Set up your assets and devices and begin acquiring data.
Before you begin, connect your devices to a power source.
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Installing InsightCM 3.8—Install the InsightCM software to your computer.
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Set up Equipment Assets—Configure your asset tree with general and equipment assets that accurately represent and organize the equipment you want to monitor.
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Add Sensors to Equipment—Assign sensor assets to each equipment asset to represent the sensors collecting data from each equipment and to enable features and trend alarm rules.
-
Add a device to InsightCM.
Map a monitoring device that is powered and collects data via wired connection to InsightCM.
Map a monitoring device that collects data wirelessly to InsightCM.
Map a monitoring device that collects thermal data via ethernet-wired connection to InsightCM.
-
Acquire data from devices.
Begin acquiring data from your hardwired devices.
Begin acquiring data from your wireless devices.
Before upgrading to InsightCM 3.8, your server must be running InsightCM 3.6 or later. See InsightCM Upgrade Process for the upgrading process.
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Backup your server by stopping the NI InsightCM 3.X and NI InsightCM MongoDB services and copying “C:\ProgramData\National Instruments\InsightCM 3.0” to a safe location. If InsightCM is configured to use non-default Database and Data File directories, backup those directories too.
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Run the installer by following the “Installing InsightCM 3.8” instructions.
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Open a web browser and navigate to http://localhost:82/icm or https://localhost:482/icm to confirm that the upgrade was successful. Clear the cache on your web browser to prevent the browser from being redirected to the previous version of InsightCM's web application. Refer to browser-specific documentation to clear the cache.
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Browse to the Assets page and confirm that the Asset tree was imported correctly.
-
Browse to the Device page and confirm that the device channels are mapped to the Asset tree correctly.
-
Update Condition Monitoring devices applications and connect to the InsightCM Server:
-
Browse to the Software tab on the Devices page.
-
Select a group of ten devices that you want to update and select Update Application. Check the configuration status of the device to see when the update finishes and the devices' Deployment Status will display Succeeded once complete.
-
Repeat this process for the next group of ten devices until all devices are updated.
Note
Custom units may not be imported and must be re-added manually after upgrading.
-
-
Double click the installer ISO to mount it.
-
Run InsightCM.exe.
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Proceed through the installation dialog until you reach the Data page. If desired, specify custom directories for the Database Folder and Data Folder. If upgrading from a previous version of InsightCM, ensure that the installer properly detected the correct directories.
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Proceed to the Summary page and select Install.
-
A server reboot might be required during installation. If prompted, select Restart and wait for the server to reboot. Sign back into the same user account you were using previously and the installation will proceed automatically.
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After the installation is completed, select Launch InsightCM and confirm the web UI successfully launches.
InsightCM stores data in both a central database and as files on disk. By default, data is automatically moved from the Database to the Data directory after 30 days. This archiving process results in better performance by decreasing memory used by the InsightCM database and more uniform load time for viewing data in the Data Viewer. The archived data can still be accessed in the Data Viewer. By default, the following directories are used:
-
Database Directory:
C:\ProgramData\Cutsforth\InsightCM\MongoDB
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Data Directory:
C:\ProgramData\Cutsforth\InsightCM\Files
For optimal performance, Cutsforth recommends using separate SSDs for each data directory. Custom directory locations can be specified when installing InsightCM.
Map your condition-monitoring system on InsightCM using location, equipment, and sensor assets.
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Organize your assets–Use location assets as an organizational element before adding equipment and sensors.
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Add equipment assets–Define the equipment assets in your condition monitoring system on the Asset Configuration page.
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Add sensor assets to equipment–Configure sensor assets for the equipment you are monitoring.
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Add a smart motor pump–Configure equipment on the asset configuration page to populate analysis and alerts in the Reliability dashboard based on your equipment data.
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Validate your assets–Verify that you have configured your assets correctly.
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Add notes and instructions–Add notes and instructions about an asset if multiple people are monitoring it.
Refer to Adding Cutsforth Monitoring Devices to configure your monitoring device and/or data source(s) and create data groups.
Use location assets as an organizational element before adding equipment and sensors.
Before you begin, determine how you will organize your assets on the Asset Configuration page. For example, you can group assets based on location, the technology you use to monitor your assets, or the structure of a computerized maintenance management system (CMMS).
Add location assets at any level of your asset tree to keep your assets organized.
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Click Configuration () and select Assets.
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Above the left-hand asset tree, click Add.
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Expand General and select Location.
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Give the location asset a descriptive name and specify how many location assets with this name to add.
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Click OK.
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Repeat steps 1-5 as needed.
Now begin adding equipment assets.
Define the equipment assets in your condition monitoring system on the Asset Configuration page.
Now that you have set up the organization of your asset tree using location assets, begin adding equipment assets, assets that represent your equipment.
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Click Configuration () and select Assets.
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Select a location asset and click Add.
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In the resulting dialog box, expand Equipment and select an equipment type from the list.
Note
Refer to the List of Equipment Asset Types to see configuration requirements for each equipment asset type.
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Give the equipment asset a descriptive name and specify the number assets you want to add to your asset tree.
-
Click OK.
Now that you have added your equipment, add sensor assets and configure data collection behavior using each asset's configuration tabs.
Configure sensor assets for the equipment you are monitoring.
Before you begin, add equipment assets to the Asset Configuration page.
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Click Configuration ().
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Select an equipment asset that needs sensors.
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Click Add and expand the Sensors section.
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Expand the type of device that will monitor your asset and select a sensor.
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Enter a descriptive name for the sensor asset in the Name text field.
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Specify how many of this asset to add and click OK.
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Repeat steps 2–6 to define additional sensors until you have defined all sensors.
Note
To configure wireless data collection settings, refer to Configuring Data Collection for Wireless Equipment.
You have finished constructing your asset tree.
You are ready to add a monitoring device and to map device channels to the sensors you just added.
Verify that you have configured your assets correctly.
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Click the Configuration button () to navigate to the Asset Confirmation page.
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Select the asset(s) you want to validate.
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Click Validate. InsightCM displays validation errors if there are any.
There are no validation errors
A notification saying there are no errors appears. No further action required.
There are validation errors
The Validation Results dialog box appears with a list of validation errors. Take note of the errors, click OK , fix the errors, and re-validate until there are no validation errors.
Add notes and instructions about an asset if multiple people are monitoring it.
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Click Configuration () and navigate to the Asset Configuration page.
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Select an asset and click the Description tab in the right-hand asset configuration panel.
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Click the Add button in the Comments toolbar to add a note or specific instruction about the selected asset.
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Click the Add button in the Attachments toolbar to add an attachment relevant to the selected asset.
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You can add standard notes and attachments to all existing and future assets of a specific type by modifying the Comments and Attachments section in the Description configuration tab on the Asset Definitions page.
An important part of the configuration for an asset is the lists of features that InsightCM calculates each time the asset collects data. You can review and configure the list for a given asset on the Features tab of the Asset Configuration page.
Note
You cannot edit pre-configured features - only features that you add to an asset or an asset type.
Feature Name |
Type |
Description |
---|---|---|
Active Power |
MCSA |
Total input active power, in watts or kilowatts, of the motor |
Apparent Power |
MCSA |
Total input apparent power, in volt-amperes or kilovolt-amperes, of the motor |
Average Temperature |
Thermal Imaging |
The average temperature across an ROI |
Crest Factor* |
Vibration |
|
Delta Temperature |
Thermal Imaging |
The difference between the maximum temperatures of two or more ROIs |
Derating Factor |
MCSA |
The value to derate the motor output based on the calculated motor voltage unbalance in compliance with NEMA MG 1-2014 |
Derived Peak* |
Vibration |
|
Effective Service Factor |
MCSA |
|
Efficiency |
MCSA |
Motor efficiency in percentage |
Envelope Total Power |
Vibration |
The total energy in the envelope spectrum. |
Gap |
Vibration |
The DC value of the signal |
Kurtosis |
Vibration |
Where () is the fourth central moment and () is the standard deviation. |
Line Frequency |
MCSA |
Line frequency, in Hz, of the voltage bus |
Load |
MCSA |
Output load, in kilowatts or horsepower, of the motor |
Maximum Temperature |
Thermal Imaging |
The highest temperature across an ROI |
MCSA RMS |
MCSA |
The RMS values of voltage or current waveforms in volts or amperes |
MCSA Speed |
MCSA |
Motor rotational speed in revolutions per minute (RPM) |
Minimum Temperature |
Thermal Imaging |
The lowest temperature across an ROI |
Peak-Peak* |
Vibration |
The greatest positive peak minus the least negative peak |
Percent Full Load Amps |
MCSA |
Maximum RMS for motor startup currents each cycle in percentage of the full load amperes on the motor nameplate |
Percent Load |
MCSA |
Motor load, in percentage of the full load on the motor nameplate |
Phasor: Magnitude |
MCSA |
Magnitude of the fundamental phasor, in volts or amperes, of voltage or current waveforms |
Phasor: Phase |
MCSA |
Phase of the fundamental phasor, in degrees, of voltage or current waveforms |
Power Factor |
MCSA |
Power factor of the motor |
Reactive Power |
MCSA |
Total input reactive power, in volt-ampere reactives or kilovolt-ampere reactives, of the motor |
RMS* |
Vibration |
The root mean square of the signal |
Rotor Bar Sideband |
MCSA |
Maximum magnitude, in decibels, of rotor bar sideband harmonics. The decibel reference is the fundamental component magnitude in the spectrum |
Smax |
Vibration |
The maximum value of shaft vibration in two dimensions. This feature is available only for displacement sensors that are part of a pair of orthogonal probes. InsightCM Server also requires that each sensor in a pair have the following properties configured on the Properties tab of the Asset Configuration page. Otherwise, InsightCM Server logs an error value (-1, by default). Smax is the result of the following equation, which complies with the ISO 79194:1996(E) standard. where
|
Startup Peak Amps |
MCSA |
Maximum instantaneous peak value, in amperes, of startup motor currents |
Startup Time |
MCSA |
Time duration, in seconds, for the motor to remain in startup state |
Temperature |
Vibration |
N/A |
Torque |
MCSA |
Output torque, in Newton meters or pound-foot, of the motor |
Torque Ripple |
MCSA |
|
Total Power in Band |
EMSA |
The spectral energy in all frequency ranges |
True Peak |
Vibration |
The absolute value of the greatest positive peak or the least negative peak, whichever is greater |
Unbalance |
MCSA |
Unbalance, in percentage, of three-phase voltage buses or three-phase motor currents in compliance with NEMA MG 1-2014 |
*The data is AC-coupled for the purpose of calculating this feature. If a sensor is configured as DC-coupled, the InsightCM Server AC couples its data for the purpose of calculating these features. |
Energy in Signal |
Other Spectral Bands |
Residual Value |
---|---|---|
At 1x, 2x, and 3x the running speed |
1x Magnitude |
All the energy from the 2x and 3x components of the signal. |
At 1x, 2x, and 3x the running speed |
The energy from the 3x component of the signal. |
|
At 1x, 2x, and 3x the running speed |
Zero |
|
At 1x, 2x, and 3x the running speed |
A custom spectral band from 0.8 to 3.2 orders |
Zero |
At 1x, 2x, and 3x the running speed of 60 Hz |
A custom spectral band from 50 Hz to 70 Hz |
All the energy from the 2x and 3x components of the signal |
On the Asset Configuration page, the Properties tab in an asset's configuration panel contains a subset of these properties. The properties available for a particular asset vary based on the property definition of that asset type.
Property |
Required Toolkit |
Description |
Additional Information |
---|---|---|---|
1x Magnitude Reference |
None |
The 1x magnitude value when the shaft is at slow-roll speed |
On the Data Viewer page, Bode and Polar viewers subtract this slow-roll value from channel data so that the plots start at 0. |
1x Phase Reference |
None |
The 1x phase value when the shaft is at slow-roll speed |
On the Data Viewer page, Bode and Polar viewers subtract this slow-roll value from channel data so that the plots start at 0. |
B |
|||
Bandwidth (Hz) |
EMSA |
The amount of data to acquire around a center frequency |
N/A |
Bearing Clearance Unit |
None |
The units in which the Horizontal Bearing Clearance and Vertical Bearing Clearance properties express the maximum possible orbit of the shaft centerpoint inside the bearing |
N/A |
Bearing Start Position |
None |
The location of the shaft within its bearing housing when at rest, whether at the top, middle, or bottom of the housing |
N/A |
C |
|||
Calibration Factor |
MCSA |
The gain factor applied to the voltage or current sensor data |
N/A |
Coefficient K |
CMS |
Calculated using the Winter-Kennedy Method Relative Flow Measurement |
|
Coupling |
None |
AC or DC |
N/A |
Current Phase A |
MCSA |
The current transformer asset node corresponding to phase A of the motor current channels |
When only two of the three current phase channels are configured in the Group Properties section of the Properties tab, InsightCM calculates the data of the third current phase channel. |
Current Phase B |
MCSA |
The current transformer asset node corresponding to phase B of the motor current channels |
When only two of the three current phase channels are configured in the Group Properties section of the Properties tab, InsightCM calculates the data of the third current phase channel. |
Current Phase C |
MCSA |
The current transformer asset node corresponding to phase C of the motor current channels |
When only two of the three current phase channels are configured in the Group Properties section of the Properties tab, InsightCM calculates the data of the third current phase channel. |
Custom Coefficients A |
None |
The A constant of the Callendar-Van Dusen equation |
Enter a value for this property when you specify |
Custom Coefficients B |
None |
The B constant of the Callendar-Van Dusen equation |
Enter a value for this property when you specify |
Custom Coefficients C |
None |
The C constant of the Callendar-Van Dusen equation |
Enter a value for this property when you specify |
D |
|||
Detection Mode |
EMSA |
Determines how amplitude is detected: |
N/A |
Detection Time (seconds) |
EMSA |
The time, in seconds, that a sensor takes to acquire amplitude at a point |
N/A |
Digital Threshold |
None |
Specifies what voltage values indicate that the channel is on or off |
For example, if you set the digital threshold to 2, values greater than or equal to 2 indicate that the channel is on while values below 2 indicate that the channel is off. The range of valid threshold values is 0-60. This property is only available on the 9219 module. |
Double Integration Cutoff |
None |
The frequency, in Hz, at which to set the highpass filter when performing double integration on asset data |
N/A |
E |
|||
Efficiency @ 75% Load (%) |
MCSA |
The motor efficiency as a percentage when the load is three quarters of the full load |
N/A |
Efficiency @ 50% Load (%) |
MCSA |
The motor efficiency as a percentage when the load is half of the full load. |
N/A |
Efficiency @ 25% Load (%) |
MCSA |
The motor efficiency as a percentage when the load is a quarter of the full load |
N/A |
Estimate Stator Resistance |
MCSA |
Whether the motor stator resistance value is manually specified by the user or estimated by the InsightCM Server |
InsightCM Server estimates the motor stator resistance based on the motor nameplate parameters. If the motor nameplate information is not appropriately specified, the accuracy of the estimation may be affected, which then affects the accuracy of the motor Torque Ripple and Torque Waveform calculation. The following motor nameplate parameters will affect the stator resistance estimation: Synchronous Speed (RPM), Full Load Speed (RPM), Load, Full Load Efficiency (%), and Full Load Amps (amp). |
F |
|||
Full Load Amps (amp) |
MCSA |
Specify the motor full load current in amperes according to the motor nameplate |
N/A |
Full Load Efficiency (%) |
MCSA |
The motor full load efficiency as a percentage according to the motor nameplate |
N/A |
Full Load Speed (RPM) |
MCSA |
The motor full load speed in rotations per minute according to the motor nameplate |
N/A |
Full Scale Voltage |
EMSA |
The largest voltage range you expect the HFCT to detect |
N/A |
G |
|||
Gap Voltage Reference |
None |
The DC value, in volts, of the displacement probe when the shaft is at rest |
The Data Viewer page subtracts this value from the DC voltages measured during normal operation and combines the results to generate accurate plots in the Shaft Centerline viewer. |
H |
|||
Horizontal Bearing Clearance |
None |
The horizontal diameter of the maximum bearing clearance, expressed in the units the Bearing Clearance Unit property specifies |
The Data Viewer page uses this value to display the maximum bearing clearance line in orbit and Shaft Centerline viewers. |
I |
|||
Input Range |
None |
The input range of the module to which the channel belongs in the same pre-scaled units in which the module acquires data |
You can find this value in the module [Operating Instructions and Specifications] document. |
IEPE |
None |
Specifies to power IEPE sensors via the physical connection to the channel. When true, the device also reports open and short conditions for the channel. Set this property to true for IEPE sensors |
N/A |
L |
|||
Load |
MCSA |
The motor full load in the unit configured by the Load Unit property according to the motor nameplate |
N/A |
Load Unit |
MCSA |
The unit of the motor load from horsepower or kilowatts |
N/A |
Low Frequency Cutoff |
None |
The value at or below which InsightCM attenuates frequencies. Attenuation occurs immediately after acquisition and prior to any feature calculations. If you specify a low frequency cutoff value of zero, InsightCM does not attenuate any signal frequencies. |
N/A |
M |
|||
Manufacturer |
MCSA |
The motor manufacturer according to the motor nameplate |
N/A |
Model |
MCSA |
The motor model according to the motor nameplate |
N/A |
N |
|||
Nominal Frequency |
MCSA |
The nominal frequency of the line power to the motor |
N/A |
Nominal Line Voltage (volt) |
MCSA |
The nominal line voltage, in volts, of the voltage bus |
N/A |
Nominal Speed |
None |
The theoretical speed if there is no load on the motor |
N/A |
Number of Intervals |
EMSA |
The number of sections an EMSA frequency range is divided into |
N/A |
O |
|||
Offset |
None |
The y-intercept, [b], of the linear scale ( [y] = [mx] + [b] ) applied to pre-scaled data |
To disable scaling, enter an offset of 0 and a slope of 1. |
P |
|||
Pair Sensor |
None |
The name of another asset to pair with this one for the purpose of generating an orbit plot you can view on the Data Viewer page |
N/A |
PI Point Name |
None |
The name of a PI point whose data you want to display on the Data Viewer page. For example, |
Refer to the Point Mappings Tab on Historian Page topic for more information about PI point names. |
Power Factor |
MCSA |
The motor power factor at full load according to the motor nameplate |
N/A |
Probe Angle |
None |
The angle in degrees at which the sensor is positioned around the shaft |
The following image shows the driver-to-driven perspective of a shaft with two sensors attached. For the sensor that is angled to the right on the shaft, the probe angle is between 0 and 180 degrees. For the sensor that is angled to the left, the probe angle is between 0 and -180 degrees. |
Pulses Per Revolution |
None |
The number of pulses the tachometer generates per revolution of the shaft. Refer to the sensor documentation to determine this value. |
N/A |
R |
|||
R0 |
None |
The sensor resistance in ohms at 0 degrees Celsius |
The Callendar-Van Dusen equation requires this value. Refer to the sensor documentation to determine this value. |
Rated Volts (volt) |
MCSA |
Specify the motor rated voltage in volts according to the motor nameplate |
N/A |
Resistance Configuration |
None |
The number of wires to use for resistive measurements |
N/A |
Reverse Polarity |
None |
Enable this control if the polarity of the sensor is reversely wired |
N/A |
Rotation Direction |
None |
The direction the shaft turns, whether counterclockwise or clockwise relative to the 12:00 position when you look down the shaft starting from the motor, from the driver-to-driven perspective |
N/A |
RTD Configuration |
None |
The number of wires to use for resistive measurements and the typical sensor resistance:
|
N/A |
RTD Type |
None |
The type of RTD connected to the asset |
If you select custom, you must use the three Custom Coefficient properties to supply the coefficients for the Callendar-Van Dusen equation. |
S |
|||
Sensitivity (mV/EU) |
None |
The sensitivity value, in millivolts per engineering unit, taken from the documentation for the connected sensor |
N/A |
Sensor Ratio |
MCSA |
The ratio of the sensor converting the raw signal to a lower level signal acquired by C Series voltage or current modules |
N/A |
Serial Number |
MCSA |
The motor serial number according to the motor nameplate |
N/A |
Service Factor |
MCSA |
The service factor of the motor according to the motor nameplate |
N/A |
Single Integration Cutoff |
None |
The frequency, in Hz, at which to set the highpass filter when performing single integration on asset data |
N/A |
Slope |
None |
The slope, [m], of the linear scale ( [y] = [mx] + [b] ) applied to pre-scaled data |
For example, a module might acquire data in volts, but that module might be used with a temperature sensor that outputs 100 mV for every 1 °C. You can set this property to 0.01 to implement the conversion from V to °C. To disable scaling, enter an offset of 0 and a slope of 1. |
Speed Ratio |
None |
The ratio of the speed reference value to the asset speed |
For example, enter a value of 4:10, if the sensor that the asset maps to is located on a part of the equipment that is spinning 2.5 times faster than the speed reference. |
Speed Reference |
None |
An asset referenced by other assets for the purpose of calculating speed values to correlate with measurement data |
N/A |
Start Frequency (Hz) |
EMSA |
The frequency at which the HFCT begins a frequency sweep |
N/A |
Stator Resistance (ohm) |
None |
The Stator Resistance in ohms |
This option is hidden if you enables the Estimate Stator Resistance button. The accuracy of the specified Stator Resistance affects the accuracy of the motor Torque Ripple and Torque Waveform calculation. |
Stop Frequency (Hz) |
EMSA |
The frequency at which the HFCT ends a frequency sweep |
N/A |
Synchronous Speed (RPM) |
MCSA |
The synchronous speed in rotations per minute of the motor |
N/A |
T |
|||
Tachometer Hysteresis (volt) |
None |
An offset from the Tachometer Threshold that the tachometer signal must cross before the device monitoring the tachometer can detect a new pulse |
This value is always positive. For instance, if the Tachometer Threshold (volt) is -5 V, the Tachometer Hysteresis (volt) is 1 V, and the Tachometer Slope is "falling", this signal must cross -4 V before the device will detect another pulse. |
Tachometer Slope |
None |
The direction of slopes in the signal, whether rising or falling, that causes the device to measure a pulse when the slopes cross the Tachometer Threshold |
N/A |
Tachometer Threshold (volt) |
None |
The unscaled value at which slopes in the signal of the specified direction cause the device to measure a pulse |
As an example, if the Sensitivity property for the tachometer channel is 200 mV/EU and a pulse should be detected at 80 mils, this property should be set to 16 V. Tachometer Threshold (volt) = Sensitivity * Tachometer Threshold (scaled). |
Thermocouple Type |
None |
The type of thermocouple connected to the asset |
Thermocouple types, named with letters, differ in composition and measurement range. |
Terminal Configuration |
None |
|
N/A |
U |
|||
Unit |
None |
The units in which to measure sensor data on the asset it monitors. For MCSA devices, the units of voltage and current channels match the units of the Voltage and Current asset types on the Units tab of the System page. The default unit for voltage channels is volts, and the default unit for current channels is amperes. |
The units in which to measure sensor data on the asset it monitors. NA |
V |
|||
Vertical Bearing Clearance |
None |
The vertical diameter of the maximum bearing clearance, expressed in the units the Bearing Clearance Unit property specifies |
The Data Viewer page uses this value to display the maximum bearing clearance line in orbit and Shaft Centerline viewers. |
Voltage Bus |
None |
The asset name of the voltage bus to which the motor is connected |
N/A |
Voltage Phase A |
MCSA |
The potential transformer asset corresponding to phase A of the voltage bus voltage sensors |
When you only configure two of the three phase sensors on the Properties tab, InsightCM calculates the data of the third phase sensor. |
Voltage Phase B |
MCSA |
The potential transformer asset corresponding to phase B of the voltage bus voltage sensors |
N/A |
Voltage Phase C |
MCSA |
The potential transformer asset corresponding to phase C of the voltage bus voltage sensors |
N/A |
W |
|||
Wiring Configuration |
MCSA |
The connection type of the voltage bus sensors |
N/A |
In the following illustration, the Tachometer Slope property is set as Falling.
In this example, the signal demonstrates the following behavior.
-
The device measures a pulse when the raw voltage signal first falls below the value of the Tachometer Threshold property, as shown in the graph.
-
The signal immediately rises above and then falls below the threshold when the keyway slot passes the proximity probe. However, the device does not measure a second pulse because the signal does not also rise above the hysteresis level.
-
The signal rises above both the threshold and hysteresis levels, which means the device is able to measure a pulse again when the signal falls below the threshold a third time, near the end of the graph.
Set up monitoring devices in InsightCM to which the hardware maps.
Before you begin, work with your IT department to retrieve the correct IP addresses for each monitoring device.
Select the type of monitoring devices you are adding to InsightCM and complete the corresponding tasks for each device type below.
Add a Cutsforth monitoring device that is wired to sensors, the network, and a power source on InsightCM. |
|
Add a device that communicates wirelessly with endpoints on InsightCM. |
|
Add a thermal imaging device on InsightCM. |
Now that you have added your Cutsforth monitoring devices, begin customizing your condition monitoring system.
Familiarize yourself with the following concepts to help you work with Cutsforth monitoring devices that are wired to sensors, the network, and a power source.
For more information regarding module types and compatibility, refer to Continuous Monitoring Device Hardware for InsightCM.
Cutsforth Monitoring Devices are available in the following models:
-
High-Performance Condition Monitoring Systems—Supports periodic and continuous file collection when equipment enters an operating state of interest, such as a run-up or coast-down. The CMS-9036 is an example of a Transient, Periodic, and Event Recorder system.
-
General Purpose Monitoring Systems—Supports periodic file collection when triggered by time or data triggers. The CMS-9065 and CMS-9068 are examples of Periodic and Event Recorder systems.
When you add a new device, InsightCM requires you to specify the device type. The device type describes the CompactRIO controller and the software application on the device. For example, the CMS-9068 is based on the cRIO-9068 and runs an application designed for monitoring systems.
Each device model has one or more device types that it supports. For example, High Performance Condition Monitoring Systems include device types based on the cRIO-9047 and the cRIO-9036; General Purpose Monitoring Systems include device types based on the cRIO-9068, cRIO-9065, cRIO-9055, and cRIO-9058. Each device runs a different application.
The device type also determines which arrangements of I/O modules within the device chassis are supported.
The application for High-Performance Condition Monitoring device types supports up to eight dynamic C Series I/O modules, such as the Cutsforth 9232. You must fill module slots in ascending order starting with slot 1. You must fill slots 1 and 2. You cannot skip any slots, but you do not have to use every slot.
These device types come in two formats: one that powers IEPE sensors via the physical connection to the channel and one that does not.
InsightCM supports a set of arrangements for static and/or dynamic C Series I/O modules in the chassis. The following table lists the module types you can install under each arrangement, but does not represent all possible valid configurations.
Note
You do not need to fill every slot, but you must fill slots in ascending order starting at slot 1.
CMS-9068
Chassis Slot Number |
Supported Module Arrangements in CMS-9068 |
|||
---|---|---|---|---|
1 |
Static |
Dynamic |
Dynamic |
Dynamic |
2 |
Static |
Dynamic |
Dynamic |
Dynamic |
3 |
Static |
Static |
Dynamic |
Dynamic |
4 |
Static |
Static |
Dynamic |
Dynamic |
5 |
Static |
Static |
Dynamic |
Dynamic |
6 |
Static |
Static |
Dynamic |
Dynamic |
7 |
Static |
Static |
Static |
Dynamic |
8 |
Static |
Static |
Static |
Dynamic |
Chassis Slot Number |
Supported Module Arrangements in CMS-9065 |
||
---|---|---|---|
1 |
Static |
Dynamic |
Dynamic |
2 |
Static |
Dynamic |
Dynamic |
3 |
Static |
Static |
Dynamic |
4 |
Static |
Static |
Dynamic |
If the arrangement you choose contains any dynamic modules, such as the Cutsforth 9232, install dynamic input modules in adjacent slots beginning with slot 1. You must fill slot 1, but you do not need to fill every slot in the chassis.
For a list of I/O modules that Cutsforth Monitoring Devices support, contact Cutsforth customer support.
Firmware |
---|
Cutsforth Monitoring Devices run preinstalled firmware, the permanent software on the device that performs lower-level operations than the device application. You do not directly interact with firmware unless you receive an updated or patched version. Use the Package Management page to upload the firmware so you can apply it to devices. Then, use the Software tab on the Device Configuration page to update the firmware on a device to the new version. |
Applications for Devices |
---|
The Software tab on the Device Configuration page displays an overview of the application types and versions running on each device. Update device applications to the latest version and reset the firmware to the preinstalled version from the Software tab. You do not directly interact with the application unless you receive an updated or patched version. Use the Package Management page to upload the application so you can apply it to devices. The Package Management page refers to applications as system images. |
Device Configurations |
---|
A device configuration is a collection of properties that controls how a device operates, including how and when it acquires data and collects files. Define the configuration for a device on its Device Configuration page in InsightCM. Click Update Configuration at the top of the Device Configuration page each time you make a change to a device's configuration to send the updated configuration to the device. The device might require several minutes after the last time you click Save to download the configuration and come online again. |
Add and configure a Cutsforth monitoring device that is wired to sensors, the network, and a power source.
Before you begin, configure assets on the Asset Configuration page.
-
Click the Configuration pull-down () and select Devices.
-
Click Add.
-
In the New Device dialog box, connect to an online or offline device.
Option
Description
Connect to an online device
-
Select Connect to an online device and enter the IP address in the textbox.
-
To check for common problems that prevent a device from connecting to InsightCM and coming online, click the Connect button. The web application opens the Test Connection dialog box and checks for problems. If the check fails, this dialog box provides troubleshooting information.
-
Select your device type from the Device Type pull-down menu.
-
Configure the slots to match the module configuration on your physical device.
-
Enter the following names for the device.
-
Device Name—The name you want to appear throughout the web application. Assign an easily identifiable name, such as one that indicates the physical device location or the equipment it monitors.
-
Hardware Name—The hostname of the device, which is in the format of
NI-cRIO-ModelNumber-SerialNumber
by default. If the device is online, InsightCM automatically populates this name. Otherwise, find the two values printed on a label on the back of the device.
-
Connect to an offline device
-
Select your device type from the Device Type pull-down menu.
-
Configure the slots to match the module configuration on your physical device.
-
Once you have added an offline device, transfer a connection file to your offline device.
-
-
Click Finish to add your device to the server.
Now that you have added continuous monitoring devices, map device channels and data groups.
Map sensors to device channels and group all sensors for an equipment asset into a data group. You can configure data collection behaviors for each data group.
Ensure that you have added at least one equipment asset with sensor assets on the Asset Configuration page.
Data groups enable you to organize data from device channels monitoring the same equipment into one data event. Since each equipment asset has a defined set of operating states, create one data group per equipment asset.
-
Click the Configuration pull down () and select Devices.
-
Double-click the device whose channels you want to map.
Note
For wireless and thermal imaging devices, add wireless sensor endpoints and/or discover ROI cameras directly from the device's configuration page to enable devices to collect data.
-
Select the Equipment Mapping tab and click Add/Remove.
-
Click Add, select the equipment level asset, and click OK.
Note
If you remove the Default data group from this section, your device channels will automatically be reassigned to the data group you added.
You created a new data group.
-
Click the Channels tab and select one of the channels.
-
Click Select Data Group and select the new data group from the pull-down.
-
Once you assign the data group to your channels, select a channel and select a sensor in the right-hand asset tree to map a channel to a sensor asset.
-
Repeat steps 4–5 until you have mapped each of the sensors to a channel.
-
Add additional data groups to the device if you are mapping remaining channels to sensor assets associated with different equipment.
-
Above the Equipment Mapping tab, click Validate.
-
Above the device's configuration tabs, click Back to Devices.
-
Select the device whose channels you configured and click Update Configuration under the Devices tab.
After you send the connection information to the device, it automatically connects to the server.
Complete the following steps to verify that the device connects successfully.
-
In the web application, click the Configuration pull-down () and select Devices.
-
On the Devices tab, verify that the Connection Status column for the device says Online, which means the device finished updated and connected successfully to the server.
Connect your offline device to the InsightCM Server by transferring a connection file to the device.
If you added the device configuration without entering the IP address, the device cannot yet connect to InsightCM because it does not have the information needed to connect to the server. Complete the following steps to transfer credentials to the device.
-
Click the Configuration pull-down () and select Devices.
-
Find the device connection file you exported when you added a device to the InsightCM Server.
-
If you did not export a connection file, return to the Device Configuration page.
-
Copy the file to a USB drive folder named upload in the following directory:
<RootLevel>:\InsightCM
. -
Insert the USB into the USB port on the controller front panel and note that the USER1 LED light will switch from blinking to solid when the device is reading the connection file.
-
When the USER1 LED returns to blinking steadily, remove the USB drive.
-
From the Device Configuration page, select the device to which you manually transferred a connection file, click the Action menu () and select Reboot.
When the device is online with all relevant channels mapped to sensors, test your device's ability to acquire data. Automatic acquisitions occur periodically, but you can force an acquisition at any time using Force Trigger.
Complete the following steps to test whether or not the channels in your device can acquire data.
-
Click the Configuration pull-down () and select Devices.
-
On the Devices tab, select the device you added.
-
In the Action () menu, select Force Trigger to perform an acquisition from all channels.
-
Click the Layout () button on the viewer toolbar, hover over Chart Type, and select Thermal Image to change the viewer to one that can view thermal imaging data.
-
Wait several seconds for the acquisition to be complete before clicking the Data Viewer () button to view the Data Viewer page. Click on a feature level asset for the equipment and confirm that data has been acquired.
Note
Before data is available, devices must finish performing the acquisition and the InsightCM server must receive and store the data. The duration of a force-triggered acquisition is based on the file length of the equipment's Default operating state.
For a complete list of ways you can configure a device to perform acquisitions, refer to Methods for Initiating Device Acquisitions.
-
Repeat the force acquisition several times to acquire multiple data sets.
Wireless gateways, wireless monitoring devices, and wireless vibration sensors eliminate the need for extensive wiring by using wireless technology to transmit equipment data to the InsightCM server for analysis while maintaining high levels of data acquisition.
A MON-10496 is a wireless gateway device that sends data to the server and receives data from endpoints. Endpoints are wireless devices and wireless sensors that communicate data to the MON-10496.
Note
Environmental factors—such as physical obstruction and severe weather—can affect the performance of the wireless gateway and wireless monitoring device. Configurable factors—such as frequency and size of data collections—can also affect the performance of the wireless monitoring gateway, the wireless device, and the wireless sensor.
The endpoint is configured from the MON-10496's Device Configuration page and is added with an association to an equipment asset.
A MON-10467 is a wireless vibration measurement device that sends data wirelessly to the MON-10496 and can be configured with the following sensors:
A MON-10411 is a wireless vibration sensor that sends data wirelessly to the MON-10496 and has the following built-in sensors:
Add a wireless monitoring device and an endpoint to the InsightCM server.
-
Click the Configuration pull-down () and select Devices.
-
Click the Add button.
-
In the New Device dialog box, you can add a device in two ways.
Option
Description
Connect to an online device
-
If you do not know the IP address of your device but it is online, select Connect to an online device and click Browse to see a list of devices on the same subnet as the server machine.
-
Select a device from the Subnet Devices dialog box and click OK.
-
Click Connect and the web application will automatically perform tests to verify the device IP address, firmware, connection, and hardware.
-
Select the wireless device type from the Device Type pull-down.
-
Configure the slots as needed to match the module configuration on your physical device.
-
Give the device a descriptive name in the Device Name text field.
Connect to an offline device
-
If your device is offline, ensure that the Connect to an offline device option is selected and click Next.
-
Configure the slots as needed to match the module configuration on your physical device.
-
Give the device a descriptive name in the Device Name text field.
-
Once you have added an offline device, transfer a connection file to your offline device.
-
-
Click OK and you will be automatically redirected to the Endpoints tab of the wireless monitoring device's configuration page.
-
Click Add pull-down menu and select Offline to add the endpoint as an offline device.
-
Enter the serial number of your endpoint, designate the endpoint type as Wireless Sensor for a MON-10411 or Wireless Device for a MON-10467, and click OK.
-
In the Select Wireless Equipment dialog box, select a wireless equipment asset to associate the wireless device endpoint with and click OK to add your endpoint.
-
Use the pull-down under Channel in the Endpoint configuration panel to assign which channels from the wireless gateway correspond to each sensor associated with the equipment.
Note
If you have added more than one endpoint, you may need to resolve the collection time schedule by clicking Schedule and then Resolve All. If you do not resolve the collection time, wireless endpoints will spend additional time communicating with the gateway, which decreases endpoint battery life.
Now you have successfully added a wireless monitoring device and an endpoint to your InsightCM server. Wireless devices default to having one collection time. You can reconfigure collection time in the Collection tab of the wireless equipment's configuration panel.
When the wireless gateway is online with all endpoints mapped to sensor assets, you can test your wireless device's ability to acquire data. Automatic acquisitions occur periodically, but you can force an acquisition at any time by using Force Trigger.
Complete the following steps to acquire data from one of your endpoints.
-
Click the Data Viewer () button.
-
Expand one of the wirelessly monitored equipment assets, select a sensor asset, and then select one of the features. By selecting a feature, you activate the Trend viewer chart.
-
In the Trend viewer chart, click the Action menu () and select Force Trigger to acquire data from the endpoint mapped to this equipment asset.
-
Wait several seconds for the acquisition to complete and click the Refresh button to confirm that your device received new data points.
-
Repeat the force acquisition several times to acquire multiple data sets.
-
Select a feature level asset for a different equipment asset to confirm in the Trend viewer chart not yet populated with new data.
For a complete list of ways you can configure a device to perform acquisitions, refer to Methods for Initiating Device Acquisitions.
Using thermal cameras, monitor thermal data in a large area without extensive wiring to thermocouples.
Device Type |
Compatible Camera(s) |
Sensor Asset Type |
Description |
---|---|---|---|
IR-31201 |
FLIR A35, FLIR A65 |
Delta, ROI |
Supports up to two thermal cameras. See the IC-3120 help for more information. |
IR-90552 |
Xi410 |
Delta, ROI |
Supports up to ten thermal cameras. See the cRIO-9055 help for more information. |
1Connects directly to the device controller by ethernet connection, not by channels on a module.
2Connects to the device through a Power over Ethernet (PoE) adapter, not by channels on a module.
Add a thermal imaging device to collect temperature data from thermal cameras.
-
Click Configuration () and select Devices.
-
In the Devices tab, click Add.
-
Select Connect to an online device and enter the IP address in the textbox.
-
Click the Connect button. The Test Connection dialog box prompts you if the device fails to connect to the server machine and come online. Resolve all failures before continuing.
-
Click Next.
-
If the device passes all connection tests, the web application detects and displays the controller. Click Next.
-
Enter the two types of names for the device.
-
Device Name—The name that will appear throughout the web application.
-
Hardware Name—The hostname of the device, which is in the format of
NI-IC-ModelNumber-SerialNumber
by default. If the device is online, the server automatically populates this name. Otherwise, you can find the two values printed on a label on the back of the device.
-
-
Click Finish.
-
When the web application prompts you to send the connection information to the device web server, click Yes.
Discover and add the FLIR A35 and/or FLIR A65 cameras you will use to monitor your equipment's thermal data.
Ensure that you have completed the steps in Adding a Thermal Imaging Device and that you have the serial number for each camera you intend to add.
-
Click Configuration () and select Devices.
-
On the Devices tab, double-click the device to which the camera(s) connect.
-
On the Cameras tab, click Add.
-
In the Add Cameras dialog box, click Discover and the serial numbers of all valid cameras connected to the device appear in the table.
-
Select the cameras you want to add and click Apply.
-
When prompted, enter a descriptive name for each camera and click OK.
Set up the Xi410 Optris cameras you will use to monitor your equipment's thermal data before you add and configure them on InsightCM.
Before you begin, ensure the computer you use for the initial camera setup is compatible with PIX Connect software and you can change the network settings securely.
-
Install and launch the latest version of PIX Connect software as an administrator.
-
Connect the Xi410 camera to the computer using the provided USB cable.
-
Click Devices and verify that PIX Connect recognizes the camera.
-
Click Help > About and verify that the Imager Firmware version on the camera is at least 3814 or newer.
-
Click Devices > Ethernet Settings.
-
Set Device Address to 192.168.0.101.
-
Set Send to address to 192.168.0.100.
-
Set Subnet Mask to 255.255.255.0.
-
Set Port to 50000.
-
Disable the Auto assign port number checkbox to better track what data is coming from which camera.
-
Set Listen on port number to 50000 (or—if another camera—to the same port number you assigned to this camera).
-
Click OK.
-
Click Tools > Configuration.
-
On the Device tab, input a Temperature Range.
-
On the External Communication tab, select the Enable checkbox under Direct temperature mode.
-
Click OK.
-
Click Devices > Set configuration to device to push your configuration settings to the camera. Once the progress bar at the bottom of the window is complete, you have successfully configured your Optris camera.
-
Disconnect and set aside the USB cable.
-
Connect the camera to the Power over Ethernet (PoE) adapter.
-
Using an ethernet cable, connect the PoE adapter to the PoE Switch.
-
Using another ethernet cable, connect the PoE Switch to the computer.
-
On the computer, navigate to View network computers and devices in File Explorer.
-
Select Network and Sharing Center.
-
Click Change adaptor options.
-
Set up your ethernet port for a connection test with the Optris camera.
-
Select the Ethernet port that is connected to your Optris camera and click Change settings of this connection > Properties.
-
Select Internet Protocol Version 4 (TCP/IPv4) > Properties.
-
Select Use the following IP address.
-
Set IP address to 192.168.0.100.
-
Set Subnet mask to 255.255.255.0.
-
-
Test the ethernet connection to the Optris camera.
-
Launch PIX Connect.
-
Click Devices and select the Optris camera you want to test.
-
Select the Connect checkbox and verify that the UDP Port number is 50000.
Note
If you change the port number between when you configured it during initial camera setup, you have to re-enter the correct port number each time you launch the software.
As a result, your operating system firewall may request permission to communicate.
-
Select Private networks and Public networks and click Allow access.
-
Confirm that the direct temperature mode checkbox is enabled.
-
Click Tools > Configuration > External Communication.
-
Confirm that a live image from the camera shows on the computer and that the Connected to IP address matches the one you set for the Optris camera during setup.
-
-
Close PIX Connect and disconnect the PoE switch from the computer.
-
Using an ethernet cable, connect the PoE Switch to the secondary ethernet port on the IR-9055.
Configure your thermal imaging device and sensors in InsightCM.
Discover and configure the Xi410 Optris cameras on InsightCM.
Before you begin, complete the set-up process for the Optris cameras and add a thermal imaging device. Have your camera IP address(es) and port number(s) ready.
-
Click Configuration () and select Devices.
-
On the Devices tab, double-click the device to which the camera(s) connect.
-
On the Cameras tab, click Add.
-
In the Add Cameras dialog box, click Discover and the IP addresses and port numbers of all valid cameras connected to the device appear in the table.
-
Select the cameras you want to add and click Apply.
-
When prompted, enter a descriptive name for each camera and click OK.
Define the section of a camera image that you want to monitor for thermal data.
Complete the following steps to define a Region of Interest (ROI) to monitor using your thermal imaging camera and device.
-
Click the Configuration pull-down () and select Devices.
-
In the list of devices on the Devices tab, double-click the device connected to the camera for which you want to define an ROI.
-
On the Cameras tab, select the camera that monitors the equipment for thermal data and click Manage ROIs.
-
In the [Camera Name] ROIs dialog box, click Add.
-
In the New ROI dialog box, select the piece of equipment the camera is monitoring.
-
In the box at the bottom of the New ROI dialog box, enter a descriptive name for the ROI and click OK.
-
In the ROIs dialog box, click the Capture Image button.
-
Use the Rectangle ROI or Polygon ROI button to draw an ROI on the captured image.
-
Without capturing a new image each time, repeat Steps 2–7 until you have added all your ROIs.
-
Click Close when you are finished adding ROIs.
Deltas measure the difference between two ROIs that have the largest temperature difference in a group of two or more ROIs. The delta is calculated by subtracting the lowest maximum temperature from the highest maximum temperature of a set of ROIs selected. You can set alarm conditions on deltas to monitor when the difference between ROI temperatures exceeds the value you specify.
Complete the following steps to configure an ROI Delta.
-
Click the Configuration () button and ensure that you are on the Asset Configuration page.
-
In the asset tree, select the piece of equipment that contains the ROIs for which you want to configure a delta.
-
Click Add and select Sensors » Thermal Imaging » Delta in the New Asset dialog box.
-
Enter a descriptive name for the delta and click OK.
-
On the Properties tab for the new ROI delta, click the Edit button next to the Camera field.
-
In the Camera dialog box, select the camera containing the ROIs you want to configure a delta for, click OK and a new row for ROIs should appear.
-
Click the pull-down next to the ROIs field and select the ROIs you want the delta to compare. Your changes will be saved automatically.
You can monitor delta values using the thermal imaging viewer on the Data Viewer page after you send the connection information to the device.
Create and configure data groups to group data from channels mapped to sensors that monitor the same piece of equipment into one data event.
For more information on data groups, refer to the Data Groups topic. If you are seeking to add endpoints on a wireless device, refer to the Adding Wireless Gateways and Endpoints topic.
-
Click the Configuration pull-down () and select Devices.
-
Double-click a device to navigate to the device's configuration page.
-
In the Equipment Mapping tab, click the Add/Remove button and then click Add to display the Select Location dialog box.
-
Select the top-level asset for the data group. This will likely be an equipment asset.
-
Click Select, then OK.
-
Select a channel in the Channels section and click Select Data Group.
-
In the Select Data Group dialog box, select the data group you just created in the Data Group listbox.
-
Click OK to assign the channel to that data group.
To learn how to map channels on your device to sensor-level assets in your data group, refer to the Mapping Device Channels and Data Groups topic.
Learn what data groups are and when they may be useful.
When you configure a device in InsightCM, you assign the device channels to one or more data groups. A data group is a set of channels mapped to sensors that monitor the same piece of equipment. Data groups are useful in situations where a single device monitors more than one piece of equipment.
Assigning the channels monitoring each piece of equipment to different data groups allows you to configure unique behavior for each group of channels even if all of the channels belong to the same device.
Locate or add the IP address of a device to add it to the server.
Before you begin, power on your Cutsforth monitoring device and connect a removable drive. Use either a type C drive or a type A drive with a type C converter. If you are using an encrypted USB flash drive, make sure that it is formatted to use the FAT32 file system.
Once you have mounted your Cutsforth monitoring device, either find and use the device's IP address or set the IP address to one you receive from your IT department. In either case, save a copy of and update several fields in the device's networkInfo.json file.
The following table shows all supported values for the IP Address Request Mode field:
Value |
IP Address Type |
---|---|
|
Static |
|
DHCP or Link Local |
|
Link Local Only |
|
DHCP Only |
-
Insert the USB drive into the USB port on the controller front panel.
When the USER1 LED light is solid, it indicates that the device is reading from or writing to the settings file.
-
Remove the USB drive when the USER1 LED starts blinking again.
-
Insert the USB drive into a USB port on a computer.
-
Navigate to the following directory on the USB drive:
<RootLevel>:\InsightCM\download\NI-cRIO-ModelNumber-SerialNumber
-
Create an upload folder in the InsightCM folder if one does not already exist.
-
Save a copy of the networkInfo_<device hostname>.json to the following location on the USB drive:
<RootLevel>:\InsightCM\upload
-
Open networkInfo_<device hostname>.json.
-
Locate the IP address within the object that contains
"IsPrimary":"true"
.The following name/value pair defines the IP address:
IPAddr:x.x.x.x
-
Enter a new value in the IP address field for the primary object.
-
To assign a static IP address, change the IP Address Request Mode value to 1.
-
Enter new values in the Subnet Mask and Gateway fields in the primary object according to the information you receive from your IT department.
-
Save and close the file.
-
If you made changes to the file, complete the following steps to apply your changes to the device:
-
Insert the USB drive back into the USB port on the controller front panel.
When the USER1 LED light is solid, it indicates that the device is reading network and connection properties.
-
You can remove the USB drive when the USER1 LED returns to blink steadily.
-
Reinsert the USB drive into a computer and browse to <RootLevel>:\InsightCM.
-
Verify the applied folder contains networkInfo_<device hostname>.json.
-
The server implements authentication for users by providing permissions to groups of users. Permissions serve as access rights that control the ability of the users to view or make changes to specific pages in the web application. Therefore, you might not see pages, tabs, or components described in this help system, or you might not be able to edit particular settings. When possible, this help system documents the permissions required to perform actions so you can seek assistance from a user who possesses the required permissions.