PlusSmart · Exclusive i-ALERT distributor for ASEAN, Australia and New Zealand
i-ALERT® – wireless vibration sensors that monitor pumps, motors and fans 24/7
The i-ALERT sensor measures tri-axial vibration, surface temperature and run time. It mounts on the bearing housing with a magnet in minutes – no cabling, no shutdown. Data goes to the i-ALERT AI platform, which learns each machine’s baseline and warns early when something changes, while PlusSmart engineers diagnose the root cause with remote FFT analysis.
- Tri-axial vibration
- Temperature
- Run time
- Wireless, battery powered
- i-ALERT AI
Why vibration is the most widely used condition-monitoring method
Most mechanical faults in rotating equipment – unbalance, misalignment, soft foot, bearing wear, cavitation – change the dynamic forces on the bearings, and those forces show up as vibration. Vibration changes much earlier than temperature or noise: by the time a bearing is hot and noisy, there are often only days to weeks left, while vibration trends can warn weeks to months ahead.
Monthly route-based measurements with a portable analyzer can miss fast-developing faults and require people to walk the plant. Wireless sensors such as i-ALERT measure continuously and automatically, catching changes between rounds and short events such as starts and mode changes.
Reading vibration levels: ISO 10816-3 / ISO 20816-3
For industrial machines, vibration severity is usually assessed as RMS vibration velocity (mm/s) on the bearing housing, 10–1000 Hz. ISO 10816-3 (now ISO 20816-3) defines four zones:
| Machine group (ISO 10816-3) | Foundation | A/B – new, good | B/C – long-term limit | C/D – damage likely |
|---|---|---|---|---|
| Group 2: 15–300 kW | Rigid | 1.4 mm/s | 2.8 mm/s | 4.5 mm/s |
| Group 2: 15–300 kW | Flexible | 2.3 mm/s | 4.5 mm/s | 7.1 mm/s |
| Group 1: above 300 kW | Rigid | 2.3 mm/s | 4.5 mm/s | 7.1 mm/s |
| Group 1: above 300 kW | Flexible | 3.5 mm/s | 7.1 mm/s | 11.0 mm/s |
Absolute limits are only a starting point. What matters more is the trend against the machine’s own baseline: a pump that normally runs at 1.5 mm/s and rises to 3 mm/s within two weeks is a concern even though it is still below the C/D limit. i-ALERT AI learns a baseline for every machine and alarms on both thresholds and rate of change.
Every fault has a vibration signature
| Fault | Spectrum signature (1× = running speed) | Typical action |
|---|---|---|
| Unbalance | Dominant 1× radial, stable phase | Dynamic balancing, clean build-up on impeller or fan |
| Misalignment | High 1× and 2×, high axial vibration | Laser shaft alignment, check pipe strain |
| Looseness, soft foot | Many harmonics of 1×, sometimes ½× | Tighten bolts, check base and foundation |
| Bearing defect | Outer race, inner race and ball frequencies (non-integer multiples of 1×), rising high-frequency acceleration | Plan bearing replacement, check lubrication |
| Pump cavitation | Broadband, random high-frequency vibration | Check NPSH, suction level, operating point |
| Operating far from BEP | Rising vane-pass frequency (vanes × 1×), hydraulic pulsation | Correct the operating point, consider ReliaPump |
How i-ALERT works
- Mount on the bearingMagnetic base on a flat metal surface close to the load zone – no drilling, no cables.
- Measure 24/7Tri-axial vibration, surface temperature and run/stop status recorded continuously; battery powered.
- Cloud learns the baselineData goes via gateway or phone to i-ALERT AI, which learns each machine’s normal behaviour.
- Alarm and prioritiseThreshold and trend alarms; PlusSmart engineers run remote FFT diagnosis and recommend actions.
What i-ALERT includes
i-ALERT sensor
- Vibration, temperature, run time
- Magnetic mount, installs in minutes
- Rugged for dusty, humid industrial sites
- Pumps, motors, fans, gearboxes, compressors
i-ALERT AI platform
- Baseline learned per machine
- Threshold and trend alarms
- One screen for many plants and countries
- Management reports, CMMS integration
Powered by PlusSmart
- Advanced alarm management, fewer false alarms
- Remote FFT diagnosis by engineers
- ROI calculation and periodic reports
- Combined with oil, electrical and drive data
Where to mount the sensor
- Close to the bearing, in the load zone: the further from the bearing, the more the signal is attenuated; never on fan covers or thin guards.
- Flat, clean surface: the magnet must seat firmly to transmit high-frequency vibration; on curved or non-magnetic surfaces use an adhesive or stud mount.
- Keep one fixed position: mark location and orientation for consistent trends; do not move sensors between machines.
- Typical centrifugal pump: one point on the motor drive end and one on the pump bearing housing – enough to tell motor-side from pump-side faults.
Results
Frequently asked questions
Does i-ALERT need cabling or external power?
No. The sensor is wireless, battery powered and magnet-mounted. No shutdown is needed for installation.
Can it be used in dusty, humid or outdoor locations?
Yes. i-ALERT is designed for industrial rotating equipment and runs in thousands of plants, including mining and oil and gas. For hazardous areas, confirm the version and Ex certification before installation.
How many machines should we start with?
Usually the 5–10 most critical or most failure-prone machines, run as a demo for a few weeks, then expand.
What vibration level means we must stop the machine?
Under ISO 10816-3, a 15–300 kW machine on a rigid foundation above about 4.5 mm/s RMS is in the damage zone. Decisions should still be based on trend and spectrum: a low level rising quickly can be more dangerous than a high but stable level.
Works with
- ElectroSine – electrical signature analysis for remote motors
- Poseidon Trident™ – oil and wear-debris monitoring for gearboxes
- PlusSmart Analytics – rank all pumps from existing data
- Knowledge: getting started with predictive maintenance
Pumps failing again and again? Book an i-ALERT demo
A short site visit to choose the first 5–10 machines; you collect data for a few weeks, PlusSmart analyses it and sends a report – you see the value before deciding to scale. Quotations are confirmed directly by PlusSmart Technology.
Hoan Tran – Sales Director, PlusSmart Vietnam
Phone/Zalo: +84 879 848 668 · Email: sales@hoantrantdh.com