NEXUS User Manual

NEXUS is Sensoteq's unified production management platform. It connects warehouse intake, quality assurance, box packing, order fulfilment, non-conformance management, and reporting into a single real-time system — synchronising data between internal SQL databases and Salesforce.

Modules at a Glance

• Warehouse Book-In — Log incoming stock against a Salesforce BI reference.
• QA Control — Pass or fail sensors and gateways through QA1 and QA2.
• Sensor Box Pack — Consolidate sensors into labelled boxes of up to 8.
• Order Packing — Assign packed boxes and devices to Salesforce sales orders.
• NCP Log & Block — Flag defective units to prevent them being shipped.
• Rework Logger — Record the reason and detail of any rework action.
• Global Search — Trace any device's full history across the database.
• Build Reports — View and export production build statistics.
• Site Health (NBHDW) — Monitor deployed sensor and gateway diagnostics.
• Nexus Chat — LLM assistant trained on Sensoteq documentation.

Access & Login

Every module requires a username and password. Credentials are validated against the NEXUS server on each login. All actions are logged against your username. Access the platform at https://nexus.sensoteq.com.

User Levels

Forgot Password

Use the Reset Password link in the NEXUS footer, or navigate directly to the password reset page. You will need access to the email address associated with your account.

Navigation

The top navigation bar (injected on every page) provides quick links to all modules. On screens narrower than 820 px the nav collapses into a Menu button.

• The NEXUS — By Sensoteq logo on the left is the brand mark and links back to the home screen.
• Reports is a dropdown containing Analytix and PulseCM sub-reports.
• The currently active page is highlighted with a blue gradient pill in the nav links.

ID Reference

NEXUS accepts several different ID formats depending on the module and device type. When scanning, always use the QR code or barcode on the physical unit — the system will parse and normalise the ID automatically.

Warehouse Book-In

The first step for all incoming stock. A unit must be Booked In before it can be QA'd, packed, or shipped. Book-In ties a physical device to a Salesforce Book-In record (BI-XXXXX) and records the received date.

Step-by-Step

1. Log in with your NEXUS credentials (Operator level or above).
2. Enter the Book-In Reference (e.g. BI-00123) and click Load or press Enter. The system pulls part number, supplier, description, and expected quantity from Salesforce.
3. Select the correct Device Type from the dropdown: Sensor, Gateway, CHI Sensor, or VHM Sensor.
4. Place the cursor in the Scan ID field and scan the unit's QR code (or type the ID manually).
5. Press Enter or click Book In Item. A green success message confirms the record. An audio chime also plays.
6. Repeat for each unit. The progress bar and counters update in real time — watch Scanned increase and Remaining decrease.
7. When all units are scanned the remaining counter turns green. The session is complete.

Remove Mode

If you scan a unit by mistake, toggle the Remove Item Mode checkbox. The interface turns red and the button changes to REMOVE ITEM. Scan the incorrect unit to deduct it from the count. Toggle back to normal mode when done.

Changing Sessions

Click Change BI in the scanning interface to return to the session setup screen and start a new BI reference. This does not delete previously scanned records.

QA Control

Digital quality assurance checkpoints replacing paper travellers. Each unit must pass QA1 before it can be packed. Sensors optionally go through QA2 as a final cosmetic / enclosure check.

QA Stages

• QA1 — Initial PCB, battery, and current test check. Available for both Sensors and Gateways.
• QA2 — Final enclosure and cosmetic check. Sensors only. The QA2 option is automatically disabled when Gateway is selected.

Step-by-Step

1. Log in (Operator or above). Manufacturer, Sales, and Engineering accounts are blocked from this module.
2. Select the Product Type: Sensor or Gateway.
3. Select the QA Stage: QA1 or QA2 (QA2 is greyed out for gateways).
4. Enter the Product ID in the text field (scan the QR or type manually), then click QA this ID or press Enter.
5. A green flash and chime confirm a pass. A red flash and buzzer indicate a failure — read the error message for details.

Camera Scanner (Mobile)

On mobile devices or if you have a webcam, click Start Scanner to activate the camera QR reader. Once a code is scanned it appears in the Last scan field. Click QA Scanned ID to submit it.

Already QA'd Warning

If a unit has already been QA'd, the system shows a warning asking if you want to overwrite. This is intended for re-test scenarios — confirm only if you are intentionally re-running QA on a unit that has been physically re-tested.

Validation Rules

• Unit must have been Booked In first.
• Unit must not have an active NCP block.
• Units that have failed battery or current tests (flagged in SQL) will be rejected.
• QA2 cannot be submitted before QA1 is complete on the same unit.
• Only QA1 is available for Gateways.

Sensor Box Pack

Consolidates individual sensors into labelled shipping boxes. Each box holds a maximum of 8 sensors. A box must be loaded as the active box before sensors can be added to it.

Setting the Active Box

1. Log in (Operator or above).
2. Scan or type a Box ID (format: BOX-001000) into the Box ID field and click Set Active Box or press Enter. The box contents and remaining space are loaded.
3. The active box ID appears in a blue badge at the top of the card. Click Change to swap to a different box.

Adding Sensors to a Box

1. Ensure the correct box is active.
2. Set the mode toggle to Add.
3. Scan the Sensor ID into the Sensor ID field and press Enter or click Go.
4. The system checks packability (QA passed, not NCP blocked, not already in another box). A success message shows remaining spaces. The contents table updates immediately.

Removing a Sensor

Switch the mode toggle to Remove, scan the Sensor ID, and press Enter. The sensor is removed from the current active box.

Checking Packability

Switch the mode toggle to Check and scan a Sensor ID to verify whether it can be packed without actually adding it. The status message will show "Packable" or list the specific reasons it cannot be packed.

Next Box & Label Printing

Click Next Box (Print Label) to pull the next unassigned box from the queue for your user and immediately send the label to the printer. The label is a 60×29 mm thermal label containing the Box ID and a QR code. After printing, scan the new Box ID manually to make it your active box.

Order Packing

Final fulfilment step. Links packed boxes and individual devices to a Salesforce Sales Order, ready for despatch. The system cross-checks device part numbers against the order line items.

Loading a Sales Order

1. Log in (Operator or above). Engineering and Sales accounts are blocked.
2. Enter the Sales Order number (e.g. 00013937) and click Load Order or press Enter.
3. The order details panel shows the customer name, order status, and a table of expected line items (part numbers and outstanding quantities).
4. The count cards at the bottom show how many Sensors, CHI, VHM, and Gateways are already packed against this order in the database.

Scanning Modes

Use the Scan Mode toggle to switch between scanning individual devices or whole boxes:

• Device mode — Select the hardware type (Sensor / CHI / VHM / Gateway), then scan the device ID. The Hardware toggle is visible only in Device mode.
• Box mode — Scan a Box ID (BOX-XXXXXX). All sensors inside the box are assigned to the order at once.

Assign vs Remove

Use the Action toggle to switch between Assign (link device to order) and Remove (unlink device from order). Press Enter after scanning to trigger the current action automatically.

Pre-check

Click Pre-check after entering a device ID to verify it is valid and packable before assigning it. This does not change any data — it is a read-only validation.

Part Mismatch Warning

If the device's part number does not match the expected part numbers on the Sales Order, a warning dialog appears showing the mismatch. You must actively confirm to proceed — this safeguard prevents mis-packing the wrong product variant into an order.

NCP Log & Block

The Non-Conformance Protocol module prevents defective units from being packed or shipped. Any unit that fails a physical inspection or test should be blocked here immediately.

Blocking a Unit

1. Log in (any level except Manufacturer).
2. Select the device type from the dropdown: Sensor, Gateway, CHI, or Weir VHM.
3. Scan or enter the device ID into the Enter ID field.
4. Enter the NCP Number (e.g. NCP-1234).
5. Click Block. The status message confirms the unit is blocked and shows the user who actioned it.

Unblocking a Unit

Only Admin users can unblock. The Unblock button is disabled for all other levels. Follow the same steps as blocking but click Unblock instead. Ensure the underlying defect has been resolved before unblocking.

Retest Bypass Engineering Admin

Visible only to Engineering and Admin users. Sets the retest_bypass flag on a sensor, which changes packability rules to allow the unit through after a supervised retest. Use only when instructed by the engineering team.

Bulk Bypass Admin

Visible only to Admin users. Upload a CSV file with Sensor IDs in the first column (header row is skipped). Preview the parsed IDs before confirming. The system processes all IDs and reports success/failure counts. A progress bar tracks processing in real time.

NCP Dashboard

The NCP Dashboard (/ncpblocker/dashboard.html) provides a management view of all active and resolved NCP records. It uses a distinct industrial design and is intended for supervisors tracking open defects across the production floor.

Rework Logger New

Records the details of any rework action performed on a unit. Rework entries are linked to a Salesforce Purchase Order and Service Pack number, giving full traceability from defect to resolution.

Step-by-Step

1. Log in (Operator or above — Viewer and Guest are blocked).
2. Enter the PO Number (format: PO-XXXXX) and click Lookup. The system queries Salesforce and returns all associated SP numbers.
3. Select the relevant SP Number from the dropdown. Part number, revision, and outstanding quantity are shown. If only one SP exists, it is selected automatically.
4. Scan the unit's UID (sensor, gateway, CHI, or VHM ID) in the Unit Scan field and press Enter. The system looks up the unit in the database and displays its current status (type, test date, firmware, NCP status, etc.).
5. Select the Rework Type from the dropdown. Available types include: Solder Bridge, Missing Component, Wrong Component, Damaged Component, Cold Solder Joint, PCB Damage, Firmware Flash Failure, Mechanical Damage, Connector Issue, Label Error, Test Failure – Retry, and Other.
6. Optionally add Notes for more detail.
7. Click Submit Rework. The record is saved and appears immediately in the Session History table below.

Session History

The session history table shows all rework entries logged in the current browser session. It is cleared when the page is refreshed. Columns: Time, UID, PO / SP, Rework Type, Notes, logged by.

Site Reports

A reporting tool used to generate and review site-specific data exports and operational reports from the NEXUS database.

Certificates

A module for managing and viewing device-specific certification records. Use this to verify that units meet required compliance standards before shipment.

Weir EOL Upload New

A specialized utility for parsing and uploading end-of-line (EOL) test files generated by legacy test equipment for Weir sensors. This ensures production test data is captured accurately in the NEXUS database.

How to Use

1. Log in with your NEXUS credentials.
2. Drag and drop your .txt test files into the Drop Zone, or click Browse Files to select them.
3. The system parses the files and displays a summary table of test results (Sensor ID, HW ID, RSSI, etc.).
4. Review the parsed data in the preview table. Valid records are marked by PASS/FAIL badges.
5. Click Upload to Nexus to transmit the validated data to the NEXUS server.

Global Search

The "god view" of the NEXUS database. Use this to trace the complete history of any device — from booking in, through QA, box packing, and final order — along with all flags and timestamps.

What You Can Search

Result Cards

Each result card shows:

• Current status flags (QA1, QA2, Battery test, NCP block)
• Book-In reference and received date
• Box ID (if packed) and associated Sales Order
• Firmware version, module type, and test result
• Timestamps for every interaction
• Full lineage — which order the unit shipped with

Build Reports New

Provides production build statistics pulled directly from the NEXUS database. Used by production supervisors and management to monitor daily and weekly output metrics.

Using Build Reports

1. Log in with your NEXUS credentials.
2. Select a date range using the date pickers to scope the report period.
3. Click Load Report to fetch data from the database.
4. The report displays production totals broken down by device type (Sensor, Gateway, CHI, VHM), QA pass rates, and daily output trends.
5. Use the Export button to download the report as a CSV for use in Excel or other tools.

QualityLLM New

An AI-powered quality assessment tool that generates comprehensive reports by analyzing Salesforce Non-Conformance (NCP) data, SQL production flags, and Jira work logs.

How to Generate an AI Report

1. Navigate to the **QualityLLM** page.
2. Enter a valid NCP Number (e.g., NCP-00010).
3. (Optional) Configure your Jira credentials in the **API Settings** panel if you want the report to include Jira issue history.
4. Click Generate Report. The system will gather data from multiple sources and present a final assessment.

Site Health Dashboard (NBHDW)

Connects to the live Sensoteq cloud API to pull diagnostic data from deployed sensors and gateways at customer sites. Used by field engineers and support teams to assess hardware health remotely.

Selecting Sites

After syncing, all sites your token has access to appear in the left-hand panel. Click a site to load it. Hold Ctrl and click to select multiple sites simultaneously and compare data across locations.

Use the Filter input above the site list to search by site name.

Diagnostic Vitals Table

Click Recalculate Averages to fetch the last 360 data samples for every sensor point across your selected sites. The table shows:

• Voltage (Avg) — Highlighted red if below 2800 mV (low battery threshold).
• Volt Δ — Voltage spread (max − min) across the sample window.
• RSSI (Avg) — Signal strength. Highlighted amber if below 40.
• Temp (Avg) — Average ambient temperature at the sensor.
• RF Val % — RF validity percentage. Highlighted red if below 50%.
• Last Seen — Highlighted red if the sensor has not reported in over 24 hours (offline).

Gateway Infrastructure Table

Shows all gateways for the selected sites with online/offline status, last seen time, internal temperature, signal quality, and signal strength averages.

Statistics Bar

The four stat boxes at the top show:

• Points — Total sensor measurement points across selected sites.
• Offline — Count of points not seen in 24+ hours.
• Gateways — Total gateway count.
• Overall Health — HEALTHY (green), ATTENTION (amber, some offline), or ALARMING (red, active alarms).

Exporting Data

Click Export CSV to download the current vitals table as a comma-separated file, suitable for analysis in Excel or for sharing with customers.

PulseCM Report

The PulseCM sub-report (accessible via the Reports dropdown in the nav) provides a customer-facing connectivity and monitoring summary report. Requires the same API token.

Nexus Chat

An LLM-powered assistant trained on Sensoteq documentation. Useful for looking up specifications, installation guidance, and troubleshooting steps without leaving the NEXUS interface.

How to Use

1. Log in with your NEXUS credentials.
2. The chat interface loads automatically. Type your question in the input bar and press Enter or the send button.
3. The assistant responds with information sourced from Sensoteq documentation.

MQTT Unlock New

Generates secure engineering unlock keys for MQTT-enabled gateways and sensors. This tool is used by the field engineering team to access restricted device configurations.

How to Generate an Unlock Key

1. Log in (Engineering or Admin level).
2. Enter the Device Serial Number.
3. Enter the Challenge Code provided by the device.
4. Click Generate Key. The system will calculate the secure response using the NEXUS encryption service.
5. Copy the generated key and enter it into the device interface.

Password Reset

If you have forgotten your password, visit the Password Reset page linked in the footer of every NEXUS page. You will need access to the email address registered to your account.

If you do not receive a reset email within a few minutes, check your spam folder. If the problem persists, contact IT at customerservice@sensoteq.com and request a manual account reset.

Troubleshooting

Scanner Not Working

Barcode scanners must be configured in Keyboard Emulation (HID) mode — not serial/COM port mode. Click into the input field before scanning; the cursor must be in the field or the scan output will go nowhere. If the scanner beeps but nothing appears, check the field is active (blue border).

"BI Reference Not Found"

The BI record does not exist in Salesforce, or was entered incorrectly. Check the Salesforce Book In list and confirm the exact reference. The format is BI-XXXXX with leading zeros.

"Error: Unknown" or Red Banner

Usually a network timeout or a malformed ID. Check your network connection, then press Ctrl + R to refresh the page and try again. If the error persists for a specific ID, verify the ID format matches the expected pattern for that device type.

"Not Authorised"

Your user level does not permit this action. Common examples:

• Viewer accounts cannot scan or submit data.
• Manufacturer accounts are blocked from most modules.
• Only Admin users can Unblock NCP units.
• Only Admin / Engineering users can see the Retest Bypass panel.

Contact IT to request a level upgrade if you need access that your current level does not provide.

Unit Fails Packability Check

When a sensor cannot be added to a box, the reason is shown in the status message. Common causes:

• QA not complete — The unit has not passed QA1 (and QA2 if required).
• NCP Blocked — The unit has an active block. Contact the supervisor who issued the NCP to assess whether it can be released.
• Already in a box — Use Global Search to find which box the unit is currently in, then remove it from that box first.
• Battery flag set — The unit has a low-battery or test-fail flag in the database. Engineering or Admin can apply a retest bypass if the unit has been re-tested and passed.

Box ID Not Accepted

Box IDs must begin with BOX- followed by digits (e.g. BOX-001000). If your scanner produces a URL or extra characters, check the QR code format on the label and contact IT if labels are being printed incorrectly.

Camera / QR Scanner Won't Start (QA Module)

The camera scanner requires the page to be served over HTTPS. If you see an error about a secure context, ensure you are accessing NEXUS via the https:// URL. Also check that your browser has permission to access the camera — look for a blocked camera icon in the browser address bar and click it to allow access.

Site Health: No Sites Appearing

Enter your API token in the field at the top right and click Sync Access. If the site list still doesn't load, the token may be expired or incorrect. Request a new token from IT or your account manager.

Login Request Failed / Server Error

NEXUS cannot reach the backend server. This is usually a network issue or the server is temporarily offline. Check your internet connection, wait a moment, and try again. If the issue persists, contact IT — the server may need to be restarted.

Getting Help

For urgent production issues, contact IT directly. For general queries, email customerservice@sensoteq.com with a description of the problem, the module you were using, and the ID(s) involved.