Manual

igus^® smart plastics i.Sense

Safety¶

Read this manual completely before commissioning and observe all safety and installation instructions. If integrated into an overall system, this information must be passed on to the end user.

Warranty applies only in accordance with the specifications stated in this manual and is limited to repair or replacement of the i.Sense. igus^® accepts no liability for integration tasks, consequential damages, misuse, or unauthorized modifications; the right to make changes to the product and documentation is reserved.

The i.Sense may only be operated if the safety and installation instructions are observed, the housing is mounted in compliance with ESD/EMC requirements, the device is unmodified and in perfect condition, and the operating limits specified in the technical data are adhered to.

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Qualified Personnel

The i.Sense may only be operated and maintained by qualified specialist personnel.

• Personnel must have read and understood this manual and any additional documentation that may exist.

• Personnel must be familiar with all relevant applicable standards, regulations, and accident prevention regulations.

• Personnel must be able, through their training, to anticipate or recognize potential hazards that may arise during use of the system.

• Personnel must be able to ensure the safety of persons and objects when using the sensor unit in the overall system.

• Personnel must be trained in the handling of ESD-sensitive devices and must take all necessary precautions.

Please provide the text you'd like me to translate.### Intended Use

Purpose and Scope

• i.Sense:modul II is a microprocessor-based DIN rail module (diagnostic tool) for the continuous evaluation of connected i.Sense sensors.
• The goal is the detection of unusual operating conditions (e.g. blockage/breakage) on igus^® e‑chain systems^®, in order to avoid unplanned machine downtime.
• Via eight potential-free contacts, a rapid machine response to unexpected operating conditions can be triggered.
• Configuration and sensor data download are performed via USB and WiFi.

Requirements

• Use the device exclusively in accordance with its intended use. The protection of persons is not guaranteed if the device is not used as intended.
• igus^® GmbH accepts no liability for damages arising from use other than the intended use.
• Read this original operating manual before commissioning. Knowledge of the original operating manual is part of the intended use.

Foreseeable Misuse

• Any use other than that specified under "Intended Use" or any use beyond that scope shall be considered unintended use.

The following uses are not permitted, in particular

• in safety-relevant circuits
• in rooms with explosive atmospheres
• on machines and plants with vibrationsPlease provide the text you'd like me to translate.

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The following notice boards will appear several times in the manual. They are classified so that the degree and type of hazard are indicated.

Product Overview¶

Operating Modes¶

Table 2: Product Overview

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Technical Data¶

Table 3: Mechanical Specifications

Please provide the text you'd like me to translate. | Electrical Specifications | | | --- | --- | | Power supply (terminal X7)
| 24V DC (1A max.)
| | Power supply potential-free contacts (terminal X4)
| 24V DC (0.3A max.)
| | Output voltage (terminal X1 and X2)
| 5V DC
| | Output voltage (terminal X3)
| 5V DC (0.5A max.)
| | Output voltage (terminal X5 and X6)
| 24V DC
| | Residual ripple | 100mV pp |

Table 4: Electrical Specifications

Table 5: Interfaces

Table 6: Storage Capacity

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Table 7: Ambient conditions

Installation¶

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Mechanical Installation¶

• Vertical, TS35 DIN rail
• Vibration-free mounting location
• Connection space: 50mm vertical, 35mm
• Avoid heat build-up, ensure adequate ventilation

Please provide the text you'd like me to translate. Electrical Installation

Power Supply

Table 8: Power Supply

Connector Assignment and Sensor Connection
1. Press the orange spring of the respective wire opening into the connector by hand or with pliers and hold it there.
2. Insert the wire into the opening up to the stop.
3. Release the orange spring so it extends back out of the connector. Check that the stranded wire is securely seated.

Figure 2: Connector Assignment and Sensor Connection

Connections, LEDs and Buttons¶

Wiring Diagram¶

Potential-Free Contacts¶

Table 9: Potential-Free Contacts

Schematic Diagram: Connection of Potential-Free Contacts to Customer Control System¶

Figure 5: Schematic Diagram: Connection of Potential-Free Contacts to Customer Control System

Communication Interface¶

Connection of the UART Interface¶

Connection of the ComBox

Table 10: UART Interface

Sensors¶

Table 11: Maximum adjustable force limit values

Terminals X1/X2 2mV/V Force Measurement¶

igus^® Strain Gauge Sensors for Tension-Compression Force Measurement on igus^® e-chain systems^®:¶

Figure 6:

Strain gauge sensor on KMA
Strain gauge (SG) sensor in a set with a second "dummy" for mounting on igus^® KMA connection elements for e-chain systems^® of series E2, E4, P4 Connection: Four-wire, M12 industrial connector Pin assignment: igus^® strain gauge sensors with CF10.03.05.INI cable

Table 12: Connection Terminal X1 / X2

Load cells integrated in floating carriers¶

Figure 7: Vishay load cell Model 616 1t Load cells integrated in the metal structure of the floating carrier for all igus^® e-chain systems^® Connection: Seven-wire, Harting HAN 3A M20 EMC industrial connector

Pin assignment: Vishay load cell Model 616, 1t

Table 13: Connection Vishay load cell Model 616 1t to Terminal X1 / X2

Pin assignment: Vishay load cell Model 620, 2t

Figure 8:

Vishay load cell Model 620 2t

Table 14: Connection Vishay load cell Model 620 2t to Terminal X1 / X2

Load cells integrated in cable pull force sensors¶

Load cells (as in floating carrier) integrated in the metal structure of the strain relief for igus^® e-chain systems^® of series E4.42, E4.56, E4.80, 4040, 5050, P41.56, P41.80 Connection: Eight-wire, Harting HAN 3A M20 EMC industrial connector

Pin assignment: Vishay load cell Model 616, 1t

Table 15: Connection Vishay load cell Model 616 1t to Terminal X1 / X2

Pin assignment: Vishay load cell Model 620, 2t

Table 16: Connection Vishay load cell Model 620 2t to Terminal X1 / X2

Pin assignment: ME-Messsysteme load cell KD40s, 200kg

Table 17: Connection ME-Messsysteme load cell Model KD40s 200kg to Terminal X1 / X2 Principle of cable pull force sensor Structure of cable pull force sensor

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Terminals X5 / X6 4-20mA¶

Breaking Force Sensor Integrated in SLS Housing¶

Figure 11: Breaking Force Sensor Assembly

Breaking force monitoring on the floating carrier for mounting on igus^® KMA connection elements or steel connection elements for e-chain systems^® of the E4 and P4 series Special features: Inner width >350mm 2x sensor on carrier required Chain length >35m 1x sensor on carrier, 1x sensor on fixed point, knot of the polymer rope in the middle of the e-chain^® Special dividers must be positioned in the e-chain^® Connection: Four-wire, M8 industrial screw connector, CF10.03.05.INI Pin assignment:

Table 18: Connection of 100mm slider sensor (MAT0090096) to terminal X5 / X6

Cylindrical Sensor / Roller Sensor¶

Breaking force monitoring on the floating carrier for mounting on igus^® KMA connection elements or steel connection elements for e-chain systems^® of the E4 and P4 series Connection - Via pigtail side 1 on sensor side 2 Harting HAN 3A - Four-wire, Harting HAN 3A M20 EMC industrial connector Pin assignment:

Table 19: Connection of roller sensor to terminal X5 / X6

Mounting plate for cranes

Please provide the text you'd like me to translate. Sensor orientation:

Built-in acceleration/orientation monitoring of the module, measurement is performed in all three spatial directions Connection - Already integrated in the module Figure 14: Orientation of internal acceleration sensor

Commissioning and User Interface¶

Figure 16: Establishing a connection to the user interface

USB¶

• Use a USB-A -> micro-USB cable.
• Plug the microUSB into i.Sense:modul II, USB-A into the PC.
• Access the user interface via IP address 10.0.0.1 in the browser address bar.

Figure 17: IP address (USB)

Driver Installation¶

1. Download the security key here:
   https://www.catalog.update.microsoft.com/Search.aspx?q=usb%5Cvid_0525%26pid_a4a2
2. Open Device Manager
3. Select Network Adapters / RNDIS device
4. Click Update Driver
5. Select the folder from the download
6. Click "Install"

Alternatively: 1. Download the installation package here:
https://igus.widen.net/s/wlttsptqwb/sma_rdis-network-device-driver 2. Extract the compressed file 3. Run and install the installation package

WLAN (AdHoc)¶

• Activate the AdHoc network by pressing the "Reset" button on the front of the i.Sense:modul II for approximately 5 seconds.
• Within a few seconds, the WiFi network will appear with the SSID igus-isense.

Figure 18: AdHoc SSID

• Connect to the network igus-isense
• Access the user interface by entering the IP 10.0.0.1 or 192.168.128.1 in your browser address bar.

Sensor Commissioning¶

EC.P¶

1. Place e-chain^® in the middle of the travel path
2. Set offset (user interface → Configuration, Sensor 1 and/or 2)
3. Force limits are pre-configured by igus^®

CF.P¶

1. Place e-chain^® in the middle of the travel path
2. Set offset (user interface → Configuration, Sensor 1 and/or 2)
3. Force limits are pre-configured by igus^®

EC.B¶

1. No calibration required

Operating the User Interface¶

• Three-bar menu in the upper left corner

• Options: Sensors, Configuration, Alert Management, Wi‑Fi Setup

Figure 19: User interface menu

Configuration¶

Sensors: - Select "Configuration" from the 3-bar menu in the upper left - Move the "configuration mode" slider to on (orange) - Enter data in the respective fields - Click the "Update Configuration" button

Zero Adjustment (Tare):

The tare function allows the force measurement to be referenced to the current state. When Tare is triggered, the currently applied measured value is adopted as the new reference point. Internally, the Force Offset is adjusted accordingly, so that the measurement from this point on is relative to this new reference value.

When to use:
- after installation or changes to the mounting situation
- when a constant residual value is displayed in the idle state
- before a measurement series, to relate the display to the current operating state

CSV separator: - Default semicolon (;) - USA/Japan etc. comma (,)

When using multiple i.Sense:modul II devices: - Adjust USB IP address

If required, adjust the WiFi SSID device identification: - Default iSense-[nine-digit serial number]

Figure 20: Sensor Configuration

Sensors¶

• Five columns (top to bottom): sensor status, graph (last minute), current values, configured limit values, "Reset Sensor" button

Table 21: Sensor status indicators

Figure 21: Sensor user interface

Sensor Reset¶

• Click the Reset button below the sensor
• A window for code entry will appear

Figure 22: RESET SENSOR button

Data Download¶

• Measurement data can be downloaded as a CSV file for each sensor.
• Set the data volume in the field: 1h, 6h, 1d, 2d, 3d, 4d, 5d, 6d, 7d.

Figure 23: CSV data download

• Additionally, all available measurement data can be downloaded as an sqlite database:
• Database: all data over a period of at least 1 month
• Database History: Min./Max. values over a period (1h) over a longer time span

Figure 24: SQL database download

Alert Management¶

• Select "Alert Management" from the 3-bar menu in the upper left
• Select sensor

Figure 25: Sensor selection

• Assign alert type

Figure 26: Alert type

• Enter data

• Limit low: lower threshold value
• Limit high: upper threshold value
• Warning Text: text in SMS (max. 100 characters)

Figure 27: Threshold values and warning text

• Set warning level

Figure 28: Warning level

• Set repeat interval

Figure 29: Repeat interval

• Enter phone number of SMS recipient

Figure 30: Phone number of SMS recipient

• Set permission level:
• 1 – may perform Reset
• 2 – read-only access

Figure 31: Permission level

• Clicking "Create" adds the alert message to the table on the right.
• The alert message can be deleted using the Delete button.

Figure 32: Message management

Wi‑Fi Setup¶

• Use the SCAN button to search for available Wi‑Fi networks.
• Select a network via "Select a Wi‑Fi".
• The SSID is displayed in the lower field.
• Enter the Wi‑Fi password in the "Password" field.
• Click "CONNECT" to connect the i.Sense:modul II to the selected Wi‑Fi network.
• The current network settings are displayed in the right window.

Figure 33: WiFi Setup

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Performing Updates (Node-RED Frontend & Firmware)¶

Updates are part of product maintenance and should be applied regularly.

1) Update Node-RED Frontend (automatic)¶

The Node-RED frontend is updated automatically as soon as the module is connected to a Wi-Fi network.

Procedure for pending updates: 1. Connect the module to a Wi-Fi network. 2. Wait until the automatic Node-RED update is complete. 3. The update is complete when the module restarts automatically.

2) Performing a Firmware Update (manual)¶

Firmware updates must be applied manually.

Procedure for pending updates¶

1. Open the Technical Settings menu item in the user interface.
2. Enter the password you have chosen or the default password 1905.
3. Select the latest firmware package.
4. Start the installation and wait until the process is fully complete.
5. Afterwards, check the firmware version and the correct functioning of the system.

Please provide the text you'd like me to translate. The identifier at the beginning of each sensor message is structured according to the following format.

XXXXX;

Table 22: Sensor identifier structure

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Load Cells and Strain Gauge Sensors¶

Table 23: Structure of output string for load cells and strain gauge sensors

Breaking Force Sensor¶

Table 24: Structure of output string for breaking force sensor

Acceleration Sensor¶

Table 25: Structure of output string for acceleration sensor

Example Strings¶

1W101;24.03.2021;12:34:01;+07000;+05000;-01453;-05000;-07000;05;05;050;-00980;;1;\r\n 2D101;24.03.2021;12:34:01;+05000;+03000;-00453;-03000;-05000;01;01;100;-00580;;1;\r\n 3B101;24.03.2021;12:34:01;0010;0050;0090;0099;15;35;1;\r\n 4B101;24.03.2021;12:34:01;0010;0045;0090;0099;15;35;1;\r\n 5A101;24.03.2021;12:34:01;+01;-02;+02;\r\n

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Warnings (Alerts)¶

Table 28: Warnings, errors and potential-free contact

Errors¶

Table 29: Definition red flashing

Table 30: Definition red lit

Maintenance¶

Inside the i.Sense:modul II, on the circuit board, there is a battery of type CR1225 3V (see red marking in Figure 1 on the right). During the period in which the 24V supply voltage is switched off, the battery ensures that the date and time are retained. The battery must be replaced as soon as the status LED labelled "Replace Battery" lights up yellow (see red marking in Figure 1 on the left).

Figure 1: IS.EC.U04.04.01.0 - Battery

When replacing the battery, completely disconnect the device from the power supply. Disconnect all connected terminals from the device and remove the device from the DIN rail. Remove the front sticker and unscrew the 4 screws on the right unlabelled half of the housing.

(Should the sticker be damaged during opening, please contact igus^® customer service to order a replacement). The left and right sides of the housing can then be carefully pulled apart at the front and back using the thumbs, from top to bottom.

Troubleshooting¶

• No connection to the device possible.
  • Check whether network adapter / RNDIS driver is installed
  • If necessary, reinstall the driver (p. 19)
• Loss of connection or problems with the user interface:
  • Reload the page
  • In the menu, click again on the desired view
  • If this fails, restart the device and try again.
  • If this attempt also fails, please contact customer service (p. 31).
• The device is not retrieving all sensor data, what now?
  • Check all connectors and restart the system.
  • Otherwise, contact customer service (p. 31)

FAQS¶

• How are the sensor limits set?
  • User interface -> Configuration mode
• How do you retrieve the determined sensor data?
  • Under the User interface section, the individual steps for operating the user interface are listed.
• Is it possible to download the data from the user interface?
  • Under the User interface section, one option for downloading the sensor data is mentioned.

Abbreviation¶

Definition of Terms¶

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Circuit Diagrams¶

Attached after page 31.

Regulatory & Legal¶

Compliance with EU Directives The CE marking on the i.Sense confirms conformity with the following European directives:

The applicable directives are listed in the EU Declaration of Conformity for the respective device.

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Note on the Cyber Resilience Act (CRA) The i.Sense contains digital components. Such products are subject to the security requirements of the EU Cyber Resilience Act (Regulation (EU) 2024/2847). The CRA stipulates that software and networked devices must be operated securely and kept up to date throughout their entire lifecycle.

To ensure that you can use the i.Sense reliably and securely, please observe the following: - Install provided firmware and software updates on a regular basis. - Use secure network and access settings. - Change default passwords immediately after commissioning. - Disable interfaces or services that are not required.

If you notice a technical anomaly or a potential security vulnerability, please report it via the official igus support channel or through the service portal. The CRA also requires that users have access to information about security support, known risks, and update processes. Further details can be found in the documentation for this product or from your national market surveillance authority.

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Note on EU Dual-Use Regulation (EU) 2021/821 Individual electronic components and sensors in the i.Sense may, depending on their technical configuration, be subject to the EU Dual-Use Regulation (EU) 2021/821. This regulation governs goods that can be used in both civilian and military applications.

An export licence may therefore be required for export to countries outside the EU. Whether this applies depends on the destination market, the intended use, and the specific technical configuration.

Please verify the following before transferring or exporting the product: - whether export restrictions apply to your destination country, - whether your application is considered security-critical or military in nature, - whether authorisation is required under applicable regulations.

Further information is available from your national export control authority (e.g. BAFA in Germany) or in the official EU documentation.

Service¶

Customer Service

de-smartplastics-service@igus.net
+49 (0) 2203 9649 9806

Technical support for igus^® smart plastics

Documentation/FW

https://www.igus.de/info/i-sense-modul-2

Download of manuals, FW updates and certificates

Website smart Plastics

https://www.igus.de/info/vorausschauende-wartung-smart-plastics

Option to order sensors, processing units and further accessories

Contact

www.igus.de

info@igus.de

+49 2203 9649-9507

Imprint

© 2026

All rights reserved by

igus^® SE & Co. KG

Spicher Str. 1a

51147 Cologne