Before You Start
Confirm the correct sensor position on the asset before mounting. Refer to the Smart Trac Sensor Positioning article if you need guidance.
A rigid, secure connection between the sensor and the asset is essential for reliable vibration data. Any looseness will compromise reading quality.
The Smart Trac Ex cannot be installed using the screw attachment method. Use structural adhesive only.
Which Mounting Method Should You Use?
The right method depends primarily on the asset's surface temperature and vibration level.
Method | Surface Temperature | Best For |
Structural Adhesive (DP8805NS) | 61°F to 151°F (16°C to 66°C) | Flat surfaces, moderate vibration |
Adhesive + Holder | 61°F to 151°F (16°C to 66°C) | Limited access, slightly irregular surfaces, cold environments (with pre-heating) |
Screw Attachment | Above 151°F (66°C) or high vibration | Situations where adhesive cannot cure properly |
Important: For environments with prolonged exposure to chlorine or substances with high oxidative potential, structural adhesive is not recommended. Use the screw attachment method instead.
Surface Preparation
Complete this step before any mounting method.
Required materials: file or coarse sandpaper, degreaser or isopropyl alcohol, clean cloth, PPE (gloves and safety glasses).
Use a file or coarse sandpaper to remove loose paint, oxidation, and solid particles from the area where the sensor will be installed.
Apply degreaser or isopropyl alcohol to the area. Make sure no oil residue remains on the surface.
Dry the area completely with a clean cloth before proceeding.
Important: A surface with oil, paint, or moisture will prevent proper adhesion and may cause the sensor to detach during operation.
Smart Trac Installation
Method 1: Structural Adhesive (DP8805NS)
Required materials: 3M™ DP8805NS adhesive, file or coarse sandpaper, degreaser or isopropyl alcohol, clean cloth, PPE.
Complete the Surface Preparation steps described above.
Apply a small amount of 3M™ DP8805NS adhesive to the sensor base.
Press the sensor firmly against the surface for 5 to 60 seconds.
a. On flat surfaces: 5 seconds is sufficient.
b. On sloped or slightly curved surfaces: maintain pressure longer until the sensor holds.
Wait 24 hours for a full cure before turning on the equipment or exposing the sensor to intense vibration.
💡 Tip: For overhead installations where the sensor is suspended or inverted, the adhesive bears additional stress from the sensor's own weight. In those cases, request the Smart Anchor accessory from the support team; it works as a backup anchoring point to ensure the sensor does not detach.
Expected result: After 24 hours, the sensor will be rigidly bonded to the surface with no looseness or movement when pressed laterally.
Method 2: Adhesive + Holder
Use this method when surface access is limited, when the surface is slightly irregular, or when ambient temperature is below 61°F / 16°C (see the cold environment variation below).
Required materials: Holder, 3M™ DP8805NS adhesive with applicator and mixing nozzle, file or coarse sandpaper, degreaser or isopropyl alcohol, clean cloth, PPE.
Complete the Surface Preparation steps on the area where the Holder will be bonded.
Remove the adhesive backing from the Holder and press it firmly onto the asset for 5 seconds.
Attach the mixing nozzle to the 3M™ DP8805NS cartridge. Discard the first 1–2 inches of adhesive onto a piece of paper before applying to the sensor.
Apply adhesive to the magnetic base of the sensor.
Insert the sensor into the Holder immediately after applying the adhesive. Press firmly for 5 to 60 seconds.
Wait 24 hours for a full cure. Keep surface temperature between 61°F and 151°F (16°C and 66°C) during this period.
Expected result: The Holder will be bonded to the asset and the sensor will be securely seated inside it, with no visible gap. The sensor should not shift when pressed.
Variation: Holder in Cold Environments (surface below 61°F / 16°C)
Add to materials: heat gun and pyrometer (optional).
Before Step 1 above, use a heat gun to warm the surface to 77°F – 90°F (25°C – 32°C). Measure with the pyrometer if available.
Complete Steps 1 through 6 above normally.
During the first hours of curing, prevent the surface from cooling below 61°F / 16°C.
Method 3: Screw Attachment — M8
Warning: This method cannot be used on the Smart Trac Ex.
Required materials: drill, 6.8 mm drill bit, M8×1.25 tap + tap wrench, 19 mm (gen2) or 17 mm open-end wrench, socket (black cup) + torque wrench, brush or compressed air, cutting fluid (recommended), center punch and hammer, ruler or tape, degreaser or isopropyl alcohol, clean cloth, PPE.
Use a center punch and hammer to mark the exact installation point. This prevents the drill bit from slipping when you start drilling.
Use a ruler or tape to mark 12 mm on the 6.8 mm drill bit to control the maximum drilling depth.
Drill until you reach the 12 mm mark. Use cutting fluid to ease drilling and preserve the bit. Confirm that the asset housing is thick enough to support a 12 mm hole without breaking through the inner wall. If in doubt, contact Tractian support before proceeding.
Thread the hole using the M8×1.25 tap: turn one full rotation clockwise, then half a rotation counterclockwise to clear chips. Repeat until you reach 12 mm depth.
Remove chips using a brush or compressed air. Clean the area with degreaser or isopropyl alcohol and dry completely.
Complete the Surface Preparation around the hole.
Thread the M8×1.25 sensor screw into the hole until it bottoms out, turning clockwise.
For orientation adjustment (aligning X, Y, Z axes), rotate the magnetic base slightly counterclockwise.
With the sensor aligned, hold the base with the 19 mm or 17 mm open-end wrench and tighten the sensor with the torque wrench fitted with the socket. Add approximately 10° of additional rotation to secure the final lock.
Expected result: The sensor will be rigidly mounted on the asset, aligned with the equipment's axes, with no looseness. It should not rotate when force is applied by hand.
Smart Trac Ultra Installation
Method 1: Structural Adhesive (DP8805NS)
Required materials: 3M™ DP8805NS adhesive with applicator and mixing nozzle, file or coarse sandpaper, degreaser or isopropyl alcohol, clean cloth, PPE.
Important: The surface must be between 61°F and 151°F (16°C and 66°C) for proper adhesive curing.
Complete the Surface Preparation steps described at the beginning of this article.
Attach the mixing nozzle to the 3M™ DP8805NS cartridge. Discard the first 1–2 inches of adhesive onto paper before applying.
Apply adhesive to the magnetic base of the Smart Trac Ultra.
Press the sensor firmly against the surface for 5 to 60 seconds.
a. On flat surfaces: 5 seconds is sufficient.
b. On curved or sloped surfaces: maintain pressure longer.
Wait 24 hours for a full cure.
Expected result: The sensor will be rigidly bonded to the asset with no looseness or movement when pressed laterally.
Method 2: Adhesive + Holder
Required materials: Holder, 3M™ DP8805NS adhesive with applicator and mixing nozzle, file or coarse sandpaper, degreaser or isopropyl alcohol, clean cloth, PPE.
Complete the Surface Preparation steps on the area where the Holder will be bonded.
Remove the adhesive backing from the Holder and press it onto the asset for 5 seconds.
Attach the mixing nozzle to the 3M™ DP8805NS cartridge. Discard the first 1–2 inches.
Apply adhesive to the magnetic base of the Smart Trac Ultra.
Insert the sensor into the Holder immediately after applying adhesive. Press firmly for 5 to 60 seconds.
Wait 24 hours for a full cure. Keep surface temperature between 61°F and 151°F (16°C and 66°C) during this period.
Expected result: The Holder will be bonded to the asset and the sensor securely seated inside it, with no visible gap.
Variation: Holder in Cold Environments (surface below 61°F / 16°C)
Add to materials: heat gun and pyrometer.
Use the heat gun to warm the surface to 77°F – 90°F (25°C – 32°C). Measure with the pyrometer.
Complete Steps 1 through 6 above normally.
During initial curing, prevent the surface from cooling below 61°F / 16°C.
Method 3: Screw Attachment with Embedded-Screw Base
Use this method when the surface temperature exceeds 151°F (66°C) or when the asset's vibration level makes adhesive bonding impractical.
Required materials: embedded-screw base (M8×1.25), 40 mm fixed wrench, 17 mm fixed wrench, 5 mm Allen key, torque wrench, permanent marker, drill + 6.8 mm drill bit + M8×1.25 tap (if the asset has no M8 hole), center punch and hammer, ruler or tape, degreaser or isopropyl alcohol, clean cloth, PPE.
Step 1 — Remove the original Smart Trac Ultra base
Using the 40 mm and 17 mm wrenches together, carefully unscrew and remove the original magnetic base from the sensor. Position the 40 mm wrench on the sensor body and the 17 mm wrench on the base, turning counterclockwise.
Step 2 — Attach the new embedded-screw base to the sensor
Thread the new embedded-screw base directly onto the sensor. Once the base and sensor faces meet, use the 40 mm and 17 mm wrenches to tighten the connection with an angle of approximately 4°.
Step 3 — Mark the axis alignment
Using a permanent marker, draw a line on the base. Align this mark with the axis of the word "TRACTIAN" engraved on the sensor body. This mark is your alignment reference during installation on the asset.
Then remove the base from the sensor (turn counterclockwise). The base goes onto the asset; keep the sensor separate for now.
Step 4 — Prepare the hole on the asset (if needed)
If the asset does not have an M8 hole at the desired location:
Use a center punch and hammer to mark the drilling point.
Mark 12 mm on the 6.8 mm drill bit.
Drill to the mark.
Thread the hole using the M8×1.25 tap: one full rotation clockwise, half a rotation counterclockwise to clear chips. Repeat to 12 mm depth.
Remove chips with a brush or compressed air. Clean and dry the surface. Confirm that the asset housing is thick enough for a 12 mm hole. If in doubt, contact Tractian support before proceeding.
Step 5 — Mount the base on the asset
Position the base in the asset hole. Make sure the alignment mark is correctly oriented relative to the asset's axis.
Use the 5 mm Allen key to start threading.
Hold the base with the 17 mm wrench to prevent rotation, and tighten with the torque wrench set to 20 N·m.
Step 6 — Thread the sensor onto the installed base
Thread the Smart Trac Ultra onto the base already fixed to the asset. Use the two wrenches:
a. One wrench to hold the base (prevent it from rotating).
b. The other to rotate the sensor until its axes are correctly aligned with the asset.
Confirm that the mark made in Step 3 is aligned with the reference point on the asset.
Step 7 — Verify alignment and secure
Press the sensor lightly in all directions to confirm there is no looseness. If adjustment is needed:
Unscrew the sensor counterclockwise.
Reposition the base if necessary.
Re-thread the sensor and confirm alignment.
Expected result: The sensor will be securely fixed, aligned with the asset's axes, and stable with no movement when pressed. The Smart Trac Ultra will remain stable even under high-vibration operation.
Chemical Resistance
This table applies to sensors installed using the screw attachment method. See the note at the end for adhesive installations.
Substance | Resistance | Substance | Resistance |
Solvents |
| Bases |
|
Water | 1 | Calcium hydroxide | 1 |
Xylene | 1 | Potassium hydroxide (caustic potash) | 1 |
Acetone | 1 | Magnesium hydroxide | 1 |
Methanol | 1 | Sodium hydroxide | 2 |
Ethyl acetate | 1 | Ammonium hydroxide | 1 |
Butyl acetate | 1 | Sodium hypochlorite | 3 |
Benzene | 1 | Oils |
|
Methyl isobutyl ketone | 1 | Diesel fuel oil (20, 30, 40, 50) | 1 |
Methylene chloride | 1 | Fuel oil (1, 2, 3, 5A, 5B, 6) | 1 |
Heptane | 1 | Hydraulic oil (synthetic) | 2 |
Cyclohexane | 1 | Silicone oil | 2 |
Toluene | 1 | Soybean oil | 1 |
Trichloroethylene | 2 | Mineral oil | 1 |
Hexane | 1 | Fuels |
|
Alcohols |
| Diesel fuel | 1 |
Butyl alcohol | 1 | Gasoline | 1 |
Ethyl alcohol | 1 | Kerosene | 1 |
Isopropyl alcohol | 1 | Other |
|
Methyl alcohol | 1 | Seawater | 1 |
Acids |
| Detergents | 1 |
Acetic acid | 1 |
|
|
Citric acid | 1 |
|
|
Hydrofluoric acid | 4 |
|
|
Lactic acid | 1 |
|
|
Hydrochloric acid | 4 |
|
|
Sulfuric acid | 2 |
|
|
Nitric acid | 4 |
|
|
Phosphoric acid | 1 |
|
|
Chromic acid | 2 |
|
|
Formic acid | 1 |
|
|
Hydrogen peroxide | 2 |
|
|
References:
1 = Excellent resistance
2 = Good resistance
3 = Medium resistance
4 = Low resistance
Important: Adhesive mounting is not recommended for environments with prolonged exposure to chlorine or substances with high oxidative potential. If the substance you are dealing with is not listed or shows low resistance (4), contact Tractian support before installing.
Operating Temperature Range
Smart Trac (Standard Version)
Characteristic | Range |
Ambient temperature | –40°F to +194°F (–40°C to +90°C) |
Surface temperature | –40°F to +250°F (–40°C to +121°C) |
IP rating | IP69K |
Humidity | Suitable for high-humidity environments |
Smart Trac (Ex Version)
Characteristic | Range |
Ambient temperature | –40°F to +185°F (–40°C to +85°C) |
Surface temperature | –40°F to +250°F (–40°C to +121°C) |
💡 Tip: For installations on high-temperature surfaces, screw attachment is the recommended method. Structural adhesive only cures properly between 61°F and 151°F (16°C and 66°C).
Common Issues
The sensor detached after adhesive installation.
Likely cause: the surface was not properly cleaned before application, the adhesive was applied outside the recommended temperature range, or initial pressure time was too short.
Solution: Remove the sensor, sand and clean the surface again, and repeat the procedure, pressing firmly for at least 30 seconds. Verify that surface temperature is between 61°F and 151°F (16°C and 66°C).
The sensor is misaligned after screw installation. Likely cause: the base was tightened before the orientation was adjusted. Solution: Unscrew the sensor (not the base), rotate it counterclockwise to the correct alignment, and tighten again. For the embedded-screw base method, if adjustment is not sufficient, loosen the base, reposition it, and re-tighten.
The hole was drilled deeper than 12 mm.
Likely cause: the depth mark on the drill bit was not set or shifted during drilling. Solution: If the hole broke through the housing wall, contact Tractian support before proceeding with the installation.
If the issue persists, contact Tractian support.