Tester for fluid monitors
A portable fluid monitoring controller tester system for fluid monitoring equipment includes a control panel, electrical interfaces, and associated circuitry for simulating the fluid overfill sensors and other features of a trailer. The tester is a self-contained device that meets or exceeds various safety standards applicable to operating in an explosive environment. The tester may be powered, at least partially, by the fluid monitoring controller to which it is connected or from another power source, such as a battery. The tester has intrinsically safe outputs, and is configured to simulate different types of sensor systems found in fuel tanker trailers, including 2-Wire Optical, 5-Wire Optical, and Thermistor sensors. The tester is further configured to simulate ground circuits and the truck identification module (T.I.M.) of the fuel tanker trailer. The tester includes an enclosure that is impact and temperature resilient, and provides protection against windblown dust, rain and splashing water.
1. A portable tester of fluid monitoring controllers, comprising:
an electrical connector configured to be removably connected to a cable;
a plurality of selector switches electrically coupled to the electrical connector; and
an electronic circuit coupled to the electrical connector and the selector switches, the electronic circuit configured to simulate, via the electrical connector, an output signal of either a 2-wire fuel tanker trailer fluid overfill sensor or a 5-wire fuel tanker trailer fluid overfill sensor based on a selected state of the selector switches.
2. The tester of claim 1 , wherein the output signal represents a wet fluid overfill sensor condition while the selector switches are in a first state, and a dry fluid overfill sensor condition while the selector switches are in a second state that is different than the first state.
3. The tester of claim 1 , further comprising an enclosure that is water resistant, impact resistant, and temperature resistant.
4. The tester of claim 1 , wherein the tester is configured to be electrically coupled, in place of a fuel tanker trailer, to a fuel terminal fluid monitoring controller, such that signals output via the electrical connector to the fuel terminal fluid monitoring controller simulate signals output by one or more fuel tanker trailer fluid overfill sensors.
5. The tester of claim 1 , wherein the output signal represents a simulated output of an optical fluid overfill sensor.
6. The tester of claim 1 , wherein the output signal represents a simulated output of a thermistor.
7. The tester of claim 1 , wherein the electronic circuit is further configured to simulate, via the electrical connector, a truck identification code based on the selected state of the selector switches.
8. The tester of claim 1 , wherein the electronic circuit is further configured to simulate, via the electrical connector, a short circuit based on the selected state of the selector switches using one of a resistive ground and a diode ground.
9. The tester of claim 1 further including circuitry configured to limit voltage within the tester to approximately 15 Vdc or less and current within the tester to approximately 250 mA or less, wherein the circuitry does not include a capacitive element.
10. A system comprising:
a fluid monitoring controller; and
a portable tester comprising:
an electrical connector configured to be removably connected to a cable;
a plurality of selector switches electrically coupled to the electrical connector; and
an electronic circuit coupled to the electrical connector and the selector switches, the electronic circuit configured to simulate, via the electrical connector, an output signal of either a 2-wire fuel tanker trailer fluid overfill sensor or a 5-wire fuel tanker trailer fluid overfill sensor based on a selected state of the selector switches, the tester configured to be electrically connectable to the controller via the cable.
11. The system of claim 10 , further comprising the cable of claim 1 for electrically connecting the controller to the tester.
12. The system of claim 10 , wherein the controller is configured to prevent a fuel transfer via a fuel terminal loading rack while the selector switches are in a first state, and further configured to permit the fuel transfer while the selector switches are in a second state that is different than the first state.
13. The system of claim 12 , wherein the first state represents a simulated fluid overfill fault or other contingent condition of a fuel tanker trailer, and wherein the second state represents a simulated normative condition of the fuel tanker trailer.
14. The system of claim 10 , wherein the selector switches are controlled by a microprocessor.
15. The system of claim 14 , wherein the microprocessor is configured to analyze and compare monitoring signals, timing and voltage to a standard.
16. The system of claim 15 , wherein the microprocessor is configured to compile the analyzed signals, timing and voltage for a certification report.
17. The system of claim 15 , wherein the microprocessor is configured to transmit the analyzed signals, timing and voltage to a system distinct from the system via a network connection.
18. The system of claim 17 , wherein the network connection includes at least one of a wired connection and a wireless connection.
19. The system of claim 18 , wherein the wireless connection includes at least one of a WI-FI connection, a BLUETOOTH connection, and a ZIGBEE connection.