The Yokogawa Sushi Sensor represents a comprehensive family of wireless condition monitoring devices designed to address one of the most persistent challenges in process industries: the need for fragmented and labor-intensive sensing systems. Instead of relying on multiple isolated devices and extensive wiring to monitor vibration, pressure, temperature, and steam trap performance, the Sushi Sensor line provides a unified wireless infrastructure for asset condition monitoring across large-scale industrial facilities.
Modular Architecture for Flexibility and Serviceability
The Sushi Sensor family employs a modular design philosophy that emphasizes flexibility, maintainability, and scalability. Rather than a single, all-in-one multi-parameter sensor, the line consists of specialized modules—each optimized for specific measurement functions—connected through a shared LoRaWAN wireless communication backbone.
The XS770A is a fully integrated wireless vibration sensor that combines tri-axial vibration measurement with built-in surface temperature sensing. Introduced as the first product in the Sushi Sensor series, it laid the foundation for Yokogawa’s broader Industrial IoT (IIoT) monitoring ecosystem.
The XS530 pressure measurement module and XS550 temperature measurement module both interface with the XS110A wireless communication module. This modular pairing enables the measurement components to remain mounted in place during maintenance. At the same time, the XS110A can be detached for battery replacement, thereby dramatically improving service efficiency and minimizing process disruptions.
The XS822 steam trap monitoring module also connects with the XS110A and incorporates acoustic and temperature sensing elements to automatically detect and classify steam trap operating conditions. Together, these modules provide plants with a cohesive, interoperable sensing architecture that scales from pilot installations to full plant coverage without requiring re-engineering of infrastructure.
Shared Wireless and Environmental Design Standards
All Sushi Sensor products share a standardized technical foundation that defines their performance, durability, and connectivity. Each uses LoRaWAN® wireless technology, offering long-range communication—up to approximately six miles (ten kilometers) under ideal conditions—while maintaining very low power consumption and robust interference resistance. This makes the system suitable for large industrial sites such as refineries, petrochemical complexes, and power generation plants, where traditional wired installations are costly and inflexible.
The devices feature rugged environmental protection, with IP66 and IP67 ratings for dust and water resistance, and are designed for installation in hazardous environments with explosion-proof certifications, including ATEX and IECEx. Battery life can be extended up to ten years under specified conditions (such as one-hour reporting intervals, moderate ambient temperatures, and optimal signal strength), minimizing lifecycle costs and reducing the frequency of maintenance visits in hazardous or remote areas.
XS770A: Wireless Vibration and Temperature Sensing for Rotating Equipment
The XS770A vibration sensor forms the backbone of condition-based maintenance programs for rotating machinery. It measures vibration velocity and acceleration along three axes, as well as a composite value for overall vibration, while simultaneously recording surface temperature. These parameters allow early detection of bearing degradation, imbalance, and shaft misalignment in motors, pumps, compressors, and fans.
By leveraging its wireless LoRaWAN communication, the XS770A can be deployed in locations that were previously difficult or unsafe to monitor—such as elevated piping, confined spaces, or high-temperature zones—without the need for costly wiring runs. When vibration anomalies are detected, maintenance teams receive timely alerts that allow intervention before minor mechanical issues evolve into equipment failures or costly process shutdowns.
XS530: Pressure Measurement for Process Insight
The XS530 pressure measurement module provides accurate monitoring of gauge pressure in gases and liquids. When paired with the XS110A wireless module, it becomes a self-contained, battery-powered transmitter suitable for both high- and low-pressure applications. The sensor’s wetted materials are engineered to resist corrosion in demanding process conditions, supporting long-term stability and low drift.
Pressure data from the XS530 often serves as a critical complement to vibration and temperature measurements on adjacent equipment. For example, a gradual pressure fluctuation correlated with increased vibration amplitude can reveal pump cavitation or progressive valve leakage. This multi-parameter context—made possible by combining readings from different Sushi Sensor modules—provides a depth of diagnostic capability that single-parameter devices cannot achieve.
XS550: Dual Thermocouple Input for Broad Temperature Applications
The XS550 temperature measurement module accommodates dual thermocouple inputs compliant with nine IEC standards, including types B, E, J, K, N, R, S, T, and C. This allows it to measure a wide range of process and surface temperatures, from cryogenic conditions to furnace-level heat. Typical applications include monitoring temperature profiles in multistage heat exchangers, detecting energy losses from steam leaks, and tracking the temperatures of refractory surfaces in furnaces and vessels.
Because the XS550 connects to the detachable XS110A wireless module, technicians can replace batteries or update communication components without needing to remove the temperature measurement hardware from the process. This feature reduces maintenance time, prevents unnecessary dismounting of probes, and minimizes exposure to hot or hazardous areas.
XS822: Automated Steam Trap Monitoring
Steam traps play a vital role in maintaining steam system efficiency, yet they are notoriously difficult to monitor using manual inspection methods. The XS822 steam trap monitoring module automates this process by combining acoustic and temperature sensing to evaluate trap performance and classify operational status.
By continuously analyzing the sound and temperature patterns associated with condensate discharge, the XS822 can distinguish between regular operation and failure modes such as blowing (steam loss) or plugged (condensate retention) traps. The device requires no configuration for specific trap types or manufacturers—it automatically learns and identifies trap conditions, transmitting simple failure or non-failure status to host systems.
This automation converts a historically manual, schedule-based maintenance task into a continuous, data-driven process. Plants benefit from measurable energy savings, reduced steam losses, and lower carbon emissions, while maintenance teams can prioritize repairs based on actual performance rather than routine inspection intervals.
Unified Wireless Infrastructure and Analytics Integration
From an infrastructure perspective, the Sushi Sensor’s LoRaWAN-based network architecture enables robust, plant-wide deployment. Thousands of endpoints can communicate through strategically placed gateways, transmitting data to Yokogawa’s cloud-based analytics platforms or on-premises systems. Within these systems, condition data populates dashboards that display equipment health trends, risk levels, and recommended maintenance actions.
This centralized visibility transforms maintenance operations from a reactive response to a predictive intervention. Instead of waiting for breakdowns, engineers can anticipate failure patterns, optimize spare-parts inventory, and schedule repairs when they will have the least operational impact. Over time, this approach extends equipment lifespans and boosts overall plant reliability.
Safety and Deployment Advantages
Wireless remote monitoring also enhances personnel safety by reducing the need for manual inspections in confined spaces, at elevation, or in hazardous areas. Technicians no longer have to routinely approach hot equipment, pressurized lines, or areas with explosive atmospheres to gather data.
Since its market introduction, more than 30,000 Sushi Sensor units have been deployed globally across diverse industries, demonstrating proven reliability in challenging operating environments and validating Yokogawa’s vision for wireless, modular condition monitoring.
A Scalable Platform for Digital Transformation
The Sushi Sensor family aligns seamlessly with broader Industrial IoT and predictive maintenance initiatives. By utilizing specialized sensors that share a common wireless infrastructure, plants can implement comprehensive condition monitoring without the cost, complexity, or wiring density associated with legacy systems.
As facilities evolve, the modular architecture allows incremental expansion—beginning with vibration monitoring on critical assets, adding steam trap monitoring for energy optimization, and later incorporating pressure and temperature measurement to complete a fully integrated program. Each stage builds toward a unified, data-driven maintenance strategy.
For process industries pursuing higher reliability, greater energy efficiency, and safer operations, the Yokogawa Sushi Sensor family delivers a technically proven, scalable foundation for condition-based maintenance. It exemplifies how modern wireless sensing technology can reshape operational excellence—merging rugged industrial design, intelligent measurement, and long-range connectivity into a cohesive platform built for the future of smart manufacturing.
