Wireless Motor Sensor for Predictive Maintenance – Leap Sensors

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, and receive alerts via text and/or email. Avoid costly downtime and gain operating insight. It’s like having X-ray vision into your key processes.

This motor condition monitoring sensor is ideal for an IoT predictive maintenance program/cbm maintenance.

  • 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.

Part of the breakthrough Leap Sensors® system for the IIoT.


Watch the video tutorial below.  (Demonstration starts at 10:00 mark).


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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 machine condition based monitoring system as part of a condition based maintenance program.

  • Monitors the top 3 predictors of impending motor failures.
    • Motor vibration monitoring sensor detects maximum and average vibration on 3 axes 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 clamp) detects increased electrical current to motors to detect overloads.
  • Fast and easy to install.
    • Magnetic or screw 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

  • Connects to K-type thermocouple using standard miniature flat pin connectors.
  • 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 1 wire (one phase) of the electrical current.
  • Split core for easy installation. Clamp opens, then snaps shut around the wire.
  • 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).

Leap Wireless Sensor Transceiver Node Specifications

  • Transmission Distance to a gateway – typically 1500 feet in open air. Several hundred feet in an industrial environment.
  • Battery Life – 5 to 10 years in typical applications.
    • Different enclosures are available to balance battery size and battery life.
  • Rugged Sensor Enclosure
    • Sealed all-metal enclosure with mounting flanges.  2.44 x 1.33 x 4.73 inches
  • Sensor Mounting Options
    • Screw mount flanges standard.
    • Magnetic mount – optional.
  • High Operating Temperature – Standard sensor -40C to 85C (-40F to 185F).
    • High operating temperature option available: -40C to 125C* (-40F to 260F). Unique to Leap Sensors.
      • *Accelerometer is limited to 85C (185F).
      • *Amp clamp is limited to -20C to 50C (-4F to 120F).
  • 2-way Communication with the sensor through the user interface:
    • Name the sensor, set sensor sampling time interval, set wireless transmit time interval, over-the-air firmware updates.
    • Gateways send an acknowledgement to the sensor that the data was received for high reliability.
  • Data Logger: When sensors do not receive an acknowledgement from the gateway that the radio transmission was received, the sensor will store the time-stamped data on-board (up to 10,000 readings) until the gateway connection is established.
  • Reliable Industrial Over the Air Radio Communication
    • Industry-standard 802.15.4 with Direct Sequence Spread Spectrum (DSSS).
    • Gateway “handshake” acknowledgements of successful transmission and sensor data logging for extra reliability.
  • Over the Air Protocol – Standard and established 6LoPan and Thread.
  • Data Security – AES encryption. Standard and established TLS security.
  • FCC certified.

Leap Wireless Sensors Gateway (Receiver) and User Interface Software

  • See the Leap Sensors gateway page and the Leap Sensors User Interface options page for more detailed information.
  • Leap Sensors wirelessly transmit data to a gateway*.
    • Gateway can support over 250 sensors that are in range. (Additional gateways can extend sensor coverage.)
    • The gateway then passes the data to the Leap user interface software. The user interface software may be hosted on the gateway (and connected to a PC with a USB cable), on the password-protected Leap Sensors Cloud web site, or an on-site server.
  • User interface supports: logging-in, set user rights, view sensor data, set email and text alerts (cloud version), graph sensor data, download data to excel, add or subtract sensors, update firmware, and other functions.

*Custom-ordered leap sensors are available with a direct-to-cellular option where no gateway is needed and the data is sent directly to a cloud server. Contact us for more information.

About Leap Sensors®

Better Design – Better Data – Better Decisions™

Based on Phase IV Engineering’s 25 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 condition monitoring.

  • 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 starting with a Password Authenticated Key Exchange (PAKE).
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This wireless sensor is ideal for:

  • Critical motor monitoring
  • HVAC  motor monitoring
  • Blower  motor monitoring
  • Conveyor motor monitoring
  • Grinder motor monitoring
  • IoT condition monitoring
  • Motor condition monitoring
  • Part of a predictive maintenance system

Patents pending.

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