Universal Base Platform Wireless Sensor – 2 Thermocouple Temperature, Analog Input – Amp Clamp, Full Bridge Input – Strain / Pressure, 4-20 mA Input, 3 Axis Vibration, Switch Input, CAN Bus, 2 I2C I/O – Humidity, Switch Input, I2C Display
Leap Sensors are specially designed to be customized. If this isn’t exactly what you need, please contact us.
Overview of the Universal Base Platform Leap Wireless Sensor
Most Leap Wireless sensors are built off of one “Universal Base Platform” circuit board. This board covers the vast majority of industrial wireless sensing needs. This allows Phase IV Engineering to quickly configure an industrial sensor for a specific application.
Thermocouple Sensor Specifications
- Connect a K-type thermocouples using standard Omega miniature flat pin connectors (see photos).
- Standard Type K Accuracy – see accuracy details on Omega Thermocouple web site.
- 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.
Amp Clamp Sensor Specification
- Monitors 1 wire (one phase) of the electrical current going to a wire.
- Typically supplied with an AcuAmp ACTXXXX-10. See datasheet.
- Split core for easy installation. Camp opens, then snaps shut around the wire.
- Configurable up to current readings from 2 to 2000 amps.
- End user is responsible for proper installation.
- 0-10V signal is sent to the Leap Sensor transmitter via a shielded cable.
- Amp clamp rated from -20C to 50C.
Vibration Sensor Specifications
- Vibration sensor can mount with the provided magnet or threaded stud.
- Vibration sensor is connected to the Leap Transmitter with a shielded cable.
- An industrial communication protocol allows long cables (if needed) between the sensor and wireless transmitter.
- 3 axis g-force reading taken.
- G-force readings up to +/- 16 G.
- Accelerometer operating temperature: -40 to 85C.
- Accelerometer is powered by the Leap transmitter module.
- On-board storage for 174762 sets of 3-axis (x, y, z) g-force samples with 12 bits of resolution.
- Data is typically processed by a powerful on-board microprocessor using FFT algorithms. Processed vibration analysis is then sent to the radio transmitter.
- Typical Sampling and Analysis (can be adjusted to each application).
- Accelerometer is checked every 15 minutes.
- Each axis is sampled at 1 KHz (up to 5 KHz sampling available, if needed).
- Samples are taken for 3 seconds.
- Average and maximum g-force readings are reported for each axis.
- 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.
- Configurable High G-force Event – Instant Wake-up and Transmit function – optional.
I2C Humidity Sensor Specification
The humidity sensor is typically mounted on the outside of the Leap Sensor enclosure for fast response times and accurate readings.
For detailed specifications on the humidity sensor, see the Leap Humidity Sensor web page.
Strain (Load, Weight) Sensor Specification
Leap Strain sensors support nearly all types of strain sensors. The most common type of strain sensor used is a full-bridge foil strains sensor with individual strain sensor gage factors of around 2.0. Higher resistance gages of 1000 ohms, or greater, are preferred (but not required) to extend battery life.
Balancing resistors can be added to also support half-bridge and quarter bridge configurations.
- Strain Sensor Range: typically +/- 2000 u-Strain for a total range of 4000 u-Strain. The range can be custom configured for a specific application.
- Strain Sensor Resolution: <sensor range> / 4000
- Sensor Typical Accuracy: <sensor range> / 1000
The Leap wireless strain sensor has shielded cable with 4 wires that attach to a full-bridge strain sensor. The amplification of the signal inside the electronics module can be adjusted to change the range of strain that the sensor can sense.
The wireless sensor requires that the strain sensor be balanced to zero at zero strain levels.
Pressure sensors are typically integrated using analog Honeywell PX2 or PX2 series of pressure sensors. The Leap Sensor can support many other types of pressure sensors that have other outputs – see below.
Switch Input Specification
Using a 2-wire cable, the Leap Sensor can take any switch input such as a limit switch, magnetic switch, or reed switch.
Flexible Sensor Inputs and Outputs Facilitate Fast Prototyping and Custom Sensors
4 – 20 mA Input
This highly versatile Leap Sensor can be integrated with a huge range of industrial sensors that have a standard 4 – 20 mA output. The Leap Sensor configuration supports the conversion of the 4 – 20 mA output to the desired units of measure (such as pressure, voltage, temperature…).
The Leap Sensor provides the power to the 4 – 20 mA sensor (only) when it is read so no external power is needed to the 4 – 20 mA sensor and long Leap Sensor battery life is preserved.
Each application may customization and expert consulting services. Contact us with your specific needs.
Analog Input – Supports a Wide Range of Analog Sensors
If an Amp Clamp is not needed, the Leap Sensor transmitter can be connected to any type of analog output or resistive ratiometric sensor.
2 I2C Input and Output
Leap Sensors have 2 I2C communication ports that can support a wide range of I2C sensors and I2C outputs (such as displays) using the I2C bus.
4-Bridge Input – Supports a Wide Range of Analog Sensors
If a strain sensor is not needed, the 4-bridge input on the Leap Transmitter module can be used to support a wide range of sensors. This circuit includes a precision voltage source for ratiometric sensors and a high-precision instrumentation amplifier.
2 On/Off I/O
The Leap Sensors have 2 pins that can support a single-bit input or output. This I/O may be used for switch inputs or simple LED outputs.
CAN Bus Supports a Wide Range of Industrial Digital CAN-bus Sensors
Leap Sensors have an on-board CAN bus that is ideal for integrating industrial sensors with a CAN bus to the wireless transmitter. The wired CAN bus is highly immune to RF and electrical noise that are common in industrial applications. CAN bus sensors can also be “daisy chained” on one cable so that many different types of sensors can be attached along one cable that is connected to the Leap transmitter.
Leap Wireless Sensor Transmitter 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.
- *Amp clamp is limited to -20C to 50C.
- 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.
- Sensor Data Logging – When sensors do not receive an acknowledgement from the gateway that the radio transmission was received, the Leap Sensor will store the time-stamped data on-board 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 “hand-shake” 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.
- One gateways support 250 sensors that are in-range. Additional gateways can extend the sensor coverage.
- Battery – user-replaceable 3.6V battery.
Leap Wireless Sensors Gateway (Receiver) and User Interface Software
See the Leap Sensors gateway products web page and the Leap Sensors User Interface options web page for more detailed information.
Leap Sensors wirelessly transmit their data to a gateway*. This gateway can support over 250 sensors. 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.
High-Value Features Unique to the Leap Wireless Sensor Product Line
These sensors are a true leap advancement in IoT industrial wireless sensing.