Predictive Maintenance

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Our wireless sensors for predictive maintenance monitor temperature, vibration, current, and more to help you predict equipment failure before it happens. Avoid costly unexpected shutdowns and get more insight into your critical processes.

  • This Leap wireless transceiver node can integrate any off-the-shelf PRT or RTD Temperature sensor. The external industrial sensor may be powered by an optional 12 or 24V power supply driven from the over-sized Leap Sensor node battery. No external power source is needed with the 12/24V power supply option (LP-1TXX). See below for other options to configure this industrial wireless sensor node to your exact needs. Contact us for help integrating the best sensor probe for your application.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This Leap wireless sensor has a standard mini thermocouple connectors that can connect to any thermocouple. (Standard products comes with K-Type thermocouples.) Other thermocouple types are also available - type-B, type-S, etc. Because thermocouples can be used over a wide temperature range and thermocouples come in a huge range of probe types, this sensor addresses many industrial applications - and is one of our most popular industrial wireless sensors.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This Leap wireless sensor has two standard mini thermocouple connectors that can connect to any K-type thermocouple.   Because thermocouples can be used over a wide temperature range and thermocouples come in a huge range of probe types, this sensor addresses many harsh industrial applications.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Coming Soon

    This Leap wireless sensor has eight standard mini thermocouple connectors that can connect to any type of thermocouple (type K is standard). Because thermocouples can be used over a wide temperature range and thermocouples come in a huge range of probe types, this sensor addresses many harsh industrial applications.  
  • The Leap wireless thermowell sensor can integrate 1 to 9 PT100 thermowells. See our standard offerings below. Contact us if you need a different temperature probe. Part Numbers: LBI0-xT04 - 4" probe, LBI0-xT05 - 6" probe, LBI0-xT06 - 12" probe.   x=number of thermowells.     Part of the breakthrough Leap Sensors® system.   This wireless sensor is typically customized to specific applications.  The price is for the basic, one-thermowell model. Include your requirements and we will reply with an exact quote. Build your quote here:
  • Ultra-low temperature (ULT) sensor system gives continuous remote monitoring of the internal temperature of ultra-low temperature (ULT) freezers. Set alerts via phone, text, or email to know about issues even if you're not on-site. Streamline auditing processes. Ideal for temperature-critical applications such as laboratories, medical facilities, vaccine storage, medicine storage. This remote monitoring system for ULT freezers is designed with key features exclusive to Leap Sensors:
    • High accuracy RTD sensing at ultra low temperatures - as low as -196ºC (-320ºF).
    • Temperature probe is verified and calibrated at 3 points: -60ºC, -40ºC, and +5ºC (-76ºF, -40ºF, and +41ºF)
    • Optional industrial door-open sensor helps troubleshoot temperature alerts, as well as tracking each time the door is opened. Time that door is left open is reported - and alarms can be set on excessive door-open time.
    • Optional wall transformer powers the sensor and also alerts power outages. On-board battery backup assures sensor node operation during power outages.
    Contact us to find the best combination of features for your facility.     Build your quote here:
  • The Leap wireless refrigerator and freezer temperature sensor continuously monitors the internal temperature of your refrigerator or freezer. Set alerts via phone, text, or email to know about issues even if you're not on-site. Streamline auditing processes. Ideal for temperature-critical applications such as laboratories, medical facilities, vaccine storage, medicine storage. This refrigerator/freezer monitoring system is designed with key features that are only available in the Leap product line:
    • Single sensor and dual sensor (2 temperature and 2 door-open sensors) available.
    • Paper-thin cable maintains gasket seal integrity.
    • Easily replaceable NIST-traceable tip for simple calibration.
    • Industrial door-open sensor helps troubleshoot temperature alerts, as well as tracking each time the door is opened.  Sensor device node takes a reading and transmits every time the door is opened and closed.
    • Time that door is left open is reported - and alarms can be set on excessive door-open time.
    • Optional wall transformer powers the sensor and also alerts power outages. On-board battery backup assures sensor node operation during power outages.
    • Fast, simple installation with cold-proof foil stickers and adhesive-backed hook-and-loop.
    • Thermal mass bottle prevents false alarms from defrost cycles or when the door is opened.
    • Know for sure the sensor is connected & working with LED indicator light.
    Contact us to find the best combination of features for your facility.    

    Note: transceiver node configuration

    The transceiver node can be configured with one or two temperature sensors, replaceable calibrated temperature probes, zero to two door-open sensors, an optional thermal bottle, and battery power or wall power. Please specify the configuration that you need and we will send you a final quote to your exact specifications. Build your quote here:
  • This highly versatile industrial sensor supports 9 miniature, low-mass precision RTD temperature sensors connected to a high-temperature transceiver node in an industrial enclosure.
    • 3-wire RTD connection supports long cables while also maintaining high temperature accuracy.
    • The entire sensor is rated to operate up to at least 125C (257F).
    • Readings as fast as every 3 seconds for each of the 9 sensors.
    • Data logging capability when the transceiver node is not linked to a gateway.
        Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Wireless rtd temperature sensor is embedded in ultra-strong magnet to mount the transceiver node to your equipment in seconds. Ideal for monitoring large gearboxes, bearings, and motors for overheating. Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Vibration sensor can measure G-forces. Vibration sensor takes a simple yet highly effective approach in monitoring maximum and average g-force trends of +/-16G and can sample at up to 5 KHz on all 3 axes. The accelerometer has optional advanced on-board edge computing FFT capabilities. Customized options include vibration, tilt, and shock events. Up to 8 vibration modules can be attached to one transceiver node. The vibration module also includes a temperature sensor.

    Video Demonstration and Tutorial

    wireless motor monitor video demonstration

    Transceiver Node Configuration

    Vibration+Temperature Modules: The number of vibration/temperature modules (1-8) connected to the Vibration Transceiver Node can be selected on the vibration module page. Build your quote here:
  • This unique motor sensor combines 3 different sensors in one multi-sensor node: temperature, vibration, and electrical current. Get continuous remote monitoring of these key predictors of motor failure. Receive alerts via text, email, or phone. Avoid costly downtime and gain operating insight. It's like having X-ray vision into your key processes.

    Video Demonstration and Tutorial - Wireless Motor and Rotating Equipment Sensor - Vibration, Temperature, Electric Current

    wireless motor monitor video demonstration
    • The only system currently available that combines all three types sensors on one transceiver node. Get sophisticated monitoring at a real-world price.
    • Installs quickly & safely: temperature sensor and vibration sensor (accelerometer) install quickly with industrial-strength magnets or screw mount. Current sensor is a split-core amp clamp.
    • The standard vibration sensor takes a simple yet highly effective and proven approach by sampling at 5KHz and edge-computing the data to report RMS acceleration, RMS velocity, and peak acceleration.
    • Store data & manage alerts with our SensorManager.com software, or integrate into your own PLC or other software.
    This motor condition monitoring sensor is ideal for an IoT predictive maintenance program or condition-based monitoring & maintenance.   Part of the breakthrough Leap Sensors® system for the IIoT. Build your quote here:
  • This vibration and temperature module connects over the CAN bus to the Wireless Motor Monitor transceiver node and send temperature and vibration data.   Part of the breakthrough Leap Sensors® system for the IIoT.   Build your quote here:
  • Coming Soon.  Contact us for details.

    This Leap vibration and temperature device node could not be easier to install. The ultra-strong magnet mounts the device node to the equipment in seconds.  Vibration and temperature is conducted through the magnet to the accelerometer and temperature sensor. Ideal for monitoring large gearboxes, bearings, and motors to detect impending failures. Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Ideal for monitoring temperature with a non-contact IR sensor. Standard model measures temperatures from -20C to 1000C with a 20:1 field of view. Contact us if you need an application specific wireless sensor with different specifications.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This unique Leap wireless sensor is less than 5mm thick and supports 9 ultra-small, high-accuracy RTD sensors.
    • 3-wire RTD connection supports long cables while also maintaining high temperature accuracy.
    • The entire sensor is rated to operate up to at least 125C (257F).
    • Readings as fast as every 3 seconds for each of the 9 sensors.
    • Data logging capability when the transceiver node is not linked to a gateway.
    Ideal for these processes:
    • Silicon wafer processing
    • Scientific experiments
    • Paint and coatings curing
    • Temperature profiling over a surface
        Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This Leap Sensor comes with a fast-to-install split-core AC amp clamp to sense the AC electrical current going to equipment. Amp clamps are a powerful industrial tool to monitor power usage and to monitor equipment for conditions that predict impending failures.  A change in AC current to industrial equipment can be an early indication to plan downtime to prevent failures during production. A wide range of amp clamps can be integrated with the Leap system.  Contact us with your specific needs.    
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    Prices, Quotes, Questions...

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    Price for 0-50A AC RMS current transformer.  Contact us for pricing on other current transformer options.
  • The Pressurized Dew Point (PDP) wireless sensor monitors the dew point temperature inside compressed air lines. Because water condenses at a higher temperature when the air is pressurized, the sensor sends an alert when the temperature inside the air lines is nearing the dew point. This provides the plant maintenance team ample warning to take action to head off major equipment malfunctions and damage. This Leap sensor integrates the Michell Easidew EA2 Moisture Meter.     Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Wireless pressure transceiver integrates with every type of WIKA pressure transducer - 4-20mA, 0-10V, and I2C outputs. This version transmits directly to a cellular tower and does not require a gateway to pass the data to cloud software. Ideal for remote locations or for installations without power for a gateway. The external industrial sensor may be powered by an optional 12 or 24V power supply driven from the over-sized dual-D Leap Sensor node battery.  No external power source is needed with the 12/24V power supply option.  The Leap transceiver node may also be optionally powered by an external voltage source. See below for other options to configure this industrial wireless sensor node to your exact needs. Contact us to find the best combination or let us know which WIKA sensor you would like us to integrate.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • One of our most popular sensors, the wireless transceiver node can integrate 2 to 12 standard RTD or PRT temperature sensors. Ideal for applications that need temperature monitoring of multiple items, or temperature gradients across a large area. Select from a wide range of off-the-shelf precision RTD or PRT temperature sensors. 3-wire configuration assures high accuracy. Contact us to find the temperature sensor configuration that is the best fit for your application.   PRT RTD temperature senors priced separately. Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Get instantaneous flow rate information without cutting into pipes and running signal wires. The Leap Sensors wireless transceiver node can integrate with a wide range of ultrasonic and Doppler clamp-on flow meters. Connect to plant software with the Modbus interface or use Leap's cloud-based software. Due to the large power consumption of ultrasonic and Doppler flow meters, the flow meter must be powered by 120V. Data from the flow meter is sent wirelessly via a gateway to the software. Clamp-on flow meters are available for a wide range of pipe sizes from 0.5 to 48 inches. Use for metal or plastic pipes. Contact us to find the best clamp-on flow sensor for your application.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This groundbreaking sensor node integrates a discrete pulse flow meter to count units of flow (i.e. gallons, liters, etc) as liquid flows through a line. Unit can also be used as an incremental encoder for monitoring machinery speeds and total output. The transceiver node times individual pulses and their accumulated counts as they occur. It then uses edge computing to determine current flow rates and total volume of liquid passing through the meter. The edge logic also identifies when flow has stopped, duration of flow events, and duration of stop events. For ease of analysis, the node calculates both instantaneous rate of flow and its duration since the last sensor data reset, as well as a value to indicate if flow is currently occurring.
    • Monitors 11 different output variables, such as pulses, flow rate, total pulses, total volume, etc. See specifications for more details.
    • Transceiver node is powered by a 120V wall transformer that plugs into a jack on the bottom of the enclosure (no battery powered options available.) Data is transmitted wirelessly via a gateway to the software.
    • Connects to the Leap Wireless Sensor System with a secure 2.4GHz, FCC-certified radio.
    • Count-reset button on top of the node enclosure resets the total flow at the end of a measurement period. Users can also set automated resets based on time of day.
    • This unit is a variation of the Leap production counter, with modifications to account for flow measurement and volume totals.
    Contact us to find the flow meter sensor that best fits your application.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This specially-designed wireless temperature sensor has 9 precision RTDs. The entire transceiver node can operate up to 250ºC (482ºF) - the highest-temperature-rated enclosure we offer. The node is less than 1 inch (2.5 cm) thick - able to ride on a wafer or circuit board through a reflow oven. For wafer temperature monitoring, RTD sensors are ultra-thin and small for a fast response to temperature changes. For other applications, virtually any other RTD sensor can be integrated, including pointed insertion probes for meat or food processing. 3-wire configuration on RTDs assures extra accuracy and immunity to the high-temperature environments. Sensor cable lengths can be made to order. Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Wireless transceiver node with an RS485 Modbus RTU interface can read up to 10 Modbus registers to track valuable machine monitoring data. Can be used with almost any Modbus RTU sensor and communication device. Contact us to discuss best options for your application. Connect the transceiver node to a variable frequency drive (VFD) to collect data such as electric current draw, voltage levels, RPM, temperatures, and error conditions. Ideal for predictive maintenance or automated process auditing. Due to the high-power consumption of the Modbus RTU interface, this transceiver node typically uses a external power source to power the node. Battery power is an option if data sampling and transmitting is done every few hours.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • The Leap wireless pressure transceiver can integrate with every type of WIKA pressure transducer - 4-20mA, 0-10V, and I2C outputs.

    Configured to Your Exact Application

    The external industrial sensor may be powered by an optional 12 or 24V power supply driven from the over-sized Leap Sensor node battery.  No external power source is needed with the 12/24V power supply option (LP-1PXX).  See below for other options to configure this industrial wireless sensor node to your exact needs. Contact us to find the best combination or let us know which WIKA sensor you would like us to integrate. See the data sheet for detailed specifications.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
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