Hi G Tek IGAV143916 Users Manual
Wireless Monitoring Solutions for Security and Management
Tanker Truck Monitoring System
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User’s Guide
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P/N: UM4718
Date: 31-AUG-06
Rev: 1.2
Tanker Truck Monitoring System User’s Guide I
About This Guide
AAbboouutt TThhiiss GGuuiidde
This User Guide provides the information required to install and configure the hardware and
software required to run the Fleet application.
e
Preface
RReevviissiioonn HHiissttoorryy
The revision history for this document is shown in Table
Version Date Description
1.0 22-MAY-06 Initial
1.1 9-Aug-06
1.2 31-Aug-06
Table 1-1: Revision history
1-1.
Tanker Truck Monitoring System- User’s Guide II
Preface
Warnings and Safety
Waarrnniinnggss aanndd SSaaffeettyy
W
ATTENTION
• The TTMS system is distributed to a commercial/industrial use only, and should only be handled by
personnel authorized by Hi-G-Tek representatives.
• Installation must be performed according to this User Guide.
• Using only certified antennas: It is the responsibility of the installer to ensure that when using the
outdoor antenna kits in the United States ( or where FCC rules ap ply), only those antennas certified with
the product are used. The u se of any antenna other than those certified with the product is expressly
forbidden in accordance with FCC rules CFR47 part 15.204.
The FCC Wants You to Know
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to Part 15 of the FCC rules. These limits are design ed to pr ovide reasonable pr otection
against harmful interference in a residential installation. This equipment generates, uses and can
radiate radio frequency energy and, if not inst alled and used in accordance with the instructions,
may cause harmful interference to rad io communications. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause harmful
interference to radio or television reception, which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the interference by one or more of the
following measures:
a) Reorient or relocate the receiving antenna.
b) Increase the separation between the equipment and receiver.
c) Connect the equipment to an outlet on a circuit different from that to which the
receiver is connected.
d) Consult the dealer or an experienced radio/TV technician.
FCC Warning
Modifications not expressly approved by the manufacturer could void the user
authority to operate the equipment under FCC Rules.
Instructions concerning human exposure to radio frequency
electromagnetic fields:
A distance of at least 20cm. between the equipment and all persons should be
maintained during the operation of the equipment.
Tanker Truck Monitoring System- User’s Guide III
Terminology
Preface
TTeerrmmiinnoollooggyy
Term Description
Seal DataSeal, or any other Hi-G-Tek sealing device.
AVL Reader DataReader which is connected to an AVL device.
HF Reader A DataReader that uses High Frequency long-range radio frequencies to communicate
with the DataSeals.
LF Reader A DataReader that uses Low Frequency short-range radio frequencies for communication
with the DataSeals. For example MicroReader, DataPort, Hand-Held Terminal.
SA Reader Stand Alone Reader with no direct connection to PC. Such a Reader does have
connection to a modem device (i.e. GPRS modem or DataRadio modem) which provides
communication to PC.
PC Personal Computer running the Data Collection program.
Tanker Truck Monitoring System- User’s Guide IV
Table of Contents
Preface
TTaabbllee ooff CCoonntteennttss
About This Guide...................................................................................... .................................... II
Revision History............................................................................................................................ II
Warnings and Safety .................................................................................................................. .III
Terminology....................................... ................................................................................ ...........IV
Table of Contents................................................... ... .. ...... .. ... ..... ... ..... ... ... ..... ... .. ...... .. ..................V
Intr
oduction to the TTMS System
1.1 System Operation ................................................... .. ................................ ...................................3
1.2 Seals................................ ...........................................................................................................4
1.2.1.1 Seals for Valves......................................................................................................4
1.2.1.2 Seals for Hatches ...................................................................................................4
1.3 TTMS Reader....................................................... ..... ... ..... ...... ..... ... ..... ..... ... ..... ...... ..... ... .............5
1.3.1 AVL Reader........................................................................................................................5
1.3.1.1 AVL Reader Ports and Indicators.............................................................................6
1.3.1.2 AVL Reader J1/J2 Molex Ports Pinout.......................................................................8
1.3.1.3 AVL Reader I/O Electrical Characteristics .................................................................9
1.3.1.4 AVL Reader Block Diagram......................................................................................9
1.3.2 AVL Antenna ....................................................................................................................10
1.3.3 GPS Cellular Module..........................................................................................................10
1.3.4 Seal Status Indicator and Protection Box............................................................................11
1.3.4.1 Seal Status Indicator ............................................................................................11
1.3.4.2 Protection Box......................................................................................................13
1.4 Setup and Management Software ............................ .. ... ..............................................................14
1.4.1 Setup and Analysis SW ....................................................... ... ...........................................14
1.4.2 Management SW Module ..................................................................................................14
1.4.3 SAP Driver .......................................................................................................................14
1.4.4 Hi-G-Tek OCX...................................................................................................................14
............................................................ ...............................1
Initial System Setup...................................................................................................................15
2.1 General............................................ .........................................................................................15
2.2 Preliminary Setup............................................................................ ................................ ...........16
Tanker Truck Monitoring System- User’s Guide V
Preface
Table of Contents
2.3 Grouping and Connecting the System Elements...........................................................................16
2.4 Configuring the Seals.................................................................................................................17
2.5 Configuring the Reader and Refineries ........................................................................................21
2.6 Defining the Truck Configuration .......................................................... ................................ ......22
2.6.1 Configuring Application Parameters ...................................................................................25
2.6.2 Verifying the Seal Status Indicators Operability ....................................... ...........................26
2.6.3 Verifying Communication between Reader and Seals.................................................... ... ...27
2.7 Configuring Coordinates of the Authorized Refineries...................................................................27
2.8 Fleet Management SW .............................................................. ... ................................ ... ...........30
2.8.1 Seal Configuration and Management..................................................................................31
2.8.2 Reader Configuration and Management .......................................................... .. .................31
2.8.3 Monitoring Events.................................. .. ... ... ................................ .. ................................ .31
2.8.4 Event Notification Options................................ ... ... ................................ ...........................31
2.8.5 Report Generation Options............................. .. ... ................................ ... ...........................31
Installation..................................................................................................................................32
3.1 Overview................................................................................................ ...................................32
3.1.1 Hardware Installation ................................. ... .. ................................ ................................ .32
3.2 Seal Installation........................................................ .................................................................33
3.2.1.1 Filling Hatches Installation ....................................................................................33
3.2.1.2 Draining Valves Installation................................................ .. ... ..............................34
3.3 Truck Cabin Installation-Preabmle...............................................................................................36
3.4 Truck Cabin Installation..............................................................................................................36
3.4.1 Preparing the Cabin..........................................................................................................39
3.4.2 Interconnecting the Units..................................................................................................39
Setup and Analysis............................................ ................................ ........................................ 39
4.1 Overview................................................................................................ ...................................39
4.1.1 Launching the Application ........................... ... ................................ ...................................39
4.1.2 Defining Seal Ids........................................................ ................................ ......................39
4.1.3 Configuring Application Parameters ...................................................................................40
4.1.4 Verifying LED Display............................................. .. ................................ .........................41
4.1.5 Interrogating Seals................................................................................ ...........................42
4.1.6 Configuring Site Coordinates .............................................................................................43
4.2 Fleet Management SW .............................................................. ... ................................ ... ...........44
4.2.1 Seal Configuration and Management..................................................................................44
4.2.2 Reader Configuration and Management .......................................................... .. .................45
4.2.3 Monitoring Events.................................. .. ... ... ................................ .. ................................ .45
Tanker Truck Monitoring System- User’s Guide VI
Preface
Table of Contents
4.2.4 Event Notification Options................................ ... ... ................................ ...........................45
4.2.5 Report Generation Options............................. .. ... ................................ ... ...........................45
Technical Specifications......................................... .......................................................... ........ 46
5.1 AVL Reader Technical Specifications................................... ... ... ...................................................46
5.2 Seal Status Indicator Specifications.............................................................................................48
5.3 Protection Unit……………………………………………………………………………………………………………………….49
Tanker Truck Monitoring System- User’s Guide VII
1
IInnttrroodduuccttiioonn ttoo tthhee TTTTMMSS SSyysstteemm
Hi-G-Tek’s Tanker Truck Monitoring System (TTMS) secures the tanker fueling hatches and
decanting valves and enables continuous real time remote monitoring of the vehicle at all points
on the route. Any unauthorized attempt s to access the secured hatches or valves are recorded
on the seals and invoke real-time, detailed alarms at the Control Center.
The tanker access points are secured with programmed electronic seals. These are monitored by
a Reader installed in the truck cabin. The Reader reports, via GPRS or SMS, to the remote
control center of any unusual events al ong with clock and location information acquired through
GPS. The control center can also transmit commands or information to the seals via the Reader.
An LED display mounted inside the cabin provides visual indication of the status of each seal,
enabling the operator at the refinery to see, at a glance, whether an attempt has been made to
tamper with the vehicle hatches or valves – before authorizing the fueling procedure.
Fleet Application User’s Guide 1
System Operation
Introduction to the TTMS System
GPS
Communication
AVL Reader
LED Seal Status
Indicator
Main features and capabilities
• Real time alerts transmitted to the control center through GPRS (in addition to SMS)
• GPS location tracking and clock
• Remote control and management of the system elements from the control center
• Areas of valid refinery and gas station areas are configured to prevent unauthorized
• System is configurable to support one or two tankers, where configuration can be easily
• Independently runs routines to monitor the seals for unusual events defined according to
• Battery backup mode ensures continuous operation a nd support of the essential features in
• LED display provides a local visual indication of the status of the seals to the operator or
Control Center
Hatch/Valve seal
Figure 1-1.
activities outside the defined sites
modified
specific scenarios
case the power supply from the vehicle is interrupted
inspector
Tanker Truck Monitoring System- User’s Guide 2
System Operation
1.1 System Operation
The valve and cover of each section are protected by an electronic seal with sensors. The
seals are monitored by the Reader installed in the cabin. The seals record various events
(according to the configuration) and transmit notifications such as open/closed to the Reader
via HF.
The TTMS Reader forwards the events received from the seals to the Control Center via
cellular, along with location and time information received via GPS. In the other direction,
commands from the Control Center are forwarded b y the Reader to t he seals.
In addition, the Seal Status Display shows, at a glance, a summary of the status of each seal
as OK (GREEN) or tampered (RED).
The following figure illustrates communication between the TTMS Reader and the other system
elements.
Introduction to the TTMS System
Tanker Truck Monitoring System- User’s Guide 3
Seals
1.2 Seals
UL recognized for Intrinsic Safety - file number: E256795
The seals are portable, reusable electronic devices installed on each hatch and valve. The seals
perform the following functions:
• Physically secure the access point (hatch or valve)
• Monitor the access point through sensors and generate status information and alarms
corresponding to various programmed conditions
• Store user data for retrieval
Two types of seals are provided in the TTMS : hatch seals and valve seals. The seals differ in
the length of the locking pin and the mounting bracket.
Introduction to the TTMS System
1.2.1.1 Seals for Valves
There are two types of valve seals whose closing mechanism c orresponds to different types of
valves:
• Valves that close through a circular CCW (up to 270°) turn of the handle
• Valves that close through a perpendicular pull of the handle – north to south
The following figures show seals assembled on valves with a ‘pull’ closing mechanism
1.2.1.2 Seals for Hatches
Tanker Truck Monitoring System- User’s Guide 4
TTMS Reader
1.3 TTMS Reader
The TTMS Reader performs the following functions:
• Monitors the seals
• Receives clock and location co-ordinates from GPS
• Transmits seal events to the Control Center, along with GPS coordinates
• Transfers seals status information to the Seal Status Display
• Forwards commands from the Control Center to the seals
The TTMS Reader consists of two interconnected modules installed inside the cabin, and the
corresponding antennas:
• AVL Reader module and corresponding antenna
• GPS and Cellular (i.e. GPRS/GSM) module and corresponding antennas - add on (off the
shelf unit (manufactured by STARCOM)
The AVL unit is described in detail in the following sub-section (information on the STARCOM
unit is supplied in the corresponding User Manual).
Introduction to the TTMS System
1.3.1 AVL Reader
NOTE: This section provides a general description of the AVL Reader, functions and connections.
For a full description of the AVL specifications, refer to 5.1
The AVL Reader uses active wireless technology to p rovide automatic processing and real-time
monitoring of cargos during transit. The reader powered from the truck power (24V) is installed
inside the truck's cabin
sensors simultaneously in order to verify their presence and status. The reader uses two RF
channels (LF, HF) for communication. It is equipped with back-up battery and supports two
RS232 chan nels in addi tion to one R S485 channel for communicating with other devices of the
Tanker Truck Monitoring System (TTMS).
As aforesaid the AVL Reader performs three major functions:
• Communicates (two-way) with and monitors the seals over a HF channel
• Transfers (two-way) information between the seals and the GPS/Cellular modem
• Provides seal status to the Seal Status Dis play
Communication with the seals
The AVL Reader communicates with the seals via a HF antenna that is i nstal led external ly on t he
cabin roof – on the side of the valves on which seals are installed (usually passenger side). The
AVL Reader is powered via the vehicle’s battery.
, It has read/write capabilities for communicating with the cargo/tank
Reader Setup
The AVL Reader is configured via a local connection between the Reader and a computer on
which the AVL Reader Config application is installed and launched.
Tanker Truck Monitoring System- User’s Guide 5
TTMS Reader
1.3.1.1 AVL Reader Ports and Indicators
The unit interfaces and connections are shown in the following figures:
Introduction to the TTMS System
• One side (Figure
• The other sid e ( Fig ur e
1-2) contains the AVL antenna connections and LED indicators;
1-3) provides the connections required for power, setup and interface
to the GPS/Cellular Modem.
The following figure shows the antenna connections and indicators.
Figure 1-2. AVL Reader Antenna Connection Side
AVL Antenna connection
PWR indicator
COMM indicator
AVL Antenna Port Description
Reverse polarity SMA connector (antenna specifications ar e given in section 1.3.2
LED Indicators
LED Description
Power Indicates power status and firmware download status (during firmware
upgrade).
o Power ON and self-test - color alternates between GREEN an d
RED for several seconds: GREEN – OK, RED – fault
o Firmware download: Blinking during download process
COMM Communication:
• RED – unit is transmitting data
• GREEN – unit is receiving data
Tanker Truck Monitoring System- User’s Guide 6
TTMS Reader
Introduction to the TTMS System
The following figure shows the AVL Reader Power & COM connector side.
J1 – 12 pin connector
J2 – 10 pin connector
Figure 1-3. AVL Reader Connector Interfaces
AVL Reader Molex Port Functions
The following table provides a description of the AVL ports.
Table 1-1. AVL Reader J1 J2 Port Function Descriptions
Port Description
J1 10 pin connector. Provides the following functions (see
• RS232 connecti on to cellular modem.
• Power: +24V (from truck supply).
• One input auxiliary.
• One output auxiliary.
J2 12 pin connector. Provides the following functions (see
• RS485 communication to Display Unit(s).
• Local RS232 Setup and Config connection to PC
• Auxiliary connections – thre e ou tputs , on e input
Table 1-2
Table 1-3
for pinout):
for pinout):
Tanker Truck Monitoring System- User’s Guide 7
TTMS Reader
1.3.1.2 AVL Reader J1/J2 Pinout
Table 1-2. J1 Connector Pinout
Pin Signal
1 EXT Input
2 NC
3 EXT Output 3
4 -Vin (GND)
5 +Vin (+24VDC)
6 RS232 – T xD J45 to LCU
7 RS232 – RxD J45 to LCU
8 RS232 – COMM J45 to LCU
location command unit
Introduction to the TTMS System
9 NC
10 NC
Table 1-3. J2 Connector Pinout
Pin Signal
1 NC
2 EXT Output 1
3 NC
4 EXT Output 2
5 -Vin (GND)
6 +Vin (+24VDC)
7 RS485 A
8 RS485 B
9 RS485 COMM
10 RS232 – COMM
11 RS232 – TxD
12 RS232 – RxD
Tanker Truck Monitoring System- User’s Guide 8
TTMS Reader
1.3.1.3 AVL Reader I/O Electrical Characteristics
The following table provides the characteristics for the External Interrupt and Output.
Table 1-4. AVL Reader I/O Characteristics
I/O Type Description
External Interrupt Input Active Low
Max input voltage = ±30VDC
Max ViL = 1VDC
Output Open collector general purpose output
Current must be limited to 20mA typical, 50mA
max.
Voltage max = 30V
Max VOL at 50mA = 1V
Introduction to the TTMS System
1.3.1.4 AVL Reader Block Diagram
Tanker Truck Monitoring System- User’s Guide 9
TTMS Reader
1.3.2 AVL Reader Antenna
A magnet mount type antenna is supplied with the system for use with the AVL Reader.
ATTENTION: Use only the antenna supplied with the system.
Introduction to the TTMS System
Figure 1-4 : AVL Reader- 916.5MHz Antenna ( corresponded to reverse polarity SMA connector)
Manufacturer Panorama Antennas
Type Magnet Mount Antenna
AS-U for 433.92MHz models Model No.
ASF-3061 for 916.5MHz models
1.3.3 GPS Cellular Module
The LCU500 manufactured by STARCOM is an Add on (off the shelf unit) in the TTMS. It integrates a GPS
receiver, a cellular network modem (GSM/GPRS/EDGE, CDMA/1X). The system monitors various vehicle
sensors, and provides the customer with a vast variety of real-time activities and information about the
vehicle.
The AVL Reader communicates with the LCU500 via RS-232 . From the moment the system is set, the
electronic sensors and AVL Reader begin to routinely communicate with the driver and control center,
reporting any activity involving the hatches, valves as well as the status of the truck, for complete monitor ing
and security.
The GPS – Cellular Module (GPRS) performs the following functions:
• Continuously receives clock and location updates via GPS
• Transmits data between the AVL Reader and the Control Center, where data transmitted to
the Control Center is sent with the clock and location information.
REFER to the CORRESONDING - LCU500 DATA SHEET FOR COMPLETE
INFORMATION.
Tanker Truck Monitoring System- User’s Guide 10
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