Wireless Monitoring Solutions for Security and Management TTMS Tanker Truck Monitoring System Installation and Operation User’s Guide P/N: UM4718 Date: 31-AUG-06 Rev: 1.
Preface About This Guide About This Guide This User Guide provides the information required to install and configure the hardware and software required to run the Fleet application. Revision History The revision history for this document is shown in Table 1-1. Table 1-1: Revision history Version Date Description 1.0 22-MAY-06 Initial 1.1 9-Aug-06 1.
Preface Warnings and Safety Warnings and Safety 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 apply), only those antennas certified with the product are used.
Preface Terminology Terminology 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.
Preface Table of Contents Table of Contents About This Guide .......................................................................................................................... II Revision History............................................................................................................................ II Warnings and Safety ................................................................................................................... III Terminology.............................
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 ...............................................
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................................................
1 I n t ro d u c t i o n t o t h e T T M S S y s t e m 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 attempts 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.
Introduction to the TTMS System System Operation GPS Communication Control Center AVL Reader Hatch/Valve seal LED Seal Status Indicator Figure 1-1.
Introduction to the TTMS System 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.
Introduction to the TTMS System 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.
Introduction to the TTMS System TTMS Reader 1.
Introduction to the TTMS System TTMS Reader 1.3.1.1 AVL Reader Ports and Indicators The unit interfaces and connections are shown in the following figures: • One side (Figure 1-2) contains the AVL antenna connections and LED indicators; • The other side (Figure 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. AVL Antenna connection PWR indicator COMM indicator Figure 1-2.
Introduction to the TTMS System TTMS Reader 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 Table 1-2 for pinout): • RS232 connection to cellular modem.
Introduction to the TTMS System 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 – TxD J45 to LCU 7 RS232 – RxD J45 to LCU 8 RS232 – COMM J45 to LCU location command unit 9 NC 10 NC Table 1-3.
Introduction to the TTMS System 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 External Interrupt Input Description 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 1.3.1.
Introduction to the TTMS System 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. Figure 1-4 : AVL Reader- 916.5MHz Antenna ( corresponded to reverse polarity SMA connector) Manufacturer Panorama Antennas Type Magnet Mount Antenna Model No. AS-U for 433.92MHz models ASF-3061 for 916.5MHz models 1.3.
Introduction to the TTMS System 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 Status Indicator interfaces to the TTMS System (specifically to the AVL Reader unit) through a Protection Box.
Introduction to the TTMS System TTMS Reader Table 1-5. Display Unit Connector Port Description RS485 Connection to Protection Box Table 1-6. Display Unit LED Status LEDs Description 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.
Introduction to the TTMS System TTMS Reader 1.3.4.2 Protection Unit The Protection unit is located in the truck's cabin. It interfaces between the AVL Reader and the Seal Status Indicator, filtering the AVL Reader signal and splitting it in installations 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.
Introduction to the TTMS System 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: 1.4.
2 Initial System Setup 2.1 General The first phase in the installation consists of verifying that the system elements are operational 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 recommended to perform the setup phase at the Hi-G-Tek distributor site or office.
Initial System Setup 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.
Initial System Setup 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 Setup application to an AVL Reader through an RS232 cable. NOTE: This does not necessarily have to be the AVL Reader installed on the truck. PICTURE OF AVL READER TO COMPUTER CONNECTION Figure 2-1. RS232 Connection to AVL Reade 2. Launch the application Seal Setup application.
Initial System Setup Configuring the Seals 3. Define the communication parameters between the AVL Seal Config application and the 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 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. • In the AVLR Connector field, select…. • Click Apply.
Initial System Setup 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. 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 displayed in the right column.
Initial System Setup Configuring the Seals 7. Click-and-drag each seal to one of the check marked locations corresponding 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. 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 corresponding message is displayed in the right window area.
Initial System Setup Configuring the Reader and Refineries 2.
Initial System Setup 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. Used to configure system elements for a specific truck. See section 2.6 Sites 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.
Initial System Setup Defining the Truck Configuration To define the truck configuration 1. In the AVL Configuration window, click the Truck Configuration tab. The following window appears. Truck Configuration tab Tab editing options Definitions for Tank 1 Definitions for Tank 2 Figure 2-2.
Initial System Setup Defining the Truck Configuration 2. In the general area, define the following fields: • 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.
Initial System Setup Defining the Truck Configuration 4. Click Replace to update the Reader with the new 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.
Initial System Setup 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.
Initial System Setup 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 sent from the seal to the 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. Figure 2-7. Events Tab 2.
Initial System Setup Configuring Coordinates of the Authorized Refineries The coordinates must be configured along with the radius of each refinery where the truck may stop.
Initial System Setup Configuring Coordinates of the Authorized Refineries Are these options relevant when clicking “Read” button? 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.
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 with 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 received at the fleet application.
Initial System Setup 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.
3 Installation ATTENTION: Installation should be performed by authorized personnel and according to the necessary safety precautions. 3.1 Overview 1. If the system was not checked on site, verify that the elements are operational 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.
Installation 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. Placement of AVL Reader, LCU 500, Protection Unit and cable connections 7. Verifying system installation 3.2 Seal Installation 3.2.1.1 Filling Hatches Installation 1.
Installation Seal 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 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 of the locking unit. 9. Paint the welded areas with appropriate paint. 10.
Installation Seal 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 appropriate paint.
Installation 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.
Installation Truck Cabin Installation NOTE: The AVL Reader unit are fed from the 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 Protection Unit- J1 • Ground the Protection unit (from its grounding wire only) to vehicle chassis.
Installation 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 . 7.
Setup and Analysis Overview 4 Setup and Analysis 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 3. Configuring application parameters 4. Verifying that the LED Seal Status Indicators are operational 5.
Setup and Analysis Overview License Seal IDs Reader ID(?) LED Display ID(?) 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, enter the seal ID numbers of all the hatch and valve departments. 6.
Setup and Analysis Overview 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 the 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 operationability 1. Click the Seal Status Indicators tab in the menu toolbar.
Setup and Analysis Overview 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.
Setup and Analysis Overview 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 execute command and verify that all ‘attach’ commands 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.
Setup and Analysis Fleet Management SW 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.
Setup and Analysis 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.
5.Technical Specifications 5.1 AVL Reader Technical Specifications RF Characteristics: 916MHz Model HF Tx/Rx Channel (Operating Frequency) LF Tx/Rx 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 433.
5.Technical Specifications AVL Reader Technical Specifications Interfaces: RS232 For setup and configuration. For interface with the GPS/Cellular Modem RS485 Protected. For communication with Seal Status Indicators.
5.Technical Specifications Seal Status Indicator Specifications 5.
5.Technical Specifications Protection unit 5.3 Protection unit Power Requirements: Power supply type External Voltage Input Nominal 24VDC Minimum 9VDC Maximum 32VDC Voltage Output 12VDC Power Consumption (Connected to two Display Units - via Protection Unit) 7W Max Interfaces: RS485 Protected channel For communication with Seal Status Indicators.