Swapping or Relocating a Sensor: How to do it safely and maintain accurate records

Sensors get changed for two common reasons: replacing a faulty/expired unit with a new one, or moving an existing sensor to a different position to improve coverage, reliability, or signal quality. In both cases, safety comes first, and traceability comes second. A consistent record of what changed, where, when, and why helps with support, repeat-issue analysis, auditability, and maintaining confidence in dashboards, alerts, and reports.

Use the sensor change form

Before you start (or immediately after the work is complete), please submit the sensor change form so we can update the asset history and configuration records. We cannot process a sensor change without a completed form advising of all of the details:

Sensor Replacement or Relocation Form

When to use this process

Use this process if you are:

• Swapping an old sensor for a new sensor (faulty, damaged, end-of-life, upgrade, or preventative replacement) 
• Relocating an existing sensor (moving the same unit to a new position on the same machine/line, or to a different asset) 
• Doing both (relocating and replacing as part of one intervention)

Before you start

• Make it safe 
  • Follow your site’s lockout/tagout (LOTO) and isolation procedures. Sensors often sit within powered circuits and near moving machinery. If you are unsure about isolation, stop and involve a qualified engineer. 
• Confirm what you’re changing Identify whether you are:
  • Replacement: old sensor out, new sensor in 
  • Relocation: same sensor moved to a new location 
  • Replacement plus relocation: new sensor installed in a different location than the old one
• Verify the correct sensor and compatibility 
  • Check the sensor model/part number (not just the serial number). 
  • If the replacement is not like-for-like, confirm it is approved and compatible (mounting, connector, power requirements, measurement range, and environmental rating). 
• Capture evidence (recommended) 
  • A couple of quick photos can save time later:
  • Sensor in situ before change (showing placement) 
  • Label/nameplate for serial/model 
  • Sensor in situ after change (showing final placement)

Performing the change

Replacing an old sensor with a new one

• Isolate power and ensure the machine is safe 
• Remove the old sensor carefully and protect the connector/cable 
• Install the new sensor using the correct mounting and torque (if specified) 
• Restore power and check the sensor is detected and behaving as expected

Relocating an existing sensor

• Isolate power and ensure the machine is safe 
• Remove the sensor and inspect the connector/cable for damage 
• Install the sensor in the new position, ensuring: Clear line-of-sight or correct standoff distance (as applicable) 
• No interference from guards, vibration, or product flow 
• Restore power and verify readings/triggering at the new location

What we need from you (via the form)

• The form ensures we update records correctly and quickly. Please include:
• Site/area/line/machine/component and sensor location detail 
• Change type: replacement, relocation, or both Old and new serial numbers (for replacements), or the serial number being moved (for relocations) 
• Reason for change and production impact/urgency (if relevant) 
• Date/time of the change and who performed it 
• Photos and any post-change validation notes (recommended)

If you are unsure

If you are not confident about compatibility, safe installation, or how the change might affect data quality, submit the form and contact support before proceeding. It’s usually faster to confirm first than to troubleshoot later.