Device Overview
Introducing NCD’s Long Range Industrial IoT Wireless 4-20mA Current Receiver, boasting up to a 2 Mile range using a wireless mesh networking architecture. It incorporates a High resolution 16-bit ADC that samples 4-20mA analog inputs at user defined intervals and transmits the result to remote modems and gateways. Between samples, this device enters a ultra-low power sleep mode to minimize power consumption. This Industrial IoT Wireless 4-20mA Current Receiver has an additional feature of detecting change in current every 7 seconds (user configurable) and sending out ADC samples if the change in current is greater than 10% (user configurable). Both features work simultaneously to support multiple application areas in one package.
This Industrial IoT Wireless 4-20mA Current Loop Receiver has on board 16V buck boost power supply, thus eliminates requirement of external power supply. This power supply is used to power up the external 4-20mA sensor. This device can be used with any 2 wire 4-20mA sensor/device into a wireless nodes.
This Industrial IoT Wireless 4-20mA Current Loop Receiver is powered by just 6 AA batteries and a 10 years battery life can be expected depending on environmental conditions and the data transmission interval. Optionally, this sensor may be externally powered. This product has capabilities of supporting 6-32VDC external power supply (Optional).
Features
- Industrial Grade 4-20mA Current Loop Receiver
- Input Range 0-20mA with 15-bit Resolution
- On Board 16V Supply to Power up the external 4-20mA Devices
- Supports 2 and 3 Wire Devices
- Auto ADC Transmission on Analog Voltage Change Detection
- Converts 4-20mA devices into Wireless Nodes
- 2 Mile Line-of-Sight Range with On-Board Antenna
- Superior LOS Range of up to 28 Miles with High-Gain Antennas
- Wireless Mesh Networking using DigiMesh®
- Open Communication Protocol for Easy Software Integration
- Validates and Retries Lost Communication Packets
Wireless Technology
The NCD Industrial range of sensors utilizes DigiMesh, a proprietary networking technology designed by Digi® International. It is especially suitable for IIoT applications as it provides a number of benefits over conventional wireless stacks:
- Long range – up to 1000 feet indoors and 2 miles+ in open areas (line-of-sight) with the included antennas
- Mesh networking topology – no single point of failure, self healing network with high redundancy.
- Long battery life due to low power consumption – up to 10 years
- Simplified provisioning – extending the mesh network via repeater at no additional configuration complexity
- Works in the 868MHz, 900MHz and 2.4GHz bands – worldwide region interoperability.
Battery Life
| Specifications | Minimum | Nominal | Maximum | Notes |
|---|---|---|---|---|
| Batteries | 2 | 6 | 6 | May be Powered by 2 or 4 AA Batteries |
| Battery Life 1 TPD | 10 Years | TPD Transmissions per Day | ||
| Battery Life 12 TPD | 8 Years | TPD Transmissions per Day | ||
| Battery Life 24 TPD | 5 Year | TPD Transmissions per Day | ||
| Battery Life 96 TPD | 3 Year | TPD Transmissions per Day |
The Truth About Battery Life
Under the best of circumstances, the best non-rechargeable batteries commonly available today are limited to a 10 year non-working shelf life in a room temperature environment. Factors such as actual usage, temperature, and humidity will impact the working life. Be wary of any battery claims in excess of 10 years, as this would only apply to the most exotic and expensive batteries that are not commonly available. Also note that most battery chemistries are not rated for use in extreme temperatures. NCD only uses the best Non-Rechargeable Lithium batteries available today, which are also rated for use in extreme temperatures and have been tested by our customers in light radioactive environments. Lithium batteries offer a 10 year maximum expected shelf life due to limitations of battery technology. NCD will never rate sensor life beyond the rated shelf life of the best batteries available today, which is currently 10 years.
Applications & Use-cases
This sensor is a versatile device that brings a new level of precision and reliability to uptime monitoring across a wide range of industrial applications. Its unique combination of digital and analog sensing technologies, coupled with robust wireless communication and a durable enclosure, makes it an ideal choice for diverse environments and challenging operational conditions.
Industrial IoT Long Range Wireless 4-20mA Current Receiver Applications
Current Output Analog Sensor Interface
This application involves using the wireless receiver to collect data from analog sensors that output their signals in the 4-20mA current loop standard. Many industrial sensors—such as temperature, pressure, and flow sensors—use this 4-20mA interface because it is robust over long distances and less susceptible to electrical noise. The receiver acts as the interface between the sensor’s analog output and the wireless transmission system, converting the current data into digital form and transmitting it over a long range to a monitoring system (e.g., a computer, cloud server, or SCADA system). This eliminates the need for complex wiring infrastructure and enables real-time data acquisition from sensors deployed in hard-to-reach or remote locations.
Wireless Flow Meter Monitoring
Flow meters, which measure the rate at which a fluid or gas moves through a pipe, often output a 4-20mA signal proportional to the flow rate. The wireless receiver enables real-time, remote flow monitoring by collecting the flow data from these flow meters and transmitting it wirelessly over a long distance to a central monitoring system. This application is particularly useful in industries such as oil & gas, water treatment, or chemical processing, where flow meters are distributed across large, often remote, installations.
Long Range Wireless 4-20mA Current Monitoring
This use case refers to the receiver’s ability to monitor any 4-20mA current-based sensors or devices across long distances wirelessly. The 4-20mA current loop is a standard for transmitting analog signals, especially in industrial environments, because the current remains constant over long distances, making it ideal for remote monitoring. The receiver captures the current readings from these sensors and sends the data wirelessly to a gateway or central server, often many miles away, depending on the environment and use of long-range wireless technology (such as LoRa).
Read Sensors Like Force, Strain Gauge, Pressure, Flow Meter
Many sensors that measure force, strain, pressure, and flow output their data as a 4-20mA current signal. The wireless receiver is capable of reading the current from these specialized sensors and wirelessly transmitting the data over long distances to a monitoring or control system. This is particularly useful in structural health monitoring, industrial equipment maintenance, or any application where physical forces or pressures are critical to monitor.
Industrial IoT Long Range Wireless 4-20mA Current Receiver Use-cases
Remote Monitoring of Water Treatment Facilities
In water treatment plants, various sensors (e.g., pressure, flow, or level sensors) often provide data using a 4-20mA signal. This receiver can wirelessly gather data from such sensors spread across large, remote locations. Operators can monitor critical parameters like water pressure, flow rates, and chemical levels in real time without being physically present, ensuring system efficiency and enabling early detection of issues.
Oil and Gas Pipeline Monitoring
Oil and gas pipelines require constant monitoring for pressure and flow to prevent leaks or blockages. Sensors used in these applications typically output a 4-20mA signal. The long-range wireless receiver can collect this data from remote or hard-to-reach locations along the pipeline, transmitting it to a central monitoring system. This reduces the need for manual inspections and enables proactive maintenance.
Industrial HVAC System Performance Monitoring
In large industrial facilities, HVAC systems are crucial for maintaining optimal working conditions. Sensors measuring airflow, temperature, and system pressure often use the 4-20mA standard. The receiver can wirelessly gather this data from multiple HVAC units across a facility, helping facility managers monitor system performance, optimize energy consumption, and schedule maintenance before failures occur.
Agricultural Irrigation Systems
Modern irrigation systems rely on sensors to measure soil moisture levels, water pressure, and pump performance. These sensors often output a 4-20mA signal. The wireless receiver can collect data from sensors spread over vast agricultural fields, allowing farmers to remotely monitor irrigation conditions. This ensures efficient water usage, reduces labor costs, and enhances crop yields through precise, real-time monitoring.
