AiSight Aion User manual

User Manual
AiSight Aion

AiSight GmbH
Gertraudenstraße 10-12, 10178 Berlin | [phone] | [email protected]
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Contents
1. Introduction .................................................................................................................... 3
2. Definitions and glossary ............................................................................................... 3
3. Proper handling ............................................................................................................. 5
3.1. Caution and warnings ........................................................................................... 6
3.2. Risk assessment .................................................................................................... 6
3.3. Compliance ............................................................................................................. 6
4. Datasheet ....................................................................................................................... 8
5. Service and installation instructions ......................................................................... 11
5.1. Mounting ............................................................................................................... 11
5.1.1. Sensor orientation ....................................................................................... 11
5.2. Powering ............................................................................................................... 13
5.2.1. Powering with the ac power supply ......................................................... 15
5.2.2. Powering with dc cable .............................................................................. 15
5.2.3. Powering with the AiSight Aion battery pack ......................................... 16
5.2.4. Cable management ..................................................................................... 18
5.3. Connecting ............................................................................................................ 21
5.3.1. Required parts .............................................................................................. 21
5.3.2. Sensor node overview ................................................................................. 21
5.3.3. Wi-Fi requirements ..................................................................................... 21
5.3.4. Provisioning .................................................................................................. 21

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1. Introduction
The Aion measures the vibrations, magnetic fields, and heat created by your
machines. These sensor nodes collect machine information and transmit data to our
machine learning algorithm for processing. As a result, we can detect anomalies and
faults in your machine and prevent bigger failures. Once a fault is detected you will
receive a notification providing the information you need to plan maintenance in
advance, avoiding the need for unplanned production stops.
In order for us to give you the best and most accurate results, it is important that
you carefully read and understand this instruction manual.
2. Definitions and glossary
Package: the package received by the client is a recycled paper box that includes the
sensor node, power supply, and mounting interfaces.
Sensor node: the AiSight sensor node (Aion).
Power supply: the 90~240 V ac to 24 V power supply to power the sensor node with
24 V dc.
Power cable: the cable with M8 4-pin connector powers the sensor with 24 V from
machine panels, other local dc power sources, or the battery pack. In the last case,
the power cable is also used as a signal line since it allows communication between
the sensor node and the battery pack.
Battery pack: the AiSight Aion battery pack.
MAC address: a unique identifier number for each sensor node, also known as a serial
number.
Mounting interface: any mechanical or chemical combination used to attach the
sensor node to the machine.
Provisioning application (app): a smartphone application that connects with the
sensor node via BLE to input the Wi-Fi credentials.
Bluetooth Low Energy (BLE): a low power consumption wireless technology
standard used for exchanging data between fixed and mobile devices over short
distances using short-wavelength UHF radio waves.
Wi-Fi network: a wireless technology standard used for exchanging data between
fixed and mobile devices over medium-range distances with higher data rates, also
providing access to the internet.

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Machine Insight Center: web application used to access the machine status, features,
and anomalies.
User: end client of the Aion.
Cloud: provides storage and processing of the user’s machines’ vibration, magnetic
field, and temperature data.
This manual contains the requirements for the correct installation, provisioning, and
operation of the Aion, designed for the sole purpose of condition monitoring. It must
only be handled and installed by trained personnel.
Not following this manual may cause malfunction of the sensor node, unprecise
anomaly detection, or damage to the machines and to the environment.
AiSight must be notified of any abnormal behavior from or defect in any Aion, and
will provide maintenance or replacement of the malfunctioning or damaged sensor
node.
The user is not authorized to open or to perform any maintenance actions on the
sensor node and power supply.

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3. Proper handling
Proper handling of the AiSight Aion sensor node is critical to prevent any damage.
The following situations should be avoided at all times:
● Dropping the Aion or hitting the unit against sharp or hard surfaces
● Using excessive force when mounting the Aion
● Exposing the Aion to temperatures above 85°C
● Exposing the Aion to any reactive chemicals
● Recharging the Aion battery pack: the Aion battery pack contains primary cells,
which can’t be recharged. Do not attempt this!
During installation of the Aion, avoid the following situations:
● Touching the pins of the Aion connector or its power supply with any metal
tools or conductive devices
● When using the magnet mounting accessory:
● Impact (due to magnetic attraction) when mounting the sensor on the
desired surface.
● Operator body parts coming between the magnet and metal surface
● Pacemaker wearers: a distance lower than 20 cm from the exposed
surface of the magnet
● When using the swivel mounting:
● Forcing the mounting without the presence of a thread
● Handling of the power cable (when used instead of the power supply) by
untrained electrical personnel
The user’s environmental, health, and safety (EHS) manager must be consulted to
ensure the safe installation of the sensor. The technicians who are responsible for the
installation must follow all EHS guidelines, use the required personal protective
equipment (PPE) and use the proper and indicated tools.
For adhesive mounting options, the cure time must be respected before the
operation of the machine restarts.
The power supply cable or the power cable alone must be securely tied to fixed
parts of the body of the machine, cable trays, or ducts. It's suggested to use cable
ties, clips, and clamps.

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3.1. Caution and warnings
Caution indicates a hazard that could cause minor personal injury, or
property damage if ignored.
A warning indicates a hazard that could cause severe personal injury,
death, or substantial property damage if ignored
3.2. Risk assessment
The risk assessment of the sensor is based on the CENELEC GUIDE 32 and can be
shared on demand. Please contact AiSight for any further information.
3.3. Compliance
Federal Communications Commission (FCC) Compliance Statement – Aion (HVIN: V4PRO)
This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) this device may not cause harmful interference and (2)
this device must accept any interference received, including interference that may
cause undesired operation.
Caution: Any changes or modifications not expressly approved by the party
responsible for compliance could void the user’s authority to operate the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class
B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
!
!

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• Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Federal Communications Commission (FCC) Compliance Statement – Aion BP
This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) this device may not cause harmful interference and (2)
this device must accept any interference received, including interference that may
cause undesired operation.
Industry Canada (IC) Compliance Statement - Aion (HVIN: V4PRO)
[EN] This device complies with Industry Canada license-exempt RSS standard(s).
Operation is subject to the following two conditions: (1) this device may not cause
interference and (2) this device must accept any interference, including interference
that may cause undesired operation of the device.
[FR] Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux
appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions
suivantes: (1) l’appareil ne doit pas produire de brouillage et (2) l’utilisateur de
l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est
susceptible d’en compromettre le fonctionnement.
Industry Canada (IC) Compliance Statement - Aion BP
[EN] This device complies with Industry Canada license-exempt RSS standard(s).
Operation is subject to the following two conditions: (1) this device may not cause
interference and (2) this device must accept any interference, including interference
that may cause undesired operation of the device.
[FR] Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux
appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions
suivantes: (1) l’appareil ne doit pas produire de brouillage et (2) l’utilisateur de
l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est
susceptible d’en compromettre le fonctionnement.

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4. Datasheet
Compliance and safety
Compliant with
CE, FCC, IC
Vibration measurements
Type
3-axis digital accelerometer
Bandwidth
6.3 kHz
Acceleration range
Up to ±16 g
Resolution/sensitivity
<0.5 mg/LSB
Magnetic measurements (2)
Type
3-axis digital geomagnetic sensor
Bandwidth
1.6 kHz
Magnetic range
±160 mT
Resolution/sensitivity
30 μT
Temperature measurements
Refresh rate
104 Hz
Temperature range
-40 to 105°C
Resolution/sensitivity
256 LSB/°C
Environmental
Sensor node temperature range
–20 to 85°C
Cable (sensor node to battery pack)
temperature range
Fixed: -10°C to +80°C
Flexible: -5°C to +80°C
Power supply temperature range
-20 to 60°C
AiSight battery pack temperature range
-20 to 60°C
Ingress protection
IP67
Salt and mist
Standards IEC 60068-2-11: 2000

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Power
Alternating current power supply
Input connector
IEC Type C
Input voltage
90 – 264 V ac
Input frequency
47 – 63 Hz
Output voltage
24 V
Maximum output ripple
<200 mV pk-pk
Output power
>18 W
Direct current cable
Interface connector 1
M8, 4 pins
Interface connector 2
BB-02XXMA-QL8MPP
AiSight battery pack
Cell chemistry
Lithium thionyl chloride
Output voltage
3.6 V
Autonomy
Lifetime up to 5 years1
Cable length
1 m (shielded cable)
Dimensions
86 mm x 86 mm x 48 mm
Weight
200 g
Connector
M8, 4-pin female
Compliance, emission, immunity, and safety
External power supply certifications
CE, UL, TUV, TUV/GS, Energy
Efficiency Level VI; European CoC
Tier 2
Battery pack certifications
CE, FCC, UN38.3, IEC62133
Emissions and immunity approvals
EN55022 Class B, EN61000-3-2
Class A, EN61000-3-3, EN55024,
+ additional certifications
depending on the model
Safety approvals
IEC60950-1, EN60950-1,
UL60950-1
1Estimation of expected lifetime upon specific acquisition interval.
1
Lifetime expectation only under specific data acquisition profile at room temperature. Environmental
conditions and/or different data acquisition profile may lead to a reduction of the expected lifetime.

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Connectivity for provisioning (Bluetooth)
Protocol
Bluetooth 5.0
Radio
Receiver with –97 dBm sensitivity,
Class-1, transmitter, AFH
Connectivity for operation (WiFi)
Protocol
802.11 b/g/n (802.11 n up to 150
Mbps)
Frequency range
2412 to 2484 MHz
Integrated antenna
Able to connect to
routers/gateways up to 60 meters
in industrial environments.
User Interface
Machine Insight Center
Custom-made client solution
Physical (3)
Dimensions
72 mm x 61 mm x 29 mm
Weight
150 g
Mounting accessories
M5 tapped hole, magnet, motor
fins adaptor, screw pad adaptor,
food contact safe cyanoacrylate or
industrial-grade epoxy
Connector
M8, 4-pin male

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5. Service and installation instructions
To successfully install the Aion and access the data in the AiSight Machine Insight
Center, three steps are needed:
1. Mounting: mount the Aion with the help of the provided mounting accessories
2. Powering: connect the Aion to power
3. Connecting: provision the Aion with Wi-Fi credentials
4. Operating: read data from AiSight Machine Insight Center
Steps 1. Mounting and 2. Powering MUST be performed by qualified
personnel.
5.1. Mounting
5.1.1. Sensor orientation
The Aion includes triaxial vibration and magnetic field sensors. The axes for both
measurements are configured as shown in Figure 5.1. The “x” axis is aligned with the
logo, while the “y” is aligned with the M8 connector. The “z” axis covers the resulting
dimension, perpendicular to the body of the sensor.
Figure 5.1 - Sensor orientation
X
Z
Y
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The first step is to identify the ideal mounting position on the machine. As we are
measuring the vibration of the machine, and we rely on very good transmission of
data, it is not recommended to attach the sensor simply anywhere on the machine.
Ideally, if a probable failure location is known, it is recommended to place the
sensor as close as possible to this location.
Steps
1. Identify the best monitoring position on the machine
2. Start by cleaning the surface of your machine with the cleaner and cloth. Be sure no
dirt is remaining.
3. Sand the surface to improve the mounting contact and then clean the surface again
of sanding residue.
4. Carefully slide the protective metal ring from the magnet using pliers
5. Apply the Aion to the previously prepared surface
For additional information regarding mounting the Aion, please contact AiSight.
Safety Precautions
The AiSight magnet is very strong. It is necessary to take exceptional
care when handling it in the vicinity of magnetic surfaces and the user's
fingers.
When handling magnets and magnet systems, persons wearing pacemakers
should be especially careful. A minimum distance of 20 cm must be maintained from
the device, as otherwise the pacemaker could temporarily malfunction. The use of
magnets and magnet systems in explosive atmospheres is unsafe. Falling magnets
could generate sparks and shatter.
!

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5.2. Powering
Three options to power the sensor can be used depending on customer preference
and contract details. The first option is to use the custom ac power supply compatible
with the product, the TRE25R240 with 3 m long cable and female M8 4-pin
connector, as shown in Figure 5.2.
Figure 5.2 - AiSight custom power supply with M8 connector
In cases where an ac connection is not possible close to the machine (either
because of physical or safety constraints), the customer can also use a 2-wire or 4-
wire cable with M8 4-pin female connector to directly connect the sensor node from
existing machine panels or switchboards that have dc connection from 3 to 40 V (24
V recommended). A cable with an over-molded connector or a cable with a field
installable connector, as shown in Figure 5.3 can be used. For either case, the cable
must be designed for industrial use, have internal and external insulation jackets and
have the UL94 classification V0 or higher (5VB or 5VA).
The sensor node consumes a maximum of 3 W and supports a power supply
voltage from 3 to 40 V dc, with a preferred supply of 24 V dc.

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Figure 5.3 - Example of a cable with M8 female plug connector
Only authorized and technically trained personnel should handle and
install the power supplies and cables, specifically when access to panels
and switchboards is necessary.
In case none of the previous options are applicable, the sensor node can be
powered by the Aion battery pack, specifically designed by AiSight to fulfill the
power needs of the sensor node. The battery pack can be connected to the sensor
node through 1 m shielded cable with male/female M8 4-pin connector (provided by
AiSight).
Figure 5.4 – AiSight battery pack
!

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5.2.1. Powering with the ac power supply
The TRE25R240 power supply accepts voltage levels from 90 to 264V ac, with a
maximum input current of 0.7A. Overcurrent protection and exclusive breakers can
be set by the user if required.
The power supply includes a cable with power plug (CEE 7 or NEMA).
The ac connection must be at a distance equal to or less than 3 linear meters from
the installation of the sensor node. The power supply must be connected to the ac
mains, in a vibration and stress-free environment, as stable as possible. The preferred
connection points are wall outlets or secure outlets on the floor. The outlets can also
be connected via an extension cord, as long as the connection end is safe and secure.
The power supply doesn't share the same ingress protection level as the sensor
node. The customer must take care during installation to protect the power supply
against ingress by choosing an appropriate location with limited dust and water.
5.2.2. Powering with dc cable
When using a cable (4x0.25 mm²minimum) with an over-molded female M8 4-
pin connector (Figure 4.9) the cable follows the industrial standard, including the pin
numbers and colors. The sensor node accepts from 8 to 40 V dc and the
recommended voltage is 24 V dc. The customer must observe that most cables are
limited to 30 V. The M8 connector must follow the IEC 61076-2-104 standard with
A-coding. The cable construction must be IP65 or higher, built either with PVC or
PUR materials with UL94 rating HB or superior.

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5.2.3. Powering with the AiSight Aion battery pack
The battery pack option is strongly recommended when access to a power supply
is difficult or not possible (i.e., no ac plugs in proximity, no access to a machine panel).
The battery pack can be attached to any metal surface in proximity to the sensor node
thanks to the magnet on its back.
Figure 5.5 - The BP must be aligned so the text reads left to right with the cable extended
towards the floor, or as close as possible
Necessary Equipment
● Surface cleaner and cloth
Steps
1. Identify the best installation point in proximity to the sensor Node
2. Start by cleaning the target point with the cleaner and the cloth. Be sure no
dirt is remaining.
3. Carefully slide the protective metal plate from the magnet using pliers
4. Connect the battery pack to the sensor node through 1 m shielded cable with
a male/female M8 4-pin connector (provided by AiSight). The recommended
torque for mating the connector is 0.4 N•m; over- or under-torque might cause
a deterioration of the mating surfaces or result in a poor and unstable
connection, respectively.

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The battery pack has been designed to guarantee the sensor node a lifetime of up
to 5 years if, during the installation, the following conditions have been fulfilled:
• Install the battery pack in an upright position, since the capacity of the cells
is affected by the orientation
• Affix a zip tie around the cable to a point on the machine to prevent the
device from falling in the event it is knocked from its mounting
• Install the battery pack at a point where the temperature is close to the
environment temperature. Although the battery pack has been designed to
operate from -40°C to +85°C, the available capacity of the cells is influenced
by the temperature
Even though the battery pack complies with the European Union
Waste Electrical and Electronic Equipment (WEEE) Directive, the
user is not permitted to discard the battery pack. When the Aion
battery pack is close to the end of life, the user must ship it back
to the address indicated on the contract; AiSight will provide a
new Aion battery pack without additional costs. The user must
not open the Aion battery pack under any circumstances. Any
misuse of the device might lead to injuries or harmful situations.
Safety precautions
The back of the Aion battery pack includes a very strong magnet. It is
necessary to take exceptional care when handling it in the vicinity of
magnetic surfaces and the user's fingers.
When handling magnets and magnet systems, persons wearing pacemakers
should be especially careful. A minimum distance of 20 cm must be maintained from
the device, as otherwise the pacemaker could malfunction temporarily. The use of
magnets and magnet systems in explosive atmospheres is unsafe. Falling magnets
could generate sparks and shatter.
Additionally avoid placing the battery pack in environments with harsh corrosive
chemicals, as this can corrode the enclosure and expose the batteries. It is strongly
recommended to not use the battery pack in environment where there is high
!

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concentration of: strong mineral acids, water, and alkali solutions. In cases like this a
power adapter is best to use as there is no risk of battery corrosion.
The Aion battery pack contains primary cells. The cells used in this
device may present a risk of fire or chemical burn if mistreated. Do not
recharge, disassemble, heat above 100°C, or incinerate. Batteries must
not be replaced by the user.
In the remote event of fire involving the battery pack, it is important to react as
indicated below:
1. Lith-X (Class D extinguishing agent) is the only effective suppressant for fires
involving lithium batteries. If the cells are directly involved in a fire DO NOT
USE: WATER, SAND, CO2, HALON, and DRY POWDER, OR SODA ASH
EXTINGUISHERS.
2. If the fire is in an adjacent area and the cells are either packed in their original
containers or unpacked, the fire can be fought based on fueling material, e.g.,
paper and plastic products. In these cases, the use of copious amounts of cold
water is an effective extinguishing media. The storage area may also employ
a sprinkler system with cold water.
In case of firefighting, wear a self-contained breathing apparatus to avoid
breathing irritant fumes (NIOSH approved SCBA & full protective equipment). Wear
protective clothing and equipment to prevent bodily contact with the electrolyte
solution. Fire may be fought only from a safe fire-fighting distance. Evacuate all
persons from the immediate area of the fire. During thermal decomposition,
generation of chlorine (Cl2), hydrogen chloride (HCl), and sulfur dioxide (SO2) can
occur.
5.2.4. Cable management
A cable is present in both powering alternatives and it must be securely installed
independently. The customer can install the cable inside distribution trays and ducts.
For external installation, if existing cables (for power or communication) or safe
mechanical lines or fixed machines parts are present, the cable can be attached to
them by using cable ties. If there is no support or existing cables, cable tie holders
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can be installed in flat surfaces. Ensure the surface is clean and degreased before
installing adhesive cable tie holders.
Once the cable is close to the sensor mounting point, some safety precautions must
be taken to provide enough distance from any moving parts (i.e., shafts, belts). Since
the connector must be screwed to the sensor node and/or to the battery pack, some
slack must be ensured. The connector and cable cannot introduce any traction on the
sensor node and/or to the battery pack, since this may compromise the sensor reading
and functionality.
The suggested external installation procedure with adhesive cable tie holders is
described below.
1. Observe the complete path of the cable before starting the installation.
2. Draw lines or use a level if necessary to mark the support points. In case of
using the battery pack, keep in mind that this system uses a shielded cable.
The performance of the cable is guaranteed if the curvature radius is greater
than 37.5 mm or 60 mm for fixed or mobile installations respectively
3. Clean all the surfaces with industrial surface cleaners (i.e., Loctite 7063 or
7061).
4. Install the cable tie holders.
5. Lay the cable and install all the cable ties partially.
6. Ensure some cable slack close to the sensor mounting location. In case of using
the battery pack as power supply for the sensor node, the same considerations
regarding the cable are applicable.
7. Finish all cable ties and cut the excess edges.
8. Connect the first end to the ac plug or 24 V dc supply. Only in case of powering
through Aion battery pack, connect the M8 female connector to the battery
pack and turn the connector in clockwise direction until a secure connection is
achieved. Recommended torque is 0.4 N•m [3.54 lb-ft].
After the cable is securely installed, the M8 connector must be plugged into the
sensor:
1. Verify the polarity of both parts and align them.
2. Push (without turning) the connector until it reaches the limit.

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3. Turn the connector in clockwise direction until a secure connection is achieved.
Recommended torque is 0.4 N•m [3.54 lb-ft].
Once the power is on, the sensor node's status LED will visually indicate the status
of the connection. The white light will indicate that the sensor is on. The light
should shortly change to a red color, which will indicate that the sensor is ready for
the next step.