Wireless Monitoring Solutions for Security and Management
Tanker Truck Monitoring System
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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
TTMS Reader
1.3.4 Display Unit and Protection Unit
The Display unit is located inside the truck's cabin. It provides the operator a local visual
summary of the condition of the seals (tampered or OK). The TTMS system supports two Seal
Status Indicator boxes: one for each tank – according to the truck configuration. The Seal St atus
Indicator interfaces to the TTMS System (specifically to the AVL Reader unit) through a
Protection Box.
Both units are described in the following sections.
1.3.4.1 Seal Status Indicator
The seal stat us indicator unit provides status indicat ion of the tamper conditions of all hatches
and valve seals. The unit is powered from protection unit (+12VDC regulated). It supports 16
LEDs that corresponding to each hatch or valve sensor of the tanker. Each Seal Status Indicator
unit communicates with the AVL Reader over RS-485 serial communication protoc ol.
Introduction to the TTMS System
NOTE: For trucks supporting two tanks, two units are installed.
Each Seal Status Indicator unit contains two rows of LED displays, corresponding to the hatches
and valves and a set of system LEDs providing general status information. The LEDs are lit RED
or GREEN according to the status of the seal ( Table
1-6).
LEDs corresponding to seals
installed on hatches/valves
General indicators
Bracket
RS485 port with cable
Figure 1-5. Display Unit
Tanker Truck Monitoring System- User’s Guide 11
TTMS Reader
Table 1-5. Display Unit Connector
Port Description
RS485 Connection to Protection Box
Table 1-6. Display Unit LED Status
LEDs Description
Introduction to the TTMS System
Individual Seal
LEDs
GREEN - Seal closed, non-tampered conditions
RED Steady - Seal open, tampered condition
RED Blinking – Seal not detected by Reader
System Status RED – general fault indication
GREEN – normal operation
GREEN Blinking – system initialization in process
Table 1-7. J1 Connector Pinout
Pin Signal
1 -Vin (GND)
2 RS485 B
3 RS485 COMM
4 RS485 A
5 +Vin (+12VDC)
Tanker Truck Monitoring System- User’s Guide 12
TTMS Reader
g
1.3.4.2 Protection Unit
The Protection unit is located in the truck's cabin. It interfaces between the AV L Reader and the
Seal Status Indicator, filtering the AVL Reader signal and splitting it in install ations with two Seal
Status Indicator units. (The Protection Box is transparent to the system.)
Interface to the AVL Reader and to each of the Seal Status Indicators is provided via RS485
communication. The output interface to the Seal Status Indicators include a +12V regulated
power line.
NOTE: The power and RS485 signals are delivered to Display unit via fuses and other p rotective
components in order to provide Over Curren t and Over Voltage protection.
The Protection Box is shown in the following figure.
Introduction to the TTMS System
Connection to
AVL Reader
Connection to Seal
Status Indicators
Figure 1-6. Protection Unit
Table 1-8. J1 Connector Pinout Table 1-9. J2/J3 Connector Pinout
Pin Signal
1 NC
2 RS485 COMM
3 -Vin (GND)
4 RS485 B
5 RS485 A
6 +Vin (+24VDC) EXT Input
Pin Signal
1 -Vout (GND)
2 RS485 COMM
3 NC
4 +Vout (+12VDC)
5 RS485 B
6 RS485 A
Groundin
Terminal
Tanker Truck Monitoring System- User’s Guide 13
Setup and Management Software
1.4 Setup and Management Software
Hi-G-Tek’s system is set up and configured through a local RS232 connection to the AVL Reader
from a computer (usually laptop) on which two setup application are installed:
• Seal Config SW – used to configure the group of seals to be installed on the truck
• AVL Config SW – used to configure the Reader and the authorized fueling sites
1.4.1 Setup and Analysis SW
The Setup and Analysis SW is used to configure the TTMS HW elements according to the
installation topology, to verify the responses of the devices after the installation and to
troubleshoot. The Setup and Analysis SW is an intuitive GUI application installed on a computer
(usually a laptop) that is connected to the TTSM Reader (AVL Reader module) through a local
(RS232) connection. Management SW Module
Introduction to the TTMS System
The Hi-G-Tek Management SW module provides management and monitoring op tions specific to
the Hi-G-Tek TTMS system elements. It is integrated into the user’s management application and
is accessed through a dedicated menu option.
Tanker Truck Monitoring System- User’s Guide 14
2
IInniittiiaall SSyysstteemm SSeettuupp
2.1 General
The first phase in the installation consists of ver ifying that the system elements are op erational
and performing site configuration procedures such as configuring the system topology, defining
authorized refinery zones, etc. The Setup procedure is performed using the Configuration Tool
software application.
NOTE: It is r ecommended to perform the setup phase at the Hi-G-Tek distributor sit e or office.
If the zone definitions (coordinates and area) of the refineries are not available, they may be
physically mapped at each refinery according to the instructions in section 2.7.
This chapter provides step-by-step instructions on all the operations required at the initial phase.
It includes:
• Interconnecting the TTSM System elements;
• Connecting and launching the Configuration tool;
• Performing th e basic setup an d c onfiguration procedures;
Fleet Application User’s Guide 15
Preliminary Setup
2.2 Preliminary Setup
The Setup procedure includes the following steps:
1. Grouping the system elements and performing the required interconnections.
2. Configure the seals using the Seal Config Application
3. Defining the Reader and authorized refineries
4. Configuring application parameters
5. Verifying that the LED Seal Status Indicators are operational
6. Interrogating the seals and verifying response
7. Configuring the Readers’ site coordinates
The steps above complete the installation procedure.
Initial System Setup
2.3 Grouping and Connecting the System Elements
Physically group the seals, TTMS Reader elements and LED Seal Status comprisi ng a specific sit e
installation. Interconnect the TTMS Reader Elements and the LED Seal Status according to the
following figure.
Tanker Truck Monitoring System- User’s Guide 16
Configuring the Seals
2.4 Configuring the Seals
NOTE: Install the Seal Setup application on the computer from which the system will be
configured.
1. Connect a computer running the Seal Setu p application to an AVL Reader through an RS232
cable.
NOTE: This does not necessarily have to be the AVL Reader installed on the truck.
Initial System Setup
PICTURE OF AVL READER TO COMPUTER
CONNECTION
Figure 2-1. RS232 Connection to AVL Reade
2. Launch the application Seal Setup application. The following window appears.
Tanker Truck Monitoring System- User’s Guide 17
Configuring the Seals
3. Define the communication parameters between the AVL Seal Confi g application and t he AVL
Reader as follows:
• Click the Ports button. The following dialog appears.
• In the AVL Reader field, select the COMM port corresponding to the computer port to
• In the AVLR Connector field, select….
• Click Apply. The AVL Seal Config window is invoked.
4. Clear the Screen by clicking the Clear button and then checkmark each relevant location
(C1, C2, C3, etc. for hatches and V1, V2, V3 for valve).
Initial System Setup
which the AVL Reader is connected.
NOTE: The seals may also be configured using a DataPort. If a DataPort is connected, define the
LFT field.
NOTE: Only the checkmarked location will be available for configuration.
Tanker Truck Monitoring System- User’s Guide 18
Configuring the Seals
5. Click Interrogate to read all the seals in the Reader’s zone. The detected seals are
displayed in the left column.
Initial System Setup
6. Select all the seals that will be installed on the truck (or click Select All and deselect the
irrelevant seals) and then click the Æ button. The relevant seals will be disp layed in the right
column.
Tanker Truck Monitoring System- User’s Guide 19
Configuring the Seals
7. Click-and-drag each seal t o one of the check marked locations correspon ding to where that
seal will be installed on the truck (section and valve or hatch). Repeat until all seals have
been dragged to their destined locations.
Initial System Setup
8. Click Config to record a map of all seals and their locations, in every seal in the installations.
As each seal is written, the correspondin g message is displayed in the right wind ow area. If
the configuration is successful, the message “Configuration Completed Successfully”
appears.
NOTE: You may have to repeat the command by clicking Retry Config.
Tanker Truck Monitoring System- User’s Guide 20
Configuring the Reader and Refineries
Initial System Setup
2.5 Configuring the Reader and Refineries
Tanker Truck Monitoring System- User’s Guide 21
Defining the Truck Configuration
e dialog includes the following tabs:
Tab Description
General
Parameters
CC1020
HF RF Commands
Memory
EEPROM
Truck Configuration Required for configuration.
Sites
Initial System Setup
Used to configure system elements for a specific truck. See section
2.6
Application
Parameters
Events
Firmware Download
Display Boxes
2.6 Defining the Truck Configuration
This tab is used to configure the system elements for a specific tank truck. This includes the
following:
• Number of tanks supported by the truck - one or two tanks
• ID of the seals to be installed on each tank – according to their compartment and location
• ID of the AVL Reader and AVL U nit s
• Seal Status Indicator
• Additional information
This procedure enables the elements to communicate with each other and allows identification at
the Control Center.
This tab is also used to update the configuration when changes are made in the system. For
example, seals are removed or replaced, tanks are added or r emoved (to trucks where this is
relevant), etc.
Tanker Truck Monitoring System- User’s Guide 22
Defining the Truck Configuration
To define the truck configuration
1. In the AVL Configuration window, click the Truck Configuration tab. The following
window appears.
Initial System Setup
Definitions for
Tank 1
Definitions for
Tank 2
Truck Configuration tab
Tab editing options
Figure 2-2. Truck Configuration Window
The tab is divided into three main areas:
• General – used to define the general information on the truck
• Tank-1 and Tank-2 areas - each including the corresponding seals and Seal Status
Indicator information, configuration and updating options.
Tanker Truck Monitoring System- User’s Guide 23
Defining the Truck Configuration
2. In the general area, define the following fields:
Initial System Setup
• Truck ID - enter the truck identification. This is usually the
license plate.
• LCU – enter the ID on the LCU label (i.e 365 as illustrated below)
e.g. of LCU ID
Figure 2-3. Example of LCU Identification Label
• Tanks – check the tanks associated with the current truck (1/2). This will enable either
one or both configuration areas.
3. Configure the seal IDs according to their location, for Tank-1 and Tank-2 (if relevant):
• Verify that the Active box is check for every valve and hatch where a seal is installed.
• Verify that the Autoread opt ion is checked. This causes the Reader to periodically read
the seal IDs and update the data
The following figure shows the General (Truck ID, LCU, etc.) and Tank-1 option. (The
options for Tank-2 are identical to those of Tank-1.)
Active hatch seals
Active valve seals
NOTE: The Seal Status Indicator serial number and version are updated automatically upon enabling
Autoread or clicking Read.
NOTE: T o read once, disable Autoread and click the Read button. To Clear all the data, click
Clear.
Check to interrogate
seals automatically
Seal Status Indicator
Figure 2-4. Partial Tab Showing Tank-1 and Editing Options
Tanker Truck Monitoring System- User’s Guide 24
Defining the Truck Configuration
4. Click Replace to update the Reader with th e ne w information or changes.
5. Click the Read button and the Reader ID and the Seal Status Indicator Serial Number will
appear in their respective fields.
6. To complete the configuration, click the Attach button to transfer all setup information to
Reader.
Taking truck (and trailer) out to an uncovered area where GPS access can be tested.
2.6.1 Configuring Application Parameters
1. Click Application Parameters tab in menu toolbar. The following window appears.
Initial System Setup
Figure 2-5. Application Parameters Tab
2. Adjust the application parameters.
Verify that the AVL unit ID numbers are recorded in the server.
Tanker Truck Monitoring System- User’s Guide 25
Defining the Truck Configuration
2.6.2 Verifying the Seal Status Indicators Operability
The Seal Status Indicators tab is used to view and test the operability of the Seal Status
Indicators. It contains buttons for testing the Seal Status Indicator LEDs by setting them to
Green, Red, Off, etc. and shows the status of each LED.
To verify and test Seal Status Indicator operability
1. In the AVL Configuration window, click the Seal Status Indicators tab. The following
window appears.
Command buttons
Initial System Setup
Seal Status
Figure 2-6. Seal Status Indicators Tab
The tab is divided into two areas, one for each Seal Status Indicator. Each area contains
LEDs that mirror the status of the corresponding Seal Status Indicator LEDs, and buttons for
testing the Seal Status Indicator LED responses.
LED Color Indications:
• Green – seal closed
• Red – seal open
• Off – seal not enabled
2. Begin by verifying that the display is operational for each Seal Status Indicator:
• Click All Green and Apply. All the corresponding LEDs should be Green.
• Click All Red and Apply. All the corresponding LEDs should be Red.
3. You toggle individual LEDs between Red, Green and flickering by repeatedly clicking on the
checkbox of the seal representation.
Tanker Truck Monitoring System- User’s Guide 26
Configuring Coordinates of the Authorized Refineries
2.6.3 Verifying Communication between Reader and Seals
The Events tab is used to verify the communication between the Reader and the seals by
interrogating the seals, invoking events which are s ent from the seal to th e Reader and through
to the AVL Reader application where they are displayed.
To interrogate the seals
1. Click the Events tab from the menu toolbar. The following window appears.
Initial System Setup
Figure 2-7. Events Tab
2. Click the MIP Start button. A list of allocated seals, identified by the Reader, is shown.
3. Click Interrogation button to execut e command and verify that all ‘attach’ command s are
OK.
NOTE: If there is no response, perform another interrogation.
4. Click Get Application Status and view response prompt – GPS OK, battery, etc.
2.7 Configuring Coordinates of the Authorized Refineries
Configure the coordinates of every refinery site where the tanker truck, on which this system
will be installed, will be authorized to fill up. Seals can only be armed (SET command) at these
locations.
Tanker Truck Monitoring System- User’s Guide 27
Configuring Coordinates of the Authorized Refineries
The coordin ates must b e configu red alon g with th e radius of each refin ery wher e the truc k may
stop. The coordinates are configured according to the following criteria:
• The radius is square shaped
• Minimum radius – 30 meters
• Allowed GPS deviation – approximately 2 meters
• The number of filling stations at the refinery
• The distance of the filling stations from the edge of the refinery or the road
NOTE: One method of taking measurements is send ing a tanker truck on which the seals are
installed, opening and closing the seals at each refinery location and analyzing the events
indicating the location at the Control Center. If this method is used, it is recommended to
perform the procedures at each refinery a number of t imes and take an average of the exact
location.
Initial System Setup
Figure 2-8.
To define the coordinates
1. In the AVL Reader Configuration window, click the Sites tab. The following window appears.
Tanker Truck Monitoring System- User’s Guide 28
Configuring Coordinates of the Authorized Refineries
Figure 2-9. Sites Tab
2. Click Add and define the coordinates of each site (row) as follows:
• Enter the site Name.
• Enter the Longitude coordinates.
• Enter the Latitude coordinates.
• Eps. Longitude
• Eps. Latitude
• Mask
Initial System Setup
Are these options
relevant when
clicking “Read”
button?
Tanker Truck Monitoring System- User’s Guide 29
2.8 Fleet Management SW
• Verify (using the Fleet Management SW) that the command (Get Status) of the unit
invokes the appropriate response. (i.e. location). If OK, means there is com wit h the server
in both directions.
• Make sure all seals are closed. And then perform SET.
• Verify that all LEDs are green.
• Open each of the seals, hatches and valves. V erify that the correct status is received at the
fleet application.
Fleet Application User’s Guide 30
Fleet Management SW
2.8.1 Seal Configuration and Management
• Defining seal parameter thresholds
• Writing and reading seal’s electronic manifest such as cargo type, source, destination,
etc.
• Viewing seal status
• Viewing events stored on seals
• Sending commands to seals – Set, Read Events, etc.
2.8.2 Reader Configuration and Management
• Configuring Readers to forward interrogation (Verify) responses and seal initiated events
(Bursts) from specific seals in order to optimize operation
• Configuring Verify command (interrogation) parameters per Reader to op timize operation
in specific zones
2.8.3 Monitoring Events
Initial System Setup
• Burst and Verify events
• Real-time display of seal events such as opening of locks, tampering, motion, etc.
• Each event is displayed with detailed information fields such as event source, generation
time, Reader ID, etc.
• Filtering displayed information according to user defined criteria
2.8.4 Event Notification Options
Users can be notified of events through a variety of methods:
• SMS, E-mail and Voice messages to defined destinations
• Sound or visual on-screen alarms
2.8.5 Report Generation Options
Users can generate reports based on received events b y filtering the received events according
to various user defined criteria such as date, event type, source, Reader ID, etc.
The selected events can then be saved as a *.TXT file.
Tanker Truck Monitoring System- User’s Guide 31
3
IInnssttaallllaattiioonn
ATTENTION: Installation should be performed by authorized personnel and according to the
necessary safety precautions.
3.1 Overview
1. If th e system was not checked on site, verify th at the elements are op erational by following
the procedures described in section TBD.
2. Install the seals on the hatches and valves.
3. Verify the operation of each seal – after the installation.
4. Fill the installation form with the serial number of every element in the system.
5. Install the cabin elements.
6. Check the installation again.
3.1.1 Hardware Installation
The hardware installation consists of the following main phases:
1. Seal installation: upper filling hatches and lower draining valves
Fleet Application User’s Guide 32
Seal Installation
1. Verifying responses of all seals.
2. Planning the location of the communication units (Reader, LCU 500, antennas, etc.), in the
truck cabin.
3. Seal Status Indicator placement.
4. Layout and routing of cables.
5. For fiberglass cabins only – installation of metal bracket for antenna
6. Placemen t of AVL Reader, LCU 500, Protection Unit and cable connectio ns
7. Verifying system installation
3.2 Seal Installation
Installation
3.2.1.1 Filling Hatches Installation
1. Remove all previous installations (handles, chains, etc.)
2. Place the Locking unit and the seal housing on the two opening plates so that the locking
unit is located on the upper plate and the installation tool - while still in the seal housing - is
located on the lower plate.
3. Move the Locking unit knob towards the installation tool ( re fer to Figure
NOTE: Make sure the installation tool is touching the side of the upper plate and is adjacent to it
Figure 3-1. Locking and Seal Housing Units
4. Weld small footholds to the locking unit and the seal housing without damaging the
installation tool.
3-1).
Locking Unit
5. Remove the installation tool and we ld the locking unit and the seal housing.
6. After the units cool off, u se the m icro- reader to verify that the seal is functional; temporarily
install the seal as illustrat ed in Figur e
Tanker Truck Monitoring System- User’s Guide 33
3-2 and perform a reading.
Seal Installation
7. Remove the seal until the installation is complete.
8. Weld a handle to the upper opening plate in a manner that will not hamper the functionality
9. Paint the welded areas with appro priate paint.
10. Install the seal inside the seal-housing, fasten the screws, and secure the screw with
Installation
NOTE: The LED should be green when the locking unit is closed, and red when it is opened.
Figure 3-2. Temporary Installed Seal
of the locking unit.
appropriate thread locking adhesive (refer to Figure
3-2).
The following figure shows an example of a completed hatch installation.
Housing Unit
Lower opening
plate
Figure 3-3. Example of Completed Hatch Installation
3.2.1.2 Draining Valves Installation
1. All devices which were used to lock the handle of the draining valves should be removed.
2. Fasten the device to its location by welding its backside (refer to Figure
3-4).
NOTE: The location of the device should not constrain the movement of the handle and should
allow the pin of the seal to go through the hol e in the hand le. If needed, add r ulers to which the
device could be fastened.
Tanker Truck Monitoring System- User’s Guide 34
Seal Installation
Installation
Welding Areas
Figure 3-4. Draining Valve Locking Unit
Figure 3-5. Valve and Locking Unit
3. Install the seal inside the seal-housing, fasten the screws, and secure the screw with
appropriate thread locking adhesive (refer to Figure
3-6).
Figure 3-6. Installing the seal inside the housing
4. Paint the welded areas with appro priate paint.
Tanker Truck Monitoring System- User’s Guide 35
Preface -Truck cabin Installation .
3.3 Preface -Truck cabin Installation .
NOTE: Installation should be performed by a certified car electrician and according to all
applicable standards.
3.3.1 Preparing the Cabin
Begin by unscrewing the dashboard covers on the passenger half and laying it bare in order
to locate the place in the dashboard that contains the least number of wires and
connections. This is usually on the side of the pas senger, since on the driver’s side, all the
clocks and sensors are located.
3.3.2 Interconnecting the Units
Installation
Figure 3-7. TTMS Architecture
3.4 T ruck Cabin Installation
The installation procedure in the cabin consists installing the electronic units: AVL Reader, AVL
Unit (GPRS Modem), and external antenna with a magnetic base (connected to the AVL R ea d e r ),
GSM Antenna, Protection unit and LED Display unit.
1. Open the Dashboard.
2. Place and install AVL Reader and Protection unit in upper front storage compartment
(dashboard).
Tanker Truck Monitoring System- User’s Guide 36
Truck Cabin Installation
A
NOTE: The AVL Re ader unit ar e fed from th e vehicle supply. The supply should be connected
through a 2A fuse before the ignition switch; Use only provided Fuse + Fuseholder !
3. Power & Grounding connections:
• Connect the power lines (J1) via the in-line fuse (2A) to the vehicle supply (24VDC).
• Connect between AVL reader- J2/12pin and Protecti o n Unit- J1
• Ground the Protection unit (from its grounding wire only) to vehicle chassis.
• Ground the AVL Reader (from its grounding stud only) to vehicle chassis.
Installation
Grounding Wire
(50cm)
4. Install the GPS – Cellular Module (LCU500) on the dashboard next to the windshield.
Protection unit
Grounding Stud
VL Reader
• Connect communication cable between AVL reader- J1/10pin and LCU500- RJ/middle
connector( as shown below)
• Connect the GSM antenna (either on the dashboard or on the side window)
• Connect the cable power (J12) to vehicle supply (24VDC)
GPS –Cellular Module
(LCU500)
5. Position the AVL Reader external antenna as close as possible t o the center of the cabin’s
roof and route the antenna cable toward AVL Reader.
Tanker Truck Monitoring System- User’s Guide 37
Truck Cabin Installation
6. Install the Seal Status Indicator at the side of the passenger’s seat. Route the display
cable from the Seal Status Indicator toward the protection unit –J2/6pin in dashboard .
Installation
7. Setup + Testing (application)
Tanker Truck Monitoring System- User’s Guide 38
Overview
4
SSeettuupp aanndd AAnnaallyyssiiss
4.1 Overview
The Setup and Analysis SW tool is used for commissioning the TTMS system and verifying that
the system units have been installed correctly. The Setup procedure includes the following steps:
1. Launch the application and connect the RS232 cable to the AVL Reader.
2. Defining the tank seal IDs of the truck
Setup and Analysis
3. Configuring application parameters
4. Verifying that the LED Seal Status Indicators are operational
5. Interrogating the seals and verifying response
6. Configuring the Readers’ site coordinates
The steps above complete the installation procedure.
4.1.1 Launching the Application
• Connect computer to AVL Reader through an RS232 cable.
• Launch the Setup application
4.1.2 Defining Seal Ids
The seals securing the tanker hatches and valves must be defined.
To define seal IDs
1. Click the Truck Configuration tab from the menu toolbar. The following window appears.
LCU = identification of STARCOM ID No. label
ID 07324 = Tank ID (use Replace ID to change)
Enter each seal ID where TF: are the common first letters of all seals and the rest are the
individual numbers. Seal Status Indicator serial number and version are read.
If changes are made, click Replace to update reader with new info.
Add tank – if
Tanker Truck Monitoring System- User’s Guide 39
Overview
License
Reader
ID(?)
LED
Display
ID(?)
Setup and Analysis
Seal IDs
Figure 4-1. Truck Configuration Window
2. Verify that the Autoread checkbox is checked.
3. Click the Read button and the Reader ID and the Seal Status Indicator Serial Number will
appear in their respective fields.
4. Enter the Truck ID and check the number of tanks in the configuration currently
implemented (1/2).
5. In the Tank 1 and Tank 2 field areas, ent er the seal ID numbers of all the hatch and valve
departments.
6. Click the Attach button to transfer all setup information to Reader.
Taking truck (and trailer) out to an uncovered area where GPS access can be tested.
4.1.3 Configuring Application Parameters
1. Click Application Parameters tab in menu toolbar. The following window appears.
Tanker Truck Monitoring System- User’s Guide 40
Overview
Setup and Analysis
Figure 4-2. Application Parameters Tab
2. Adjust the application parameters.
Verify that the AVL unit ID numbers are recorded in the server.
4.1.4 Verifying LED Display
The LED Seal Status Indicators mirror the status of th e seals, securing the tanker hatches and
valves. The user must verify that the displays view the open/closed statuses of all the seals.
To verify Display operationabili ty
1. Click the Seal Status Indicators tab in the menu toolbar. The following window appears.
Tanker Truck Monitoring System- User’s Guide 41
Overview
Setup and Analysis
Figure 4-3. Seal Status Indicators Tab
2. Verify that the display is operational: Green – Seal Closed; Red – Seal Open.
• Click All Green and Apply
• Click All Red and Apply
3. Verify that display responds accordingly
4. Wavel various commands to display and view responses.
4.1.5 Interrogating Seals
The Events tab of the Set GUI is used in order to verify the communication between the Reader
and the seals and that the events are being transmitted to the Reader.
To interrogate the seals
1. Click the Events tab from the menu toolbar. The following window appears.
Tanker Truck Monitoring System- User’s Guide 42
Overview
Setup and Analysis
Figure 4-4. Events Tab
2. Click the MIP Start button. A list of allocated seals, identified by the Reader, is shown.
3. Click Interrogation button to execut e command and verify that all ‘attach’ command s are
OK.
NOTE: If there is no response, perform another interrogation.
4. Click Get Application Status and view response prompt – GPS OK, battery, etc.
4.1.6 Configuring Site Coordinates
The coordinates of the various locations that the Tanker Truck is to pass must be defined….
1. Click the Sites tab. The following window appears.
Tanker Truck Monitoring System- User’s Guide 43
Fleet Management SW
Setup and Analysis
Are these options
relevant when
clicking “Read”
button?
Figure 4-5. Sites Tab
2. Click Add and enter all the relevant refineries with coordination and geo-fence according to
the following parameters:
Name Name of site
Longitude Longitude coordinates of site
Latitude Latitude coordinates of site
Eps. Longitude
Eps. Latitude
Mask
4.2 Fleet Management SW
• Verify (using the Fleet Management SW) that the command (Get Status) of the unit
invokes the appropriate response. (i.e. location). If OK, means there is com wit h the server
in both directions.
• Make sure all seals are closed. And then perform SET.
• Verify that all LEDs are green.
• Open each of the seals, hatches and valves. Verify that the correct status is rec eived at the
fleet application.
Tanker Truck Monitoring System- User’s Guide 44
Fleet Management SW
4.2.1 Seal Configuration and Management
• Defining seal parameter thresholds
• Writing and reading seal’s electronic manifest such as cargo type, source, destination,
etc.
• Viewing seal status
• Viewing events stored on seals
• Sending commands to seals – Set, Read Events, etc.
4.2.2 Reader Configuration and Management
• Configuring Readers to forward interrogation (Verify) responses and seal initiated events
(Bursts) from specific seals in order to optimize operation
• Configuring Verify command (interrogation) parameters per Reader to optimize operation
in specific zones
4.2.3 Monitoring Events
Setup and Analysis
• Burst and Verify events
• Real-time display of seal events such as opening of locks, tampering, motion, etc.
• Each event is displayed with detailed information fields such as event source, generation
time, Reader ID, etc.
• Filtering displayed information according to user defined criteria
4.2.4 Event Notification Options
Users can be notified of events through a variety of methods:
• SMS, E-mail and Voice messages to defined destinations
• Sound or visual on-screen alarms
4.2.5 Report Generation Options
Users can generate reports based on received events b y filtering the received events according
to various user defined criteria such as date, event type, source, Reader ID, etc.
The selected events can then be saved as a *.TXT file.
Tanker Truck Monitoring System- User’s Guide 45
55..TTeecchhnniiccaall SSppeecciiffiiccaattiioonnss
5.1 AVL Reader Technical Specifications
RF Characteristics:
916MHz Model
HF Tx/Rx Channel
(Operating Frequency)
LF Tx/Rx
433.92MHz Model
HF Tx/Rx Channel
(Operating Frequency)
LF Tx/Rx
Performance Characteristics
Channel : 916.5 MHz
Modulation : FSK with 40KHz deviation
Data rate : 16KHz
Channel : 125KHz channel
Modulation : Amplitude Modulation
Data rate : 4KHz data rate
Channel : 916.5 MHz
Modulation : FSK with 40KHz deviation
Data rate : 16KHz
Channel : 125KHz channel
Modulation : Amplitude Modulation
Data rate : 4KHz data rate
Range Up to 30 meter radius (depending on
obstructions and topology)
Back-up Battery Provides a minimum of 3 hours in typical
operation.
NOTE: Back-up Battery is NOT replaceable .Do not try to replace back-up battery with any kind of
rechargeable battery inside the unit.
Fleet Application User’s Guide 46
AVL Reader Technical Specifications
5.Technical Specifications
Interfaces:
RS232 For setup and configuration.
For interface with the GPS/Cellular Modem
RS485 Protected. For communication with Seal
Status Indicators.
SMA Reverse polarity Used for connection to antenna
Power Requirements:
Power supply type External
Voltage Input Nominal 24VDC
Minimum 9VDC
Maximum 32VDC
Power Consumption (Connected to two Display Units - via
Protection Unit)
Physical Characteristics:
7W Max
Dimensions 56x98x34mm (not including antenna)
Weight 350gr
Environmental
Conditions
As per SAEJ1455 cabin installation
Part Numbers:
Model P/N R.F Communication Channel
916 MHz IG- AV1-43-916 HF Channel Only
916 MHz IG- AV2-43-916 HF + LF (125KHz) Channel
433.92MHz IG- AV1-43-433 HF Channel only
433.92MHz IG- AV2-43-433 HF + LF (125KHz) Channel
Standards:
916 MHz Model FCC compliance - pending
433 MHz Model CE compliance - pending
Tanker Truck Monitoring System- User’s Guide 47
Seal Status Indicator Specifications
5.2 Seal Status Indicator Specifications
Power and Communication interface:
Power +12VDC regulated (via Protection Box)
Interface RS485 -Towards AVL Reader (via Protection Box)
Physical Characteristics:
5.Technical Specifications
Dimensions 120 x 64 x 30 mm
Weight 400gr
Environmental
Conditions
Operating Temperature : 0°C to +50°C
Storage Temperature : 0°C to +70°C
Humidity : 50% non-condensing
Part Numbers:
P/N Description
IG- FLD-01 Hebrew caption
IG- FLD-02 English caption
Standards:
916 MHz Model FCC compliance - pending
433 MHz Model CE compliance - pending
Tanker Truck Monitoring System- User’s Guide 48
Protection unit
5.3 Protection unit
Power Requirements:
Power supply type External
Voltage Input Nominal 24VDC
Voltage Output 12VDC
Power Consumption (Connected to two Display Units - via
Interfaces:
RS485 Protected channel For communication with
5.Technical Specifications
Minimum 9VDC
Maximum 32VDC
Protection Unit)
7W Max
Seal Status Indicators.
Physical Characteristics:
Dimensions 56x98x34mm (not including antenna)
Weight 350gr
Environmental
Conditions
As per SAEJ1455 cabin installation
Part Numbers:
P/N
IG-PRT-01 Protected RS485 lines + 12VDC regulated
Standards:
916 MHz Model FCC compliance - pending
433 MHz Model CE compliance - pending
Tanker Truck Monitoring System- User’s Guide 49
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