Condition monitoring for rotating equipment in industrial plants
Condition monitoring is the practice of measuring the mechanical and thermal state of rotating machinery while it runs, so that wear, misalignment, imbalance and bearing damage are detected before they cause unplanned downtime. The LOGGON-400 condition monitoring system from LOGGON TECH collects velocity, acceleration, displacement and temperature signals from machines and converts the operating state into spectral health features by digital signal processing. These features form the basis for preventive maintenance: maintenance intervals are planned from measured trend data rather than from calendar intervals or run hours. The system is built from wireless vibration and temperature sensors, a wireless gateway, and a multi-channel monitoring instrument, and is intended for plant engineers and maintenance teams who need continuous data on pumps, motors, fans, gearboxes and similar rotating assets.
Category overview and where it is used
The range covers three functional levels. At the machine level, battery-powered wireless sensors are mounted on bearing housings or machine frames and record vibration and temperature at fixed intervals. At the network level, a wireless gateway collects data from up to 64 sensor nodes and forwards it for processing. At the plant or service level, the multi-channel monitoring instrument provides a compact acquisition point for continuous monitoring and can be combined with remote expert diagnosis.
Typical installation points include:
- Pumps and fans in water, HVAC and process service, where bearing degradation shows up as rising high-frequency vibration.
- Electric motors and gearboxes on production lines, where imbalance and misalignment appear in velocity spectra.
- Cooling towers, compressors and conveyors in plants where cable routing to each machine is impractical.
- Machines in areas requiring explosion protection, where intrinsically safe sensors are mandatory.
Because the sensors are wireless and battery powered, the cost of installation is dominated by mounting and commissioning time rather than by cable trays and conduit. This makes dense coverage of secondary assets practical, not only of the few machines already connected to a wired online system.
Models in this range
LOGGON-401 wireless vibration and temperature sensor
A battery-powered, triaxial sensor for direct mounting on the machine. It records vibration in three axes and surface temperature, with more than 2 years of working time from its battery.
| Frequency range | 10–5000 Hz |
|---|---|
| Vibration range | ±16 g peak, triaxial |
| Temperature range | -40 to +125 °C |
| Protection | IP67 |
| Explosion protection | Exia IICT4Ga (intrinsic safety) |
| Power | Battery, working time over 2 years |
LOGGON-401B wireless sensor
A variant of the wireless sensor with a narrower operating temperature range and an output set covering acceleration, velocity and spectrum data.
| Vibration range | ±16 g peak, triaxial |
|---|---|
| Frequency range | 10 Hz–5000 Hz |
| Operating temperature | -40 to +85 °C |
| Explosion protection | Exia IICT4Ga |
| Data types | Acceleration, velocity, spectrum |
| Power | Battery |
LOGGON-410 wireless gateway
The network coordinator for the wireless sensors. One gateway manages up to 64 nodes and is housed in an IP67 flameproof enclosure, so it can be installed close to the machines on the shop floor.
| Node capacity | Up to 64 nodes |
|---|---|
| Operating temperature | -20 to +60 °C |
| Enclosure | IP67 flameproof |
| Power supply | 100–265 V or 8–24 V (as published; confirm AC/DC designation) |
LOGGON-V1 multi-channel monitoring instrument
A compact instrument for continuous monitoring, intended for fast installation where early fault signs have already been observed. It supports up to 64 nodes, offers an Ethernet port and an optional 4G module, and can run from an internal rechargeable battery or from mains supply. Remote expert diagnosis service is available with this model.
| Node capacity | Up to 64 nodes |
|---|---|
| Transmission rate | Typically 200 kbps |
| Communication | 1 Ethernet port; optional 4G module |
| Operating temperature | -40 to +60 °C |
| Power | Rechargeable battery or mains |
How to select
Selection starts from the machine and the fault modes you need to catch. Confirm the frequency range first: bearing and gearmesh frequencies of interest must fall inside the 10–5000 Hz band of the sensors. Then check the environment. The LOGGON-401 covers surface temperatures up to +125 °C and suits hot bearing housings; the LOGGON-401B covers -40 to +85 °C (its operating temperature). Both carry the published Exia IICT4Ga marking, so verify that this marking matches your hazardous-area classification before mounting. For wet or washdown areas, check the rating per model: the LOGGON-401 sensor and the LOGGON-410 gateway carry IP67 ratings.
Next, size the network. Each gateway manages up to 64 nodes; count the measurement points per machine (typically drive-end and non-drive-end bearings, plus the motor) and group nodes so that each gateway covers one machine group or one plant area. Check the supply available at the gateway location: 100–265 V or 8–24 V, as published for the gateway (confirm the AC/DC designation). Where remote diagnosis support is required, or where a wired network connection exists, the LOGGON-V1 provides the acquisition point and connectivity. Finally, plan the data path: spectral features are the basis for trend analysis, so agree in advance which features are reviewed, at what interval, and by whom.
Integration and communication
The condition monitoring system is arranged in two tiers. Wireless sensors transmit to the LOGGON-410 gateway or to the LOGGON-V1 instrument. The LOGGON-V1 provides one Ethernet port and an optional 4G module for its plant-network connection; the LOGGON-410's uplink interface is confirmed per project. The V1's Ethernet connection allows data to be forwarded to a server or to the remote expert diagnosis service. The V1's documented figures list a typical transmission rate of 200 kbps; the link carries the sensors' measured data — acceleration, velocity and spectrum are the documented data types. Plan IP addressing and access rights with your IT team before installation, and confirm that the mounting positions give reliable radio coverage back to the gateway; a site survey with a few nodes is the most reliable way to verify this.
FAQ
Can the sensors be mounted in hazardous areas?
Both the LOGGON-401 and LOGGON-401B carry Exia IICT4Ga intrinsic safety marking. The suitability of the marking for your zone and gas group must be confirmed against your area classification before installation.
How many sensors does one gateway support?
The LOGGON-410 gateway manages up to 64 nodes, and the LOGGON-V1 instrument supports up to 64 nodes. Group nodes by machine or plant area to keep data review manageable.
What data do the sensors provide?
Vibration in three axes and surface temperature. The LOGGON-401B provides acceleration, velocity and spectrum data; the LOGGON-400 system converts the collected signals into spectral health features by digital signal processing.
How is the system powered?
The sensors are battery powered, with more than 2 years of working time for the LOGGON-401. The gateway accepts 100–265 V or 8–24 V (as published), and the LOGGON-V1 runs from a rechargeable battery or mains supply.
For a quotation or a technical review of your application, provide the machine list, measurement points per machine, ambient and surface temperatures, area classification and the supply available at each gateway position. LOGGON TECH can then confirm the sensor variant, node count and gateway arrangement for your plant.