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Installation Support

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SmartSense — Warehouses Self Installation Guide

Table of Contents

  1. Components for Install
  2. Temperature Monitoring Overview
  3. Warehouse Installation Planning
  4. B Gateway Installation
  5. Z Gateway Installation
  6. BZ Gateway Installation
  7. Z Sensor Installation
  8. Pairing a Z Screen with a Z Sensor
  9. Optional NIST/Humidity Sensor Installation
  10. B Sensor Installation
  11. Data Logger Usage

Install Sheet Download

Components for Install

Temperature Monitoring Overview

Every warehouse has unique monitoring requirements. This section describes the general premise, but your monitoring equipment may look different from what is here.

A Dry Storage
Verify temperature and humidity of sensitive products to ensure the highest quality.

B Refrigerators and Freezers
Receive real-time alerts whenever cold storage inventory or equipment has a temperature excursion.

C Gateways
All of our gateway products are plug and play. Once installed in an area with good cellular coverage, they will automatically pair with sensors and report to the dashboard.

D Dashboard
Provides real-time oversight of product temperatures for visibility into compliance and reefer performance to identify risks.

Warehouse Installation Planning

The first step in warehouse deployment is sourcing a warehouse layout schematic. Using the schematic, SmartSense will collaborate with you to scope the gateway and sensor locations. The map will guide the installer on the appropriate locations for the hardware. A standard application will consist of 10 temperature monitoring points. Typically, cooler and freezer zones are deployed, while ambient zones are optional.

Sample warehouse map:

SmartSense Gateway Installation

Please follow the installation guidelines for your specific gateway.

B Gateway Installation

  1. Identify the location where you would like to install the B Gateway.
    • The location must have a non-switched power outlet.
    • Must be able to receive a strong cellular signal.
    • Have a smooth surface that can receive screws or have a mounting point to secure the B Gateway 6' from the floor.
    • Must be near the area where you will install sensors. When installing multiple B Gateways, your sensors will report to the nearest gateway.
    • For large walk-in units where the B Gateways are installed inside the unit, select power outlets near fire exits or doors to provide the best opportunity to obtain a cellular signal. It is recommended, but not required, that the sensor that is furthest from the gateway has more of a direct line of sight.
  2. Prior to mounting the B Gateway, use the install sheet to note the B Gateway ID found on the bottom label (ex. F029706) and the location where the B Gateway is installed (this will be needed to complete setup of SmartSense reporting).
  3. Attach the included power adapter to the B Gateway wire harness by connecting the male and female connectors.
  4. Mount the B Gateway, 6' or higher above the ground in your chosen location using zip ties or other fastener of your choice. The B gateway needs to be mounted vertically so that the integrated antenna is pointed towards the ceiling.

  5. Plug the B Gateway into the power outlet and use zip ties to neatly bundle the cords to avoid unintended unplugging of the gateway.
  6. After powering the B Gateway, allow 30 minutes for the gateway to propagate and begin communicating. Login to SmartSense and confirm that all B Gateways are communicating.

Z Gateway Installation

  1. Identify a location where you would like to install the Z Gateway.
    • The location must have a non-switched power outlet.
    • Must be able to receive a strong cellular signal (see step 4).
    • Have a clean smooth surface to mount the Z Gateway 6' from the floor.
    • Must be near the area where you will install sensors. When installing multiple Z Gateways, your sensors will report to the nearest gateway.
  2. The next steps require a charged battery. If your Z Gateway does not power on, please charge for 20 minutes before moving to the next steps.
  3. Prior to mounting the Z Gateway, use the install sheet.pdf to note the Z Gateway ID on the back label (ex. 990000000000000000000) and the location where the Z Gateway is installed (this will be needed to complete setup of SmartSense reporting).
  4. Use Signal Finder mode to optimize placement.
    • Using a paperclip, press and hold the power button. All four LEDs will turn on.
    • Continue to hold until the LED labeled "STATUS" begins to flash.
    • The "STATUS" LED will become solid, indicating the Z Gateway is in Signal Finder mode for approximately 3 minutes.
    • Move the Z Gateway until a signal is found. The bottom three LEDs will illuminate bottom to top to indicate signal strength.
    • For more information see: smartsense.co/signal-finder-mode.
  5. Once a good signal has been found, pull off the adhesive strips and affix 3-4 velcro strips to the back of the Z Gateway.

  6. Place the "DO NOT UNPLUG" sticker next to the outlet powering your Z Gateway.

  7. Attach the included power adapter if you have not already done so.
  8. Mount the Z Gateway 6' or higher above the ground, in your chosen location, by removing the protective paper to expose the adhesive on the attached velcro strips and then pressing the Z Gateway firmly to the wall. The Z Gateway needs to be mounted vertically so that the external antenna is pointed toward the ceiling.
    Note: If installing on metal or moisture retaining surfaces in an outdoor warehouse setting, install using self-tapping sheet metal screws through the mounting holes on the Z Gateway.

  9. Plug the Z Gateway into the power outlet and use zip ties to neatly bundle the cords to avoid unintended unplugging of the gateway.

  10. Watch the light sequence on the gateway; the "STATUS" light should start blinking green. See the Z Gateway LED Reference Guide below for more information.
  11. After powering the Z Gateway, allow 30 minutes for the gateway to propagate and begin communicating. Login to SmartSense and confirm that all Z Gateways are communicating.

    LED Reference Guide
    LED 1 Blink 2 Blinks 3 Blinks Fast Blinking
    Status Last transmission successful Last transmission successful, but low signal Attempting to transmit wireless sensor reading Attempting to transmit local reading
    Power Charging from external power Low battery N/A N/A
    Info No sensor Wireless sensor connected Battery too low to use modem N/A
    Failure Failed to communicate with server No signal Device not registered Modem error

BZ Gateway Installation

  1. Identify a location where you would like to install the BZ Gateway.
    • The location must have a non-switched power outlet.
    • Must be able to receive a strong cellular signal (See step 4).
    • Have a clean smooth surface to mount the BZ Gateway 6' from the floor.
    • Must be near the area where you will install sensors. When installing multiple BZ Gateways, your sensors will report to the nearest gateway.
  2. The next steps require a charged battery. If your BZ Gateway does not power on, please charge for 30 minutes before moving to the next steps.
  3. Prior to mounting the BZ Gateway, use the install sheet.pdf to note the BZ Gateway ID on the back label (ex. 450000000000000000000) and the location where the BZ Gateway is installed (this will be needed to complete setup of SmartSense reporting).
  4. Press the power button on the side of the BZ Gateway to turn the gateway on.
  5. Use Signal Finder mode to optimize placement.
    • Hold the power button for more than 2 seconds but less than 5 seconds.
    • A white LED will flash repeatedly to indicate you are in Signal Finder mode.
    • To achieve the best connectivity, move the BZ Gateway around the install location until the white LED begins to quickly blink (a blinking red LED indicates a poor cellular signal).
    • Maximum signal strength is represented with a white LED flash every 200ms (the faster the white LED blinks indicates a stronger cellular signal).
    • Once a good location has been found, quickly press and release the power button to exit Signal Finder mode.
    • For more information see: smartsense.co/signal-finder-mode.
  6. Once a good location has been found, pull off the adhesive strips and affix 3-4 velcro strips to the back of the BZ Gateway.
  7. Mount the BZ Gateway 6' or higher above the ground in your chosen location by removing the protective paper to expose the adhesive on the attached velcro strips and then pressing the BZ Gateway firmly to the wall. The BZ Gateway needs to be mounted vertically so that the integrated antenna is pointed toward the ceiling.
  8. Plug the BZ Gateway into the power outlet and use zip ties to neatly bundle the cords to avoid unintended unplugging of the gateway.
  9. Watch the light sequence on the BZ Gateway; the blue LED on the bottom should be on and the LED on the front should start blinking white. See the BZ Gateway LED Reference Guide below for more information.
  10. After powering the BZ Gateway, allow 30 minutes for the gateway to propagate and begin communicating. Login to SmartSense and confirm that all BZ Gateways are communicating.

    LED REFERENCE GUIDE
    Status White LED Red LED Description
    Power On - 1 long white LED flash
    Last Upload Successful - 1 short white LED flash every 30s
    Low Battery 1 short white LED flash followed by 1 short red LED flash, every 30s
    Low Battery Preventing Communication - 1 short red LED flash, every 30s
    Low Cellular Signal 1 short white LED flash followed by 2 short red LED flashes, every 30s
    No Cellular Signal - 2 short red LED flashes, every 30s
    Contact SmartSense Support - 3 short red LED flashes, every 30s
    Hardware Failure - Continuous blinking red LED


Z Sensor Installation

Identify the area that you want to monitor. You should have completed the site survey as part of the gateway installation. Be sure that your sensors and gateway will be within the range of each other by installing the gateway as close to the sensors as possible.

  1. Install your Z Sensors in the most at-risk area that you are monitoring.

  2. If you are mounting in a refrigerator, place the sensor near the door as this will be the warmest area.
  3. If you are monitoring an ambient area, place the sensor higher as heat rises.
  4. Quickly press the power button on the Z Sensor and Z Screen to turn the devices on.

  5. Three LED lights will display on the Z Sensor, indicating it has powered on, then go out.
  6. If communicating correctly, the device will display no LED lights, but a green LED light will flash, followed by a yellow LED flash every few minutes.
  7. Once powered on, the Z Screen will pair with the Z Sensor that was associated during manufacturing.
    Note: This may take up to 5 minutes.
  8. Once paired, the Z Screen will show the serial number of its paired Z Sensor, as well as the current temperature reading.
  9. If your Z Sensor and Z Screen do not pair, see section "Pairing a Z Screen with a Z Sensor."
  10. To install your Z Sensor, locate the current thermometer in each area and place the Z Sensor in the same vicinity.

  11. Ensure the Z Sensor is not directly touching or surrounded by product.
  12. The Z Screen is magnetic and should be mounted to the outside of the freezer door.
  13. Using the install sheet.pdf, note the Z Sensor ID (ex. 1166600000012345678) and the Asset Name of the unit that the Z Sensor is being installed into (this will be needed to complete setup of SmartSense reporting).

Pairing a Z Screen with a Z Sensor

  1. Your Z Sensor should have arrived from the factory pre-paired. Quickly hit the power button on the Z Screen to search for its paired sensor. If this doesn't work or if the Z Sensor and Z Screen become un-paired, follow steps 2-6.

  2. Press and hold the power button on the Z Screen until you hear two separate sets of beeps, then let go. You may need to hold the Z Screen to you ear to hear the beeps. If you still can't hear them, try holding the button for about 6 seconds and let go.

  3. The Z Screen display should show a message indicating it has entered "Pairing Mode."

  4. Take the Z Sensor and quickly press and release the power button. The lights will go on then off. The green light will start flashing, indicating that the sensor is searching for a connection.

  5. You'll know the Z Screen and Z Sensor are paired when the Z Screen displays the temperature. Confirm the Z Screen is paired with the correct Z Sensor by matching the 20-digit number located on the Z Screen and the barcode sticker on the side of the Z Sensor.

  6. You can switch from a Fahrenheit display to Celsius by holding the Z Screen power button for 3 seconds, or until you hear a beep, and let go.

Optional NIST/Humidity Sensor Installation

  1. To install or replace a NIST or Humidity sensor, unscrew the protective cap or existing sensor in a counterclockwise direction and discard it.

  2. To connect a new NIST sensor, line up the arrow on the NIST sensor with the arrow on the NIST sensor with the arrow on the same port from which you just removed the old sensor. There are five pins on the Z Sensor and five holes on the NIST sensor that correspond.

  3. Gently screw the NIST sensor into the same port in a clockwise direction. Do not use excessive force, as this can damage the pins.
    Note: NIST sensors should be installed on Port 1 unless the Port 1 pins have been bent, at which point the NIST sensor can be installed on Port 2.

B Sensor Installation

SmartSense B Sensors are offered with a variety of features. Installing in a warehouse is very similar for all models or the condition that is being monitored.

SmartSense B Sensors ship from the factory powered and in broadcast mode. So, there is no need to power them on.

  1. Identify the area that you want to monitor. You should have completed this site survey as part of the gateway installation. Be sure that your sensors and gateway will be within range of each other by installing the gateway as close to the sensors as possible.
  2. Install the B Sensors in the most at-risk area that you are monitoring.
    • If you are mounting in a refrigerator, place the sensor near the door as this will be the warmest area.
    • If you are monitoring an ambient area for temperature, place the sensor higher as heat rises.
    • If you are monitoring an ambient are for humidity only, place the sensor in the middle of the area being monitored.

  3. Using the install sheet.pdf, note the B Sensor ID (ex. B0000000) and the Asset Name of the unit that the B Sensor is being installed into (this will be needed to complete setup of SmartSense reporting).
  4. Use the included zip tie to attach the B Sensor to a secure mounting point. This can be a shelf or other fixture that does not move. Ensure that the B Sensor is hanging free and is not surrounded tightly by product or other items that might distort the temperature reading.

  5. After completing your sensor installation, allow 30 minutes for the sensors to propagate and begin reporting. Login to SmartSense and confirm that all B Sensors are communicating.

Data Logger Usage

SmartSense Data Loggers operate in a hybrid mode. When they are in range of an appropriate SmartSense Gateway, they will report to the SmartSense dashboard in real-time.

They are also used to monitor conditions when a gateway is not present. In this example, the SmartSense Data Logger will store logged data locally. Real-time dashboard reporting will resume, as well as logged data will back fill, when the SmartSense Data Logger returns to an area with a SmartSense gateway.

  1. The SmartSense Data Loggers should be placed close to the product you want to monitor, but not inside the product or out of sight.

  2. The height of the SmartSense Data Logger should be viewable when the rear door is open and the attached orange lanyard should be visible so the receive can locate the SmartSense Data Logger and remove from the load.

  3. Please reference the complete SmartSense Data Logger User Guide for more complete instructions.

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