Industrial IoT Wireless Predictive Maintenance Sensor, Gen4

Three things in one wireless sensor: vibration, temperature, and AC current. The vibration channel is a 3-axis accelerometer (±16g, configurable from 100 Hz to 25.6 kHz) that runs an on-board FFT and computes RMS & Max vibration in g, RMS velocity, RMS displacement, peak vibration frequency, and shaft speed in RPM (and can stream raw time-domain data). That channel also reports its own temperature (−40 °C to +105 °C, ±1 °C) with every sample. The separate K-type thermocouple channel reaches much higher, up to 260 °C (500 °F), and the third channel measures AC current through a 100 A, 200 A, 600 A, or 1000 A current transformer.

Each signal catches a different failure mode, and each can be a false alarm on its own. Vibration reveals mechanical faults early, temperature confirms friction and overload, and rising AC current exposes strain, a seized bearing or clogged pump, that vibration and heat can miss. Trending all three together gives you high-confidence, early warning before you commit to a repair.

FFT (Fast Fourier Transform) breaks a vibration signal into the frequencies that make it up. Because bearing defects, gear-mesh, imbalance, and looseness each occur at characteristic frequencies, an on-board FFT lets the sensor tell you which fault is developing, not just that overall vibration is rising. High-pass and low-pass filters help focus on the frequencies you care about.

Yes. Alongside the computed RMS and FFT results, the Gen4 can output raw time-domain data so you can run your own FFT or feed it into an analysis pipeline. The accelerometer sample rate is configurable from 100 Hz to 25.6 kHz with a 1 to 10 second sample duration and a 6.3 kHz bandwidth.

Yes. The vibration channel is the same vibration sensor used in our 1-Channel Wireless Vibration Temperature Sensor Gen4, so it carries the same capabilities: a 3-axis accelerometer on an external mounting-reach probe, ±16g full-scale, a configurable 100 Hz to 25.6 kHz sample rate, on-board FFT, built-in machine learning, shaft-speed (RPM) reporting, and a temperature reading (−40 °C to +105 °C, ±1 °C) sent with every vibration sample. The difference is that this sensor adds two more channels, a K-type thermocouple and AC current, on the same wireless sensor.

On-board machine-learning algorithms flag abnormal vibration patterns on the sensor itself, so a developing fault surfaces without a cloud service scoring your data. Always-listening motion detect wakes the sensor when the asset moves, and you choose scheduled sampling for steady trending or interrupt-driven capture for immediate, event-based alerts. Readings are temperature-compensated, so the data stays consistent through swings in ambient plant conditions.

The vibration probe attaches to the asset three ways: a ¼ NPT thread, a ¼”-28 UNF stud, or a magnet mount for fast, tool-free placement. The enclosure itself wall-mounts or magnet-mounts nearby, and the K-type thermocouple and current sensor reach the motor. For the best high-frequency data, mount the vibration probe as close to the bearing housing as practical.

Yes. The main enclosure is IP65-rated, and the vibration probe carries a −40 °C to +105 °C operating range. The electronics carry a −40 °C to +85 °C component rating.

Up to roughly 2 miles line-of-sight on the 868/900 MHz bands. Because it uses a self-healing wireless mesh network, sensors also relay through one another to extend coverage across larger or obstructed plants.

On a field-replaceable D-cell with supercap the sensor delivers up to 5 years of battery life, depending on how often it transmits, with battery level reported on every transmission. A second model adds an external power connector for installations where a permanent wired feed is available; the standard model is battery-only.

It runs on your choice of 868 MHz, 900 MHz, or 2.4 GHz, with encrypted communication on the wireless link. The mesh forms and repairs itself, relaying data around obstacles to your gateway.

No. The sensor is a one-time purchase with no subscription or recurring cloud fee. Paired with an Atrium Gateway, you get dashboards, alerts, and reporting with no per-machine software charge, you own the hardware and the data it produces.

Wherever you choose. Data stays on your network with no required NCD cloud account. Through Atrium’s built-in Node-RED you can forward readings to AWS, Azure, Google Cloud, any MQTT broker, a local SCADA system via Modbus, or your own REST API.

Yes. The sensor is designed and manufactured in-house by National Control Devices in the USA and is RoHS compliant. Many NCD products carry a 5-year warranty, and you’ll always reach a US-based engineer for support, contact NCD to confirm coverage for your configuration.