IntelliSense® Manual
Hardware Manual
IntelliSense® Manual
Scope of this Manual
This instruction manual supports Bimba standard components only. If special components, including but not
limited to serial hubs, power supplies, and drivers, are included based on a customer’s specications or
special request, it is the customer’s responsibility to consult support materials and technical support specic
to these special components provided by the third party manufacturers. Bimba assumes no liability for misuse, misapplication, or support for components that are not the Bimba brand.
Warning
Using the equipment in a manner not specied 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: 708-534-8544 Toll Free: 800-44-BIMBA Fax: 708-235-2014
Email:cs@bimba.com•www.bimba.com
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Contents
IntelliSense® Operating Modes ................................................................................................................................... 4
Cylinder Monitoring ...........................................................................................................................................................................4
Pressure / Temperature Monitoring ....................................................................................................................................................4
IntelliSense® Architecture ............................................................................................................................................ 5
Pneumatic Architecture .....................................................................................................................................................................5
Data Architecture ..............................................................................................................................................................................5
Controls Architecture .........................................................................................................................................................................5
Power Architecture ............................................................................................................................................................................6
Architecture Examples .......................................................................................................................................................................6
Sensor Installation ...................................................................................................................................................... 11
Media Compatibility .........................................................................................................................................................................11
Sensor Mounting .............................................................................................................................................................................11
Sensor Cable ..................................................................................................................................................................................11
IntelliSense® Data Gateway Installation (optional) .................................................................................................. 13
Mounting the IntelliSense® Data Gateway ........................................................................................................................................13
Connecting to the IntelliSense® Data Gateway .................................................................................................................................13
Congure the IntelliSense® Data Gateway........................................................................................................................................14
WiFi .................................................................................................................................................................................................17
SIM Installation ........................................................................................................................................................... 20
DIP Switch Settings .........................................................................................................................................................................20
Locating the SIM .............................................................................................................................................................................21
Conguring the SIM .........................................................................................................................................................................22
Using IntelliSense® ..................................................................................................................................................... 34
Sensor Interface Module Lights .......................................................................................................................................................34
Using IntelliSense® with a PC or Data Gateway ...............................................................................................................................35
Using IntelliSense® with MODBUS RTU Networks ...........................................................................................................................45
Using IntelliSense® I/O Connector ...................................................................................................................................................46
Technical Specications ............................................................................................................................................ 48
IntelliSense® Sensor Interface Module .............................................................................................................................................48
IntelliSense® Pressure / Temperature Sensor ...................................................................................................................................49
IntelliSense® Data Gateway .............................................................................................................................................................50
IntelliSense® Fittings ........................................................................................................................................................................51
Available Accessories ................................................................................................................................................ 52
IntelliSense® Troubleshooting ................................................................................................................................... 53
FAQ .................................................................................................................................................................................................53
Appendix ..................................................................................................................................................................... 58
Network Drawings ...........................................................................................................................................................................58
Cable Pin Outs ................................................................................................................................................................................68
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IntelliSense® Operating Modes
The IntelliSense® Sensor Interface Module (SIM) can be operated in 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 information that is displayed in the software and on the SIM. Figure 1 lists the information provided in each
mode. This manual is focused on using IntelliSense® in the Cylinder Monitoring Mode. The manual will note when the
Pressure / Temperature Monitoring mode differs from the Cylinder Monitoring mode.
Cylinder Monitoring
Cylinder Monitoring mode is used to measure and analyze the performance of pneumatic cylinders.
Pressure / Temperature Monitoring
Pressure / Temperature Monitoring mode is used in system monitoring to establish alerts based on pressure and
temperature limits.
Figure 1: Information available in IntelliSense® operating modes
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IntelliSense® Architecture
IntelliSense® is designed to be scalable in its implementation. It is easy to go from a single standalone SIM to multiple
SIMs on a 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 cylinder port and the sensor tting. For more details on mounting location
and orientation, see the Sensor Installation section later in this manual.
IntelliSense® is designed to be easily tted into new and existing applications. Each IntelliSense® kit is sized based
on the included pneumatic ttings. IntelliSense® kits include two in-line push to connect ttings designed for use with
Nylon, Polyethylene, or 95-D Polyurethane tubing. Six ttings sizes are available: 5/32" or 4mm, 6mm, 1/4", 5/16" or
8mm, 10mm, and 3/8" outer diameter tubing. Custom ttings may also be used. The port on the IntelliSense® sensors is a 10-32 thread.
Data Architecture
The Data sub-system is used to provide detailed system information to monitor and diagnose the connected pneumatics. In addition, the data network is used to congure the alerts and events that dene the operation of the SIM.
There are two ways to access 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-ISRU-1.8). This cable provides a RJ45 to USB Serial connection between the PC and the IntelliSense® SIM. This conguration 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 IntelliSense® 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-D04). The 4 Port R422 to USB Hub (ISHD04) can be connected to 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
The 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.
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Power Architecture
The IntelliSense® SIM should be connected to a Class 2, limited power source or limited-energypower 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 7 (+) and pin 8 (-) of the MODBUS port
Using the IntelliSense® Junction Block (ISH-R04) is the preferred method of enabling power for option b.
Figure 2: Power option a, I/O 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 option available and DIP switch 9 must be switched to OFF (default setting is ON).
Architecture Examples
IntelliSense® has a variety of hardware congurations to meet the customers’ needs.
• Basic Monitoring / and PLC discrete inputs
• Basic Data Logging and Remote Monitoring / with PLC discrete inputs
• Basic Monitoring with MODBUS RTU Network / and PLC discrete inputs
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• 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 standalone SIM and sensor set to monitor the actuator.
Functionality
• Cylinder Condition monitoring through status indicators on SIM
• Prognostic data including cycle count, cylinder life, cycle time
• Real time condition monitoring based on status LEDs on SIM unit pressure and temperature data
• User PC only connected for initial conguration
• Use of EOT outputs with PLC installation and use of power option b
• Congure SIM
List of required components
Required Bimba Products
• 1 - IntelliSense® Basic Kit- [ISK-BMA-xxx]
o 1 - IntelliSense® Sensor Interface Module (SIM) [ISM-S1-BA1-5P]
o 2 - IntelliSense® pressure / temperature sensor [ISS-1A-7SS]
o 2 - IntelliSense® Tee ttings [ISF-T1-xxx]
• 2 - IntelliSense® sensor cable [CBL-IS-M8-x]
• 1 - IntelliSense® 0.5 meter IO cable [CBL-IS-CF-0.5]
• 1 - IntelliSense® USB programming cable [CBL-IS-RU-1.8]
Optional Bimba Products
• 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 a)
o The above products are available as a kit in the IntelliSense® Starter Kit [ISK-BMA-xxx]
• 1 – IntelliSense® Junction Block [ISH-R04] (for power option b)
User Supplied
• 12-24 VDC Cable for 120V AC power source (if not using Bimba option) to 24V Power Supply
• Computer for setup of IntelliSense® SIM
Optional
• PLC that will accepts a NPN (sinking) sensor (for use of EOT inputs)
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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
• Cylinder condition monitoring based on status LEDs on SIM unit
• Data Gateway remains connected for data logging
• User PC connects to Data Gateway for initial conguration and/or real time monitoring of the SIM unit and
attached pressure system
• Use of EOT outputs with PLC installation and use of power option b
List of Components
Required Bimba Products
• IntelliSense® Basic Kit- [ISK-BMA-xxx]
o 1 - IntelliSense® Sensor Interface Module (SIM) [ISM-S1-BA1-5P]
o 2 - IntelliSense® pressure / temperature sensor [ISS-1A-7SS]
o 2 - IntelliSense® Tee ttings [ISF-T1-xxx]
• 2 - IntelliSense® sensor cable [CBL-IS-M8-x]
• 1 - USB programming cable [CBL-IS-RU-1.8]
• 1 – IntelliSense® Data Gateway [ISG-01]
Optional Bimba Products
• 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 a)
• 1 – IntelliSense® Junction Block [ISH-R04] (for power option b)
User Supplied
• 12-24 VDC power source (if not using Bimba option)
• Computer for setup of IntelliSense® SIM
Optional
• PLC that will 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 conguring 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.
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Functionality
• Cylinder condition monitoring based on status LEDs on SIM unit
• By conguring a MODBUS RTU network between the users’ PLC/HMI (Master Device) and the SIM unit(s)
(Slave Device), the user can retrieve desired status values and alerts
• User PC connects to SIM for initial conguration and/or real time monitoring of the SIM unit and attached
pressure system
• 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 - IntelliSense® Sensor Interface Module (SIM) [ISM-S1-BA1-5P]
o 2 - IntelliSense® pressure / temperature sensor [ISS-1A-7SS]
o 2 - IntelliSense® Tee ttings [ISF-T1-xxx]
• 2 - IntelliSense® sensor cable [CBL-IS-M8-x]
• 1 - IntelliSense® USB programming cable [CBL-IS-RU-1.8]
• 1 – IntelliSense® Data Gateway [ISG-01]
Optional Bimba Products
• 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 a)
• 1 – IntelliSense® Junction Block [ISH-R04] (for connection to MODBUS network and power
User Supplied
• 12-24 VDC power source (if not using Bimba option)
• PLC with MODBUS RTU network compatibility
• Interface cable to connect RS-485 to PLC
• Computer for setup of IntelliSense® SIM
• 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
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 conguring 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.
option b)
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Functionality
• Cylinder condition monitoring based on status LEDs on SIM unit
• By conguring a MODBUS RTU network between the users’ PLC/HMI (Master Device) and the SIM unit(s)
(Slave Device), the user can retrieve desired status values and alerts
• Data Gateway remains connected for data logging
• User PC connects to Data Gateway for initial conguration and/or real time monitoring of the SIM unit and
attached pressure system
• 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 - IntelliSense® Sensor Interface Module (SIM) [ISM-S1-BA1-5P]
o 2 - IntelliSense® pressure / temperature sensor [ISS-1A-7SS]
o 2 - IntelliSense® Tee ttings [ISF-T1-xxx]
• 2 - IntelliSense® sensor cable [CBL-IS-M8-x]
• 1 - IntelliSense® USB programming cable [CBL-IS-RU-1.8]
Optional Bimba Products
• 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 a)
• 1 – IntelliSense® Junction Block [ISH-R04] (for connection to MODBUS network and power
User Supplied
• 12-24 VDC power source (if not using Bimba option)
• PLC with MODBUS RTU network compatibility
• Interface cable to connect RS-485 to PLC
• Computer for setup of IntelliSense® SIM
• PLC that will accepts a NPN (sinking) sensor (for use of EOT inputs)
option b)
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Sensor Installation
Media Compatibility
The IntelliSense® pressure sensor is designed to be used with clean dry air. A 5 micron lter should be used. If the
sensor is used with other media, it is the user’s responsibility to conrm that it is compatible with the wetted materials
in the sensor.
Table 1: Wetted Materials
Component Material
O-ring seals Buna-N
Sensor cap 303 stainless steel
Sensor element isolation barrier Silicone based gel
Port 303 and 304 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 damage 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 ow controls
and quick exhaust valves should not be located between the sensor and the cylinder.
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 tting. A situation may arise
where a different tting is required. The port on the sensor is a 10-32 UNF thread. The maximum torque for the sensor is 10 in-lb [1.13 N-m].
Sensor Cable
The SIM connects to each sensor with a four-wire Female M8 to Female M8 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 cylinder.
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Sensor 1
Sensor 2
StraightConnectortotheSIM
MaxTorqueFingerTight(2.0In.lb/0.23Nm)
Figure 4: Sensor cable installation
SensorCable
4‐WireM8F‐M8F
(CBL‐IS‐M8‐XX)
AngledconnectortotheSensor
MaxTorque3.5In.lb/0.4Nm
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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 specications section for mounted dimensions.
Figure 31: 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 congured 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
Figure 32: IntelliSense® log in screen
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The following user interface will then appear:
Figure 33: Multi-SIM Monitoring Screen
Congure the IntelliSense® Data Gateway
Data Gateway Machine Settings
Select the Conguration 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.
Max data size: The limit on the max quantity of data as percentage of disk size.
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 le corruption.
Reset to Factory Defaults: Clears any user entered changes and resets the Data Gateway to factory default
values.
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Figure 34: Machine Setup
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 following section in this document: Add or Congure 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 The 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 Conguration 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.
Figure 35: 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:
Username: Case sensitive. 3 characters minimum
Password: Case sensitive. 5 characters minimum
User can modify SIM: the user is able to modify the SIM parameters
User can modify Data Gateway: the user is able to modify Gateway parameters
Add/Save: Saves the entered changes
Cancel: None of the entered changes are saved
Delete: To delete an existing user.
Figure 36: User Setup
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Data Gateway Network Settings
The Data Gateway is a TCP/IP v4 device and following network settings can be made to enable communication:
Global Server Settings
Figure 37: Global network settings
Web Port: This denes 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: Congures 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.
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WiFi
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Figure 38: Wireless Network Settings
When the included wireless adapter is connected to the Data Gateway, the following wireless settings can be entered. Press the save button to make any changes effective.
IP Address Assignment
DHCP: Congures 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.
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Figure 39: Wired 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
rmware.
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 rmware.
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.
In order to update a Data Gateway’s software without direct connection to the internet, rst download the update le
and copy it to the root directory of a USB storage device. Plug the memory stick into one of the USB ports on the
Data Gateway and allow for the memory stick to be recognized. From the “Software” tab click “Force check for new
updates” and click the update button just as you would if connected directly to the internet.
To download the available SIM rmware, select the Install button in the Action column to the right of the desired rmware version. This will download the latest rmware 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.
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Figure 40: IntelliSense® Data Gateway Software Update
IntelliSense® Manual
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SIM Installation
DIP Switch Settings
The IntelliSense® SIM module has a bank of DIP switches that allow for a variety of different architectural congurations. The DIP switch bank is located under the rear cover of the SIM unit. Before mounting your SIM unit, it is important that the DIP switches are congured to match the installation type being used. The SIM unit’s DIP switch setting
can be grouped in two categories:
• Power Source/Discrete Output
• Network Conguration/MODBUS Settings
Figure 5: Default DIP switch settings
Table 2: IntelliSense® Sensor Interface Module Dip Switch Settings
DIP Switch Port OFF-0 ON-1 Default
1, 2, 3, 4* Both Communication ports unlinked Communication ports linked 0,0,0,0
5, 6* Modbus** 4-wire RS-422 or RS-485 2-wire RS-485 1, 1
7 Modbus
8 N/A
9 I/O Connector
10 Modbus** Unties Channel A from +5V
11 Modbus** Unties Channel B from ground
12 N/A Not Used Not Used N/A
150 ohm terminating resistor
unconnected
This switch should remain off
for all congurations
Isolates Pin 4 from ground to al-
low for EOT outputs to be used
*Switches should be changed together
**Affects both ports if they are linked (DIP 1-4 ON)
150 ohm terminating resistor con-
nected
Not Used 0
Connects Pin 4 to ground to allow
for SIM to be powered via I/O con-
nector
Ties Channel A to +5V via 680 Ω
resistor
Ties Channel B to ground via 680 Ω
resistor
0
1
0
0
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®
I/O Connector for information on wiring.
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Network Conguration/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 (default), the MODBUS Port is congured for 2-wire RS485. When OFF, the port is congured for 4-wire RS485.
When DIP switch 7 is set ON, it connects a 150 ohm terminating resistor across channels D0 and D1 of the MODBUS Port. Default is OFF. See Using IntelliSense® with MODBUS RTU Network for more information.
DIP switch 8 is not used for any valid IntelliSense® conguration. 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 intended to be placed in dirty, damp, or hazardous environments.
Panel Mount - The SIM will mount to a at panel with two #6 size screws. The gure below shows the hole
spacing for the SIM back plate.
.15 [ 3.8]
54.4
2.14
82.6±0.64
3.25±.025
USE #6 SCREWS
Figure 6: SIM Panel Mount Dimensions
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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 down, the clips will grip
onto the anges of the DIN rail. The SIM may still side laterally on the rail even when screws are tightened.
Conguring the SIM
Figure 7: SIM DIN Rail Mount
An IntelliSense® SIM can be congured either through a PC or an IntelliSense® Data Gateway.
To congure IntelliSense® using a PC, you must rst 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 Windows User Access Control and follow the instructions for selecting the installation location, if the default needs to be
changed. The software will copy all les and install. When installation is complete, the following window will appear.
Select Close to exit and then restart your computer.
Figure 8: Installation complete window
Launch the software by running Bimba IntelliSense® from the start menu under the Bimba folder.
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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 serial 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 working SIM and two
sensors.
To PC or Gateway
Figure 9: 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-D04). The hub is then connected to 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
Figure 10: SIM serial hub connection
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IntelliSense® Manual
Add or Congure 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:
1. On a PC, launch the IntelliSense® software using a web browser connected to the IntelliSense® Data Gate-
way that the SIM is connected to. The default address is http:\\10.10.20:3000.
2. Select the Conguration button on the left side of the window.
3. Select the “Cylinders” tab in the middle of the top row.
4. 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.
5. From the dropdown box, select the port address of the serial connection for the SIM that will be registered
on the computer.
6. Press the “Add” button to register the device.
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Figure 11: Add new Cylinder
IntelliSense® Manual
7. The software will show a message indicating success and the SIM will appear in the Cylinder list as “unknown” and the full port address that was previously selected.
Figure 12: 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 specied”.
Multiple SIMs
Multiple SIMS can be added to a Data Gateway by following the steps to add a single SIM. It is recommended that
each SIM is connected to the Data Gateway individually and given a distinguishing name (see editing SIM conguration) and then adding the remaining SIMs. The gure below shows a Gateway with three SIMS connected.
Figure 13: Multi-SIM Dashboard
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IntelliSense® Manual
Editing SIM Conguration
Figure 14: Cylinder Cong button
Any SIM in the main list can be congured by selecting the “Cong” button to the right of the SIM entry on the status
screen. The following conguration 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 communication parameters.
To save any changed values to the SIM memory, click the button Save Settings to SIM.
Figure 15: Save and retrieve Settings to and from the SIM
Basic SIM Settings
IntelliSense® Modes
IntelliSense® can be 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 crossed. The mode can be set by selecting the appropriate option
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IntelliSense® Manual
button shown in the gure below.
Figure 16: IntelliSense® Mode Selection
Identication
When in Cylinder Monitoring mode, three pieces of information can be entered for identifying the SIM. The rst ID is
the SIM name (60 characters max), the second is the cylinder location (40 characters) and the third is the cylinder
part number (32 characters).
Figure 17: Cylinder mode Identication
In Pressure Monitoring mode, the rst 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 (32 characters).
Figure 18: Pressure / Temperature Monitoring mode Identication
Sensor/Cylinder Setup
Enter the date that the cylinder was put into service. This section has the following commands:
a. Reset cycle count to zero: resets the current cycle count to zero.
b. Set Sensor(s) As Recognized: each sensor has a unique identier to prevent sensors from accidentally
being switched around unknowingly. Whenever a new sensor is connected 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 triggers 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 running the command, a pop-up window appears requesting the number of cycles over which to measure
the baseline (the default is 20 cycles). The SIM will then monitor the cylinder to complete the required
number of cycles and determine values for the stroke time and leakage performance of the cylinder and
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IntelliSense® Manual
store these. These baseline values are then displayed in the Alert Detection section of the conguration
screen.
Figure 19: Baseline cycle count
Alert Detection
In the alert detection section, the user enters the limits that dene 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
S1 S2
RETRACT
Figure 20: Cylinder Mode sensor position
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IntelliSense® Manual
To aid in determining the parameter limits for the alerts, the values from the baseline of the cylinder are displayed for
reference.
Figure 21: Alert detection settings Cylinder Mode
Pressure/Temperature Mode Alert Detection
In sensor mode, limits are entered for the allowable minimum and maximum levels of pressure and temperature. The
SIM will alert the users when the detected variable is outside of the dened range.
Figure 22: Alert detection Pressure / Temperature Mode
Event Detection
Figure 23: Event detection settings
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IntelliSense® Manual
Event detection parameters dene how often an estimate for the remaining cylinder life is made based on the observed change in cylinder performance. The following criteria can be entered:
Cycle count limit: Number of cycles that dene 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
Sampling Window: This is the sensitivity of detection for leakage and stroke time, and denes how long a
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.
System Snapshots: 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 dened in the
Trigger Event section.
Trigger Event: 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 denes a
change that will trigger a snapshot to be taken. When a change in the monitored parameters occurs that is equal 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.
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Figure 24: Status light activation threshold settings
IntelliSense® Manual
MODBUS Settings
Enter the MODBUS parameters used on the network.
Figure 25: MODBUS settings
• Slave address: enter the node or slave address for the SIM (see the manual section: Using IntelliSense®
with MODBUS RTU Networks)
• Select the appropriate serial parameters (table 3)
• Select the line baud rate between 4,800 and 115,200 bps
Table 3: MODBUS parameters
Data Bits Parity Stop Bit
8 None 1
8 Even 1
8 Odd 1
8 None 2
8 Even 2
8 Odd 2
SIM Maintenance Functions
The following commands are available:
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.
Backup Settings: The current SIM settings are downloaded to an XML le on the
user’s machine.
Restore Settings from Backup: The user can upload SIM settings from a previously saved XML le backup.
Restore SIM to Factory Settings: Removes all user changes, and restores the
SIM to default settings.
Reset predictive data and history: Deletes all snapshot history of changes in
the cylinder performance. Recommended when new cylinder is installed.
Update SIM Firmware: Prompts the user to select the new rmware le. See the
update rmware section in this manual for details.
Blink LEDs: This causes the SIM to ash all indicator LEDs for a few seconds, allowing it to be identied.
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Update SIM Firmware
If it is necessary to update the SIM rmware, this can be performed with a le downloaded to the user’s machine or
one that resides on the data gateway.
Select the Update SIM rmware command to launch the pop up window:
Figure 26: SIM Firmware update
PC update:
1. Download the latest SIM rmware to a location accessible from your computer.
2. Select the “Choose File” command.
3. With the le explorer in your browser, select the rmware update.
4. The update will be applied.
Data Gateway updates:
This option requires that the gateway is connected to the internet.
1. The pop-up list box displays rmware les that reside on the gateway.
2. To check if there are any newer les available, select the “About” tab in the left column of the screen, and
then select the “Software” tab.
3. The software list will show the current rmware 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
rmware version is the latest available, the message “Up To Date” will show.
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Figure 27: IntelliSense® Data Gateway check for new rmware
IntelliSense® Manual
4. Return to the SIM “Cong” screen
Figure 28: Return to Cylinder Cong Screen
5. Select the “Update SIM Firmware” command and select the upload icon to the right of the rmware le
name to load it to the selected SIM.
Figure 29: Update from Data Gateway
6. The updated rmware will be applied to the SIM.
Units
Data can be displayed in the following units:
Non-metric Metric
Pressure psi mbar
Temperature °F °C
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.
Figure 30: Change Units
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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 rmware update is available on the Gateway or
PC. While the SIM is checking for the latest rmware, Status 1 and Status 2 will be lit. After the
rmware update, the SIM will check that the installed rmware is valid. During this time, Status 1
will be lit. If the rmware fails, the check it will automatically restart the boot load process. If the
rmware fails a second time, Status 1, Status 2, and Status 3 will be lit. Go to bimba.com for the
latest rmware. When the check is successful, the SIM will enter Application mode.
Application Mode
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Figure 41: Operation of Status Lights in Cylinder Monitoring Mode
Figure 42: Operation of Status Lights in Pressure/Temperature Monitoring Mode
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 mBar(a)/psia: Toggles the pressure units used to display measurements
Hide tips: Hides the command and eld tips
Help: Provides a link to the software help le
Alerts: Provides real-time feedback if there are any alerts in the system. Selecting the tab brings a drop
down list with the detail of each alert.
Figure 43: 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 rst page that is shown after logging in to the computer or gateway and can be accessed 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 Conguration) and export logged data.
The cylinder icon next to the SIM name indicates the status of the cylinder. The cylinder 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 cylinders in the
list.
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Figure 44: 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:
Cylinder 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: Cylinder part number, as entered in the Cong screen
Started Using: Date that the cylinder started being in service, as en-
tered in the Cong screen
SIM Clock: Current time and date taken from the SIM clock. If incor-
rect, this needs to be set on the Cong page
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Operating Condition Extend Time: Current measured time for the cylinder to extend
Retract Time: Current measured time for the cylinder to retract
Sensor 1 Temp: Current measured temperature of sensor 1
Sensor 2 Temp: Current measured temperature of sensor 2
Line Pressure: Current high line pressure detected by the cylinder
Sensor 1
Pressure:
Sensor 2
Pressure:
Ambient
Pressure:
Seal Condition Rod Seal:
Rear Piston Seal:
Front Piston Seal:
Mode Shows which mode the SIM is in:
Life Remaining Estimated Days Remaining Estimated cycles remaining divide by average daily
Estimated Life Remaining Estimated cycles remaining divide by total number of
Current measured pressure of sensor 1
Current measured pressure of sensor 2
Current measured atmospheric pressure
Status of each seal
Cylinder or Pressure/Temperature Monitoring Mode
cycles
cycles
Estimated Cycles Remaining Cycle count mode: Cycle count limit - current cycle
count
Predictive mode: Estimated number cycles at time of
prediction*
*Impredictive mode: values only update when an event
occurs
Cycle Time Gives the stroke, dwell and total cycle time for extend
and retract
Sensor / SIM Condition Connection status to the SIM and sensors
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Figure 45: Cylinder Status Screen
SIM Conguration
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 is 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 temperatures 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.
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Real-time plot of pressure and temperature
Pressure and temperature measurements
Figure 46: 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
only available when accessing IntelliSense® via an IntelliSense® Data Gateway.
Events: 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.
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Figure 47: 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 le
(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 time after extending in seconds
Dwell Time – Retract Dwell time after retracting in seconds
Cycle Count Current cycle count
Average Daily Cycles The average daily cycles at the time of measurement
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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
Figure 48: Export option
2. The eld 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 elds can be dragged.
Figure 49: Export eld selector
3. By default, the export le will contain the measurement time and the two pressure measurements, P1
and P2. To add any of the available elds/columns to the exported le, press the left button over the required eld and drag 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.
Figure 50: Select variable to export
4. Items in the list can be rearranged to represent the column order in the exported le from left to right.
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5. The date and time range for the exported data can be entered as an interval between two points in time,
dened 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 reference.
It should be noted that pressure data is recorded every millisecond, giving a thousand lines of information for each second of time. The data le can be very large and unmanageable for large periods of time.
a. Download by interval
Select the Download by Interval option and enter the dates and times in the past that dene the
beginning and end of the time interval. Upon entering the dates and times, select the download
button to save a le to the local machine.
Figure 51: 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 le will be created for the entered period of seconds ending at the moment the Download button is selected.
Figure 52: Export seconds in the past
Events Export
Selecting 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 performance are detected. The SIM can store 31 snapshots in addition to the original snapshot taken as the cylinder
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baseline. If numerous snapshots are being taken within short periods of time that show an oscillation of performance,
i.e. a decrease in the performance parameter followed by an increase, the sample size should be increased to reduce
this uctuation. For more details on setting up event detection, refer to the section in this manual: Event Detection
The legend below, the table of data, explains each of the column names with units.
Selecting the Download Events button downloads all of the event snapshot data in a comma-separated value le
(CSV) for further analysis in a spreadsheet or database program.
Figure 53: Event log
Figure 54: Event log legend
Events Reason
When an Event is logged by the SIM unit it records the Reason the event was triggered. These events are coded as
follows.
• Avalueof0canmeanthreethings.
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 identied.
o The event was triggered by the improvements of the tracked parameters.
• Avalueof4meanstheeventwastriggeredbytheextendtimewindowchanginginthepositivedirection
equal or greater than the value of the “Extend/Retract time” change parameter.
• Avalueof8meanstheeventwastriggeredbytheextendtimewindowchanginginthenegativedirection
equal or greater than the value of the “Extend/Retract time” change parameter.
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4096 Retract time was above limit
2048 Retract time was below limit
1024 Extend time was above limit
512 Extend time was below limit
256 Sensor 2 Temperature is below limit
128 Sensor 1 Temperature is below limit
64 Sensor 2 Temperature is above limit
32 Sensor 1 Temperature is above limit
16 Rod Seal Failure Present
8 Front Piston Seal Failure Present
4 Rear Piston Seal Failure Present
2 Line pressure above limit
1 Line pressure below limit
• Avalueof16meanstheeventwastriggeredbytheretracttimewindowchanginginthepositivedirection
equal or greater than the value of the “Extend/Retract time” change parameter.
• Avalueof32meanstheeventwastriggeredbytheretracttimewindowchanginginthenegativedirection
equal or greater than the value of the “Extend/Retract time” change parameter.
• Avalueof64meanstheeventwastriggeredbyanincreaseindetectedrodsealleakage,inpercentage,
equal to or greater than the value of the “Cylinder leak” change parameter.
• Avalueof256meanstheeventwastriggeredbyanincreaseindetectedfrontpistonsealleakage,inpercentage, equal to or greater than the value of the “Cylinder leak” change parameter.
• Avalueof1024meanstheeventwastriggeredbyanincreaseindetectedrearpistonsealleakage,inpercentage, 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:
Following this table, a failure code for “Extend time was above limit” would be a 1024. Likewise, an event with multiple failures, such as a “Extend time was above limit” and “Line pressure above limit” would be a 1026.
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Register Description Size Register Description Size
40001
Pressure of port 1 in abs olute tenths of PSIa 2 Bytes
40023
Pres sure Fa il ure 2 Bytes
40002
Pressure of port 2 in abs olute tenths of PSIa 2 Bytes
Bit 0 - Line Pressure High
40003
Ambient pres sure in absolute tenths of PSIa 2 Bytes
Bit 1 - Line Pressure Low
40004
Pressure of port 1 in abs olute tenths of mBar 2 Bytes
Bit 2 - S ensor 1 Pres sure High
40005
Pressure of port 2 in abs olute tenths of mBar 2 Bytes
Bit 3 - S ensor 1 Pres sure Low
40006
Ambient pres sure in absolute tenths of mBar 2 B ytes
Bit 4 - S ensor 1 Pres sure High
40007
Line pressure in abs olute tenths of PSIa 2 Bytes
Bit 5 - S ensor 1 Pres sure Low
40008
Line pressure in abs olute tenths of mBar 2 Bytes
40024
Leakage Failure 2 Bytes
40009
Rod Pos iti on 2 Bytes
Bit 0 - Re ar Piston Se al
40010
Time in ms for las t extension event. 2 Bytes
Bit 1 - Front Piston Seal
40011
Time is ms for last retraction event. 2 Bytes
Bit 2 - Rod Sea l
40012
Temperature of port 1 in hundredths of a degree F 2 Bytes
40025
Temperature Failure 2 Bytes
40013
Temperature of port 2 in hundredths of a degree F 2 Bytes Bit 0 - 1 Te mp High
40014
Temperature of port 1 in hundredths of a degree C 2 Bytes Bit 1 - 1 Temp Low
40015
Temperature of port 2 in hundredths of a degree C 2 Bytes Bit 2 - 2 Temp High
40016
Cyc le c ount, low word. 2 Bytes
Bit 3 - 2 Temp Low
40017
Cycle count, hig h word. 2 Bytes
40026
Extent Fa ilure 2 Bytes
40018
Cyc le c ount limit, low word. 2 Bytes Bit 0 - Extent Ti me Hig h
40019
Cycle count limit, hig h word. 2 Bytes Bit 1 - Extend Time L ow
40020
First two bytes of SIM revision 2 B ytes Bit 2 - Retract Time High
40021
Second two bytes of SIM revisi on 2 Bytes
Bit 3 - Retract Time Low
40022
Sensor Status 2 Bytes
40027
Estimated Life Remaining above 90% - Bit 0
Estimated Life Remaining Below 10% - Bit 1
2 Bytes
Bit 0 - 1 S treaming
40028
Estimated Life Remaining Percentage between 90 and 10
Decimal value
2 Bytes
Bit 1 - 2 S treaming
40029
Life Expected T hresholds 2 Bytes
Bit 3 - 1 R ecognized
Bit 0 - Yellow Light Threshold
Bit 1 - Red Lig ht Thres hold
Bit 4 - 2 R ecognized
40030
Estimated Cycles remaining, low word
2 Byt es
40031
Estimated Cycles remaining, high word
2 Byt es
40032
Estimated Days Remaining
2 Byt es
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 communicate over a MODBUS RTU serial network. This port can be congured 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.
Congurable 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 Rate: Values of 4,800, 9,600, 19,200 (default), 38,400, 57,600, and 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
The integer data values stored in the IntelliSense® SIM Holding Registers can be accessed using the appropriate address found in the following table:
Table 4: MODBUS registry
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The IntelliSense® SIM also stores the Real Time Clock Data and Identication labels, congured by the user, as ASCII
data in the following registers:
Table 5: ASCII MODBUS Registries
Register Description Size
40501 RTC Seconds 2 bytes
40502 RTC minutes 2 bytes
40503 RTC hours (24hr) 2 bytes
40504 RTC hours (12hr) 2 bytes
40505 RTC AM/PM 2 bytes
40506 RTC day 2 bytes
40507 RTC month 2 bytes
40508 RTC year (last 2 digits) 2 bytes
40510 ID 1 string 60 bytes
40540 ID 2 string 40 bytes
40560 Part number 30 bytes
Using IntelliSense® I/O Connector
The IntelliSense® SIM unit’s I/O connector can be used to power the SIM or to utilize the two 3-wire NPN transistor outputs. These outputs are congured 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
ying leads on one end, and a 4 pin connector on the other (Figure 55: Molex 50-57-9409 connector). The underside
of this connector has an arrow to indicate the location of pin 1 (Figure 56: Underside of Molex connector with Pin 1
Indicator).
User may also purchase the 4 pin connector through a 3rd party to wire for additional lengths as needed.
Figure 55: Molex 50-57-9409 connector
Figure 56: Underside of Molex connector with Pin 1 Indicator
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IntelliSense® Manual
To use the 2 EOT outputs of the IntelliSense® SIM unit, conrm DIP switch 9 is OFF and use the following the diagram:
Figure 57: I/O connector output wiring diagram with wire colors for cable CBL-IS-CF-0.5
Note: PLC input needs to accept sinking (NPN) sensors.
To use the I/O Connector to power SIM, conrm DIP switch 9 is ON and follow the diagram below.
Figure 58: I/O connector SIM power wiring diagram
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IntelliSense® Manual
Technical Specications
IntelliSense® Sensor Interface Module
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IntelliSense® Pressure / Temperature Sensor
IntelliSense® Manual
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IntelliSense® Manual
IntelliSense® Data Gateway
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IntelliSense® Fittings
IntelliSense® Manual
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IntelliSense® Manual
Available Accessories
Accessories Part Number
IntelliSense® Data Gateway ISG-01
IntelliSense® Junction Block ISH-R04
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 to USB HUB ISH-D04
24V Power Supply PWR-020A24-DIN
Service Parts Part Number
IntelliSense® Pressure/Temperature Sensor ISS-1A-7SS
IntelliSense® Sensor Interface Module (SIM) ISM-S1-BA1-5P
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-T1-313
IntelliSense® Fitting, 3/8” OD Tubing ISF-T1-375
IntelliSense® Data Gateway DIN Rail Bracket ISG-BRKT
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IntelliSense® Manual
IntelliSense® Troubleshooting
FAQ
Application
Q: Can I use the IntelliSense® for single acting or reverse acting actuators?
A: Not at this time.
Q: Can I use IntelliSense® with SPCS valves?
A: Not at this time.
Q: Can I 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?
A: 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 I use the IntelliSense® on a double end rod (DE option) actuator?
A: IntelliSense® is currently only congured for use with single rod end cylinders.
Q: How are the baseline numbers established?
A: The base line looks at the values over the specied 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 ttings provided in each IntelliSense® Kit. The tting 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 I use 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 I use IntelliSense® with ow controls?
A: Yes. IntelliSense® works with ow 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 followed when installing the IntelliSense® system.
Q: What is the maximum cylinder frequency that can be detected?
A: IntelliSense® is designed to detect most cycle proles 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.
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IntelliSense® Manual
Q: Can I use IntelliSense® to only offer alarms when there are changes in temperature and/or pressure?
A: IntelliSense® offers congurable 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 MODBUS RTU Holding Registers and can be accessed by a controls system to create alarms or drive actions based on
user programmed conditions.
Q: How often do I 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 I 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 I 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 I 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 I contact to discuss if IntelliSense® is right for my application?
A: Use the bimba.com website to nd the IntelliSense® Certied Distributor in your area.
Q: Do I need a PLC for IntelliSense®?
A: IntelliSense® is a standalone 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 I 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 veried with Bimba’s Original Line cylinder.
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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 I install the IntelliSense® sensors?
A: The recommended installation distance for the IntelliSense® sensor and tee tting 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
ttings 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 conguration of the cable can be found in the
IntelliSense® 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 exibility 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 IntelliSense® 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 3rd party.
Q: What are the temperature ratings on the sensors?
A: The IntelliSense® sensors have an operating range of -40° F (-40° C) to 176° F (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 [325’].
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IntelliSense® Manual
Q: What is the recommended ltration for the sensors?
A: It is recommended that IntelliSense® be installed with a Class 3 ISO-8573-1/5 micron lter.
Q: What is the maximum pressure rating for IntelliSense®?
A: The operation pressure rating for the IntelliSense® sensors is 0 psia [0 bar (a)] to 200 psia [14 bar (a)].
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 I nd and download the manuals and required Software?
A: Manual’s and required software 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 device and setting cannot be made outside of the IntelliSense® conguration software.
IntelliSense® Sensor Interface Module (SIM)
Q: Are there any discrete signals included with IntelliSense®?
A: 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 connecting 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?
A: IntelliSense® supports MODBUS RTU.
DATA Network
Q: Do I 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, multiple 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 I 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 congure the IntelliSense® SIM unit. However, this cable does not need to remain connected 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 I 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 Connector 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.
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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 performance has not changed from the initial installation. When IntelliSense® predicts 90% of life remaining it will begin to display values for these elds.
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® conguration. 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?
A: 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 updated 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.
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IntelliSense® Manual
Appendix
Network Drawings
Drawing 1
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Drawing 2
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Drawing 3
60
Drawing 4
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Drawing 5
62
Drawing 6
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IntelliSense® Manual
Drawing 7
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Drawing 8
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Drawing 9
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Drawing 10
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IntelliSense® Manual
Pin on RJ45 Signal
1
RXD0
2
RXD1
3
NA
4
TXD1
5
TXD0
6
NA
7
Option V+
8
Common
Cable Pin Outs
BIMBA BRANDS I ACRO I MEAD I MFD I PNEUMADYNE I TRD
PNEUMATIC ACTUATORS • ELECTRIC ACTUATORS • HYDRAULIC ACTUATORS • VALVES • AIR PREPARATION • SAFETY & PRODUCTION
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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.comwww.bimba.com FormHM-BIM-IS-0914
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