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IntelliSense® Manual

1. 00 00 09 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt RE lt lt lt lt J lt Jj lt o J D J D D D D D D J D D o J IH o o IH J Jn J n e Jn le e HTH Jn n Register Description TT 5 2 Bytes 40023 U Line Pressure Hig Line Pressure Low Sensor 1 Pressure High Sensor 1 Pressure Low Sensor 2 Pressure High Sensor 2 Pressure Low Sensor 1 Pressure High Warn Sensor 1 Pressure Low Warn Sensor 2 Pressure High Warn Sensor 2 Pressure Low Warn 40024 Leakage Failure 2 Bit 0 Rear Piston Seal Bit 1 Front Piston Seal Bit 2 Rod Seal Temperature Failure 2 Bytes Bit 0 1 Temp Hig 1 Temp Low 2 Temp High 2 Temp Low 1 Temp High Warn 1 Temp Low Warn 2 Temp High Warn 2 Temp Low Warn 40026 2 Bit 0 Extent Time High Bit 1 Extend Time Low Bit 2 Retract Time High Bit 3 Retract Time Low Bit O Estimated Life Remaining above 90 Bit 1 Estimated Life Remaining Below 10 Bit 0 Yellow Light Threshold Estimated Cycles remaining low word E 2 Bytes 40031 Estimated Cycles remaining high word stimated Days Remaining 40032 e 40033 Time in ms for last dwell after exte
2. uod e 7 wd e 2 n Sy _bnteliSense Junction Block ISH RO4 Power Cable User Supplied Q Modbus interface Cable User Supplied 080 to RJA5 Cable CBL IS RD XX M 38422 to USB Hub ISH 004 USB Cable Supplied with ISH D04 InteSense Data Gateway ISG 01 Q Wireless or Wired Ethemet User Supplied 67 IntelliSense Manual Cable Pin Outs Bimba Manufacturing Company P O Box 68 Monee Illinois 60449 0068 Phone 708 534 8544 Toll Free 800 44 BIMBA Fax 708 235 2014 Email cs bimba com www bimba com Form HM BIM IS 091 4 Rev 1 BIMBA BRANDS ACRO MEAD MFD PNEUMADYNE PNEUMATIC ACTUATORS ELECTRIC ACTUATORS HYDRAULIC ACTUATORS VALVES AIR PREPARATION SAFETY amp PRODUCTION
3. Dimensions inches mm 4 PIN 1 0 214 54 4 3 28 43 4 RE 45 3 76 95 6 Bl 1 11 28 3 hour ape Al 20 6 48 IntelliSense Manual IntelliSense Pressure Temperature Sensor Specifications Pressure Sensing Performance Specification IntelliSense Pressure Temperature Sensor Operating Pressure 0 psia to 200 psia 302 Stainless Steel 0 to 14 bar a 303 Stainless Steel 2X maximum operating pres Accuracy 0 psi 0 bar to 87 psi Environmental Specifications 6 Up to IP69K based cables 32 0 C to 104 40 0 29 psi 20 mbar ul 40 F 40 C to 185 F 85 C 0 58 psi 40 mbar R Ti psi tt 40 F 40 C to 176 F 80 C Response Time onse Time ms se 18 206 9 80 2000Hz thr Long Term Stability 0 29 psi year 20 mbar year Random Temperature Sensing Performance Specification times each axis and Temperature Range 9 F 15 C to 127 F 60 C lt 0 02 F 0 01 C Electrical and EMS Specifications A 18 F 10 C i i Cable Installation EMC Ratin Emissions and Immunity to EN Thread Size 10 32 9 61326 2013 Maximum Torque 10 in Ib 1 12 Nm 4 kV Contact 8 kV Air 4 kV Electro Static Discharge Indi Mount with Pressure Port ndirect Orientation an Pointing Down 10 V m from 80 1000 MHz ae Class 3 ISO 8573 1 5 micron V m from 1 4 to 2 7 GHz Air Quality Ta
4. Figure 8 Multi SIM Monitoring Screen Configure the IntelliSense Data Gateway Data Gateway Machine Settings oelect the Configuration tab on the left of the screen then the Machine tab on the top On this page the following parameters can be entered Machine name A name for the gateway Data retention period The number of days that recorded temperature and pressure should be kept for disk size permitting Save All changes are lost if not saved Power off gateway Allows the gateway to be shut down without the risk of data loss or file corruption Reset to Factory Defaults Clears any user entered changes and resets the Data Gateway to factory default values MACHINE SERIAL PORTS NETWORK Status Configuration Configuration Machine name IntelliSense Data Gateway About Data retention period 30 days Save Power off data gateway Set Time Reset to Factory Defaults Figure 9 Machine Setup 14 IntelliSense Manual Data Gateway Cylinders SIMs This page is for adding connections to SIMs that the Data Gateway will monitor For more information refer to the fol lowing section in this document Add or Configure a SIM on the PC or Gateway Data Gateway User Administration The Data Gateway has user access control and multiple users can be set up with three levels of access privileges The three user levels are Read All users have read access Modify SIM Th
5. i l i u u mmm 5 Sanie T i i 5 KU E 1 i 6 ACAR OUE OMe DN 6 sp ori qi u x i A 11 YI l m l o 11 gt xs E E QH 11 SDzwrroooooowrwwrwwrwwwrr r r r rarr r z ggg_g_mn mm apas 11 IntelliSense Data Gateway Installation optional ee rennen U J T T Q T J T T 13 Mounting the Iritellisense Data Gateway UU UU LU LLL Ia Res EE E RREO NSi E E A OSOA TEA E EEA rk hej bad 13 Connecting to the IntelliSense Data kaka k kaka ka kak k ka ka nnn 19 Configure the Intellisense Data Gateway UU htt kal hln tob Do btt k la ae iude sed Wa duae sede unes dada edited queden aded clie asd 14 em TPC PU 17 SIM Installation u III III IIS HE WO NE KA H SE HE HU L e HEW HA R WA WAN w dR RO RA REG RA W AKU b ka 20 LP Wl S Rec E T T E E m T me 20 ET eter tr tee E E 21 Conigunna the GINI 22 Tab J
6. SIM MAINTENANCE FUNCTIONS Restart SIM Cycles power to the SIM Set Time Sets the date and time on the SIM to match those of the Data Gate way or PC Set Time Backup Settings The current SIM settings are downloaded to an XML file on the user s machine Backup Settings Restore Settings from Backup Restore Settings from Backup The user can upload SIM settings from a pre viously saved XML file backup Restore SIM to Factory Settings Reset predictive data and history Restore SIM to Factory Settings Removes all user changes and restores the SIM to default settings Reset cycles per day Update SIM Firmware Reset Predictive Data and History Deletes all snapshot history of changes in the cylinder performance Recommended when new cylinder is installed Blink LEDs for identification Reset Cycle per Day Sets the Average Daily Cycles to 0 Recommended when SIM is moved to a new application Update SIM Firmware Prompts the user to select the new firmware file See the update firmware section in this manual for details Blink LEDs This causes the SIM to flash all indicator LEDs for a few seconds allowing it to be identified 31 IntelliSense Manual Update SIM Firmware If it is necessary to update the SIM firmware this can be performed with a file downloaded to the user s machine or one that resides on the data gateway Select the Update SIM firmware
7. The sensor assembly should be retained to minimize stress on the pneumatic connection and sensor cable Sensor Orientation The sensor should be oriented with the port pointed down This will minimize the chance of debris clogging the port The pressure sensor is a dead end device and cannot be cleaned If the port becomes clogged a new sensor should be installed Assembly Torque The sensors included with an IntelliSense kit come pre assembled to a pneumatic fitting A situation may arise where a different fitting is required The port on the sensor is a 10 32 UNF thread The maximum torque for the sen sor is 10 in Ib 1 13 N m Sensor Cable The SIM connects to each sensor with a four wire Female 8 to Female 8 cable part number CBL IS M8 XXX The maximum length of this cable is 325 feet 100 Meters Care should be taken to not over tighten the connection to the SIM The sensor connected to the port labeled Sensor 1 should be installed at the cap or rear of the cylinder The sensor connected to the port labeled Sensor 2 should be connected to the head or rod side of the oylinder IntelliSense Manual Sensor Cable 4 Wire M amp 8F M8F CBL IS M8 XX Sensor 1 II an cU REL LL EI Straight Connector to the SIM Max Torque Finger Tight 2 0 In Ib 0 23Nm UB CORRE CLO LO DE uy Max Torque 3 5 In Ib 0 4Nm Figure 5 Sensor cable installation IntelliSense Man
8. change parameter A value of 1024 means the event was triggered by an increase in detected rear piston seal leakage in per centage equal to or greater than the value of the Cylinder leak change parameter Events Failures When an event is logged by the SIM unit it records any active failures These failures are coded as binary numbers as follows 64 Sensor 2 Temperature is above limit 8 Front Piston Seal Failure Present 4 Rear Piston Seal Failure Present _ Following this table a failure code for Extend time was above limit would be a 1024 Likewise an event with mul failures such as a Extend time was above limit and Line pressure above limit would be a 1026 44 Using IntelliSense with MODBUS RTU Networks The Intellisense SIM unit has a dedicated port labeled MODBUS This port is designed to allow the SIM to commu nicate over a MODBUS RTU serial network This port can be configured either as 2 wire default or 4 wire RS 485 See Setting the DIP Switch for more information The Intellisense SIM only utilizes READ request to its internal Holding Registers For pin out and wiring diagrams consult the Wiring Diagram section Configurable Elements Slave Address Values 1 247 are valid Default value is 1 MODBUS RTU networks of more than 31 IntelliSense SIM units are not recommended Baud Hate Values of 4 800 9 600 19 200 default 38 400 57 600 and
9. 3 The Installed column has the version number of the installed software and Update shows the ver sion available for download If they are different a command button under Action will appear to prompt updating the software If not connected to the internet it is possible to update the software on the Data Gateway via a USB drive For Data Gateway software versions 1 1 0 and older the IntelliSense Patch 1 1 must be installed before the Data Gateway can be updated via USB drive Download the IntelliSense Patch file from bimba com From a PC with access to the Data Gateway run IntellGense Patch 1 1 exe Enter the IP address of the Data Gateway and click Install F After installation is complete click close 18 IntelliSense Manual For Data Gateways with version 1 1 1 or later or that have had the IntelliSense Patch 1 1 installed the Data Gateway software can be updated with a USB drive Download IntelliSense USB software from bimba com Copy the contents of the zip file to the root directory of a USB drive Plug the USB into one of the USB ports on the Data Gateway and allow it to be recognized From the Software tab click Force check for new updates D Click the update button just as you would if connected directly to the internet To download the available SIM firmware select the Install button in the Action column to the right of the desired firm ware version This will down
10. status of the SIM unit and attached pressure system This setup also allows for data logging to be performed and stored in the Data Gateway unit regardless of a user PC connection By configuring a Modbus RTU network be tween the user s PLC Master Device and the SIM unit s Slave Device the user can retrieve desired status values and alerts If using the discrete outputs the SIM must be powered using option b IntelliSense Manual Functionality e Cylinder condition monitoring based on status LEDs SIM unit e By configuring a MODBUS network between the users PLC HMI Master Device and the SIM unit s Slave Device the user can retrieve desired status values and alerts e Data Gateway remains connected for data logging e User PC connects to Data Gateway for initial configuration and or real time monitoring of the SIM unit and attached pressure system e Use of EOT outputs with PLC installation and use of power option b List of Components Required Bimba Products e I ntelliSense Basic Kit ISK BMAx o 1 IntelliSense Sensor Interface Module SIM ISM S1 BA1 5P 2 IntelliSense pressure temperature sensor ISS 1A 7SS o 2 IntelliSense Tee fittings ISF T 1 xxx e 2 sensor cable CBL IS M8 x e 1 IntelliSense USB programming cable CBL IS RU 1 8 Optional Bimba Products e 1 24 VDC Power supply PWR 024A24 DIN if not supplied by user e 1 IntelliSense 0 5 meter IO cabl
11. use IntelliSense for single acting or reverse acting actuators A Not at this time Q Can use IntelliSense with SPCS valves A Not at this time Q Can use non Bimba Actuator Q Can use a non Bimba Actuator A Bimba does not support Intellisense being installed on other manufacturers cylinders Q What Bimba products is IntelliSense compatible with IntelliSense is compatible with Bimba Original Line Single Rod and Double Acting Cylinders For compatibility with other Bimba Cylinders please contact your Bimba representative Q Can use the IntelliSense on a double end rod DE option actuator A IntelliSense is currently only configured for use with single rod end cylinders Q How are the baseline numbers established A The base line looks at the values over the specified number of cycles and reports back the observed averages Q Is the use of cushions compatible with IntelliSense A Yes the IntelliSense is compatible with cushion applications Q How does the IntelliSense install on a cylinder A The IntelliSense Pressure and Temperature sensors are designed to be attached to pneumatic tubing using the in line fittings provided in each IntelliSense Kit The fitting is intended to be mounted 2 6 inches from the cylinder s ports There should be no other devices between the cylinder and the sensor The IntelliSense sensors should not be mounted directly to a cylinder Q Can us
12. GIN A a Sma S a Ya 34 amp 545 eee Lo qc u a Sua a aa u m mr zbggg 34 Using Intellisense with a PG or Data siuatmosiniantamdengduatanadiuanankarecuedanadawraandapeatadhornate 35 Using Intellisense with MODBUS TU haasi d y sale ln kaway Aa s d k sal n wann We B ka a n k ayaqa kek a 45 Using cense VO CONNECTION ssam taitara E n E rbr r r r r r r r rr ll ep m omnmxnxx 46 Ve GIN si M DE LE E vava EI mc 48 IntelliSense Sensor Interface Module rrt n enn eek n snn kk kk kK 48 Intellisenss Pressure 7 Temperature 49 IntelliSense Data Gateway khk kak kaka kaka 50 ili eS lt sx xzz sszs eEeEgepp oono o XV mj m 51 G hi P rp BN Dc 52 Idolb5Ssnsa 0X7ronbieshesuq ULU LULU R dk u uuu u u u 53 SS S S A ORDRE 59 PO OSEE RA Ka e k k ls dl LN neti 58 Du aza o gt s x rr 58 68 IntelliSense Manual IntelliSense Operating Modes The IntelliSense Sensor Interface Module SIM can be operated two modes Cylinder Monitoring or Pressure Temperature Monitoring The general installation and setup for these two modes is the same The modes differ in the status informat
13. Number of cycles that define the life of the cylinder without taking into account any ob served drop in performance This can be entered for an existing application where the typical life of the cylinder and the average number of daily cycles are both known Use the following formula to calculate the number of cycles Cycle count limit M x W x 30 7 Where M number of months between cylinder change W number of cycles cylinder is run per week This is the sensitivity of detection for leakage and stroke time and defines how long detected change in performance has to be maintained for it to be recognized Start with the default value and if too many system snapshots are being taken particularly ones that alternate showing an increase and decrease in cylinder life this value should be increased to reduce the sensitivity to transient changes A system snapshot is taken every time a change is detected between the current system and the previous system snapshot The size of the change to be detected is defined in the Trigger Event section Select the cylinder performance that you would like to monitor for a change The events that can be monitored for are Change in stroke time Change in cylinder leakage Change in cycles completed To activate the trigger select the check box beside it and enter the quantity that defines a change that will trigger a snapshot to be taken When a change in the monitored param eters occurs that is equ
14. f SIM Figure 46 Cylinder Status Screen EST LIFE REMAINING Total 0 000 sec 0 000 sec Status Normal Normal Normal All of the parameters for the selected SIM can be reviewed and edited on this page Please refer to the section in this manual on for more details SIM Monitoring On the monitoring screen the user 15 able to see the pressure and temperature measurements from the SIM in real time as they are made The pressure measurements are updated up to 1000 times per second 1 KHz and the tem peratures about every second 1 Hz The SIM monitoring screen has the following features Play Pause real time Pressure Temperature plot Displays real time plot of Pressure Temperature against time for approximately four seconds of data Export After the real time plot is paused it is possible to export the visible pressure and temperature data for further analysis 38 IntelliSense Manual Status J Configuration s w About MONITORING Play Export Show temperature 80 00 PSI 10 00 PSI 14 01 37 Press 67 09 psia 14 20 Temp 80 74 F 74 41 F Pressure and temperature values Real time plot of pressure and temperature Figure 47 Cylinder Monitoring Screen Export From the export page it is possible to download data logged to the Data Gateway The two main categories are Pressure and Data Logged pressure temperature and cylinder alert and performance data This data is o
15. ground to allow for SIM to be powered I O con nector H Unties Channel B from ground 680 Te Switches should be changed together Affects both ports if they are linked DIP 1 4 ON Isolates Pin 4 from ground to al low for EOT outputs to be used I O Connector Power Source and Discrete Output Settings By setting DIP switch 9 to ON the SIM unit may be powered using 4 pin I O connector See Using IntelliSense I O Connector for information on wiring This is the default setting When DIP switch 9 is OFF the user may use the EOT outputs of the 4 pin I O connector See Using IntelliSense Connector for information on wiring 20 IntelliSense Manual Network Configuration MODBUS Settings DIP switches 1 4 should be treated as one switch either all ON or all OFF When this set is turned ON the MODBUS Port and PC Port are internally connected to allow for a daisy chain layout When OFF default the ports are not internally connected DIP switches 5 and 6 should be treated as one switch either both ON or both OFF When this set is turned ON de fault the MODBUS is configured for 2 wire RS485 When OFF the port is configured for 4 wire RS485 When DIP switch 7 is set ON it connects a 150 ohm terminating resistor across channels DO and D1 of the MOD BUS Port Default is OFF See Using IntelliSense with MODBUS RTU Network for more information DIP switch 8 is not used f
16. time after extending in seconds Dwell Time Retract Dwell time after retracting in seconds Cycle Count Current cycle count Average Daily Cycles average daily cycles at the time of measurement 40 IntelliSense Manual Alert Data The following will output the state of the alarm at the time of the measurement A value of 1 indicates that the alert was active and 0 indicates that the alert was off Line Pressure High Line Pressure Low Sensor 1 Press High Sensor 2 Press High Sensor 1 Press Low Sensor 2 Press low Sensor 1 Temp High Sensor 1 Temp Low Sensor 2 Temp High sensor 2 Temp Low Extend Time Low Extend Time High Retract Time Low Retract Time High Rear Seal Failure Front Seal Failure Rod Seal Failure To export the logged data 1 Select the Pressure and Date Export option button EXPORT and Data Export s Figure 49 Export option 2 The field selector will appear On the right is a list of all of the available pieces of data On the left is a grey area where the desired fields can be dragged Select Clear Drop items in order here Data Alert Status Sensor 1 Temp Sensor 2 Temp Line Pressure Ambient Pressure Figure 50 Export field selector By default the export file will contain the measurement time and the two pressure measurements P1 and P2 To add any of the available fields columns to the exported file press the left button over the re quired field and dr
17. 115 200 bps Bit Parity Supports Even default Odd or None parity Stop Bit The IntelliSense SIM may uses 1 stop bit or 2 stop bits Static Elements Bit Count The IntelliSense SIM uses an 8 bit formatted message MODBUS Registries IntelliSense Manual The integer data values stored in the IntelliSense SIM Holding Registers can be accessed using the appropriate ad dress found in the following table Description Pressure of port 1 in absolute tenths of PSla Pressure of port 2 in absolute tenths of PSla 40003 Ambient pressure in absolute tenths of PSla Pressure of port 1 in absolute tenths of mBar Pressure of port 2 in absolute tenths of mBar 40006 Ambient pressure in absolute tenths of mBar 40007 Line pressure in absolute tenths of PSla 40008 Line pressure in absolute tenths of mBar 40009 Rod Position 40010 Time in ms for last extension event R 40011 Time is ms for last retraction event 40012 Temperature of port 1 in hundredths of a degree F 40013 Temperature of port 2 in hundredths of a degree F 40014 Temperature of port 1 in hundredths of a degree C 40015 Temperature of port 2 in hundredths of a degree 40020 First two bytes of SIM revision Second two bytes of SIM revision Sensor Status 40021 Bit 0 1 Streaming Bit 1 2 Streaming Bit 3 1 Recognized Bit 4 2 Recognized Table 4 MODBUS registry NINININININININININININININININININININIJN
18. 49 12 13 l4 E5 i16 Download by interval Download by seconds in the past and end at Download data by interval Time 00 00 Hour Minute Figure 52 Export interval b Download by last number of seconds Enter the number of seconds to go back from the current time and select the download button A file will be created for the entered period of seconds ending at the moment the Download but ton is selected Download Method Data starts at 04 Jul 2014 15 56 04 GMT 1134607 seconds ago Download by invterval Download by seconds in the past Begin data export at 300 seconds ago Download data by seconds Figure 53 Export seconds in the past Events Export oelecting the events export option brings displays a table containing all of the snapshot history taken for the cylinder being monitored by the SIM The snapshots can be reviewed in the browser to see how often changes in perfor mance are detected The SIM can store 31 snapshots in addition to the original snapshot taken as the cylinder 42 IntelliSense Manual baseline If numerous snapshots are being taken within short periods of time that show an oscillation of performance a decrease in the performance parameter followed by an increase the sample size should be increased to reduce this fluctuation For more details on setting up event detection refer to the section in this manual The legend below the table of data explai
19. E PRESSURE Firmware va se EREE M ONITOR NG Pressure Temperature Monitoring Mode Sensor Communication Sensor 1 Not detected Sensor 2 Not detected Sensor 1 and 2 Not detected Alert Indication Al Sensor 1 normal Sensor 2 normal Sensor 1 normal Sensor 2 detects alert Sensor 1 detects alert Sensor 2 normal Sensor 1 detects alert Sensor 2 detects alert e Status Sensor Interface Module SIM Pressure and temperature within limits Pressure or temperature is approaching upper limit ON SLOW FLASH FAST FLASH Al SEE ALERT INDICATION SECTION Copyright 2014 Bimba Manufacturing Company V1 Figure 43 Operation of Status Lights in Pressure Temperature Monitoring Mode 34 IntelliSense Manual Using IntelliSense with a PC or Data Gateway Top Menu Bar The Top Menu bar is located in the top right corner of the screen and is accessible from any window in IntelliSense and has the following functions User Options Logout Allows the current user to log off the system Change Password Allows the current user to change their password Switch to C F Toggles the temperature units used to display measurements Switch to Toggles the pressure units used to display measurements Hide tios Hides the command and field tips Helo Provides a link to the software help file Alerts Provides real time feedback if there are any alerts in the system Sele
20. Hardware Manual IntelliSense Manual z nteliSense Data Gate Ze IntelliSense II SIM 4 software Version 1 1 1 Firmware Version R101 IntelliSense Manual Scope of this Manual This instruction manual supports Bimba standard components only If soecial components including but not limited to serial hubs power supplies and drivers are included based on a customer s specifications or special request it is the customer s responsibility to consult support materials and technical support specific to these special components provided by the third party manufacturers Bimba assumes no liability for mis use misapplication or support for components that are not the Bimba brand Warning Using the equipment in a manner not specified in this manual can impair the safety of the equipment Technical support is available from Bimba Manufacturing Company P O Box 68 Monee Illinois 60449 0068 Phone 08 534 8544 Toll Free 800 44 BIMBA Fax 708 235 2014 Email csQbimba com www bimba com IntelliSense Manual Contents intelliSense Operating Modes LLL LLULLA AA kK ke kud ek a K n k 4 c iglesia ela fii uuu uuu Tm T mmm 4 Pressure Temperatii e qumasha sansa erbe g n Ade 4 Intensense PI G L aver yay s E Wan kul neda wead Ke kal s we n n kesa xu PUERO 5 gi A ae I za M Dr A
21. Radiated lmmunity Amplitude modulated with a 1 kHz sine wave to a depth of Compatible with 303 and 304 80 Stainless Steel Buna N and Silicone Gel Fast Transient Burst 0 5 KV Immunity to Conducted Distur 3V rms 0 15 80 MHz 80 AM bances Modulation 1 kHz Dimensions inches mm E 4 9 625 15 9 1 42 36 1 7 9 _ 14 2 HEX U 10 32 49 IntelliSense Manual IntelliSense Data Gateway specifications Quant Operating Temperature Range 32 F 0 C to 131 F 55 C 35mm DIN Rail using Brackets Relative Humidity 5 95 Non condensing Mounting Options Flush Mounted using Screw Hole 1160950 Information Technology Equipment Safety 1 General Requirements Housing _ PistcandaAluminum 18 Gauge Mild Steel Black Electro coat IntelliSense Remote Monitoring and Configuration Software USB Wi Fi Adaptor USB Extension Cable 3 0 9m IntelliSense Data Gateway Mounting Bracket 100 240VAC 10 19V DC Power Supply Dimensions inches mm 4 8 121 6 4 4 112 8 1 0 5 12 5 6 8 173 8 2 24 2 50 IntelliSense Manual IntelliSense Fittings specifications Environmental Specifications Operating Temperature Range 92 F 0 C to 140 F 60 Stainless Stee aco 14 7 ps
22. TE INPUT Sensor Pair ma Sensor 1 Sensor 2 ww NETWORK O 12 24 VDC Power Supply 9 2 AYRA intelliSense Sensor Cables IntelliSense IO Cable asm O asco Power cable User Supplied intelliSense Basic Kit Sensor Interface inteliSense USB Programming Wireless or Wired Ethernet Module and Sensor Pair ISK BMA XXX Cable CBL IS RU 1 8 Network User Supplied intelisense Junction Block ISH R04 6145 8146 User Supplied Ce te Data Gateway 61 IntelliSense Manual Drawing 5 BASIC MONITORING AND MODBUS RTU NETWORK Sensor Pair Sensor 1 Sensor 2 Status 1 Status 2 Status 3 12 24 VDC Power Supply 90 IntelliSense Sensor Cables IntelliSense USB Programming Modbus Interface Cable CBL IS M8 X Cable CBL IS RU 1 8 User Supplied IntelliSense Basic Kit Sensor Interface Module and Sensor Pair BK BMA Xxx 8648146 User Supplied IntelliSense Junction D Cable CBL IS CF 0 5 62 IntelliSense Manual Drawing 6 BASIC MONITORING AND MODBUS RTU NETWORK W PLC DISCRETE INPUT Sensor Pair Sencor 2 Status 2 Status 3 Ll l 12 24 Power Supply intelliSense Sensor Cables o IntelliSense USB Programming Modbus Interface Cable CBL IS M8 X Cable CBL IS RU 1 8
23. User Supplied IntelliSense Basic Kit Sensor Interface Module and Sensor Pair ISK BMA2XX RMS RJ45 User Supplied Power Cable User Supplied B Intellisense Junction Block Intellisense IO Cable CBL IS CF 0 5 BH ROd 63 IntelliSense Manual Drawing DATA LOGGING REMOTE MONITORING AND MODBUS RTU NETWORK Sensor Pair 7 nan Ei i Sensor 2 Status 1 Status 2 a Status 3 a IO NETWORK Q B ES Power Supply Oo 7 BOBA e e Intellisense Sensor Cables IntelliSense USB Programming o Modbus Interface Cable CBL IS M8 X Cable CBL IS RU 1 8 User Supplied IntelliSense Basic Kit Sensor Interface Intellisense Data Gateway Module and Sensor Pair Skema wx RS RAMS User Supplied IntelliSense 10 Cable Lose de tL Wireless or Wired Ethemet 3 cos Junction Block ISHR04 fk lber Supplied 64 Drawing 8 60 6 IntelliSense Manual DATA LOGGING REMOTE MONITORING AND MODBUS RTU NETWORK W PLC DISCRETE INPUT Sensor Pair n Sensor 2 3 DAMO 1 B 12 24 VDC Power Supply Intell amp ense Sensor Cables USB Programming IntelliSense Data Gateway CBL IS M8 X Cable CBL IS RU 1 8 ISG 01 Intellisense Basic Kit Sensor Interface RU46 RI45 User Supplied Wireless or Wired Ethemet Module and Sen
24. ag it to the space to the left The Select All command moves all of the column names to the left column adding them to the export report and the Clear command clears any selected column names Select All Clear Drop Items in order here Data Alert Status Sensor 1 Temp Line Pressure Sensor 2 Temp Pressure E gensor 2press _ Figure 51 Select variable to export 4 in the list can be rearranged to represent the column order in the exported file from left to right 41 IntelliSense Manual 5 date and time range for the exported data can be entered as an interval between two points in time defined as a date and time or as a period of seconds going back from the current time Above the time period selection the date and time when the gateway started logging data for the SIM is shown for refer ence It should be noted that pressure data is recorded every millisecond giving a thousand lines of informa tion for each second of time The data file can be very large and unmanageable for large periods of time a Download by interval oelect the Download by Interval option and enter the dates and times in the past that define the beginning and end of the time interval Upon entering the dates and times select the download button to save a file to the local machine Download Method Q n Data starts at Wed 02 Jul 2014 22 48 15 GMT 1357835 seconds ago mum Uv EP m 2 md 6 8 9
25. al to or greater than the entered change amounts a snapshot is taken The SIM monitors the given parameters and tracks the rate of change Status Light Activation Threshold Enter for the percentage of estimated life that the amber status 2 and red status 3 warning lights on the SIM and on the software status screen will correspond to The estimate for remaining life on cylinder performance is the estimated time for the cylinder performance to reach either the high or low limits for cylinder leakage and stroke time or the user entered cycle count limit entered in the Alert and Event Detections section STATUS LIGHT ACTIVATION THRESHOLD Status 2 order replacement cylinder Life Remaining Status 3 imminent failure Life Remaining 30 Figure 35 Status light activation threshold settings IntelliSense Manual MODBUS Settings Enter the MODBUS parameters used on the network MODBUS SETTINGS Slave address 1 Parameters 8 data bits Even parity 1 stop bit Y Transfer speed 19200 v Baud Figure 36 MODBUS settings e Slave address enter the node or slave address for the SIM see the manual section Using IntelliSense with MODBUS RTU Networks e Select the appropriate serial parameters table 3 e Select the line baud rate between 4 800 and 115 200 bps Table 3 MODBUS parameters Data Bits Stop Bit 8 Nm 1 8 Be SIM Maintenance Functions The following commands are available
26. cable CBL IS CF 0 5 Note PLC input needs to accept sinking NPN sensors To use the I O Connector to power SIM confirm DIP switch 9 is ON and follow the diagram below 12 24 VDC Figure 59 I O connector SIM power wiring diagram 47 IntelliSense Manual Technical Specifications IntelliSense Sensor Interface Module specifications Electrical and EMS Specifications 2 4 Pin Input Voltage 11 to 24VDC Regulated 1 4 Pin Molex SL Modular Current Draw SIM and 2 Sen c 4 RJ 45 R5 422 Serial EMC Rating i immunity to EN P HJ 45 RS 485 Modbus PPE 4 KV Contact 8 KV Air 4 kV 10 V m from 80 1000 MHz 35mm DIN Rail using Brackets 3 V m from 1 4 to 2 0 GHz and Mounting Options Flush mounted using Screw NR 3 V m from 2 0 to 2 7 GHz Hole J Amplitude modulated with 1 KHz sine wave to a depth of 80 Sas 05 KV on all ports 1kV on 18 Gauge Mild Steel Black wer Electro Coat Immunity to Conducted Distur rms 0 15 80 MHz 80 18 Gauge Mild Steel Black bances Modulation 1 KHz Electro Coat Software Requirements IP Rating with an available USB Port Operating Temperature 32 0 C to 131 55 C Windows 8 32 64 bity 7 32 64 bity Vista 32 64 bit XP 32 WEN 5G 15Hz 500Hz 1hr Ran 64 bit Server 2003 and 2008 32 64 bit Server 2008 R2 dom 0 amp 55 C Operating 30G 10 000 times each axis and DIN Rail Brackets
27. command to launch the pop up window PC update 1 2 F 4 SIM MAINTENANCE FUNCTIONS Set Time Select firmware file 140618 X618 3 A Backup Settings Restore Settings from Backup 140711 M711 140714 M714 Restore SIM to Factory Settings Reset predictive data and history OR Reset cycles per day Upload other firmware file Choose File No file chosen Update SIM Firmware Blink LEDs for identification Figure 37 SIM Firmware update Download the latest SIM firmware to a location accessible from your computer Select the Choose File command With the file explorer in your browser select the firmware update The update will be applied Data Gateway updates 32 This option requires that the gateway is connected to the internet 1 2 The pop up list box displays firmware files that reside on the gateway To check if there are any newer files available select the About tab in the left column of the screen and then select the Software tab The software list will show the current firmware version residing on the data gateway If there is a newer version available a command button will show allowing it to be downloaded to the Data Gateway If the firmware version is the latest available the message Up To Date will show SOFTWARE Stat iib Component Installed Update Action Configuration intel
28. crossed The mode can be set by selecting the appropriate option 26 IntelliSense Manual button shown in the figure below INTELLISENSE MODE Cylinder Monitoring Pressure Temperature Monitoring Figure 27 IntelliSense Mode Selection Identification When in Cylinder Monitoring mode three pieces of information can be entered for identifying the SIM The first ID is the SIM name 60 characters max the second is the cylinder location 40 characters and the third is the cylinder part number 82 characters IDENTIFICATION Name 59 characters remaining Location 39 characters remaining Part Number 31 characters remaining Figure 28 Cylinder mode Identification In Pressure Monitoring mode the first ID is the SIM name 60 characters max the second Is the location of sensor one 40 characters and the third is the location of sensor two 82 characters IDENTIFICATION Name 59 characters remaining Sensor 1 location 39 characters remaining Sensor 2 location 31 characters remaining Figure 29 Pressure Temperature Monitoring mode Identification Sensor Cylinder Setup Enter the date that the cylinder was put into service This section has the following commands Reset cycle count to zero resets the current cycle count to zero b Set Sensor s As Recognized each sensor has a unique identifier to prevent sensors from accidentally being switched around unknowingly Whenever a new sensor is connect
29. cting the tab brings a drop down list with the detail of each alert ADMIN HELP 654 ALERTS ALERTS e Shows the number of unread Link to Help File alerts selecting the link brings up a list Figure 44 Menu Bar Dashboard The IntelliSense dashboard is the program homepage and provides a summary of all of the SIMs connected to the computer or gateway It is the first page that is shown after logging in to the computer or gateway and can be ac cessed from any other window by selecting the Status tab on the left The IntelliSense dashboard has a list of all of the SIMs displayed along with the current status From this page it is possible to select a SIM individually to view detailed status and real time monitoring information see SIM Status and SIM monitoring sections change SIM settings SIM Configuration and export logged data The oylinder icon next to the SIM name indicates the status of the cylinder The oylinder icon at the top of the window indicates the status of the machine that the gateway is monitoring and is the worst case of all of the oylinders in the list 29 IntelliSense Manual Machine Gateway status 0 indicates worst case of the SIMs on the Gateway ntellisense amp Data Gateway STATUS CONFIG al MONITORING gt EXPORT STATUS CONFIG il MONITORING EXPORT STATUS CONFIG al MONITORING D EXPORT Good Commands to launch different screens Cyli
30. e CBL IS CF 0 5 for EOT or power option a e InteliSense Junction Block ISH RO4 for connection to MODBUS network and power option b User Supplied e 12 24 VDC power source if not using Bimba option e PLC with MODBUS RTU network compatibility Interface cable to connect RS 485 to PLC e Computer for setup of IntelliSense SIM e PLC that wil accepts a NPN sinking sensor for use of EOT inputs IntelliSense Manual Sensor Installation Media Compatibility The IntelliSense pressure sensor is designed to be used with clean dry air A 5 micron filter should be used If the sensor 15 used with other media it is the user s responsibility to confirm that it is compatible with the wetted materials in the sensor Table 1 Wetted Materials component Tuama TT 304 stainless steel sensor element isolation barrier Silicone based gel Port 303 stainless steel Sensor Mounting Mounting Location It is recommended that the sensor be placed between 2 50 8 mm and 6 152 4 mm of the cylinder To avoid dam age to the sensor do not directly mount the sensor to the cylinder The maximum distance from the cylinder to the sensor assembly is 4 1219 mm Responsiveness of the sensor may be reduced due to longer tube lengths The sensor should be mounted so that it is part of the cylinder volume Pneumatic accessories such as flow controls and quick exhaust valves should not be located between the sensor and the cylinder
31. e IntelliSense Sensor Interface Module has the ability to be a slave device on a MODBUS RTU network More information can be found in the Using IntelliSense with MODBUS RTU Networks section IntelliSense Manual Power Architecture The Intellisense SIM should be connected to a Class 2 limited power source or limited energy power source The power supply may supply 11 24 VDC There are two ways to connect power to the IntelliSense SIM Power can be supplied a over pin 3 and pin 4 of the 4 pin connector b using pin and pin 8 of the MODBUS port Using the IntelliSense Junction Block ISH RO4 is the preferred method of enabling power for option b t AIntellisense oF L 2 IntelliSense i PE biu dr Power Cable CBL IS CF 0 5 Supply Figure 2 Power option a 1 0 Port Figure 3 Power option b MODBUS Port Choosing How to Power the SIM The system architecture will dictate which power option is available for your installation The determining factor is the use of the EOT outputs If the installation calls for the use of the EOT outputs option b becomes the only power op tion available and DIP switch 9 must be switched to OFF default setting is ON Architecture Examples IntelliSense has a variety of hardware configurations to meet the customers needs e Basic Monitoring and PLC discrete inputs e Basic Data Logging and Remote Monitoring with PLC discrete inputs e Basic Monitor
32. e IntelliSense with a quick exhaust valve A Yes IntelliSense works with quick exhaust valves as long as the valve is not located between the cylinder and the IntelliSense sensor Q Can use IntelliSense with flow controls A Yes IntelliSense works with flow controls as long as the control is not located between the cylinder and the IntelliSense sensor Q Can IntelliSense be used on a lubricated system A Yes IntelliSense may be installed in a lubricated system Bimba s installation recommendations should be fol lowed when installing the IntelliSense system Q What is the maximum cylinder frequency that can be detected A IntelliSense is designed to detect most cycle profiles without additional tuning of the software If IntelliSense is not detecting cycles after 5 10 cycles contact Bimba Customer Service for assistance with advanced tuning options Q Can IntelliSense be used with a multi position cylinder A No IntelliSense does not support use with multi position cylinders 9 IntelliSense Manual Q Can use IntelliSense to only offer alarms when there are changes in temperature and or pressure IntelliSense offers configurable alarm thresholds for temperature pressure extend and retract times These values are utilized by the Intellisense SIM unit in the predictive algorithm These values are also stored in the SIM s MOD BUS RTU Holding Registers and can be accessed by a controls
33. e SIM unit s Slave Device the user can retrieve desired status values and alerts e User PC connects to SIM for initial configuration and or real time monitoring of the SIM unit and attached pressure system e Use of EOT outputs with PLC installation and use of power option b List of Components Required Bimba Products IntelliSense Basic Kit ISK BMAx o 1 InteliSense Sensor Interface Module SIM SM S1 BA1 5P o 62 IntelliSense pressure temperature sensor ISS 1A 7SS o 2 IntelliSense Tee fittings ISF T 1 xxx e 2 sensor cable CBL IS M8 x e 1 IntelliSense USB programming cable CBL IS RU 1 8 InteliSense Data Gateway ISG 01 Optional Bimba Products e 1 24 VDC Power supply PWR 024A24 DIN if not supplied by user 1 IntelliSense 0 5 meter IO cable CBL IS CF 0 5 for EOT or power option e 1 IntelliSense Junction Block ISH RO4 for connection to MODBUS network and power option b User Supplied e 12 24 VDC power source if not using Bimba option e PLC with MODBUS RTU network compatibility Interface cable to connect RS 485 to PLC Computer for setup of IntelliSense SIM e PLC that will accepts a NPN sinking sensor for use of EOT inputs Data Logging Remote Monitoring and MODBUS RTU Network with PLC Discrete Input appendix drawing 7 and 8 With this setup the user may connect to the SIM unit through the Data Gateway and visually monitor the current
34. e user is able to modify the SIM parameters Modify Gateway The user is able to modify the Gateway parameters To get to the user setup screen select the Configuration tab on the left of the screen and the Users tab at the top of the screen A list of names for the currently set up users will show MACHINE SERIAL PORTS USERS NETWORK Status Configuration eset About User admin Add New User Figure 10 User account managment To edit any user select the name in the list To add a new user select the Add New User command In both cases the edit user window will show The following can be entered or changed 0 Addnewuse Username Case sensitive 3 characters minimum Password Case sensitive 5 characters minimum Username User can modify SIM the user is able to modify the SIM parameters Password User can modify Data Gateway the user is able to modify Gateway parameters Confirm Password Add Save Saves the entered changes User can modify SIM Cancel None of the entered changes are saved User can modify data gateway Delete delete an existing user Add Cancel Figure 11 User Setup IntelliSense Manual Data Gateway Network Settings The Data Gateway 15 a TCP IP v4 device and following network settings can be made to enable communication Global Server Settings MACHINE SERIAL PORTS USERS NETWORK Status GLOBAL WIRED ETHERNET WIFI Configuratio
35. ed by the cylinder Current measured pressure of sensor 1 Current measured pressure of sensor 2 Current measured atmospheric pressure Status of each seal Shows which mode the SIM is in Cylinder or Pressure Temperature Monitoring Mode Estimated cycles remaining divide by average daily cycles Estimated cycles remaining divide by total number of cycles Cycle count mode Cycle count limit Current cycle count Predictive mode Estimated number cycles at time of prediction lmpredictive mode values only update when an event OCCurs Gives the stroke dwell and total cycle time for extend and retract Connection status to the SIM and sensors 3 Cylinder 2 Status Configuration i About Cylinder Life Cycle Count Average Daily Cylinder PN Started using SIM Clock Operating Condition f Extend time f Retract time f Sensor 1 Temp f Sensor 2 Temp f Line Pressure Sensor 1 Pressure Sensor 2 Pressure Ambient Pressure Seal Condition f Rod Seal f Rear piston seal f Front piston seal SIM Configuration CONFIG 0 cycles 0 cycles Part number not specified 09 29 2014 7 8 2015 4 51 35 PM Status Status TT Normal mm Normal I Normal al MONITORING gt EXPORT Cycle Count EST DAYS REMAINING m v EST CYCLES REMAINING Cycle Time Extend Retract Sensor SIM Condition Sensor 1 f Sensor 2
36. ed to a sensor port the status screen will show it as being unrecognized This command will store the IDs of both attached sensors to the SIM and sets them as recognized c Take baseline This command button generates a baseline A baseline tells the user how the cylinder is currently performing These values are for the users reference only and not used by the SIM On run ning the command a pop up window appears requesting the number of cycles over which to measure the baseline for Cylinder Monitoring mode or the amount of time in Pressure Temperature monitoring mode the default is 20 cycles or 30 seconds The SIM will then monitor the cylinder or pressure until Er IntelliSense Manual it completes the required number of cycles or time has elapsed and determine average values for the stroke time seal leakage Line Pressure Sensor 1 and Sensor 2 Pressure and Temperature in Cylinder Mode and Pressure 1 Pressure 2 Temperature 1 and Temperature 2 in pressure temperature mode and store these These baseline values are then displayed in the Alert Detection section of the configuration screen SENSOR CYLINDER SETUP Cylinder In Service Date 12 31 1969 Reset cycle count to zero The page at 10 1 251 107 3000 says Set Sensor s As Recognized Take baseline of current performance Enter number of cycles for baseline Cancel Figure 30 Baseline cycle count Alert Detection In the a
37. elliSense sensor units are wash down compatible with an IP69K rating The sensors would need to be connected using wash down rated cables supplied from a 39 party Q What are the temperature ratings on the sensors A The IntelliSense sensors have an operating range of 40 F 40 to 176 80 C Q Can IntelliSense be used to monitor temperature parameters A Temperature values can be tracked using the MODBUS RTU holding registers of the IntelliSense SIM These values are updated at a 1 second refresh rate Q What is the maximum cable distance from sensor to SIM A The recommend sensor maximum cable distance is 100 meters 3257 Q Is IntelliSense compatible with Hydrogen Peroxide A No the wetted material in the IntelliSense sensor and fitting include Buna N seals which are not compatible with high concentration of Hydrogen Peroxide a IntelliSense Manual Q What is the recommended filtration for the sensors A It is recommended that IntelliSense be installed with a Class 3 ISO 8573 1 5 micron filter Q What is the maximum pressure rating for IntelliSense A The operation pressure rating for the IntelliSense sensors is psia bar to 200 psia 14 bar Q What type of technology does the sensor utilize A The IntelliSense sensors use a silicone gel coated MEMS pressure sensor element Q Where do find and download the manuals and required Software A Manual s and required s
38. ense USB programming cable CBL IS RU 1 8 Optional Bimba Products 1 24 VDC Power supply PWR 024A24 DIN if not supplied by user e 1 IntelliSense 0 5 meter IO cable CBL IS CF 0 5 for EOT or power option o The above products are available as a kit in the IntelliSense Starter Kit ISK BMA xxx e 1 IntelliSense Junction Block ISH RO4 for power option b User Supplied e 12 24 VDC Cable for 120V AC power source if not using Bimba option to 24V Power Supply e Computer for setup of IntelliSense SIM Optional e PLC that will accepts a NPN sinking sensor for use of EOT inputs IntelliSense Manual Data Logging and Remote Monitoring with PLC Discrete Input appendix drawing 3 and 4 With this setup the user may connect to the SIM unit through the Data Gateway and visually monitor the current status of the SIM unit and attached pressure system This setup also allows for data logging to be performed and stored in the Data Gateway unit regardless of a user PC connection If using the discrete outputs the SIM must be powered using option b Functionality e Cylinder condition monitoring based on status LEDs on SIM unit e Data Gateway remains connected for data logging e User PC connects to Data Gateway for initial configuration and or real time monitoring of the SIM unit and attached pressure system e Use of EOT outputs with PLC installation and use of power option b List of Components Required Bimba Product
39. g SIM and two Sensors To PC or Gateway H Figure 20 SIM Direct Connect Through Serial Hub Connect the RJ 45 connector of the serial cable CBL IS RD XX to the PC port on the SIM and the DB9 connector to one of the free ports on the serial ISH DO4 The hub is then connected a free USB port on the PC or data gateway With the serial hub it is possible to connect up to four SIMs to a single USB port To PC or Gateway lt Figure 21 SIM serial hub connection 23 IntelliSense Manual Add or Configure a SIM on the PC or Gateway Ensuring that the SIM has two sensors connected with a SIM connected to a gateway using a programming cable or through a serial hub the software has to be set up to recognize the SIM The following steps illustrate how to do this 24 launch the IntelliSense software using web browser connected the IntelliSense Data Gate way that the SIM is connected to The default address is htto 10 10 20 3000 Select the Configuration button on the left side of the window Select the Serial Ports tab in the middle of the top row Click the Add New button to bring up a pop up window of all SIMs connected to serial ports on the PC or Gateway that have not been registered in the software From the dropdown box select the port address of the serial connection for the SIM that will be registered on the computer Press the Add but
40. ing with MODBUS RTU Network and PLC discrete inputs IntelliSense Manual e Data Logging Online Monitoring and MODBUS RTU Network and PLC discrete inputs All of these setups can support multiple SIM unit setups Basic Monitoring and PLC Discrete Inputs appendix drawing 1 and 2 This setup consists of a single SIM unit power source and user PC device Both power options are available With this setup the user may connect to the SIM through PC port and visually monitor the current status of the SIM unit and attached pressure system This setup can also remain connected to the pneumatic actuator to act as a stand alone SIM and sensor set to monitor the actuator Functionality e Cylinder Condition monitoring through status indicators on SIM e Prognostic data including cycle count cylinder life cycle time e Real time condition monitoring based on status LEDs on SIM unit pressure and temperature data e User PC only connected for initial configuration e Use of EOT outputs with PLC installation and use of power option b e Configure SIM List of required components Required Bimba Products e 1 IntelliSense Basic Kit ISK BMA xxx o 67 IntelliSense Sensor Interface Module SIM ISM S1 BA1 5P o 2 IntelliSense pressure temperature sensor ISS 1A 7SS o 2 IntelliSense Tee fittings ISF T 1 xxx e 2 sensor cable CBL IS M8 x 1 IntelliSense 0 5 meter IO cable CBL IS CF 0 5 1 IntelliS
41. ion that is displayed in the software and on the SIM Figure 1 Information available in Intellisense operating modes lists the information provided in each mode This manual is focused on using IntelliSense in the Oylinder Monitoring Mode The manual will note when the Pressure Temperature Monitoring mode differs from the Oylinder Monitoring mode Cylinder Monitoring Oylinder Monitoring mode is used to measure and analyze the performance of pneumatic oylinders Pressure Temperature Monitoring Pressure Temperature Monitoring mode is used in system monitoring to establish alerts based on pressure and temperature limits Cylinder Monitoring Mode Estimated values Measured values Calculated values Condition status Days remaining Sensor 1 pressure Cycle count Front piston seal Cycles remaining Sensor 2 pressure Average daily cycles Rear piston seal Cylinder life remaining Sensor 1 temperature Extend time Rod seal Sensor 2 temperature Retract time Sensor status Line pressure SIM status Ambient pressure Cycle time Dwell time Pressure Temperature Monitoring Measured values Condition Status Sensor 1 pressure Sensor status Sensor 2 pressure SIM status Sensor 1 temperature Sensor 2 temperature Figure 1 Information available in IntelliSense operating modes IntelliSense Manual IntelliSense Architecture IntelliSense is designed to be scalable in its implementation It is easy to go from a single standalone SIM
42. its 33 IntelliSense Manual Using IntelliSense Sensor Interface Module Lights Boot load mode If the SIM is connected to a Data Gateway or a PC running the IntelliSense software when it enters Boot load mode the SIM will check if firmware update is available on the Gateway or PC While the SIM is checking for the latest firmware Status 1 and Status 2 will be lit After the firmware update the SIM will check that the installed firmware is valid During this time Status 1 will be lit If the firmware fails the check it will automatically restart the boot load process If the firmware fails a second time Status 1 Status 2 and Status 3 will be lit Go to bimba com for the latest firmware When the check is successful the SIM will enter Application mode mA IntelliSense Sensor Intertace Module SIM Application Mode Proess Status 1 Status2 Status3 Sensor 1 Sensor 2 Boot Load INTELLISENSE Firmware update El BE CYLINDER MONITORING Cylinder Monitoring Mode Life remaining above specification Predictive Mode S EOT EOT Alert Active EOT EOT Vo Life remaining below critical level Cycle Count Mode EOT EOT Predictive Mode 5 Alert Active Life remaining specifications defined by user KEY ON SLOW FLASH F FAST FLASH SEE END OF TRAVEL DETECTED Process 7 Status 1 Status2 Status3 Sensor1 Sensor 2 INTELLISENS
43. la to 1647 Operating Pressure Range 1 bar a to 11 4 O Ring Sea Recommended Tubing Nylon PE 95 D Polyurethane Overpressure Minimum Rating 264 7 psia 18 3 Dimensions inches mm Part Number __ sr r oe emm 1429607 047 1145 erro mm eas 0631600 seras rem 0631600 33 IntelliSense Manual Available Accessories Number IntelliSense Data Gateway ISG 01 IntelliSense Junction Block ISH RO4 IntelliSense 2 0 Meter Sensor Cable CBL IS M8 2 IntelliSense 5 0 Meter Sensor Cable CBL IS M8 5 IntelliSense 0 5 Meter IO Cable CBL IS CF 0 5 IntelliSense 1 8 Meter USB Programming Cable CBL IS RU 1 8 IntelliSense 2 0 Meter DB9 to RJ45 Serial Cable CBL IS RD 2 IntelliSense 0 5 Meter DB9 to RJ45 Serial Cable CBL IS RD 0 5 RS422 IG USB HUB ISH D04 24V Power Supply PWR 020A24 DIN Service Parts Number IntelliSense Pressure Temperature Sensor ISS 1A 7SS IntelliSense Fitting 6mm OD Tubing ISF T1 006 IntelliSense Fitting 10mm OD Tubing ISF T1 010 IntelliSense Fitting 5 32 OD or 4mm OD Tubing ISF T1 156 IntelliSense Fitting 1 4 OD Tubing ISF T1 250 IntelliSense Fitting 5 16 OD or 8mm OD Tubing ISF 11 318 IntelliSense Fitting 3 8 OD Tubing ISF T1 375 IntelliSense Data Gateway DIN Rail Bracket ISG BRKT 92 IntelliSense Manual IntelliSense Troubleshooting FAQ Application Q Can
44. lert detection section the user enters the limits that define failure for a cylinder or pressure and temperature limits that will create an alert Cylinder Mode Alert Detection Cylinder alerts indicate allowable ranges for cylinder performance and system parameters Extend time is the time required for the cylinder to extend outwards until the end of stroke or an obstacle causes end of travel Retract time is the time for the cylinder to retract The direction of extend and retract is denoted by the default location of the sensors with S1 on the cap side of the cylinder and S2 on the rod side EXTEND gt 51 52 lt RETRACT Figure 31 Cylinder Mode sensor position 28 IntelliSense Manual To aid in determining the parameter limits for the alerts the values from the baseline of the cylinder are displayed for reference ALERT DETECTION Threshold Baseline Extend time 51 to 52 in 20 211 1400 Milliseconds Retract time 52 to 51 in 228 Milliseconds Rod seal failure in 0 00 Line Pressure Leaking Piston seal failure in 0 44 Line Pressure Leaking Line pressure in 103 00 psia Sensor 1 Temperature in 80 56 Sensor 2 Temperature in 80 47 Figure 32 Alert detection settings Cylinder Mode Pressure Temperature Mode Alert Detection In pressure temperature mode there are eight alert values that can be set for each sensor Min Pressure
45. lisense 1 0 0 18 2 el6 up to date i About intellisense firmware A 150623 M623 1 el6 up to date intellisense firmware 140618 X618 1 0 2 el6 up to date intellisense firmware 140714 M714 1 0 2 el6 up to date intellisense firmware 140711 M711 1 0 2 el6 up to date Force check for new updates Figure 38 Intellisense Data Gateway check for new firmware IntelliSense Manual 4 Return to the SIM Config screen Status sZ ID 1 not specified STATUS 1017908 MONITORING P EXPORT Status Configuration i About Figure 39 Return to Cylinder Config Screen 5 Select the Update SIM Firmware command and select the upload icon to the right of the firmware file name to load it to the selected SIM Select firmware file P 140618 X618 3 140711 M711 3 140714 M714 vr OR Upload other firmware file Choose File No file chosen Figure 40 Update from Data Gateway 6 The updated firmware will be applied to the SIM Units Data can be displayed in the following units Non metric Metric Pressure psi mbar Temperature i To change the display units select the USER menu at the top of the screen and then select the option to switch either the temperature or pressure units The change is immediately applied Logout Change Password 1 Switch to C Switch to mBar a Hide tips EF E W Mme i Figure 41 Change Un
46. load the latest firmware for storing on the Gateway and does not update the attached SIMs Refer to the following section in this manual to apply the SIM update Update SIM Firmware Status Component Installed Update Action it Configuration intellisense 1 0 0 18 2 el6 up to date di About intellisense firmware A 150623 M623 1 el6 up to date intellisense firmware 140618 X618 1 0 2 el6 up to date intellisense firmware 140714 M714 1 0 2 el6 up to date intellisense firmware 140711 M711 1 0 2 el6 up to date Force check for new updates Figure 15 IntelliSense Data Gateway Software Update IntelliSense Manual SIM Installation DIP Switch Settings The IntelliSense SIM module has a bank of DIP switches that allow for a variety of different architectural configura tions The DIP switch bank is located under the rear cover of the SIM unit Before mounting your SIM unit it is impor tant that the DIP switches are configured to match the installation being used The SIM unit s DIP switch setting can be grouped in two categories e Power Source Discrete Output e Network Configuration MODBUS Settings vna uns Figure 16 Default DIP switch settings Table 2 Intellisense Sensor Interface Module Dip Switch Settings 123 4 Boh Communication ports unlinked Communication ports linked 0 0 0 0 7 150 ohm terminating resistor 150 ohm terminating resistor con unconnected nected Connects Pin 4 to
47. lue of 0 can mean three things o This is the initial event snapshot o Was a user commanded Baseline snapshot It s recommended to take Baseline snapshot using a cycle count different then the Sampling Window so it can be easily identified o The event was triggered by the improvements of the tracked parameters e Avalue of 4 means the event was triggered by the extend time window changing in the positive direction equal or greater than the value of the Extend Retract time change parameter Avalue of 8 means the event was triggered by the extend time window changing in the negative direction equal or greater than the value of the Extend Retract time change parameter 43 IntelliSense Manual A value of 16 means the event was triggered by the retract time window changing in the positive direction equal or greater than the value of the Extend Retract time change parameter A value of 32 means the event was triggered by the retract time window changing in the negative direction equal or greater than the value of the Extend Retract time change parameter A value of 64 means the event was triggered by an increase in detected rod seal leakage in percentage equal to or greater than the value of the Cylinder leak change parameter A value of 256 means the event was triggered by an increase in detected front piston seal leakage in per centage equal to or greater than the value of the Cylinder leak
48. n GLOBAL SERVER SETTINGS a About Web port 3000 Base URL http 10 1 251 130 3000 Figure 12 Global network settings Web Port This defines the TCP port for connecting to IntelliSense Unless needed keep the default value Base URL For reference gives the full URL including port number to access the current server Save All changes must be saved to become effective Wired Ethernet The following settings are for the wired RJ 45 Ethernet port on the Data Gateway Press the save button to make the changes effective DHCP Configures the Gatway to receive TCP IP settings from a DHCP server Static Allows the user to manually enter the TCP IP address subnet mask gateway and DNS servers The data gateway has a default parameters of IP address 10 10 10 20 Subnet Mask 255 255 255 0 IP Settings When in DHCP mode displays the assigned parameters In static mode values can be entered here 16 IntelliSense Manual MACHINE SERIAL PORTS USERS NETWORK Status GLOBAL WIRED ETHERNET WIFI Configuration IP ADDRESS ASSIGNMENT us About DHCP Static IP SETTINGS IP Address 10 1 251 130 192 168 1 100 Netmask 255 255 0 0 255 255 255 0 Gateway 10 1 0 1_ 192 168 1 1 DNS Server 10 0 0 98 8 8 8 8 Figure 13 Wireless Network Settings WiFi When the included wireless adapter is connected to the Data Gateway the following wireless se
49. n the clips will grip onto the flanges of the DIN rail The SIM may still side laterally on the rail even when screws are tightened Figure 18 SIM DIN Rail Mount Configuring the SIM An IntelliSense SIM can be configured either through a PC or an IntelliSense Data Gateway To configure IntelliSense using PC you must first install the IntelliSense PC Software PC Software Installation Download the installation executable to a location on your computer and run Accept the pop up windows for Win dows User Access Control and follow the instructions for selecting the installation location if the default needs to be changed The software will copy all files and install When installation is complete the following window will appear oelect Close to exit and then restart your computer nz IntelliSense Completed Completed Figure 19 Installation complete window Launch the software by running Bimba IntelliSense from the start menu under the Bimba folder 22 IntelliSense Manual Connecting to the SIM The SIM connects to the USB port of a PC or Data Gateway with the USB programming cable or through a USB se rial hub Direct connection Connect the RJ 45 connector of the programming cable CBL IS RU 1 8 to the port labeled PC on the SIM and the other end to a free USB port on the PC or Data Gateway With everything powered on the USB connector will turn a solid green when connected to a properly workin
50. nd 2 Bytes 40034 ms for last dwell after retract 2 Bytes 45 IntelliSense Manual The Intellisense SIM also stores the Real Time Clock Data and Identification labels configured by the user as ASCII data in the following registers Table 5 ASCII MODBUS Registries Resistor Beseription T se Using IntelliSense 1 0 Connector The IntelliSense SIM unit s connector can be used to power the SIM or to utilize the two 3 wire NPN transis tor outputs These outputs are configured to indicate the EOT End Of Travel sensed by the IntelliSense system Cable part number CBL IS CF 0 5 is used to connect to the I O connector This cable is 0 5 meter in length has flying leads on one end and a 4 pin connector on the other Figure 56 Molex 50 57 9409 connector The underside of this connector has an arrow to indicate the location of pin 1 Figure 57 Underside of Molex connector with Pin 1 Indicator User may also purchase the 4 pin connector through a 39 party to wire for additional lengths as needed Figure 56 Molex 50 57 9409 connector Figure 57 Underside of Molex connector with Pin 1 Indicator 46 IntelliSense Manual To use the 2 EOT outputs of the IntelliSense SIM unit confirm DIP switch 9 is OFF and use the following the diagram Wire Color Green Sensor 1 EOT White Sensor 2 EOT VDC m Black Figure 58 I O connector output wiring diagram with wire colors for
51. nder condition is degrading order new cylinder related to each SIM Real time alarm cylinder has failed Figure 45 Multi SIM Status SIM Status The SIM status screen shows the current state of the SIM and connected cylinder and gives a summary of all of the measured parameters and an overall health rating for the cylinder The status screen has the following sections Oylinder Life Cycle Count Total number of cycles that the cylinder has run since last set up Average Daily Average number of cycles that the cylinder has run per day Cylinder PN Oylinder part number as entered in the Config screen Started Using Date that the cylinder started being in service as en tered in the Config screen SIM Clock Current time and date taken from the SIM clock If incorrect this needs to be set on the Config page 36 IntelliSense Manual Operating Condition Seal Condition Mode Life Remaining Cycle Time Sensor SIM Condi tion Extend Time Retract Time Sensor 1 Temp Sensor 2 Temp Line Pressure Sensor 1 Pressure Sensor 2 Pressure Ambient Pressure Rod Seal Rear Piston Seal Front Piston Seal Estimated Days Remaining Estimated Life Remaining Estimated Cycles Remaining Current measured time for the cylinder to extend Current measured time for the cylinder to retract Current measured temperature of sensor 1 Current measured temperature of sensor 2 Current high line pressure detect
52. nly available when accessing IntelliSense via an IntelliSense Data Gateway Fvents Monitored changes in the cylinder performance are logged as events and these events can be viewed or exported to the user s machine for further analysis Select the Export tab for the desired SIM and on the export screen select the category of data to export 39 Cylinder 2 Status STATUS CONFIG al MONITORING EXPORT Configuration About EXPORT Pressure and Data Export Events Figure 48 Data Export Screen Pressure and Data Export Logged data can be exported to the user s local machine for further analysis The format is comma separated text file CSV which can be easily opened and edited with spreadsheet or database program The following data is available for export Note that time and pressure measurements 1 and 2 are exported by default and cannot be selected by the user Measured Data Time Time and date of measurement not user selectable Pressure 1 Sensor 1 absolute pressure measurement not user selectable Pressure 2 Sensor 2 absolute pressure measurement not user selectable Sensor 1 Temperature Sensor 1 temperature Sensor 2 Temperature Sensor 2 temperature Line Pressure Absolute line pressure for the cycle Ambient Pressure Ambient atmospheric absolute pressure Extend Time Extend time for the stroke in seconds Retract Time Retract time for the stroke in seconds Dwell Time Extend Dwell
53. ns each of the column names with units Selecting the Download Events button downloads all of the event snapshot data in a comma separated value file CSV for further analysis in a soreadsheet or database program Download Event s Sample Cycle size cycles count Ambient Line Extend Retract RLTF FSFR FLTS RSFF pressure pressure time time Time taken 7 17 2014 11 46 30 AM 20 1412390 986 7 4677 6 134 7 15 2014 2 51 03 AM 25 1369996 975 8 4671 9 131 7 14 2014 2 38 43 PM 25 1360903 9748 4670 0 105 7 14 2014 2 06 04 PM 25 1360499 974 8 46744 131 00 3426 430 00 350 0 414 0 0 3325 394 0 0 3346 403 Figure 54 Event log Legend Item Definition Index Event Number Time Taken Sample Size Cycle Count Ambient Pressure Line Pressure Date that the event happened The number of cycles captured for the event Cycle count at time of event Calculated ambient pressure while the event was being taken Calculated line pressure while the event was being taken Reason Reason code Failure Failure Type Extend Time Average calculated time taken to extend the rod ms Retract Time Average calculated time taken to retract the rod ms RLTF Rear Leakage To Front FSFR Front Seepage From Rear FLTS Front Leakage To Somewhere RSFF Rear Seepage From Front Events Reason Figure 55 Event log legend When an Event is logged by the SIM unit it records the Reason the event was triggered These events are coded as follows A va
54. oftware can be downloaded from bimba com smarter Q Can IntelliSense be programmed and monitored with an HMI A When using IntelliSense on a MODBUS RTU network it is possible to display data observed onto a HMI unit If the HMI is capable of serving as a MODBUS Master device no PLC is needed However the SIM is a read only de vice and setting cannot be made outside of the Intellisense configuration software IntelliSense Sensor Interface Module SIM Q Are there any discrete signals included with Intellisense The IntelliSense SIM unit offers two discrete outputs in the form of sinking NPN transistors set to signal the retract and extend End Of Stroke often referred to as EOT in the manual MODBUS Network Q What wiring standard does the MODBUS port of the IntelliSense SIM permit A The MODBUS port on the Intellisense SIM conforms to 2 wire or 4 wire RS 485 For more information on con necting IntelliSense to a MODBUS RTU network please consult the Intellisense User Manual located at bimba com smarter Q What MODBUS network standards does IntelliSense support IntelliSense supports MODBUS RTU DATA Network Q Do need to purchase a Data Gateway to use the data logging function of IntelliSense A Yes at this time the Intellisense SIM unit does not support data logging on its own Q Is it possible to connect multiple IntelliSense SIM units on a single PC or Data Gateway network A Yes mul
55. or any valid IntelliSense configuration The default value is OFF This switch should remain in this position When DIP switch 10 is set ON it connects channel A of the MODBUS Port to 5V via a 680 ohm resistor for line polarization When using the IntelliSense in a multiple slave MODBUS network only one SIM unit should have this switch in the ON position All other slave SIM units should be in the OFF position Default position is OFF When DIP switch 11 is set ON it connects channel B of the MODBUS Port to Ground via a 680 ohm resistor for line polarization When using the IntelliSense in a multiple slave MODBUS network only one SIM unit should have this switch in the ON position All other slave SIM units should be in the OFF position Default position is OFF DIP switch 12 is not used Locating the SIM Mounting the SIM The SIM is recommended to be mounted in an electrical enclosure or another clean dry environment It is not intend ed to be placed in dirty damp or hazardous environments Panel Mount The SIM will mount to a flat panel with two 6 size screws The figure below shows the hole spacing for the SIM back plate 1182 60 64 3 25 025 Figure 17 SIM Panel Mount Dimensions 21 IntelliSense Manual DIN Rail Mount included with the SIM are clips for mounting to 35mm DIN rail The clips attach to the rear of the SIM back plate with the included 6 screws When the screws are tightened dow
56. ormance has not changed from the initial instal lation When IntelliSense predicts 90 of life remaining it will begin to display values for these fields Q Why does the Estimated Days Remaining Estimated Cycles Remaining and Estimated Life Remaining show a red circle with an exclamation point A This is an indication that the cylinder s performance is critical and action is required Action may include replacing the cylinder or verifying the IntelliSense configuration If not setup correctly the SIM may predict premature failure of a cylinder Q How does IntelliSense calculate estimated days remaining A The estimated days remaining is calculated by dividing the Estimated Cycles Remaining by the Average Daily Cycles Q How does IntelliSense calculate Average Daily Cycles IntelliSense uses a seven day rolling average to calculate the Average Daily Cycles Q My cylinder is cycling but the estimate cycles remaining is not changing A This is how IntelliSense is designed to operate in predictive mode The Estimated Cycles Remaining is only up dated when an event occurs Q How is Est Life Remaining calculated A Estimated Life Remaining is calculated by dividing Estimated Cycles Remaining by the expected life of the Cylinder ar IntelliSense Manual Appendix Network Drawings Drawing 1 BASIC MONITORING Sensor Pair Sensor 1 Sensor 2 Status 1 Status 2 Status 3 IntelliSense Senso
57. product offering monitoring of a system s performance current status and predicted life expectancy The system offers a MODBUS RTU network connection so that users can interface the system with their choice MODBUS RTU master device A PLC is not required with an Intellisense application Q Can use IntelliSense on hydraulic cylinders A At this time IntelliSense is not supported for use with hydraulic cylinders Q Do you need switches on the cylinder A Limit switches have no effect on an IntelliSense installation Q Can IntelliSense be used to monitor a valve A At this time IntelliSense has only been verified with Bimba s Original Line cylinder 54 IntelliSense Manual Hardware IntelliSense Pressure Temperature Sensor Q Does the location of the sensors matter in relation to the actuators pressure ports Does Sensor 1 have to go with the extend port Does Sensor 2 have to go with the retract port A Yes While the sensors themselves are interchangeable when installed the sensor connected to the Sensor 1 connection of the Intellisense SIM unit needs to be installed in line with the end cap port extend Conversely the sensor connected to the Sensor 2 connection of the IntelliSense SIM unit needs to be installed in line with the rod guide port retract Q How far away from the actuator can install the IntelliSense sensors The recommended installation distance for the IntelliSense senso
58. r Interface Module SIM NETWORK MEN e 12 24 VDC Power Supply IntelliSense Sensor Cables CBL IS M8 X intelliSense Basic Kit Sensor Interface Module and Sensor Pair ISK BMA XXX intelliSense IO Cable CBL IS CF 0 5 T IntelliSense USB Programming Cable CBL IS RU 1 8 IntelliSense Manual Drawing BASIC MONITORING W PLC DISCRETE INPUT sensor Pair ry Sensor 1 Status 1 a 12 24 Power Supply b IntelliSense Sensor Cables CBL IS M8 X Intelli amp ense Basic Kit Sensor Interface Module and Sensor Pair ISK BMA XXX User Supplied IntelliSense IO Cable CBL IS CF 0 5 nteliSense Junction Block ISH RO4 IntelliSense USB Programming Cable CBL IS RU 1 8 e Power Cable User Supplied 99 IntelliSense Manual Drawings BASIC DATA LOGGING AND REMOTE MONITORING Sensor Pair sensor 1 Sensor 2 Sen Status 3 12 24 VDC Power Supply Intelli amp ense USB Programming Cable CBL IS RU 1 8 nteliSense Sensor Cables CBL IS M8 X Intellisense Basic Kit Sensor Interface Wireless or Wired Ethernet Network User Supplied Cc c cr n TU ae A Lu gt lt nteliSense 10 Cable CBL IS CF 0 5 intellSense Data Gateway ISG 01 60 Drawing 4 IntelliSense Manual BASIC DATA LOGGING AND REMOTE MONITORING W PLC DISCRE
59. r and tee fitting is 2 6 inches away from either port Q What port sizes are offered A The sensor port is 10 32 It is not recommended to mount the sensor directly to a cylinder Bimba offers sensor fittings designed for 5 32 4mm 1 4 6mm 5 16 8mm 3 8 and 10mm OD Tubing More information regarding dimensions and part numbers can be found at bimba com Q Are shielded cables required A Shielded cables are not required for an IntelliSense installation Shielded cables are recommended to prevent unwanted signal interference Bimba offers shielded cables in lengths of 2 and 5 meters Part numbers for these cables can be found at bimba com smarter Information on the pin configuration of the cable can be found in the IntellilGense User s Manual which can be downloaded from bimba com Q What is the IP rating of the IntelliSense hardware A The IntelliSense sensing unit are rated IP69K The IntelliSense SIM module is rated IP50 The Data Gateway has no rating Q What is the standard BOM of part needed to set up a basic IntelliSense system A Bimba offers three kit options for IntelliSense These kits give users flexibility when it comes to upgrading their installation based on functional needs Kit information can be found in the Intellisense Catalog Q What is the warranty on IntelliSense A The Intellisense system comes with a one year hardware warranty Q Are the sensors wash down compatible A The Int
60. s ntelliSense Basic Kit ISK BMA xxx o 1 IntelliSense Sensor Interface Module SIM ISM S1 BA1 5P 2 IntelliSense pressure temperature sensor 155 1 755 o 2 IntelliSense Tee fittings ISF T1 xxx e 2 ntelliSense sensor cable CBL IS M8 x 1 USB programming cable CBL IS RU 1 8 InteliSense Data Gateway ISG 01 Optional Bimba Products e 1 24 VDC Power supply PWR 024A24 DIN if not supplied by user e 1 IntelliSense 0 5 meter IO cable CBL IS CF 0 5 for EOT or power option e 1 IntelliSense Junction Block ISH RO4 for power option b User Supplied e 12 24 VDC power source if not using Bimba option e Computer for setup of IntelliSense SIM Optional e PLC that wil accepts a NPN sinking sensor for use of EOT inputs Basic Monitoring with MODBUS RTU Network with PLC Discrete Inputs appendix drawing 5 and 6 With this setup the user may connect to the SIM through PC port and visually monitor the current status of the SIM unit and attached pressure system By configuring a Modbus RTU network between the user s PLC Master Device and the SIM unit s Slave Device the user can retrieve desired status values and alerts If using the discrete outputs the SIM must be powered using option b IntelliSense Manual Functionality e Cylinder condition monitoring based on status LEDs on SIM unit e By configuring a MODBUS RTU network between the users PLC HMI Master Device and th
61. sor Pair ISK BMA XXX Intelli amp ense Junction Block ISH RO4 Network User Supplied Intell amp ense IO Cable AA AU a obus Interface Cable Power Cable User Supplied User Supplied 65 IntelliSense Manual Drawing 9 DAISY CHAINED MODBUS RTU NETWORK W MULTIPLE SIM mm e Cy HER e 12 24 VDC Power Supply Q intelliSense Sensor Cables CBL IS M8 X e IntelliSense Basic Kit Sensor Interface Module and Sensor Pair o IntelliSense Junction Block ISH RO4 e e PLC 0 Power Cable User Supplied Modbus interface Cable User Supplied 66 Drawing 10 IntelliSense Manual DATA LOGGING REMOTE MONITORING AND MODBUS RTU NETWORK W MULTIPLE SIM Sensor Pair ws Se Sensor Pa J Sensor l p n oO n n g oO i d a i E w w E EEE w 1 fa m m m m m NM m m m M m m O a BE BBE Emod Td 9 o 12 24 VDC Power Supply IntelliSense Sensor Cables CBL IS M8 X IntelliSense Basic Kit Sensor Interface ee PLC Module and Sensor Pair ISK BMA XXX RJ45 RJ45 User Supplied Sensor Pair Sensor Pair Sensor Pair i i 6 e ms a mil m m m m m m 2 c c y
62. system to create alarms or drive actions based on user programmed conditions Q How often do need to calibrate the IntelliSense system A The IntelliSense system requires only the initial installation period to calibrate the SIM and sensor pair to the users system Q When why do need to reset the IntelliSense system A It is recommend that after you replace a failed actuator being monitored by IntelliSense the cycle count on the SIM unit be reset However due to the predictive functionality of the system the life expectancy will begin to trend upward and continue to track the system s remaining life Q How many cylinders can view on a single dash board A The IntelliSense dash board shows the basic status of Green healthy Yellow Alerted and Red Failed for all the SIM units attached to the Data Gateway The limit of SIMs that can be attached to the Data Gateway is set at 12 units Q How many cylinders can use with a single data gateway A Due to the 100 GB capacity of the Data Gateway Bimba recommends no more than 12 SIM units are attached Please keep in mind the more SIM units being logged on a Data Gateway the shorter the time frame in which data can be logged Q Who can contact to discuss if IntelliSense is right for my application A Use the bimba com website to find the IntelliSense Certified Distributor in your area Q Do need a PLC for IntelliSense A Intellisense is a standalone
63. the data provided by the SIM via a direct connection to a Windows PC or by using an IntelliSense Data Gateway to connect remotely PC To connect an Intellisense Sensor Interface Module to a PC use the IntelliSense Programing Cable CBL IS RU 1 8 This cable provides RJ45 to USB Serial connection between the PC and the IntelliSense SIM This con figuration is ideal for setting up a standalone system checking on the status of a cylinder after the SIM has sent an alert to a PLC or after a SIM status light change IntelliSense Data Gateway The addition of an IntelliSense Data Gateway greatly enhances the data gathering capabilities of an Intellisense installation The IntelliSense Data Gateway is capable of connecting 1 12 SIMs to a LAN or the internet The Intel liSense Data Gateway also has the ability to store 100 Gb of performance data Single SIM Adding a single SIM to the IntelliSense Data Gateway requires an IntelliSense Programing Cable CBL IS RU 1 8 Multiple SIM The IntelliSense Data Gateway has three available USB ports that can be used to connect IntelliSense SIMs either using an IntelliSense Programing Cable or a 4 Port R422 to USB Hub ISH DO4 The 4 Port R422 to USB Hub ISH 004 can be connected a SIM s PC port using a DB9 to RJ45 Cable CBL IS RD 0 5 or CBL IS RD 0 5 See the Cable Pin Out section of the appendix for details on the DB9 to RJ45 cable Controls Architecture Th
64. tiple IntelliSense SIM units can be connected to a single Data Gateway or PC using the IntelliSense Communication Hub ISH DB9 04 This hub allows for a single USB port to connect up to 4 IntelliSense SIM units Q Do need to order anything more than the IntelliSense Basic Kit to use IntelliSense A Yes The Intellisense basic kit does not include any cabling The user will need an Intellisense USB programming cable CBL IS RU 1 8 to configure the IntelliSense SIM unit However this cable does not need to remain connect ed if online monitoring or data logging via Data Gateway is not desired in the application Also needed are the cables to connect the two sensing units back to the SIM These cables need to be straight through 4 pin with female M8 connectors on both ends Bimba offers 2m and 5m shield versions CBL IS M8 2 CBL IS M8 5 Power Q What options to have for providing power to my IntelliSense SIM unit A The IntelliSense SIM unit requires a 11 24 VDC power source That can be connected via the unit s I O Connec tor port or the MODBUS connector port For more detailed information please refer to the Intellisense User Manual The manual can be found at bimba com smarter 56 IntelliSense Manual Software Q Why does the Estimated Days Remaining Estimated Cycles Remaining and Estimated Life Remaining show a green check mark A This is an indication that the cylinder is operating normally and perf
65. to multiple SIMs on MODBUS RTU network with remote access using an Intellisense Data Gateway The development of an IntelliSense installation requires merging of four traditionally disparate sub systems Pneumatic Data Controls and Power Pneumatic Architecture IntelliSense is intended for use with double acting single rod end Bimba Original Line Cylinders One IntelliSense Sensor Interface Module SIM and two sensors are required for each cylinder to be monitored No other pneumatic devices should be located between the oylinder port and the sensor fitting For more details on mounting location and orientation see the Sensor Installation section later in this manual IntelliSense is designed to be easily fitted into new and existing applications Each IntelliSense kit is sized based on the included pneumatic fittings IntelliSense kits include two in line push to connect fittings designed for use with Nylon Polyethylene or 95 D Polyurethane tubing Six fittings sizes are available 5 32 or 4mm 6mm 1 4 5 16 or 8mm 10mm and 3 8 outer diameter tubing Custom fittings may also be used The port on the IntelliSense sen sors is a 10 32 thread Data Architecture The Data sub system is used to provide detailed system information to monitor and diagnose the connected pneu matics In addition the data network is used to configure the alerts and events that define the operation of the SIM There are two ways to access
66. ton to register the device MACHINE SERIAL PORTS USERS NETWORK Sats SIM Port Configuration ii Add New Serial port FTDI FT232 USB Serial UART IC port 0 v 2014 Bimba Manufactui Add Cancel Figure 22 Add new Cylinder IntelliSense Manual 7 The software will show a message indicating success and the SIM will appear in the SIM list as unknown and the full port address that was previously selected MACHINE SERIAL PORTS hina SIM Port Configuration 5 unknown name FTDI FT232 USB Serial UART IC port 0 About m Add New Figure 23 Unknown cylinder 8 Select the Status tab on the left of the screen The cylinder status list will show and the newly registered SIM will have a status of ID X not specified Multiple SIMs Multiple SIMS can be added to a Data Gateway by following the steps to add a single SIM The PC software only support one SIM at a time It is recommended that each SIM is connected to the Data Gateway individually and given a distinguishing name see editing SIM configuration and then adding the remaining SIMs The figure below shows a Gateway with three SIMS connected Status E SIM 1 STATUS Zt CONFIG ul MONITORING gt EXPORT Status sim2 STATUS X CONFIG l MONITORING P EXPORT Configuration se SIM 3 STATUS 3 CONFIG ul MONITORING gt EXPORT About Figure 24 M
67. ttings can be en tered Press the save button to make any changes effective IP Address Assignment DHCP Configures the Gatway to receive TCP IP settings from a DHCP server Static Allows the user to manually enter the TCP IP address subnet mask gateway and DNS Servers Disabled Disables the Wi Fi adapter WiFi Settings ESSID Select the Access Point name from the drop down list Select the Re scan button to refresh the list Key The password key for the access point IP Settings When in DHCP mode displays the assigned parameters In static mode values can be entered here IntelliSense Manual SERIAL PORTS USERS NETWORK Status WIRED ETHERNET WIFI Configuration IP ADDRESS ASSIGNMENT About DHCP Static Disabled WIFI SETTINGS ESSID access point name Bimba Re scan Encryption WPA WPA2 Strength 81 Active No Key IP SETTINGS IP Address 192 168 1 100 192 168 1 100 Netmask 255 255 255 0 255 255 255 0 Gateway 192 168 1 ex 192 168 1 1 Save Figure 14 WiFi Network Settings Update Gateway Software If connected to the internet it is possible to update the software on the Data Gateway and download the latest SIM firmware 1 Select the About tab on the left of the screen then the Software tab 2 Under the Component column IntelliSense indicates the Gateway software The remaining items are for the SIM and sensor firmware
68. ual IntelliSense Data Gateway Installation optional Mounting the IntelliSense Data Gateway The IntelliSense Gateway is provided with a bracket and clips for mounting to a 35mm DIN rail The DIN bracket clips can be attached to the bracket so that the Gateway can be mounted edgewise if panel space does not allow the width of the Gateway Refer to the specifications section for mounted dimensions Figure 6 Two options for mounting the gateway to a DIN rail Connecting to the IntelliSense Data Gateway By default the Data Gateway is set up with a static IP address on the Ethernet port and can be configured for the end user s network Default Ethernet IP settings for the Data gateway IP Address 10 10 10 20 Subnet mask 255 255 255 0 With a computer or other web enabled device with an Ethernet port it is possible to connect directly or via a switch to the Data Gateway To access the user interface of the Data Gateway enter the following address into an approved web browser Internet Explorer 10 or Google Chrome http 10 10 10 20 3000 A login screen will show The default administrator login with full access is Username admin Password admin IntelliSense Version 1 1 0 0 Figure 7 IntelliSense log in screen IntelliSense Manual The following user interface will then appear Status Status Configuration di About 2014 Bimba Manufacturing Company All rights reserved Terms of Use
69. ulti SIM Dashboard 20 IntelliSense Manual Editing SIM Configuration Status ID 1 not specified STATUS 141798 1 MONITORING EXPORT Status Configuration a About Figure 25 Cylinder Config button Any SIM in the main list can be configured by selecting the Config button to the right of the SIM entry on the status screen The following configuration page will show Click the button marked Retrieve Current Settings to bring all of the current parameter values from the SIM memory into the web browser including the SIM version set up and com munication parameters To save any changed values to the SIM memory click the button Save Settings to SIM intelliSsense amp Data Gateway ID 1 not specified Q STATUS ul MONITORING EXPORT Firmware version M623 Save Settings to SIM Retrieve Current Settings INTELLISENSE amp MODE Cylinder Monitoring Pressure Temperature Monitoring Figure 26 Save and retrieve Settings to and from the SIM Basic SIM Settings IntelliSense Modes IntelliSense can set up to monitor cylinders or pressure In Cylinder Monitoring mode IntelliSense will monitor cylinder performance including stroke time and leakage and allow alarms to be set These alarms are triggered when the set thresholds are crossed In Pressure Monitoring mode IntelliSense will measure pressure and temperature and alert you when the set points are reached or
70. warning Min Pressure Alert Max Pressure Warning Max Pressure Alert Min Temperature warning Min Temperature Alert Max Temperature Warning and Max Temperature Alert The min warning value should always be higher than the min alert value and the max warning value should always be lower than the max alert value The SIM will alert the users when the detected variable is outside of the defined range Threshold Baseline Sensor 1 Pressure Warn Min 0 00 151 481 40 00 Sensor 1 Pressure Alert Min 0 51 48 1116 03 Sensor 2 Pressure Warn Min 0 34 58 40 00 Sensor 2 Pressure Alert Min 0 34 58 1116 03 Sensor 1 Temperature Warn Min 77 36 64 98 Sensor 1 Temperature Alert Min 59 00 77 36 90 00 Sensor 2 Temperature Warn Min 60 01 74 57 80 01 Sensor 2 Temperature Alert Min 59 00 74 57 Max 81 90 Figure 33 Alert detection Pressure Temperature Mode Event Detection EVENT DETECTION Cycle count limit 31680000 cycles Sampling window 500 cycles Trigger Event Change Extend Retract time 20 Milliseconds Cylinder leak Figure 34 Event detection settings 29 IntelliSense Manual Event detection parameters define how often an estimate for the remaining cylinder life is made based on the ob served change in cylinder performance The following criteria can be entered Cycle count limit Sampling Window System Snapshots Trigger Event

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