Packwise Smart Cap User manual

Packwise Smart Cap
Instruction manual
Version: BA_SC1_V02_ENG

Imprint
Packwise GmbH
Antonstr. 25
01097 Dresden
phone: [phone]
mail: [e-mail]
1. Edition June 2021
© 2020 Packwise GmbH
Subject to technical changes

Table of contents
1. General information about Packwise Smart Cap ...................................................... 7
1.1. Performance description ........................................................................................................7
1.2. Device data on the nameplate.................................................................................. 8
1.3. Modifications to the device ...................................................................................................8
1.4. Operating instructions.............................................................................................................9
2. Safety instructions................................................................................................... 9
2.1. Presentation of the warnings....................................................................................................9
2.2. I ntended use ............................................................................................................................. 10
2.3. Improper use........................................................................................................................... 10
2.4. General safety instructions................................................................................................... 10
2.5. Safety instructions for operation ...........................................................................11
2.6. Safety instructions for the battery ..........................................................................................11
2.7. Personal qualification...........................................................................................................11
2.8. Areas relevant for approval .................................................................................................12
2.9. IT security..............................................................................................................12
3. Structure and function ........................................................................................... 13
3.1. Overview ...............................................................................................................13
3.2. Rear view...............................................................................................................13
3.3. Functional principle ............................................................................................... 14
3.4. Transmission of measured values ..................................................................................... 14
3.5. Battery information................................................................................................ 15
4. Delivery and storage .............................................................................................. 15
4.1. Scope of delivery................................................................................................................... 16
4.2. Storage and transport conditions.......................................................................................16
5. Installation and activation ...................................................................................... 16
5.1. Environmental conditions ....................................................................................................16
5.2. Positioning the Packwise Smart Cap .....................................................................17
5.3. Preparing the mounting surface .........................................................................................17

5.4. Attaching the Packwise Smart Cap with the locking plate................................................ 18
5.5. Inserting the Packwise Smart Cap on a mounted locking plate................................... 19
5.6. Detaching the Packwise Smart Cap from a mounted locking plate ............................ 20
5.7. Activating the sensor and putting it into operation ................................................ 20
5.8. Deactivating the sensor and putting it out of operation ................................................. 21
6. Operation .............................................................................................................. 21
6.1. Measurements during operation.......................................................................................... 22
6.2. Reading measured values ..................................................................................... 22
7. Malfunctions ......................................................................................................... 23
8. Maintenance and care.......................................................................................................... 23
8.1. Checking Packwise Smart Cap .............................................................................. 23
8.2. Firmware-Update................................................................................................... 24
9. Repair and shipping............................................................................................... 24
10. Deactivation and disposal ..................................................................................... 25
10.1. Deactivation........................................................................................................................... 25
10.2. Disposal.................................................................................................................................. 25
10.3. Shipping for disposal............................................................................................................. 26
11. Technical data ....................................................................................................... 26
11.1. Device characteristics........................................................................................................... 26
11.2. Ambient conditions................................................................................................................ 26
11.3. Connectivity (transmission of measured values) ........................................................... 27
11.4. Battery .................................................................................................................. 27
12. Appendix ............................................................................................................... 28
12.1. Order information .................................................................................................. 28
12.2. Contact data.......................................................................................................... 28
12.3. Contact and support.............................................................................................. 28
12.4. Declaration of Conformity.................................................................................................... 29

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1. General information about Packwise Smart Cap
1.1. Performance description
The Packwise Smart Cap is a battery-powered sensor for filling level and temperature
measurement, as well as location and position determination of mobile and stationary liquid
containers or their filling goods.
The transmission of sensor readings via mobile radio enables stand-alone use of the
Packwise Smart Cap for remote monitoring. The Packwise Smart Cap measures and
transmits the collected measurement data outside and inside buildings in the 27 EU
countries and supports the cross-border use of mobile containers. Via mobile radio, the
collected measurement data is encrypted and transmitted to the Packwise Cloud and
displayed in the Packwise Flow web application.
Packwise Flow offers you a wide range of possibilities for optimizing and automating
your processes and setting up new processes. You can access Packwise Flow at
https://packwiseflow.de/login.

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1.2. Device data on the nameplate
The nameplate shown in the figure contains exemplary device-specific information.
No.
Description
1
Serial number of the device
2
Address of the distributor
3
QR code to call up the product URL
4
Operating temperature
5
Certifications (IP class, CE marking, production location)
6
Disposal label
7
Revision
1.3. Modifications to the device
User modifications to the Packwise Smart Cap are not permitted. If modifications are
necessary, contact Packwise.
1
3
2
Packwise Smart Cap V1
xxxxxx
Packwise GmbH
Antonstraße 25
01097 Dresden
Germany
4
5
7
6

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1.4. Operating instructions
The operating instructions and other documents are available for download at
https://packwise.de/download/.
If you have any questions, please contact: [e-mail]
2. Safety instructions
This chapter lists general safety instructions that apply as basic rules of conduct when
handling the Packwise Smart Cap.
2.1. Presentation of the warnings
If there are risks of danger to persons or damage to the device, these are indicated by
warnings. They precede the instruction to perform an action which may result in a risk of
damage.
The following warnings are used in this documentation:
WARNING
Nature and source of danger
This safety notice warns about a potentially hazardous situation that will result in serious
injury or death.
ATTENTION
Nature and source of danger
This safety notice warns about a potentially dangerous situation that may result in minor
or moderate injury.

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NOTE
Nature and source of danger
This safety notice warns about damage to the device.
2.2. Intended use
The Packwise Smart Cap is a battery powered sensor for filling level and temperature
measurement as well as location and position determination of mobile and stationary liquid
containers or their filling goods.
2.3. Improper use
The measured values are for the user's orientation only. The measured values of the
sensors are subject to various environmental influences and may deviate from the real
values. Faulty measurements cannot be ruled out. The measured values are therefore not
intended to trigger critical processes based on the sensor data, e.g. overflow stop. The
manufacturer is not liable for damage caused by improper or non-intended use.
2.4. General safety instructions
Read the instructions before installation and keep them within immediate reach.

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2.5. Safety instructions for operation
•The Packwise Smart Cap must not be operated in an explosive environment.
•The Packwise Smart Cap may only be used in a technically perfect condition.
•If any damage occurs, stop using the device immediately and contact Packwise.
•The Packwise Smart Cap must always be firmly seated on the container. Improper
attachment may result in the Packwise Smart Cap falling off the container when
moved, causing personal injury, environmental damage and property damage.
2.6. Safety instructions for the battery used
•The battery is installed so that it is not accessible to the user.
•The battery must not be dismantled and charged.
•The battery may only be replaced by the manufacturer or a person authorized
by the manufacturer.
2.7. Personal qualification
The Packwise Smart Cap may only be handled by authorized and qualified personnel.

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2.8. Area relevant for approval
If the Packwise Smart Cap is to be used in areas where approval is required, it must
be checked before use whether the device has the appropriate approval. This
information can be found on the nameplate, see section "1.2. Device data on the
nameplate" on page 8.
2.9. IT security
The Packwise Smart Cap can be turned on and off with the supplied magnet. Moving the
Packwise Smart Cap triggers a measurement and transmission process. No further
changes to the operating mode can be made on the Packwise Smart Cap directly. The
operating mode of the Packwise Smart Cap is set via the Packwise Flow web application.
The acquired measured values are stored and processed in encrypted form on the device.
The encrypted data is transmitted to the Packwise Cloud Platform via mobile networks.

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3. Structure and function
3.1. Overview
No.
Name
Description
1
Packwise
Smart Cap
Consists of an IP66/IP68 protected
housing containing the battery, the
sensor package, the SIM card and all
other relevant components.
2
O-ring
Prevents moisture from entering the
gap between the Packwise Smart
Cap and the locking plate.
3
Locking plate
with adhesive
pad
Is firmly glued to the container to be
monitored.
3.2. Rear view
No.
Name
Description
1
Position of
the magnet
and rubber
stopper
By removing the magnet, the
Packwise Smart Cap is activated.
Inserting the magnet deactivates the
Packwise Smart Cap..

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3.3. Functional principle
The Packwise Smart Cap measures and transmits the following parameters using an
integrated sensor package:
•The filling level is determined by a radar sensor using Pulsed Coherent Radar . This
method is used to determine the distance between the Smart Cap and the liquid, which
is converted into the filling level with a container-specific bearing chart.
•The location is determined by three different technologies:
•Global Navigation Satellite System (GNSS)
•Wi-Fi positioning
•Cell tower triangulation
•The movement of the Packwise Smart Cap is detected by an acceleration
sensor. It detects the movement of the device in the X-, Y- and Z-axis.
•The ambient temperature is measured by a digital temperature sensor.
3.4. Transmission of measured values
Depending on the availability of the mobile technologies (GSM/ LTE, etc.), the determined
values are transmitted wirelessly via the mobile network. The 2G (GSM), LTE-CAT-M1 or
NB-IoT (LTE-CATNB1) standards are used. By supporting different standards, connectivity
can also be ensured in remote areas and across borders in the 27 EU countries.
Detailed information on the transmission of measured values can be found in section "11.3
Connectivity (transmission of measured values)" on page 27.

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3.5. Battery information
The battery is not accessible to the user. The operating time can be strongly influenced by
the selected operating mode.
The main factors influencing the operating time are:
•the number of measurement and sending cycles.
•the type and availability of the mobile radio connection.
•the type and number of activated functionalities.
•the ambient temperature.
The battery level is determined mathematically and technically and displayed in the
Packwise Flow web application. The determined battery level is only a guide value. You
can be informed by e-mail if the battery level falls below a critical value. See also section
"11.4 Battery" on page 27.
4. Delivery and Storage
The Packwise Smart Cap is assembled when delivered. The locking plate and O-ring are
packed separately with the Packwise Smart Cap.

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4.1. Scope of delivery
Quantity
Name
1
Packwise Smart Cap
2
Locking plate
1
O-ring
1
Installation Guide
4.2. Storage and transport conditions
•Storage temperature: -20°C bis ~+60°C
•Avoid direct sunlight
•Avoid mechanical shocks
•Store in dry, dust-free environment
•Do not store in potentially explosive areas
5. Installation and activation
The Packwise Smart Cap is assembled when delivered and can be attached to the
container immediately.
5.1. Environmental conditions
•The Packwise Smart Cap must not be operated in a potentially explosive environment.
•Ambient temperature: -20 °C bis +70 °C.

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5.2. Positioning the Packwise Smart Cap
suitable location
The Packwise Smart Cap should be attached to the
top of the IBC within the area marked in blue,
between the edge and lid of the container, as
shown in the picture.
5.3. Preparing the mounting surface
Before installing the Packwise Smart Cap, make sure that the chosen surface is free of
dust, dirt or moisture.
1. Clean the chosen surface with a suitable cleaning agent.
2. Dry the surface.

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5.4. Attaching the Packwise Smart Cap with the locking plate
BEST PRACTICE
To start measuring the parameters immediately after the installation, activate the
Packwise Smart Cap before mounting, see section "5.7. Activating the sensor and
putting it into operation" on page 20.
Please note! The Packwise Smart Cap must be attached to the container within 1 minute
after activation. After 1 minute the measurements start and the radar sensor is
calibrated.
Attach the Packwise Smart Cap as shown below:
1. Pull off the adhesive protective foil.
3 Sek.
2. Press the Packwise Smart Cap firmly onto the chosen location
on the container and hold for 3 seconds.
15-20 Min
3. Wait for 15 to 20 minutes for the adhesive to dry, to prevent
later detachment.
Complete adhesive strength is achieved after 24 hours. After the drying time, the locking
plate is firmly fixed to the container.

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5.5. Inserting the Packwise Smart Cap on a mounted locking plate
If a locking plate is already installed on the container, insert the Packwise Smart Cap as
shown below:
1. Insert the o-ring into the locking plate.
2. Place the Packwise Smart Cap on the locking plate
and press firmly until it snaps in.
Make sure that the sensor has snapped on both sides.

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5.6. Detaching the Packwise Smart Cap from a mounted locking
plate
Carefully remove the Packwise Smart Cap from the
click mechanism using a flat-bladed screwdriver.
NOTE
The locking clip can break off
•Carefully remove the Packwise Smart Cap from the click mechanism using a
suitable tool e.g. flat-bladed screwdriver.
•Only by qualified personnel.
5.7. Activating the sensor and putting it into operation
To start the measurements and the data transmission, the sensor has to be activated as
shown below:
1. Remove the rubber stopper from the
bottom side of the device.
2. Take out the magnet inside to activate the sensor.
3. Place back the rubber stopper.
4. Place Packwise Smart Cap on the locking plate.
5. Put the magnet aside and store it so you can
deactivate the device again at a later time.
IMPORTANT
The Packwise Smart Cap must be attached to the container within 1 minute after
activation. After 1 minute the measurements start and the radar sensor is calibrated
to the environment.