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Wireless Condition Monitoring

Why use valuable manpower to collect vibration data on healthy machines? Why settle for measurements once a month when you can have them multiple times daily? Why have people venture into unsafe areas to collect routine measurements? Echo® Wireless Vibration Sensors can safely “look” at the machine’s health several times per day and provide immediate notification when warning or critical levels are reached. This frees up technical experts, like certified vibration analysts, for higher value tasks such as fault analysis. The Echo® Wireless Vibration Sensor and the EchoPlus® Wireless Junction Box make the set of overall vibration measurements, listed below, that provide early warning of most common machine faults. In addition to these measurements, Echo® provides accurate battery status. Using a user-programmable vibration threshold, Echo® can detect if the machine is not running and if not, skip a measurement to conserve battery power.

Echo® Wireless Vibration Monitoring System takes your measurements faster and more frequently without risking worker safety. Echo® is Class 1 Division 2 approved - it operates safely in hazardous areas, where flammable gases may be present and the potential for explosion exists. Other benefits of wireless vibration monitoring include:

  • Identify developing problems faster than with route-based method

  • Monitor remote, dangerous, and hard-to-reach points "at a glance"

  • Eliminate time that's wasted taking readings on healthy machines

  • Integrate Echo® with your PLC via Modbus® to monitor plant machinery

Industrial Sensors

IMI Sensors, a division of PCB Piezotronics, is a global designer and manufacturer of industrial vibration monitoring instrumentation such as accelerometers, vibration transmitters and switches. These industrial sensors are used to spot imbalance, bearing faults and misalignment by measuring machine vibration, providing early fault diagnosis thus reducing downtime. Our vast product line interfaces directly with data acquisition equipment including online systems and handheld data collectors.

We offer a full line of piezoelectric accelerometers, velocity sensors, dual output vibration sensors, 4-20 mA vibration transmitters, switches, relays, cables, displays and accessories. Virtually all of our products are certified for use in hazardous areas through CSA and ATEX.

Six Primary Measurements

  • RMS Velocity: RMS Velocity is the average of all velocity values captured within the sampling window and identifies low frequency faults such as unbalance and misalignment.

  • Peak Velocity: Peak Velocity is RMS Velocity multiplied by 1.414 and identifies low frequency faults such as unbalance and misalignment.

  • RMS Acceleration: RMS Acceleration is the average of all acceleration values captured within the sampling window and identifies high frequency faults such as broken rotor bars in electric motors.

  • Peak Acceleration: Peak Acceleration is RMS Acceleration multiplied by 1.414 and identifies high frequency faults such as broken rotor bars in electric motors.

  • True Peak Acceleration: True Peak Acceleration is the highest acceleration value captured within the sampling window and identifies high-frequency, impulsive faults such as rolling element bearing defects and some gear defects.

  • Crest Factor: Crest Factor is the ratio of True Peak to RMS Acceleration and is used as an indicator of fault severity with caution.


■ Transmits long distances

■ Eliminates expensive cable runs

■ Installs easily

The Echo® Wireless Vibration Sensor is a stand-alone, battery powered industrial vibration sensor. Echo® has an LED that provides visual feedback on the status of the sensor, including: on, off, measuring, transmitting or changing states. The sensor has an embedded magnetic switch and can be activated or deactivated by holding a strong magnet next to the sensor. Upon activation, the sensor makes and transmits a set of measurements. The Echo® Wireless Vibration Sensor is also offered in a hazardous area certified variation (CSA approval of 916 MHz version only.) Model CS670A01 can be used in hazardous area requiring Class 1, Division 2 certification. The model can be used in hazardous applications, such as oil wellheads, for remote wireless vibration monitoring on these machines.

WIRELESS JUNCTION BOX MODELS 672A01 & CS672A01 (916 MHz) MODEL 672A02 (868 MHz)

■ Instantly converts existing sensors to wireless

■ Runs independently or with existing junction box

■ Uses 24 VDC or battery power

The EchoPlus® Wireless Junction Box is an 8-channel junction box that instantly converts installed industrial sensors to wireless operation. This incredibly economical device periodically powers each sensor, makes the same set of overall measurements and transmits them wirelessly. The default transmission interval is 8 hours, but it is userprogrammable. Additionally, it operates as a standard junction box allowing full data collection with a portable data collector at the box. It can be powered using either standard 24 VDC or any battery between 6 and 13 VDC. The unit can be used by itself or in conjunction with an existing junction box by simply jumping wires between them.

RECEIVER MODEL 673B01 (916 MHz) MODEL 673B02 (868 MHz)

■ Requires no repeaters, gateways, or mesh

■ Outputs to Ethernet

■ Installs easily

The Echo® Receiver is a stand-alone unit that communicates point-to-point with Echo® Wireless Vibration Sensors and EchoPlus® Wireless Junction Boxes. Using an ultra-narrow bandwidth filter with Extended Range RF (ERRF) technology, it has unprecedented -145 dBm sensitivity and can detect and decode RF signals as low as about a millionth of a billionth of a milliwatt. This results in very long distance point-to-point communications in plants, eliminating the need for repeaters or complicated mesh networks. Actual tests in a typical power plant achieved successful signal transmission distances of over 1200 ft (365 m) and even through buildings. Outdoor tests have achieved transmission distances measured in miles and transmissions are at only 0.75 mW ERP using very little battery power.

Data Visualization and Analytics with Exosite's Condition Monitoring Software

For quick data visualization and analytics, Exosite offers customers a fully integrated software suite which allows you to get the system up and running with just a few steps. Its fully integrated connetcivity to PCBs Echo® condition monitoring system, what is left to do is type in your credentials and you are done!

Connect with us and learn how this system can support you in monitoring critical high value assets!

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