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Sensor data handover connects the installed measurement point to the value used by the operator. For a Modbus project, the acceptance file should identify the sensor, applicable register map, controller tag, engineering unit, quality state and test result. Successful communication alone does not prove that the displayed measurement is correct.
This guide focuses on the sensor-to-PLC or platform data path. For standards, cleaning checks and measurement history, use the calibration and handover records guide. Keep the two records linked by the same point identifier.
Define the Data Handover Boundary
| Layer | Record to retain | Acceptance question |
|---|---|---|
| Sensor point | Model, serial number, location, parameter and actual ordered output | Does the tag represent the installed device and measurement task? |
| Controller or PLC | Applicable manual revision, communication settings, register and decoding configuration | Is the intended value read and converted correctly? |
| Gateway or platform | Tag mapping, timestamp, display unit, update behavior and quality state | Can the operator distinguish a current reading from missing or stale data? |
| Operation | Alarm response, maintenance status and responsible team | Does the displayed condition lead to the agreed action? |
Keep the Applicable Register Map with the Configuration
Use the register map supplied for the installed model and configuration. Record its revision or issue date with the PLC or logger configuration. A map for a different variant can produce a plausible but incorrect result, so the model list and communication document should stay together.
For every measurement tag, record the documented function, address convention, register count, data type, unit and scaling. If the value spans multiple registers, confirm the specified word and byte interpretation in the device documentation and controller settings. Document whether the software expects a protocol address or a reference-style register number; do not resolve the difference by guessing.
Keep the configured device address, baud rate and other serial settings with the point record. If a setting changes during commissioning, retain the accepted configuration and its date. Protocol documentation explains Modbus behavior; the actual model manual defines that sensor’s registers.
Compare Values at Each Stage
First confirm that the sensor value is suitable for comparison under the selected verification method. Then follow the same point through the local controller, PLC and platform. Record values close enough in time to separate data-path differences from real water changes. Include units, timestamps and any filtering or averaging enabled at each stage.
| Observation | Check before changing the sensor | Evidence |
|---|---|---|
| Value differs by a constant factor | Unit conversion, scaling and duplicated scaling in the PLC or platform | Raw result plus decoded engineering value. |
| Value appears plausible but belongs to another parameter | Register selection, channel mapping and tag assignment | Model map paired with the actual tag. |
| Display remains unchanged after communication stops | Update interval, timeout and stale-data indication | Loss-of-communication test and displayed quality state. |
| Local and remote trends differ in timing | Sampling, logging and transmission intervals; timestamp source | Time-aligned comparison with recorded settings. |
Test Fault and Maintenance Behavior
Agree the expected behavior for communication loss, sensor removal, maintenance and restart before acceptance. Perform controlled tests using the site’s approved procedure. The operator needs to know when a value is current, unavailable or held during service; the last numeric reading should not silently appear to be a fresh measurement.
Record which team receives the event, how the affected point is named and how normal service is restored. A data-path check and a process alarm check have different purposes: one validates communication and presentation, while the other validates the configured response to an operating condition. Keep the results identifiable.
Related Sensor Documentation
The installed configuration determines which manual and communication map belong in the file. These existing product entries are examples of documentation scope, rather than a required package for every project.
YEX-S2-MPS-A Multi-Parameter Probe
Keep the ordered channel list and mapping for each reported parameter.
Link the pH tag to its model documentation and measurement-check record.
YEX-S1-RDO Optical Dissolved Oxygen Sensor
Keep the DO unit, compensation configuration and verification record with the tag.
Package the Accepted Configuration
Use one point identifier across the installation photo, model list, wiring record, communication sheet, verification record and platform tag. Retain the configuration export when the control system supports it, with its software version and acceptance date. Record unresolved issues and their responsible owner instead of treating missing evidence as a passed check.
Sensors supply data through the ordered electrical output to a compatible controller, PLC or logger. Remote access requires the appropriate gateway and network connection. Include the actual integration boundary in the file so the site knows which component owns acquisition, transmission and alarming.
Frequently Asked Questions
Does a successful Modbus response prove the measurement is correct?
No. It proves a transaction succeeded. Acceptance also needs the correct parameter, decoding, unit, point assignment and measurement verification.
Can I use the register map from a similar sensor?
Use the map applicable to the installed model and configuration. Confirm any uncertainty with the supplier before commissioning; similar product names do not establish register compatibility.
What should the register handover sheet contain?
Record the document revision, parameter, address convention, register count, data type, unit, scaling and the configured controller tag. Add serial settings and multi-register interpretation where applicable.
Why can the PLC value differ from the sensor display?
Review timing, unit conversion, scaling, register selection and filtering. A difference in the data path should be identified before recalibrating the measurement.
What should happen when communication is lost?
The accepted design should identify unavailable or stale data and apply the agreed alarm or control procedure. Test the actual configuration and retain the observed behavior.
Is a platform screenshot enough for acceptance?
A screenshot shows the displayed state at one moment. Pair it with the point identifier, unit, time, register configuration and test record so the result can be reproduced.
Does the sensor send data directly through 4G?
That depends on the actual hardware. A sensor supplying RS485 data needs a compatible acquisition device and gateway for a separate 4G connection.
What information is useful for integration support?
Provide the model, manual revision, point identifier, controller type, non-secret communication settings, expected unit and an example of the local and decoded values. Exclude passwords and network credentials from routine support records.
Prepare the Integration Scope
For a new project or replacement, provide the installed model or required parameter, expected working range, controller or PLC, output requirement, cable route and data acceptance task. State which team handles configuration and which team accepts the displayed value. YexSensor can review the applicable sensor documentation and integration scope against these details.
Technical Reading
Modbus Organization: Specifications and Implementation Guides provides the protocol reference. Sensor-specific registers must come from the applicable model documentation.
