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 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 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:
  • 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:
  • Coming Soon!

    The Leap wireless pressure transceiver integrates with any WIKA PGT21 mechanical pressure gauge. The sensor is powered by the Leap Sensor device battery. No external power source is needed. Contact us to let us help you make your selected pressure gauge wireless.   Part of the breakthrough Leap Sensors® system.   Build your quote here: Coming soon!  Contact us for pricing.
  • 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:
  • 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.
  • 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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    Contact us for pricing on your specific requirements.
  • 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.  
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    Prices, Quotes, Questions...

    Need a price or a quote? Have questions? Want to talk to an expert? Need a custom solution?
    Contact Us
  • Coming Soon

    This unique Leap wireless sensor can install in the threaded grease zerk hole in bearings.  Remove the grease zerk, install the sensor, then re-install the zerk back into the sensor. Grease guns may be used to continue grease the bearing using the zerk mounted on the Leap sensor. Mounting adapters also facilitate easy installation on any type of machine. Accelerometer readings (in all 3 axes) are taken at 5 KHz, then edge-processed into the top predictors of failures. Temperature and 3-axis vibration sensors are mounted in the stainless steel base. Send text, email, and phone alerts when temperature vibration limits are exceeded. Data integrates easily into PLCs or other plant monitoring software. Bulk accelerometer reading downloads are also available as an option.   Contact us to talk to an expert and find the best solution. 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:
  • 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:
  • The Leap wireless pressure transceiver can integrate with every type of sensor with a 0 - 10 V output.  The sensor is powered by the Leap Sensor device battery with a power supply that can be specified from 0 to 24 volts.  No external power source is needed.   Contact us to let us help you make your selected 0 - 10 V sensor wireless. 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:
  • 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.     Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • This Leap wireless transceiver node can integrate any off-the-shelf PRT or RTD Temperature sensor.

    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-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:
  • The Leap wireless 4-20 mA transceiver node can integrate with every type of sensor with a 4-20mA output.

    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 let us help you make your selected 4-20 mA sensor wireless. 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:
  • 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:
  • 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 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:
  • 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:
  • The Leap wireless pressure transceiver can integrate with every type of sensor with a 0 - 5 V output.  The sensor is powered by the Leap Sensor device battery with a power supply that can be specified from 0 to 24 volts.  No external power source is needed.   Contact us to let us help you make your selected 0 - 5 V sensor wireless. 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:
  • This very unique wireless sensor works by comparing the readings from one device node to another user-selected device node - then reporting the local pressure, local temperature - then differential pressure and temperature as compared to a user selected sensor. For example, sensor A is located outside at ambient temperature and pressure.  Sensor B is located in a clean room under positive pressure and Sensor C is located in a different part of the cleanroom under a higher positive pressure.  Sensor B could be configured to report its pressure and temperature and the differential pressure between Sensor B and Sensor A.  (See the screen shot).  Sensor C could be configured to report its pressure and temperature and the differential pressure and temperature between sensor C and sensor B. Sensor readings are reported in PSIA. Leverage the Leap SensorManager software to send text, email, or telephone alerts when a pressure, temperature, or delta-pressure or delta-temperature threshold is exceeded. Integrate the data from the differential pressure sensors into other software using our web-based API, Modbus, DNP3, or other data interface protocols. The wireless sensor can be configured with pressure sensors that have different ranges, resolutions, and accuracies for different applications. See the specification below for more information on the different options. Pressure sensors can be configured to specific applications.  The pressure and temperature sensors in the photos have the pressure and temperature sensor sealed inside the enclosure with a pressure port in the back of the enclosure.   Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • The Leap wireless transceiver can integrate with most sensors with a CAN bus interface.  The sensor is powered by the Leap Sensor device battery 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 CAN bus sensor wireless.     Part of the breakthrough Leap Sensors® system.   Contact us with the details of the CAN sensor that you want to integrate with the Leap wireless sensor system. Build your quote here:
  • The Leap ultra-low temperature sensor system gives continuous remote monitoring of the internal temperature of your ultra-low temperature (ULT) freezer (-80C). 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 that are only available in the Leap product line:
    • High accuracy sensing in the calibrated range from -80C to 5C. Calibration target temperatures are -80C, -65C, and +5C.
    • Optional door-open sensor.
    Note: This temperature sensor is connected to a cable that should not be bent when below -50C. Contact us to find the best combination of features for your facility.     Build your quote here:
  • The Leap wireless oil leak detection transceiver utilizes a blue-colored oil-sensing cable that can cover a large area. If oil contacts the cable at any point along its length, the Leap wireless transceiver will report that oil is present. The software can be configured to send text, email, and telephone alerts when oil is detected. 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 of sensor with an I2C output.  The sensor is powered by the Leap Sensor device battery 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 I2C sensor wireless.     Part of the breakthrough Leap Sensors® system.   Contact us with the details of the I2C that you want to attach to the Leap Transceiver Node. 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:
  • Integrate almost any strain sensor into a Leap Sensors wireless transceiver node for structural health monitoring (SHM) on bridges, overpasses, support beams, and more. Easy to install on existing structures. Be up & running in just a few minutes.

    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.   Strain sensors are not included. Contact us and one of our experts can recommend strain gauges for your application.  We offer easy-to-install spot-weld-on strain sensors.  We also have a Micro Measurements battery-powered spot welder available for rent. Build your quote here:
  • Integrate almost any strain sensor into a Leap Sensors wireless transceiver node for structural health monitoring (SHM) on bridges, overpasses, support beams, and more. Easy to install on existing structures. Be up & running in just a few minutes.

    Wireless Strain 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.   Strain sensors are not included. Contact us and one of our experts can recommend strain gauges for your application.  We offer easy-to-install spot-weld-on strain sensors.  We also have a Micro Measurements battery-powered spot welder available for rent. Build your quote here:
  • Integrate almost any strain sensor into a Leap Sensors wireless transceiver node for structural health monitoring (SHM) on bridges, overpasses, support beams, and more. Easy to install on existing structures. Be up & running in just a few minutes.

    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.   Strain sensors are not included. Contact us and one of our experts can recommend strain gauges for your application.  We offer easy-to-install spot-weld-on strain sensors.  We also have a Micro Measurements battery-powered spot welder available for rent. Build your quote here:
  • Wireless transceiver node designed to integrate with all types of load cell sensors.

    Wireless Load Cell Demonstration and Tutorial

    wireless strain sensor demonstration and tutorial

    wireless strain sensor demonstration and tutorial

      Contact us to find the best load cell configuration for your specific application. Part of the breakthrough Leap Sensors® system.   Build your quote here:
  • 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:
  • 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:
  • 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:
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