / re-packaging _______________________________________________________ 17
4Description of the overall system__________________________________________ 18
4.1 Construction and function ______________________________________________________ 18
4.1.1 Factors influencing measurement ______________________________________________________ 18
4.1.2 Chain sizes _________________________________________________________________________ 19

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5SLE function_____________________________________________________________19
5.1 General description ___________________________________________________________ 19
5.2 Functionality _________________________________________________________________ 19
5.3 Mounting Magnet_____________________________________________________________ 20
6Scope of delivery ________________________________________________________20
6.1 Tools required________________________________________________________________ 21
7Installation and commissioning ___________________________________________ 22
7.1 Installation __________________________________________________________________ 22
7.2 Software Installation __________________________________________________________ 27
7.2.1 Installing iwis-CCM Monitor on the PC __________________________________________________ 27
7.2.2 Installing the iwis-CCM Monitor USB driver on the PC ______________________________________ 28
7.3 Establishing a PC connection with the CCM-S _______________________________________ 33
7.4 Setting up a new chain (also initial setup) _________________________________________ 33
7.5 Reading/ Saving / Resetting the Error Log _________________________________________ 35
7.6 Error log ____________________________________________________________________ 36
7.7 Reading out elongation data locally ______________________________________________ 39
7.8 Updating the CCMS firmware ___________________________________________________ 40
7.9 Connection / pinout ___________________________________________________________ 41
8IO-Link information_______________________________________________________ 42
8.1 Installation __________________________________________________________________ 43
8.1.1 General regulations _________________________________________________________________ 43
8.1.2 IO-Link ____________________________________________________________________________ 43
8.1.3 Connection ________________________________________________________________________ 44
8.2 Device profile / Function Classes _________________________________________________ 45
8.3 Commissioning _______________________________________________________________ 45
8.3.1 IO-Link Device Description File _________________________________________________________ 45
8.3.2 Device identification _________________________________________________________________ 45
8.3.3 Starting the IO-Link System ___________________________________________________________ 45
8.3.4 Process Input Data __________________________________________________________________ 46
8.4 Parameterization _____________________________________________________________ 47
8.4.1 Index 0x0010 –0x0018: Identification parameter__________________________________________ 47
8.4.2 Set Parameters _____________________________________________________________________ 48
8.4.2.1 Index 0x0046: Scale Limit _________________________________________________________ 48
8.4.2.2 Index 0x0047: Chain Logging Time __________________________________________________ 49
8.4.2.3 Index 0x004E: Standard Command __________________________________________________ 49
8.4.3 Read Parameters____________________________________________________________________ 49
8.4.3.1 Index 0x0041: Distance ___________________________________________________________ 49
8.4.3.2 Index 0x0042: Running Time _______________________________________________________ 49
8.4.3.3 Index 0x0043: Average Speed ______________________________________________________ 50
8.4.3.4 Index 0x0044: Actual Speed _______________________________________________________ 50

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8.4.3.5 Index 0x0045: Chain Period________________________________________________________ 50
8.4.3.6 Index 0x0048: Temperature Chain __________________________________________________ 50
8.4.3.7 Index 0x0049: Temperature CPU ___________________________________________________ 50
8.4.3.8 Index 0x004A: Voltage 5V _________________________________________________________ 50
8.4.3.9 Index 0x004B: Voltage 24V ________________________________________________________ 50
8.4.3.10 Index 0x004C: Chain Direction Left __________________________________________________ 51
8.4.3.11 Index 0x004D: Number Chain Link __________________________________________________ 51
8.4.3.12 Index 0x004F: Count Measure______________________________________________________ 51
8.4.3.13 Index 0x0051: Product Specific Number ______________________________________________ 51
8.4.3.14 Index 0x0052: Custom Device Name_________________________________________________ 51
8.4.3.15 Index 0x0053: Number of acceleration data: __________________________________________ 51
8.4.3.16 Index 0x0054: Number of length data: _______________________________________________ 51
8.4.3.17 Index 0x0055: Single Link Max Positions _____________________________________________ 52
8.4.3.18 Index 0x0200: Single Link Header ___________________________________________________ 52
8.5 Diagnosis____________________________________________________________________ 53
8.5.1 Error Counter (Index 0x0020)__________________________________________________________ 53
8.5.2 Device Status (Index 0x0024) __________________________________________________________ 53
8.5.3 Detailed Device Status (Index 0x0025)___________________________________________________ 53
8.5.4 Device-specific Diagnosis (Index 0x0050) ________________________________________________ 55
8.5.5 ISDU error types ____________________________________________________________________ 56
8.5.6 Process data Status __________________________________________________________________ 57
9Technical data ___________________________________________________________ 58
9.1 Technical data CCM-S __________________________________________________________ 58
9.2 Technical drawing CCM-S _______________________________________________________ 58
10 Declaration of Conformity _______________________________________________59
11 Disassembly and disposal_______________________________________________60
12 Other applicable documents_____________________________________________ 60
13 References_____________________________________________________________60
14 Abbreviations / terms used ______________________________________________ 60

Operating Instructions
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1 Introduction
These Operating Instructions have been formulated to give generic information. Because the different variants for this
version are operated in the same way, the scope of applicability of these Operating Instructions has been extended
accordingly:
Description
iwis-Item number
CCM-S-08B IWIS
40011816
CCM-S-40 IWIS
40011822
CCM-S-10B IWIS
40011817
CCM-S-50 IWIS
40011824
CCM-S-12B IWIS
40011818
CCM-S-60 IWIS
40011825
CCM-S-16B IWIS
40011819
CCM-S-80 IWIS
40011826
CCM-S-20B IWIS
40011821
CCM-S-100 IWIS
40011827
CCM-S-24B IWIS
40011828
CCM-S-120 IWIS
40011831
CCM-S-28B IWIS
40011829
CCM-S-140 IWIS
40011855
CCM-S-32B IWIS
40011830
CCM-S-160 IWIS
40011856
The details shown in the figures may differ but have the same functional structure.
1.1 Using these Operating Instruction
Make sure that you read these Operating Instructions carefully before starting to work with the product. These Operating
Instructions contain important information that you will need for setting up and operating the product. In particular, they
describe the proper use of the product and protect against incorrect use, contain safety instructions that must be
observed and warn of risks and hazards that can arise even when the product is used properly.
Keep these Operating Instructions in a safe place so that they can be referred to a later date.
1.2 Change without notice
We constantly strive to improve our products. The information contained in this document is consequently subject to
change without notice.
1.3 Presentation of the information
In order to ensure that this document allows you to work with your product quickly and safely, the safety instructions,
symbols, terms and abbreviations used have been harmonized. To facilitate familiarization, these are explained in the
sections below.

Operating Instructions
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1.3.1 Symbols used
These Operating Instructions contain notes and information that you must observe to ensure your own personal safety
and to avoid damage to property. The safety instructions are indicated by a warning symbol and appear as follows,
depending on the risk category:
Table: Safety instruction categories
Warning symbol
Meaning
DANGER indicates a situation of immediate danger that will lead to fatal or
severe injuries if it is not avoided.
WARNING indicates a situation of potential danger that can lead to fatal or
severe injuries if it is not avoided.
CAUTION indicates a situation of potential danger that can lead to minor or
slight injuries if it is not avoided.
TAKE CARE indicates a situation that can lead to damage to property if it is
not avoided.
Table: Structure of the safety instructions
Incorrect action
Type and source of the danger
Warning symbol
Warning symbol as listed in the table
Reasons for incorrect action
Describes possible reasons for the incorrect action
Possible consequences of the
incorrect action
Describes the consequences if the information is not observed
Measure to mitigate risk
Describes how to avoid the danger
Table: Structure of a note
Symbol
Meaning
NOTE indicates important information or features and tips for using the product.

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1.3.2 Trademarks
Products, names and logos used in this document are used exclusively for information purposes and may be trademarks
of their respective owners, even if this is not explicitly indicated.
1.3.3 Notational conventions
Italic or bold typeface is used for the title of a document or for highlighting information.
Courier font is used for text that appears on the screen/display and for menu options in software.
< > is used to indicate keys on your computer keyboard (such as <RETURN>).
1.3.1 Printing
This manual was created with Microsoft Word for Windows on a PC.
This text has been printed using the Arial typeface.
Microsoft Word is a registered trademark of Microsoft Corporation.
1.4 Copyright
©Copyright 2019 iwis antriebssysteme GmbH & Co. KG
Transmission, distribution, reproduction and / or utilization of this document and its contents (in parts or amendment) are
prohibited, unless expressly authorized in writing. Offenders are liable to damages. All rights even in the event of patent,
utility model or design patent.
1.5 Liability
The principles of liability are as laid down in the iwis Terms and Conditions of Sale and Delivery, available at
www.iwis.com. No liability is accepted in circumstances that can be attributed to one or more of the following causes,
except in the event of intent or gross negligence on the part of iwis:
_Use for a purpose other than the intended purpose
_Improperly performed work on the product
_Operation of the visualization interface in the event of technical faults
_Unauthorized mechanical or electrical changes to the product, modified configuration
_Repairs carried out without authorization
_Use by unqualified staff
_The use of unauthorized replacement parts
_Faulty installation and/or improper handling
_Failure to observe these Operating Instructions

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2 Use, obligations on the operator, basic safety instructions
2.1 Intended purpose
The product is intended for industrial, not private use.
The product is intended solely for the purpose of measuring chain elongation.
Important note on the chain elongation value, inspection frequency and measurement:
The function of the product is only to provide information. No guarantee is given that the system will protect against
failure of chain drives or machine stoppages. Reliable measurements can only be guaranteed if the chain is guided on
both sides. Measurement is a contact-free process with no direct intervention in the chain drive. It must, however, be
performed in a clearly defined status, which can only be guaranteed if the chain is guided on both sides.
Measurement of future chain elongation depends on inspection and maintenance intervals, which are in turn determined
by the concrete usage scenario for the chains. External factors (e.g. inadequate lubrication, particle deposition, etc.) can
increase the rate at which a chain wears. The customer is solely responsible for defining the inspection intervals and any
special inspections.
The product does not show the evaluation of the measurements and any resultant effects on the
machine/system of the user or any measures that need to be taken. This is the sole responsibility of the
operator.
The product constitutes partly completed machinery as understood by the Machinery Directive 2006/42/EC. The product
may only be taken into operation after it has been installed in the machine/system for which it is intended and if this
machine fully complies with the requirements of the EU Machinery Directive. The product is not intended to be used
outside the system.
You are permitted to use the product as follows:
_No changes, additions or modifications may be made to the product without the authorization of the
manufacturer. This also applies to the installation of safety devices.
_The product may only be used if it is in sound technical condition. Any damage that gives cause for concern that
the product may not function correctly must be inspected by specialist staff to ensure that it does not impact on
safety. In cases of doubt, the manufacturer must be contacted ([email protected]).
_The product was designed for installation in a partly completed machine, a machine or a system.
oThe product is not intended to be used outside the system.
_The purpose of the product is to measure chains that become elongated as a result of mechanical forces.
_The CCM-S should preferably be installed in the tight strand. The relevant minimum distances and maximum
load on the measuring carriage and the overall system must be observed.
oSee the section "Technical data".
_For the best and most meaningful results, we recommend that the chain should be cleaned before it is fed into
the CCM.
_The device can be dismantled for the purposes of installation, maintenance and troubleshooting.
oAny work on the system may only be carried out as specified in the documentation, in terms of both the
scope of the work and the sequence of the work steps.
oIn the event of more extensive work, the manufacturer must be contacted ([email protected]).
_In the case of chains with attachments on one or both sides or extended pins, iwis must carry out a separate
inspection. In this event, please contact iwis ([email protected])!
The CCM is a test device and not a measuring device!

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The CCM-S is designed for operation at a point-to-point IO-Link communication interface according to the
international standard IEC 61131-9 with 230.4 kbit/s. Parameterization and device diagnostics are performed by the
IO-Link master according to the IO-Link Interface and System Specification, Version 1.1 of the IO-Link group of
companies.
The technical guidelines for setting up the IO-Link network of the PROFIBUS User Organization (PNO) must be
observed for safe operation.
Intended use is deemed to include observance of the relevant Operating and Maintenance Instructions and adherence
to the service and maintenance stipulations.
2.2 Use for a purpose other than the intended purpose
Any use other than
_that described as the intended use and
_that described in the relevant documentation
is not compliant with the intended purpose and is therefore not permitted.
The manufacturer shall not be liable for damage incurred as a result of use other than for the intended purpose.
Any risks associated with use other than for the intended purpose are the sole responsibility of the user. Use of the
product and, if present, its components other than for the intended purpose is understood to include:
_Its use for applications not explicitly approved by the manufacturer. In such cases it is imperative that you
observe the information contained in the safety notices in the associated documentation!
_Constructional modifications to the CCM that destroy the original condition.
_Inappropriate programming or configuration of the system.
_(The responsibility and liability for any risks associated with the programming and configuration of the system
lies solely with the user.)
_Never subject the product to impermissible mechanical loads. Never use the product as a handle or a step.
Never place any objects on the product.
_Do not work with the product in potentially explosive environments containing flammable liquids, gases or dust.
_The device is not to be used in the area of intensive UV radiation (e.g. disinfection lamps or similar radiation).
_Permanent contact is not permitted.
_Do not open the sensor. Check the safety lacquer or safety screw.

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2.3 General notes on use
2.3.1 Qualified personnel
The product may only be used and work on the product may only be carried out by qualified personnel.
Qualified personnel are persons who by reason of their training, experience, instruction and their knowledge of the
relevant standards, regulations, accident prevention rules and working conditions have been authorized by the person
responsible for the safety of the machine or plant to perform the appropriate activities required. They are able to
recognize and prevent potentially dangerous situations.
2.3.2 Changes to the programme
Do not make any changes to the programme (software) on the programmed system. The responsibility and liability for
any risks associated with the programming and configuration of the system lies solely with the user.
2.3.3 Replacement partsc
Only use spare parts that comply with the requirements laid down by the manufacturer and/or supplier. This condition
is always fulfilled with original replacement parts. Product liability shall cease, and the warranty shall become invalid
in the event of repairs which are carried out improperly and the use of incorrect replacement parts.
2.3.4 Technical condition
The product may only be used if it is in sound technical condition. Any malfunctions that are detected, in particular
those which could compromise safety, must be rectified without delay. Any damage that gives cause for concern that
the product may not function correctly must be inspected by specialist staff to ensure that it does not impact on safety.
In cases of doubt, the manufacturer must be contacted ([e-mail]).
2.3.5 Compliance with regulations
It must be used in accordance with its intended purpose, in a safety-conscious and risk-conscious way and in
compliance with the relevant regulations. The operator must ensure by suitable organizational and instruction
measures that the relevant safety regulations and safety rules are observed by the persons entrusted with the
operation, maintenance and repair of the product.