Sensorium™ Gateway — Universal IoT Gateway — User & Operation Manual

Operation, configuration, and maintenance of the Universal IoT Gateway.

sensorium-gateway · Revision Draft (Preliminary, PROPOSED) · 2026-07-18 · Status: PRELIMINARY

PRELIMINARY — PROPOSED VALUES. Values marked ‡ are proposed, industry-typical figures for this product class, provided so no procedure or setting is left blank. They are not measured and not final, and no value in this manual is a certification claim. Timings, indicator patterns, and intervals below are ‡ proposed and must be confirmed against the production unit before they are relied on for commissioning, safety, or service. A remaining [TBD] marks a legal/contractual term (warranty) that must not be invented. Always follow the documentation and rating label shipped with your unit. See §11 for change control.

Figure FIG-001 — Sensorium™ Gateway, the ruggedized Connect layer that aggregates field data and secures the uplink to the 5Tech Platform.

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1. Safety

Read this chapter in full before you install, operate, or service the Sensorium™ Gateway. Keep this manual with the equipment for the life of the product.

Figure FIG-002 — Signal words (DANGER · WARNING · CAUTION · NOTICE) and the hazard pictograms used in this manual.

1.1 Signal words

This manual uses four signal words. Each is paired with the pictograms in Figure FIG-002.

1.2 Qualified personnel

WARNING — Qualified personnel only. Installation, electrical connection, commissioning, and service of the Gateway must be performed only by qualified personnel who are trained in local electrical and RF safety practice and who have read and understood this manual and the installation guide. Unqualified work can cause electric shock, fire, or equipment damage.

For the purpose of this manual, qualified personnel are individuals who:

• Are trained and authorized to energize, de-energize, ground, and tag equipment per local code.
• Understand the electrical and radio-frequency hazards described in this chapter.
• Are trained in the installation and operation of the equipment and its protective devices.

1.3 Intended use

The Sensorium™ Gateway is intended to aggregate data from Sensorium™ field devices (Zone Awareness sensors and SmartBolt sensing modules) over BLE and from third-party sensors, pre-process that data at the edge, and transmit it over a secure network uplink — MQTT over TLS on Wi-Fi or Ethernet, with an optional cellular module — to the 5Tech Platform. It is designed for fixed installation at industrial and remote sites within its targeted environmental limits (ruggedized die-cast aluminium enclosure; ingress protection IP65‡ per IEC 60529 — see the datasheet §8).

Any other use is considered misuse. In particular, the Gateway is not a safety controller and not a machine-safety device: it does not by itself stop machinery or create protective zones. Its monitoring, indicators, and alerts are not a safety-rated protective function and must not be the sole means of protecting personnel.

1.4 Electrical safety

DANGER — Electric shock. De-energize and lock out/tag out all power inputs before wiring, unwiring, or servicing the Gateway. The unit has redundant power inputs (A and B) — both may be live even if one is switched off. Verify zero energy on every input before touching a terminal.

• Connect, disconnect, and service power wiring only with all supply inputs de-energized.
• The Gateway accepts a redundant 9–36 V DC supply on each input (24 V nominal); use only the supply voltage, current, and protective-device ratings confirmed on the product rating label and in the datasheet §6. Do not exceed the stated input range.
• Bond the enclosure to protective earth via the grounding/earth stud before applying power. Do not operate the unit without a verified earth connection.
• Use only supplies, fuses, and disconnects rated for the installation. The unit provides reverse-polarity protection on both inputs and DC-input surge immunity (±2 kV‡ line-to-earth, per IEC 61000-4-5); confirm the values in the datasheet §6 before energizing.

1.5 Radio-frequency (RF) safety

The Gateway transmits on Wi-Fi through external SMA-mounted antennas and, on the optional cellular variant, on a cellular radio through a separate external SMA antenna. Its Bluetooth Low Energy (BLE) radio uses an internal antenna that radiates through the non-metallic polycarbonate cap; there is no external BLE antenna to handle.

WARNING — RF exposure. Maintain a minimum antenna-to-person separation distance of 20 cm‡ from each transmitting antenna during operation. This separation is a ‡ proposed value pending radio type-approval for your region and antennas; the maximum permitted radiated power is set by that type-approval (datasheet §9) and is not yet held. Do not position personnel closer than the confirmed separation distance while the radios transmit.

• Install and orient antennas per the installation guide; use only antennas approved for the unit. Substituting antennas can violate RF-exposure and radio-type approvals.
• Do not operate a transmitter with its antenna disconnected or damaged.
• Radio type-approvals and permitted frequency bands are region-specific and not yet held (see the datasheet §9). Operate only where the radios are approved.

1.6 Environmental and handling

CAUTION — Hot surface, burn hazard. During operation the enclosure and heat-sink fins can reach an external surface temperature of up to +80 °C‡ (at +70 °C ambient and 18 W load, per datasheet §8) — hot enough to cause burns. Allow the unit to cool before handling, or wear protective gloves. Do not mount it where incidental contact is likely.

• Operate the unit only within its rated environmental limits (see the datasheet §8). The IP65‡ ingress rating (IEC 60529) is effective only when all connectors are mated or capped and all seals are intact; it is a ‡ targeted rating and not yet certified.
• Do not open, drill, or modify the sealed enclosure. There are no operator-replaceable parts inside; opening it voids the ingress rating and the warranty.

1.7 Residual risks

Even when used as intended, the following residual risks remain: electric shock from external supply wiring, RF exposure near active antennas, burns from hot surfaces, and loss of data uplink during connectivity gaps (mitigated, but not eliminated, by local edge buffering). Observe the warnings in Chapters 5–7 that address each of these.

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2. About this manual

Scope. This manual covers day-to-day operation, configuration, maintenance, and troubleshooting of the Sensorium™ Gateway by trained operators and maintenance technicians. It does not cover mechanical mounting and initial wiring — see the installation guide.

Audience. Qualified operators, maintenance technicians, and integrators as defined in §1.2.

Conventions.

• Safety notices use the signal words defined in §1.1 and appear before the step they apply to.
• Procedures are numbered, one action per step, in the imperative voice. The expected result follows the action where useful.
• ‡ marks a proposed, industry-typical value supplied so the manual carries no blank; it is not measured or final and must be confirmed against the production unit. [TBD] marks a legal/contractual value that must not be invented.
• Monospace denotes labels, order codes, indicator names, and terminal/UI text.

Related documents.

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3. Product overview & theory of operation

Figure FIG-003 — External features of the Sensorium™ Gateway with numbered callouts and legend.

3.1 What it does

The Sensorium™ Gateway is the Connect module of the 5Tech Sensorium™ family. It is the local hub for a site: it aggregates BLE data from Sensorium™ field devices and third-party sensors, pre-processes that data at the edge, and securely transmits results to the 5Tech Platform over MQTT. It is built for remote and industrial environments where reliable connectivity cannot be assumed.

3.2 Where it sits — Sense → Connect → Decide

The Gateway is the bridge between Sense (field devices) and Decide (the 5Tech Platform). Sensor data flows up through the Gateway to the Platform; monitoring, automation, and configuration flow back down.

• Sense — Sensorium™ Zone Awareness (proximity / zone-presence sensing) and SmartBolt (load, vibration, and looseness sensing) modules report conditions in the field.
• Connect — the Sensorium™ Gateway aggregates and pre-processes their data.
• Decide — the 5Tech Platform (monitoring, automation, and AI-assisted helpers) turns data into human-in-the-loop action.

3.3 Theory of operation (operator depth)

Internally, the Gateway performs four functions in sequence:

1. Field I/O — it receives data from Sensorium™ devices over BLE (an internal antenna behind the polycarbonate cap) and from third-party sensors/PLCs over its wired field interfaces.
2. Edge compute — it buffers, filters, and pre-processes that data locally, so the site keeps functioning and no data is lost during connectivity gaps.
3. Network uplink — it forwards results to the 5Tech Platform over MQTT, using Wi-Fi or Ethernet (or the optional cellular module where fitted).
4. Power & integrity — redundant power conditioning and a hardware watchdog keep it running and self-recovering.

Network uplink. The Gateway connects to the 5Tech Platform over Wi-Fi (2.4/5 GHz, external RP-SMA antennas) or Gigabit Ethernet and publishes data using MQTT. Where wired or Wi-Fi backhaul is not available, an optional factory-fitted LTE cellular module (external SMA antenna) can carry the uplink. Supported bands and the cellular option are detailed in the datasheet §7.

Edge buffering. When no network path is available, the Gateway buffers pre-processed data locally (≥ 72 h‡ store-and-forward, per datasheet §1) and transmits it once connectivity is restored.

Redundant power. Two independent 9–36 V DC power inputs (A and B) feed the unit. If one input fails, the other maintains operation without interruption. Input ratings are in the datasheet §6.

Secure uplink. The link to the 5Tech Platform is authenticated and encrypted: MQTT over TLS 1.2/1.3‡ with a per-device X.509 client certificate‡ for mutual authentication. No plaintext MQTT is offered. See the datasheet §7.

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4. Controls & indicators

Figure FIG-004 — Controls, connectors, and status LEDs with a numbered legend.

The table below lists every operator-facing control, connector, and indicator. Indicator colours and blink rates are ‡ proposed and will be confirmed against the production unit; use the legend printed on your unit and in Figure FIG-004 where it differs.

FAULT blink codes (‡ proposed). When the FAULT LED blinks red, count the blinks in each group; interpret against the legend on your unit if it differs.

NOTICE. The reset/service button is recessed to prevent accidental operation. Do not press it during normal operation unless directed by a procedure in this manual or by 5Tech support.

4.1 Reset / service button press durations (‡ proposed)

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5. Operation

The Gateway is designed for unattended, continuous operation. Once installed and commissioned (installation guide), routine operation is limited to power-on, verifying status, and orderly shutdown. Button timings and indicator patterns referenced below are ‡ proposed (§4).

5.1 Before you start

1. Confirm the unit has been installed and commissioned per the installation guide.
2. Confirm the enclosure, all connectors, and all seals are intact and mated or capped.
3. Confirm the antennas are connected and undamaged.
4. Confirm the enclosure is bonded to protective earth.

5.2 Power-on and status check

DANGER — Electric shock. Do not touch power terminals during this procedure. Both power inputs may be live. Perform only with wiring already installed and covers in place.

1. Energize power input A at the external disconnect.
2. Energize power input B at the external disconnect.
3. Observe the PWR / status LED illuminate. Expected: the LED blinks green as the unit begins its start-up sequence.
4. Wait for the start-up sequence to complete. Expected time: within 90 s‡ from power-on (cold start, 24 V, 25 °C).
5. Verify the PWR / status LED is solid green (healthy — see §4).
6. Verify the NET / uplink LED (or the WAN-CELL LED, if the cellular module is fitted) shows a connected state.
7. Verify the FAULT LED is off.
8. If the unit does not reach a healthy state, go to Chapter 8, Troubleshooting.

5.3 Confirming the uplink to the Platform

1. Confirm the NET / uplink LED (or WAN-CELL, if fitted) shows a connected state (§4).
2. Open the 5Tech Platform Monitoring view for this site.
3. Verify the Gateway appears online and is reporting current data.
4. Verify the expected field devices (Zone Awareness, SmartBolt) appear through the Gateway.
5. If the Gateway is not online within the connect time — within 120 s‡ of start-up on Wi-Fi/Ethernet, or within 300 s‡ on cellular (allowing network registration) — go to Chapter 8.

5.4 Verifying reconnection after a network interruption (optional check)

NOTICE. Perform this check only during a maintenance window; it briefly interrupts the network uplink.

1. Confirm the unit is online and reporting to the Platform.
2. With 5Tech support or per site procedure, briefly interrupt the active network path.
3. Observe the NET / uplink LED change state (returns to blinking while it re-associates).
4. Verify the unit re-establishes the uplink once the network path is restored.
5. Confirm the Platform shows no gap in data (local edge buffering covers the interruption).

5.5 Orderly shutdown

WARNING — Qualified personnel only. De-energizing supply wiring is an electrical task.

1. Confirm no critical commissioning or update is in progress (the PWR LED is not blinking amber).
2. De-energize power input A at the external disconnect.
3. De-energize power input B at the external disconnect.
4. Verify all indicator LEDs are off.
5. For service on wiring, apply lock-out/tag-out and verify zero energy on every input before touching a terminal.

5.6 Restart

1. Perform an orderly shutdown (§5.5).
2. Wait 30 s‡ to allow the unit to power down fully and internal capacitors to discharge.
3. Perform power-on and status check (§5.2).

Alternatively, where directed and with covers in place, hold the recessed reset/service button for 5 s‡ and release to restart without removing supply power (§4.1).

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6. Configuration

Most configuration is delivered from the 5Tech Platform over the secure uplink; the Gateway requires little local configuration in normal use. Parameters, ranges, and defaults below are ‡ proposed and will be confirmed against the production firmware.

6.1 Configuration methods

6.2 Configurable parameters (preliminary)

6.3 Cellular (SIM/eSIM) provisioning (optional module)

WARNING — Loss of environmental sealing. Opening the SIM/eSIM hatch breaks a seal. The unit's IP65‡ ingress protection is effective only when the hatch and its seal are correctly closed.

1. Perform an orderly shutdown (§5.5) unless hot-provisioning is confirmed supported for your firmware‡.
2. Open the gasketed SIM/eSIM access hatch.
3. Insert or provision the 4FF nano-SIM / eSIM per your carrier and 5Tech instructions.
4. Inspect the hatch seal for damage; replace if damaged (§7).
5. Close and secure the hatch until the seal is fully seated.
6. Power on (§5.2) and verify the WAN-CELL LED reaches a solid (connected) state within 300 s‡.

6.4 Applying a configuration change

1. Confirm the change is authorized for this site.
2. Apply the change from the 5Tech Platform (preferred) or the local service interface.
3. Confirm the Gateway acknowledges the change (the PWR LED returns to solid green).
4. Verify operation is unaffected (§5.2, §5.3).
5. Record the change per your site's change-control procedure.

6.5 Firmware updates

NOTICE. Do not remove power during a firmware update. Interrupting an update can leave the unit in a recovery state.

1. Confirm the update is approved for this unit and site.
2. Confirm power inputs A and B are stable.
3. Initiate the update from the 5Tech Platform.
4. Wait for the update to complete without removing power. Duration: 10–20 min‡ typical, depending on package size and uplink; the PWR LED blinks amber throughout.
5. Verify the unit returns to a healthy state (§5.2) and reports the new version.

6.6 Factory reset / recovery

CAUTION. A factory reset removes local configuration and may interrupt the uplink until the unit is re-provisioned. Perform only when directed by 5Tech support.

1. Contact 5Tech support and confirm reset is the correct action.
2. Perform the recovery sequence with the reset/service button as directed — typically hold for 20 s‡ until the LEDs indicate recovery mode, then release (§4.1).
3. Re-provision the unit from the 5Tech Platform (§6.1–§6.4).
4. Verify the uplink and field devices (§5.3).

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7. Maintenance

DANGER — Electric shock. De-energize and lock out/tag out both power inputs and verify zero energy before any hands-on maintenance. Both inputs may be live independently.

The Gateway is a sealed unit with no operator-replaceable internal parts. Maintenance is limited to external inspection, keeping seals and connections sound, and keeping the enclosure clear for cooling. Do not open the enclosure. The internal RTC backup cell (≈ 5 yr‡ life, datasheet §6) is not operator-serviceable; return the unit to 5Tech when it is due.

Figure FIG-005 — Operator-serviceable points and maintenance access of the Sensorium™ Gateway.

7.1 Maintenance schedule

Intervals below are ‡ proposed starting points; confirm against your site's maintenance policy and environment (shorten them in dusty, high-vibration, or high-temperature installations).

7.2 Cleaning the enclosure

CAUTION — Hot surface. Allow the unit to cool below hand-safe temperature before cleaning (surfaces can reach +80 °C‡, §1.6).

1. Perform an orderly shutdown (§5.5) if directed by site policy.
2. Wipe external surfaces with a soft cloth dampened with water or a mild pH-neutral detergent.
3. Do not use solvents, alcohols, abrasives, or high-pressure spray. Approved agents: water or mild pH-neutral detergent only‡.
4. Keep the heat-sink fins clear of dust and debris.
5. Confirm all seals remain intact after cleaning.

7.3 Inspecting seals and connections

1. De-energize and lock out/tag out both power inputs; verify zero energy.
2. Inspect the enclosure seams and gaskets for cracks, gaps, or deformation.
3. Inspect each connector seal and blanking cap; confirm each is seated.
4. Confirm each antenna connector is tight and each antenna is undamaged.
5. Replace any damaged seal or cap before returning the unit to service.
6. Restore power (§5.2) and verify a healthy state.

7.4 What not to do

• Do not open, drill, or modify the sealed enclosure.
• Do not substitute non-approved antennas, seals, or connectors.
• Do not return a unit to service with a damaged seal — ingress protection would be lost.

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8. Troubleshooting

Use this table for first-line diagnosis. If a fault persists after the listed action, contact 5Tech support (§10). Do not open the enclosure. Interpret indicator patterns against §4 and the legend on your unit.

DANGER — Electric shock. Any action involving power wiring requires de-energizing and lock-out/tag-out first.

If a fault cannot be resolved by these actions, record the unit serial number, the indicator states (including any FAULT blink code), and the Platform status, then contact 5Tech support before taking further action.

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9. Specifications

This manual does not duplicate specification values. All electrical, RF, mechanical, environmental, interface, and compliance specifications are maintained in the datasheet:

• Datasheet: datasheets/sensorium-gateway-datasheet/document.md

Refer to the datasheet for the authoritative figures. A brief operator-level summary of what the datasheet covers is below; consult the datasheet itself for values.

Confirmed at operator level in this manual: a ruggedized die-cast aluminium enclosure rated IP65‡ (IEC 60529, targeted, not yet certified — effective only with all seals intact and connectors mated or capped); a non-metallic polycarbonate antenna cap over the internal BLE antenna; network uplink over Wi-Fi / Ethernet (external RP-SMA antennas) with an optional cellular module (external SMA); MQTT over TLS 1.2/1.3‡ communication; redundant 9–36 V DC power inputs; local edge processing and ≥ 72 h‡ buffering; and a secure, mutually authenticated uplink to the 5Tech Platform. All numeric values remain in the datasheet.

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10. Warranty & support

Warranty. Warranty terms are [TBD] — a legal/contractual term supplied with the product or on request; it is not stated here because it must not be invented. The warranty is void if the sealed enclosure is opened or modified, if non-approved antennas or seals are fitted, or if the unit is operated outside its rated limits.

Support and service. For technical support, RMA, or service:

• 5Tech — Vancouver, BC, Canada
• Email: info@5tech.ca
• Web: https://5tech.ca

When contacting support, have ready: the unit serial number, firmware version, indicator states (including any FAULT blink code), the 5Tech Platform status for the site, and a description of the symptom and any actions taken.

WARNING — Qualified personnel only. Do not attempt internal repair. The unit has no operator-replaceable parts; return it to 5Tech for service.

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11. Revision & change control

Full change history: revision.md. Sources and cited standards: references.md.

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Figures

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This manual is preliminary; ‡ values are proposed and subject to engineering confirmation and change. See revision.md for change control, references.md for sources, and image_prompts.md for the figure/prompt index. Web publication target: /resources/manuals/gateway.