Machine monitoring for pumps, motors and equipment

Many systems provide operating or fault states through a suitable volt-free contact. A dry-contact sensor or IoT controller reads the state and transmits it wirelessly. A common alarm initially reports only a general fault state; the specific cause is investigated at the equipment.

A qualified contractor checks connections and electrical compatibility. Measuring devices with suitable interfaces may provide additional data, such as over Modbus. If no usable signal is available, temperature, pressure or vibration sensors may suit the task.

Additional sensors can reveal changes that equipment does not report itself. A temperature probe measures at a bearing, housing or pipe. A pressure sensor shows pressure trends. A current sensor provides information about electrical operating periods. Interpretation depends on the point and machine.

Vibration sensors are available for rotating machines such as pumps, motors and fans. The WISE-2410 vibration sensor measures acceleration along three axes and calculates indicators such as vibration velocity within the sensor. Interpretation depends on machine type, speed, load and mounting. Changes in readings give maintenance teams a reason to investigate.

Condition monitoring means continuously monitoring the state of a system. SECURUS offers simple condition monitoring that can be retrofitted: readings and states are stored, shown as histories and reported when limits are breached. Changes that get lost on inspection rounds stand out.

SECURUS is not a complete predictive maintenance system with automatic diagnosis and remaining service life. Whether a changed pattern indicates wear is assessed by a specialist. For that, the platform provides the data and the point in time from which something changed.

In production it is about downtime: if a pump, compressor or cooling unit fails, in the worst case the line stops. Machine monitoring with SECURUS reports faults and unusual states to maintenance, at night and on weekends too, when nobody is at the machine.

Because the sensors work by radio and mostly on batteries, older machines and auxiliary systems without their own networking can be connected as well. The data comes together in the same platform as building services, energy and indoor climate. More on typical applications can be found under production and industry.

Pumps often work unobserved in basements, shafts and plant rooms: heating and circulation pumps, booster stations, sewage lifting stations. If a lifting station fails, the water in the pump sump rises, and a fault quickly becomes water damage.

A suitable lifting station’s fault contact can be monitored. A level sensor adds sump water levels, while a leak detector reports water reaching its detection area. Teams can review the signals together and investigate on site.

To start, a single system is often enough whose failure would be expensive or annoying, such as the heating of a school, the sewage lifting station of an apartment building or a compressor in the workshop. We check which signals the system already provides and add a sensor if needed. The system is then usually connected within a short time.

With the first alerts and histories, it becomes clear which other systems are worthwhile. Because all systems run in the same platform, monitoring grows with you, without new systems or logins.

A heating fault goes to building services, a machine contact to maintenance. Schedules distinguish expected states, such as equipment switched off on the weekend, from real faults. SECURUS reports; the equipment’s controls, shutdown and safety functions remain unchanged.

Alerts appear in the dashboard with the site, equipment, trigger and time. SMS and email notifications inform the configured groups. Service partners with suitable permissions can view alerts and readings for the equipment they maintain.