Wireless Motor Monitor Sensor – Vibration, Temperature, 3 Phase Current – Leap Sensors

This unique motor sensor combines 3 different sensor in one multi-sensor node: temperature, vibration, and 3-phase electrical current. Continually monitor these key predictors of motor failure and get text and or email alerts. Avoid costly downtime.

This motor condition monitoring sensor is ideal for a predictive maintenance program.

  • Installs quickly & safely: temperature sensor and vibration sensor (accelerometer) install quickly with industrial-strength magnets. 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 SCADA or other software.
Data Sheet

 

Part of the breakthrough Leap Sensors® system.

 

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Description

Leap Sensors are specially designed to easily adapt to your specific needs. If this isn’t exactly what you need, please contact us.

Wireless Motor Sensor for Predictive Maintenance – Specifications

Designed specifically for use in a motor condition monitoring system as part of a predictive maintenance program.

  • Monitors the top 3 predictors of impending motor failures.
    • Motor vibration monitoring sensor detects maximum and average vibration on 3 axis to detect upward trends or spikes in vibration.
    • Motor temperature monitoring sensor (thermocouple) mounts on the motor or gearbox to detect over-heating.
    • Motor current monitoring sensor (amp clamps) detects increased electrical current to motors to detect overloads.
  • Fast and easy to install.
    • Magnetic mounts for temperature and vibration sensors.
    • The amp clamp is a “split core” – allowing it to quickly install around a wire – without disconnecting it.
  • Standard monitoring scenario: Sensor transmits readings every 15 minutes.
    • Temperature alerts are typically set based on normal readings.
    • Electrical current alerts are typically set above normal readings.
    • Vibration is sampled at 5 kHz on 3 axes for a few seconds in the range of 0 to 8Gs.
      • The data is edge-processed on board the sensor using proven methods where a change in trend is indicative of an impending failure.

Wireless Motor Vibration Sensor

  • Mount with the provided magnet or with threaded stud.
  • Vibration sensor is connected to the Leap sensor transceiver node via a shielded cable.
    • Long cables (if needed) are possible between the sensor and transceiver node.
  • 3 axis g-force reading taken and edge-processed into RMS acceleration, RMS velocity, and peak acceleration. Any increase in these values indicate a motor is functioning differently and likely has a problem. Each of these readings is calculated for both radial (rotating) vibration and axial vibration (parallel to the shaft of the rotating equipment).
    • RMS acceleration weights the higher frequencies.
    • RMS velocity weights the lower frequencies.
    • Peak acceleration will detect serious impact forces such as bearing defects and chipped gear teeth.
  • G-force readings up to +/- 8 G.
  • Accelerometer operating temperature: -40C to 85C (-40F to 185F)
  • On-board storage for 174,762 sets of 3-axis (x, y, z) g-force samples with 12 bits of resolution.
    • Data is typically processed by a powerful onboard microprocessor using FFT algorithms. Processed vibration analysis is then sent to the transceiver node.
  • Typical sampling and analysis (can be adjusted to each application):
    • Accelerometer is checked every 15 minutes.
    • Each axis is sampled at 5 KHz. (Up to 5 KHz sampling available, if needed).
    • Samples are taken for 3 seconds.
    • RMS acceleration, RMS velocity, and peak acceleration are transmitted.
  • Advanced Fast Fourier Transform (FFT) edge computing available
    • Sensor has a powerful microprocessor and large memory to take vibration samples and process the data at the sensor.
    • Custom edge computing algorithms using FFTs and other sophisticated methods are available.
  • Configurable high G-force event – instant wake-up and transmit function – optional.

Wireless Motor Temperature Sensor

  • Standard Option:  Temperature sensor is located with vibration sensor in the metal enclosure.
  • Optional K-Type Thermocouple
    • Connects to K-type thermocouple using standard miniature flat pin connectors (see photos).
    • Standard type K accuracy
      • Leap Sensor thermocouples are compensated for non-linear thermocouple characteristics at cold temperatures to ensure accurate readings at cold temperatures.
      • Cold junction compensation is on the Leap Sensor circuit board.

Wireless Motor Current Sensor

  • Monitors all 3 phases of AC electrical current.
  • Split core for easy installation. Clamp opens, then snaps shut around the wire.
    • Typically supplied with an AcuAmp ACTXXXX-10.  See datasheet.
  • Configurable up to current readings from 2 to 2000 amps.
  • 0-10V signal is sent to the Leap sensor transceiver node via a shielded cable.
  • Operational temperature rated from -20C to 50C (-4F to 120F).
  • Contact us with your specific current sensing requirements.

About Leap Sensors®

Better Design – Better Data – Better Decisions™

Based on Phase IV Engineering’s 30 years of wireless sensor experience, Leap is THE system designed from the ground up to meet the specific needs of industrial users. These sensors are a true leap advancement in Industrial IoT wireless sensing.

  • Modular design makes it easy & cost-effective to adapt to your specific needs – and update easily for a “future-proof” system.
  • Edge computing manages large amounts of data before transmission to software – only get information you need.
  • Bank standard data security: Multi-layered Thread network security using AES-128 data encryption.
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This wireless sensor is ideal for monitoring:

  • Motor monitoring
  • Blower monitoring
  • Pump monitoring
  • Conveyor monitoring
  • Rotating equipment monitoring

Patents pending.

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