How to Install a VIE Sensor: Self-Install Guide
VIE sensors are installed on energized transformers. No outage is required. No IT team needs to be involved. The installation uses two-part epoxy, a surface grinder, alcohol wipes, and the DeployVIE mobile app. What the technician needs most is an understanding of where to place the sensors and why placement matters.
This guide walks through the full 15-step installation procedure.
Before You Start
Tools and materials required:
- DeployVIE mobile app (installed and logged in before arriving on site)
- Surface grinder or angle grinder with appropriate disc for paint and surface preparation
- Alcohol wipes
- Two-part epoxy (supplied by VIE or specified by VIE installation guidelines)
- Adiseal weatherproof sealant
- Measuring tape
- Marker or chalk for location marking
- Camera (DeployVIE uses the device camera)
What you do not need:
- A transformer shutdown or outage window
- Local network access or IT support
- Specialized electrical or instrumentation tools
Understanding Sensor Placement Before You Install
Placement decisions made in the first step determine the quality of data for the life of the deployment. Take the time to get them right before picking up a grinder.
Three sides, not four. Sensors are placed on three sides of the transformer tank body. The front panel face is excluded because it typically provides access to bushings, terminations, and other components that require clearance for maintenance. The three available sides each capture vibration from the core phase closest to that tank face.
Center of the tank face, not near edges. Sensors placed toward the edges of the tank face are closer to structural welds and corner transitions, which can introduce vibration noise and reduce signal clarity. Center placement on the vertical tank face gives the cleanest signal path.
Not on fins. Radiator fins are mechanically decoupled from the tank body and thermally driven. A sensor mounted on a fin does not read the transformer's structural vibration. It reads fin vibration, which carries no diagnostic information about the core or windings.
Height matters. Sensor height above the base determines what the thermal model can resolve. Sensors at different heights on the same face give VIE the vertical thermal gradient that distinguishes an upper-tank thermal anomaly (insulation stress) from a lower-tank anomaly (cooling obstruction). Record and photograph each sensor's height from the base. DeployVIE will prompt you for this.
The 15-Step Installation Procedure
Step 1: Identify sensor locations.
Walk all four sides of the transformer. Select three vertical tank faces for sensor placement. Mark the preferred location on each face: center of the face, away from fins, welds, and access panels, at a height that captures the mid-to-upper tank region unless site conditions require adjustment. If the transformer has multiple sensors per phase, identify the vertical spread of positions that will give the analytics engine thermal gradient data.
Step 2: Confirm no sensors go on fins.
Before marking or grinding, verify that all selected locations are on the flat tank body, not on radiator fins or fin mounting structures.
Step 3: Mark location and measure height.
Mark each installation point clearly. Measure and record the height of each marked point from the base of the transformer. You will enter this measurement into DeployVIE at step six.
Step 4: Prepare the surface with a grinder.
Use a surface grinder to remove paint, corrosion, dirt, and surface impurities from an area slightly larger than the sensor footprint. The epoxy bond requires clean, bare metal. An insufficiently prepared surface is the leading cause of sensor adhesion failure over time.
Step 5: Clean with alcohol wipes.
After grinding, wipe the prepared surface thoroughly with alcohol wipes to remove grinding residue, dust, and oils from handling. Allow the surface to dry completely before applying epoxy. Do not touch the cleaned surface with bare hands after this step.
Step 6: Scan the sensor QR code and record in DeployVIE.
Before applying epoxy, scan the QR code on the sensor using the DeployVIE app. Enter the sensor's installation height and the transformer label or asset ID it is being installed on. DeployVIE links the sensor ID to this specific transformer and position. This step creates the installation record. Do not skip it or complete it after bonding.
Step 7: Apply two-part epoxy and bond the sensor.
Mix the two-part epoxy per the product instructions. Apply to the cleaned surface or to the back of the sensor as directed. Press the sensor firmly to the surface and hold or support it for the cure time specified by the epoxy manufacturer. Ensure full contact across the sensor footprint. Voids in the bond reduce vibration transmission and signal quality.
Step 8: Apply Adiseal sealant around the sensor perimeter.
Once the epoxy has set sufficiently to hold the sensor in place, apply a bead of Adiseal weatherproof sealant around the full perimeter of the sensor. This seal provides weather protection and additional mechanical support against the elements. Smooth the sealant bead to ensure full coverage with no gaps.
Step 9: Photograph all installed sensors via DeployVIE.
Before moving to gateway installation, photograph each sensor in its installed position using the DeployVIE app. The app associates each photo with the sensor ID and transformer record. These photos are the installation baseline and are used by VIE application engineers to verify correct placement.
Step 10: Collect transformer nameplate data.
Photograph the transformer nameplate using DeployVIE. The nameplate data (manufacturer, serial number, rating, voltage, age) is entered into the VIE platform and used to contextualize the baseline monitoring period. If the nameplate is not legible, record what is available and note the condition.
Step 11: Identify the gateway location.
Select a mounting location for the gateway that is within 100 meters of all sensors being served by that gateway, has access to a power source, and provides adequate connectivity for the selected upstream communication method (LTE antenna line of sight where possible, or Ethernet/Wi-Fi access point proximity). The gateway enclosure is IP69K and NEMA 6/6P rated. It does not require shelter from weather, but should not be placed in direct standing water or in locations that obstruct LTE signal unnecessarily.
Step 12: Power on the gateway and verify connectivity.
Power on the gateway and confirm BLE connectivity to all installed sensors and upstream connectivity (LTE or wired) to the VIE cloud platform. The DeployVIE app will show sensor connection status. Do not leave the site until all sensors are confirmed as communicating with the gateway and the gateway is confirmed as transmitting upstream.
Step 13: Route cables per site requirements and OSHA regulations.
Route power and any wired network cables in accordance with the customer's cable management requirements and applicable OSHA electrical safety regulations. Cables should be secured, protected from mechanical damage, and routed away from moving equipment or high-heat surfaces.
Step 14: Install and secure the gateway.
Mount the gateway in the identified location using appropriate hardware for the mounting surface. Ensure the enclosure is properly sealed after cable entry. Confirm the mounting is secure against wind load and vibration.
Step 15: Photograph the installed gateway via DeployVIE.
Photograph the installed gateway using the DeployVIE app, capturing the mounting position, cable routing, and antenna orientation if applicable. Submit the completed installation record through DeployVIE. VIE application engineers will review the installation photos and confirm that sensor placement and gateway configuration meet deployment standards before the baseline monitoring period begins.
What DeployVIE Records
By the end of the installation, DeployVIE has captured: sensor IDs linked to specific transformer assets, installation height for each sensor, installation photographs for each sensor, transformer nameplate data, gateway installation photographs, and gateway connectivity confirmation. This record becomes the baseline installation document for the deployment and is retained in the VIE platform for the life of the monitoring contract.