Catch Faults Early & Prevent Costly Breakdowns

Chiller Condition Monitoring

Most chiller maintenance programs react too late and cost too much. UpTime Solutions uses industrial-grade 3-in-1 sensors, smart software, and expert-guided analytics to catch issues early and keep critical chiller systems running without unexpected downtime.

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Trusted by Reliability & Maintenance Professionals

"UpTime Solutions has installed in our facility what is likely the largest wireless installation of its kind in the world – approximately 20,000 sensors over 3 million square feet. Our payback has been tremendous. We estimate a 30% reduction in downtime and a payback period of less than one year. The level of support we receive is tremendous.”

“We looked at several different technologies and we selected UpTime as our vendor of choice because of their demonstrated ability to wirelessly monitor slow-speed assets. We found their solution to be unique in the industry, and they have been very responsive to our needs. We anticipate growing with them over the next several years to cover more and more assets in the future.”

“We rely on UpTime Solutions to provide us with detailed actionable intelligence to direct our maintenance work orders. We were looking for a solution that provides us with more than an alert or an alarm. We need to know what specifically is the emerging failure mechanism with a piece of equipment and the timeframe is in which we have to address it. UpTime has provided us with those details, which saves our maintenance team time and money, and creates better floor-level buy-in to support the program.”

“I’ve worked with a lot of predictive maintenance providers during my career. As an independent contractor, I get to choose who I will install and recommend to my clients. The UpTime equipment is the best in terms of capabilities and data quality. I don’t hesitate to recommend them to my clients, and they are experts in their field.”

The UpTime Advantage for Chiller Condition Monitoring

Industry-Leading 3-in-1 Chiller Sensors

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Back in 2019, we brought the industry’s first wireless sensor to the market. Our innovative 3-in-1 sensors combine ultrasonic, vibration, and temperature detection into one wireless device. That same approach now gives teams a clearer picture of what’s happening inside compressors, motors, and rotating components, so small issues are caught before they become costly fixes that cost you money and downtime.

Expert Analysts Specialized in the Chiller Industry

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AI and computer software can flag anomalies, but they don’t come close to replacing real-world expertise. Our reliability analysts review every critical alert, identify what’s going on and where the problem is, and recommend the next step. They’ve worked extensively with HVAC and industrial cooling systems, so you’re not guessing, you’re acting with confidence.

Prescriptive Work Orders That Go Straight to Your CMMS

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UpCast uses an MQ broker to connect directly with your CMMS or EAM, so your team isn’t stuck translating data into action. Alerts are prioritized, and your team receives clear, prescriptive work orders. That means faster response times, better planning, and less downtime when something needs attention.

ISO 9001 & 27001 Certified

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We take both performance and data security seriously. UpTime Solutions is ISO 9001 and 27001 certified, which means you can rest assured knowing your monitoring program is backed by strong quality processes and reliable information security.

A Complete End-to-End System for Monitoring Chiller Performance and Condition

MistEX & MistLX

Wireless sensors designed to track ultrasound, vibration, and temperature across chiller systems, with the flexibility to scale from a single unit to a full facility rollout

MistLX: Compact, durable sensor with a small footprint that makes it easy to mount on compressors, motors, and other tight chiller components

MistEX: High-output option designed for demanding environments, with battery life that can last up to 5 years.

Shared features across both models:

Bluetooth connection to UpCastCM, UpTime’s cloud platform
IP69-rated protection for tough operating conditions
Optional stainless steel housing for wet, humid, or washdown areas

Brick T1SX

Hybrid wireless monitoring solution that brings your existing wired chiller sensors into the UpTime platform without adding batteries or rebuilding your setup

Key capabilities:

Powers and collects data from up to 15 sensor inputs
Converts junction boxes and accelerometers into wireless data hubs
Uses long-range 900 MHz connectivity for consistent coverage without changing batteries
Sends data from up to 7 accelerometers and 7 process channels, including tach, all in real time

UpCast

Cloud-based platform that brings all your chiller sensor data into one place, giving you real-time visibility into ultrasound, vibration, and temperature across your system

Built-in analytics help turn that data into clear alerts, recommended actions, and prioritized maintenance work orders for your team

Key capabilities:

Reliable diagnostics with accurate, timely alerts
Prescriptive work orders organized by importance
Seamless integration with CMMS, EAM, and Active Directory
Scalable, enterprise-level architecture powered by Cassandra and MQTT

3-in-1 Chiller Condition Monitoring

Featuring MistEX & MistLX – The Ultimate Asset Watchdogs

Ultrasound

By capturing high-frequency sound waves, ultrasonic condition monitoring can detect issues in chiller motors and compressors well before they show up in vibration or temperature data. UpTime gives your team an early warning window, allowing maintenance to be planned rather than reactive.

Vibration

Vibration monitoring gives you a clear read on how your chiller equipment is actually running. Every compressor, motor, and pump has its own vibration signature, and changes in that pattern can point to developing issues. Instead of relying on routine maintenance that can be hit-or-miss, your team can spot problems early and address them before they lead to unexpected downtime.

Temperature

Relying only on overload relay usually means chiller motor issues are caught after heat and current have already spiked. UpTime’s Mist sensors track temperatures up to 175°F and align that data with vibration trends, while the platform analyzes patterns over time to help your team catch problems earlier and more accurately.

Ultrasound Detects

Mechanical Stress Indicators

Early signs of overheating in compressors and motors
Rapid temperature rise under normal operating load
Localized hot spots on compressor housings or motor bearings

Structural & Seal Integrity

Looseness in mounting hardware or pipe hangers
Deterioriating isolation pads
Cracked or fatigued structural welds

Pump & Cooling Tower Components

Cavitation in chilled water and the condenser water pumps
Bearing wear in cooling tower fan motors and drive assemblies
Imbalance signatures in rotating fan assemblies

Earliest Stage Bearing and Compressor Wear

Subtle friction changes in compressor and motor bearings
Turbulence changes in high-speed rotating components
Early metal contact signatures before vibration thresholds are reached

Vibration Detects

Rotor and Compressor Health

Bearing defects in compressor and motor assemblies
Rotor imbalance and eccentricity in drive motors
Early signs of wear in high-speed rotating components

Alignment and Coupling Performance

Misalignment between motor and compressor shafts
Coupling wear or deterioration affecting power transfer
Soft foot conditions impacting equipment stability

System Stability and Mounting

Mechanical looseness within chiller housings or frames
Resonance issues tied to operating speeds
Base, skid, or mounting instability affecting performance

Pumps, Fans, and Auxiliary Components

Imbalance or wear in condenser or chilled water pumps
Fan blade imbalance in cooling towers or air-cooled chillers
Vibration transfer between interconnected chiller components

Temperature Detects

Compressor and Motor Heat Trends

Rising temperatures in compressor and motor housings
Heat buildup from internal friction or mechanical strain
Gradual temperature increases that signal declining efficiency

Refrigerant System Performance

Abnormal temperatures across evaporator and condenser coils
Inefficient heat exchange due to fouling or scaling
Temperature imbalances tied to improper refrigerant charge

Cooling Tower & Condenser Water Performance

Elevated water temperatures reducing system capacity
Poor heat rejection across the cooling tower
Fan motor overheating from airflow restriction or mechanical issues

Flow and Load-Related Conditions

Elevated temperatures from restricted water or refrigerant flow
Increased load causing compressors to run hotter than normal
Temperature inconsistencies across system loops

How To Get Started With a Chiller Condition Monitoring Pilot Trial

Most of our customers see a return within 2 to 12 months, along with more than a 3x drop in unexpected chiller downtime. If you want to see how it performs in your own facility, our pilot is the best place to start.

Reliability Assessment

Connect with our sales team to see if the system is a good fit for your chiller setup and operational goals.

Installation & Setup

ur team handles the on-site setup, getting your chiller condition monitoring system up and running with minimal disruption.

Expert Support & Review

Our analysts keep a thorough watch on your equipment, flag unusual readings, and deliver clear work orders. We’ll also check in regularly to fine-tune your maintenance program.

Industries We Support With Chiller Condition Monitoring Solutions

Protect your line’s bottom line by maximizing the ROI on your capital equipment.

Ready to get every ounce of value from your assets? Let’s talk.