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 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:
  • A great way to measure tank level when a non-contact method is required, this sensor mounts inside the lid of a tank, using an ultrasonic signal that bounces of the surface of the liquid to measure its depth.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This unique wireless sensor remotely measures the depth of a liquid in a tank or pond using a submersible pressure sensor. The Leap Sensor transceiver node uses edge computing to convert the pressure measurement to liquid depth. Completely battery-powered - no external power source needed. Optional water- and weather-proof enclosure protects the sensor transceiver node. Optional direct-to-cellular technology for remote locations. Data is sent directly to a cloud server. Contact us for the best combination of pressure sensor and other options for your application.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This unique wireless pressure sensor has the best of both worlds - a mechanical gauge from WIKA integrated into a wireless sensor node. Get the advantages of wireless monitoring alerts, live data, and data storage, while still being able to check current pressure at a glance. Standard WIKA Bourdon tube pressure gauge scale ranges 0 to 1.6 bar to 0 to 400 bar. Other options available. Contact Us to integrate an application-specific pressure sensor with the Leap Sensors wireless system. See the data sheet for detailed specifications.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Wireless transceiver node integrates from 2 up to 12 standard thermocouples to one wireless sensor node. Every thermocouple type is supported (K-type, T-type, B-type, J-type, S-type, N-type.) Ideal for multi-point monitoring of extreme low or high temperatures. Select from a wide range of off-the-shelf thermocouples and integrate up to 12 of them to one node with a standard mini bladed connector. Contact us to find the best thermocouple configuration that is the best fit for your application.   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:
  • 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:
  • 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:
  • The wireless Range Extender acts as a repeater to extend the wireless transmission distance between sensor nodes and the gateway. When a sensor is out of range of the gateway, one or two range extenders may be placed between the two devices to bridge the wireless transmission gap. Range Extenders are powered by 5VDC from a 120VAC wall transformer.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • 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:
  • This wireless sensor communicates via a cellular transmission for remote temperature & flood monitoring. The internal antenna keeps the transceiver node small and resistant to damage. Sensor transceiver node combines standard mini k-type thermocouple connector for temperature sensing (wide temperature range) and a water sensor for flood detection. No gateway required – ideal for remote locations where standard sensors won’t work. Sensor node transmits via cellular link directly to cloud-based user interface. Receive alerts by email or text. “Practically battery-free”™ - Long battery life (up to 10 years, depending on application & transmission interval). Customize to your specific needs, including options to transmit only when designated thresholds are exceeded.     Part of the breakthrough Leap Sensors system.   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

    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.  
  • Put all of your most important sensor data and graphs on one page with the Dashboard option in the Leap software. Dashboards can be configured for you by the Phase IV Engineering team - or select the option to configure your own dashboards.  
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  • This Leap wireless transceiver node integrates two standard industrial pressure sensors along with two thermocouples. (Type K is standard, but other types can also be integrated). The sensor is powered by the Leap Sensor device battery with a power supply that can be specified - 12 or 24 volts. No external power source is needed.   Contact us to let us help you make your selected pressure sensors and thermocouples wireless. Part of the breakthrough Leap Sensors® system.   Build your quote here: Contact us for pricing for your unique configuration.
  • Wireless transceiver node designed to integrate with any ring force transducer that has one of these outputs: mV/V, 4-20 mA, or 0-10V.  The Leap transceiver node provides power to the ring force transducer. Ideal for monitoring preloads, testing equipment, clamping forces, and remote ongoing force and load monitoring. Contact us to find the best ring force transducer configuration for your specific application.       Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Breakthrough technology uses CAN bus to "daisy chain" multiple load cell interface modules to one wireless Leap transceiver node. Anywhere from 2 to 30 load cell modules can be added to the bus. Each load cell module can support 2 full-bridge mV/V load cells, for a total of up to 60 load cells per transceiver node. Edge processing at the strain sensor level assures a high-quality conversion of the sensor voltage reading to a digital reading, which can then be reliably sent via the CAN bus to the wireless transceiver node. Industrial CAN bus cables can be over 600 feet long. Ideal for wireless monitoring loads and force in several places along structural components such as I-beams, girders, support columns, etc. Contact us to find the best strain sensor configuration for your specific application. Part of the breakthrough Leap Sensors® system. Contact us for pricing on your specific configuration. Build your quote here:
  • Sensor transceiver node designed to integrate with a wide range of linear position sensors and crack monitors with common outputs such as 0-5V, 4-20 mA, and RS485. The crack monitor is powered from the battery in the Leap transceiver node. When combined with a wireless transmitter, these sensors are very effective at monitoring changes in cracks or other movement over time in remote locations.     Part of the breakthrough Leap Sensors® system.   The linear sensor that meets your specific requirements will be integrated and tested with this device node. Contact us to find the best linear position configuration for your specific application. This external linear crack sensor is not included in this price but will be included in a final quote. Build your quote here:
  • Breakthrough technology uses CAN bus to "daisy chain" multiple small strain gauge sensor modules to one wireless Leap transceiver node. Anywhere from 1 to 16 strain gauge modules can be added to the bus. Each CAN strain module can support 2 full-bridge resistive strain gauge sensors, for a total of up to 32 full-bridge strain gauges per transceiver node. Edge processing at the strain sensor level assures a high-quality conversion of the sensor voltage reading to a digital reading, which can then be reliably sent via the CAN bus to the wireless transceiver node. Industrial CAN bus cables can be over 600 feet long. Ideal for wireless monitoring of strain in multiple points along structural components such as I-beams, girders, hanging structures, support columns, railways etc., as well as industrial applications such as rotating shafts in engines, turbines, etc.

    Wireless Strain Demonstration and Tutorial

    wireless strain sensor demonstration and tutorial

    wireless strain sensor demonstration and tutorial

    Contact us to find the best strain sensor configuration for your specific application.     Part of the breakthrough Leap Sensors® system.   Multiple strain sensing modules attach to the transceiver node over a CAN bus. Each module can support two full-bridge strain sensors. The strain modules are ordered separately. Contact Us and an Application Engineer will work with you to provide a detailed final quote that meets your specific application. 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:
  • The Leap wireless flood detection transceiver utilizes an orange-colored liquid sensing cable that can cover a large area.  If water contacts the cable, at any point along its length, the Leap wireless sensor will report that a liquid is present. The software can be configured to send text, email, and telephone alerts when water is detected. A configuration screen allows for entering saturation levels to report the level of wetness. Contact us with questions or to request a custom length of the water detecting cable.     Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • The Leap wireless pressure transceiver can integrate with every type differential pressure switch with a "dry contact" switch output. The differential pressure switch featured with this product is a Cleveland Controls Air Sensing Switch, HVAC/General Purpose Type, 0.02 to 0.8 Differential (In. WC). Contact us to find the best combination or let us know which pressure switch you would like us to integrate.     Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • Integrate any sensor with an RS485, RS485 Modbus, or RS232 output into the Leap Sensors system to convert it to a wireless sensor. The sensor is powered by the battery in the Leap transceiver node with a power supply that can be specified from 3.6V to 24 volts. No external power source is needed. Contact us to let us help you make your selected RS485 or RS232 sensor wireless.     Part of the breakthrough Leap Sensors® system.   Build your quote here:
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