Legacy pressure sensors (think: 10+ years old) are workhorses—reliable, paid for, and familiar to your team. But connecting them to modern testing software can feel like plugging a flip phone into Wi-Fi. The good news: You don’t need to replace them. Here’s how to bridge the gap.

Use analog-to-digital converters (ADCs):
Most legacy sensors output analog signals (0–10V or 4–20mA). An ADC (e.g., National Instruments USB-6001) converts these to digital data the software can read. Look for:

· 16-bit resolution (to preserve sensor accuracy).

· 8+ channels to connect multiple sensors at once.

· USB or Ethernet output (compatible with most software).

Add a protocol converter:
If your sensor uses an old serial protocol (RS-232/485) and your software speaks Ethernet, a converter (e.g., Lantronix UDS1100) translates between them. It’s plug-and-play for 90% of setups.

Update the sensor’s “brain”:
For critical tests, swap out the sensor’s circuit board with a modern module (e.g., Omega DP25B). You keep the original probe (proven in your tests) but gain USB/Ethernet connectivity.

Tame calibration headaches:
Legacy sensors often lack digital calibration logs. Fix this by:

· Manually entering calibration data into the software’s asset management tool.

· Attaching an RFID tag to each sensor—scan it before testing to pull up calibration records.

When to replace:
If a sensor is <0.5% accurate or can’t handle your software’s sampling speed, it’s time to retire it. But for most, integration is cheaper than replacement (≈$200 in converters vs. $1,000+ for a new sensor).

Got a stubborn legacy sensor? Share its make/model, and we’ll find an integration hack.