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TankAlarm v1.0 - Industrial Tank Monitoring System

Release Date: December 11, 2025
Version: 1.0.0
Platform: Arduino Opta + Blues Wireless Notecard

A production-ready industrial monitoring system for remote tank level monitoring, alarm management, and fleet coordination using cellular IoT connectivity.

🎯 Overview

TankAlarm is a complete industrial monitoring solution designed for reliable, remote tank level monitoring with SMS/email alerts. Built on the Arduino Opta industrial controller platform with Blues Wireless cellular connectivity, it provides enterprise-grade reliability without requiring WiFi or wired network infrastructure at remote sites.

System Architecture

The system consists of three components:

  • Client - Remote monitoring device (deployed at tank sites)
  • Server - Central data aggregation and alerting hub (office/headquarters)
  • Viewer - Read-only monitoring device (optional, for remote viewing)
  ┌─────────────┐         Cellular (Blues)        ┌─────────────┐
  │   CLIENT    │────────────────────────────────▶│   SERVER    │
  │  (Remote)   │  ◀─── Configuration/Commands    │ (HQ/Office) │
  │             │                                  │             │
  │ • Monitors  │                                  │ • Dashboard │
  │ • Sensors   │                                  │ • Alerts    │
  │ • Alarms    │                                  │ • Config    │
  └─────────────┘                                  └─────────────┘
                                                          │
                                                    Ethernet LAN
                                                          │
                                                   ┌─────────────┐
                                                   │   VIEWER    │
                                                   │ (Read-Only) │
                                                   └─────────────┘

✨ Key Features

Client (Remote Monitoring)

  • Multi-Sensor Support - Monitor up to 8 objects per device
    • Analog voltage (0-10V)
    • 4-20mA current loop (pressure sensors, level transmitters)
    • Digital on/off (float switches)
    • Pulse counting (flow meters, RPM sensors)
  • Flexible Object Types - Tanks, engines, pumps, gas systems, flow meters
  • Intelligent Alarming - Configurable high/low thresholds with hysteresis and debouncing
  • Rate Limiting - Prevents alert flooding during transient conditions
  • Relay Control - Automated shutoff with multiple modes (momentary, until_clear, manual_reset)
  • Remote Configuration - Update all settings via server web interface
  • Persistent Storage - LittleFS internal flash (no SD card required)
  • Watchdog Protection - Automatic recovery from system hangs
  • Low Power Design - Optimized for battery/solar operation

Server (Central Hub)

  • Web Dashboard - Real-time monitoring of all clients
  • SMS & Email Alerts - Immediate notifications for alarm conditions
  • Daily Reports - Scheduled email summaries
  • Remote Client Management - Configure any client from web interface
  • RESTful API - Programmatic access for automation
  • Fleet Management - Centralized control via Blues Notehub
  • FTP Backup/Restore - Configuration archiving
  • Client Console - Real-time serial log viewing for troubleshooting
  • PIN Authentication - Secure access to configuration endpoints

Viewer (Read-Only Display)

  • Dashboard-Only - No configuration access
  • Stale Data Warnings - Visual indicators for outdated readings
  • Minimal Attack Surface - Secure deployment for public areas
  • Notecard Sync - Automatic data updates from server

🔧 Hardware Requirements

Client Hardware

  • Arduino Opta Lite - Industrial controller (STM32H747XI dual-core)
  • Blues Wireless for Opta - Cellular Notecard carrier board
  • Arduino Opta Ext A0602 (optional) - 4-20mA analog expansion for sensors
  • Sensors - Compatible with 0-10V, 4-20mA, digital, or pulse outputs
  • Power Supply - 12-24V DC (solar + battery recommended for remote sites)

Server Hardware

  • Arduino Opta Lite - Industrial controller
  • Blues Wireless for Opta - Cellular Notecard carrier board
  • Ethernet Connection - RJ45 to local network
  • Power Supply - 12-24V DC

Viewer Hardware (Optional)

  • Arduino Opta Lite - Industrial controller
  • Blues Wireless for Opta - Cellular Notecard carrier board
  • Ethernet Connection - RJ45 to local network
  • Power Supply - 12-24V DC

📋 Sensor Compatibility

Tested Sensors

Type Model Interface Application
Pressure Transmitter Dwyer 626-06-CB-P1-E5-S1 4-20mA Tank level (0-5 PSI)
Float Switch Dayton 3BY75 Digital High/low level detection
Hall Effect Sensor Generic Pulse Engine RPM monitoring
Flow Meter Generic Pulse Liquid flow rate

Sensor Interface Types

  • Digital (Float Switches) - Binary on/off, 3.3V/5V compatible
  • Analog Voltage - 0-10V (via Opta Ext A0602)
  • 4-20mA Current Loop - Pressure transmitters, level sensors
  • Pulse Counting - Flow meters, RPM sensors (up to 10 kHz)

🚀 Quick Start

1. Hardware Setup

Client (Remote Site):

  1. Install Blues Wireless for Opta carrier on Arduino Opta
  2. Activate Notecard at blues.io
  3. Connect sensors to appropriate inputs
  4. Connect 12-24V DC power (solar recommended)

Server (Office/HQ):

  1. Install Blues Wireless for Opta carrier on Arduino Opta
  2. Activate Notecard at blues.io
  3. Connect Ethernet cable to local network
  4. Connect 12-24V DC power supply

2. Software Installation

Prerequisites:

  • Arduino IDE 2.x or later
  • Arduino Mbed OS Opta Boards core (via Boards Manager)

Required Libraries:

  • ArduinoJson v7.x or later
  • Blues Wireless Notecard (latest)
  • LittleFS (built into Mbed core)
  • Ethernet (built-in)

Installation:

  1. Clone this repository
  2. Install TankAlarm-112025-Common library: 
    # Windows PowerShell (as Admin)
New-Item -ItemType Junction -Path "$env:USERPROFILE\Documents\Arduino\libraries\TankAlarm-112025-Common" -Target "C:\path\to\ArduinoSMSTankAlarm\TankAlarm-112025-Common"
  3. Open the appropriate sketch in Arduino IDE:
    • Client: TankAlarm-112025-Client-BluesOpta/TankAlarm-112025-Client-BluesOpta.ino
    • Server: TankAlarm-112025-Server-BluesOpta/TankAlarm-112025-Server-BluesOpta.ino
    • Viewer: TankAlarm-112025-Viewer-BluesOpta/TankAlarm-112025-Viewer-BluesOpta.ino
  4. Update PRODUCT_UID to match your Blues Notehub project
  5. Compile and upload

3. Blues Notehub Configuration

  1. Create account at notehub.io
  2. Create a new product for your TankAlarm system
  3. Create two fleets:
    • tankalarm-server - For server device(s)
    • tankalarm-clients - For all client devices
  4. Claim all Notecards into the product
  5. Assign each Notecard to the appropriate fleet

Detailed Instructions:

4. Access Web Dashboard

  1. Power on the server and wait for network connection
  2. Check serial monitor (115200 baud) for IP address
  3. Navigate to: http://<server-ip>/
  4. Configure server settings and SMS/email recipients
  5. Configure clients remotely via the dashboard

📊 Technical Specifications

Client Specifications

  • Lines of Code: 3,551
  • Memory Footprint: ~150KB flash, ~30KB RAM
  • Monitors per Device: Up to 8
  • Sample Interval: Configurable (default: 30 minutes)
  • Alarm Hysteresis: Configurable per monitor
  • Watchdog Timeout: 30 seconds
  • Cellular Connectivity: Blues Wireless Notecard (LTE-M/NB-IoT)
  • Data Persistence: LittleFS internal flash
  • Power Requirements: 12-24V DC, ~2W typical

Server Specifications

  • Lines of Code: 9,225
  • Memory Footprint: ~300KB flash, ~100KB RAM
  • Max Clients: 32 (expandable)
  • Max Tanks: 64 total across all clients
  • Web Server: HTTP (port 80)
  • API Endpoints: 15+ RESTful endpoints
  • Network: Ethernet (10/100 Mbps)
  • Data Persistence: LittleFS internal flash
  • Power Requirements: 12-24V DC, ~3W typical

Viewer Specifications

  • Lines of Code: 876
  • Memory Footprint: ~100KB flash, ~20KB RAM
  • Web Server: HTTP (port 80) - read-only
  • Network: Ethernet (10/100 Mbps)
  • Power Requirements: 12-24V DC, ~2W typical

📡 Communication Architecture

Fleet-Based Routing (Blues Notehub)

The system uses Blues Notehub fleet-based routing for device-to-device communication:

  1. Client → Server: Telemetry and alarms routed to tankalarm-server fleet
  2. Server → Client: Configuration updates routed to specific client device IDs
  3. Server → Viewer: Status updates sent for dashboard display

Advantages:

  • No hardcoded device IDs in firmware
  • Simplified fleet management
  • Automatic routing via Notehub
  • Scalable to hundreds of devices

Data Flow

CLIENT                      BLUES NOTEHUB              SERVER
  │                               │                       │
  ├─── telemetry.qo ──────────────┤                       │
  │         (level data)          │                       │
  │                               ├─── fleet routing ────▶│
  │                               │                       │
  ├─── alarm.qo ──────────────────┤                       │
  │      (alarm event)            │                       │
  │                               ├─── fleet routing ────▶│
  │                               │                       │
  │                               │                       ├─ SMS/Email
  │                               │                       │  Alerts
  │                               │                       │
  │                               │◀─── config_push.qi ───┤
  │                               │   (new config)        │
  │◀──── route: device_id ────────┤                       │
  │     (config received)         │                       │

🛡️ Security Features

Authentication

  • PIN-based Access Control - Protect configuration endpoints
  • Optional PIN - Can be disabled for trusted networks
  • Session-based - PIN verified per-session

Input Validation

  • All POST endpoints validate JSON structure
  • Buffer overflow protection on string inputs
  • Range checking on numeric values
  • HTTP 400/401/500 status codes for error conditions

Network Security

  • HTTP Only - Deploy on trusted local networks
  • No Internet Exposure - Server should not be internet-facing
  • Ethernet Isolation - Physical network segmentation recommended

Note: HTTPS/TLS not currently supported. For internet-facing deployments, use VPN or reverse proxy with TLS termination.

📖 Documentation

Installation & Setup

Advanced Features

Code Reviews & Architecture

🧪 Testing & Deployment

Pre-Deployment Testing Checklist

  • Hardware Validation

    • All sensors reading correctly
    • Relay control functioning
    • Cellular connectivity stable
    • Ethernet connectivity stable

  • Software Validation

    • Firmware version 1.0.0 confirmed
    • All clients reporting to server
    • Alarms triggering correctly
    • SMS/email alerts delivering
    • Web dashboard accessible

  • Network Testing

    • Blues Notehub routing configured
    • Fleet assignments verified
    • Server IP address documented
    • Firewall rules configured (if applicable)

  • Burn-In Testing

    • 48-hour continuous operation test
    • Watchdog recovery test
    • Power cycle recovery test
    • Network failover test

Deployment Checklist

  1. Flash all devices with v1.0.0 firmware
  2. Configure Blues Notehub fleet assignments
  3. Set server IP address and network configuration
  4. Configure SMS/email recipients
  5. Test alarm notifications
  6. Test relay control
  7. Verify web dashboard access
  8. Document device serial numbers and locations
  9. Establish backup schedule (FTP recommended)

🔮 Roadmap

v1.1 (Planned)

  • HTTPS/TLS support
  • Enhanced email formatting (HTML, attachments)
  • Historical data logging (30-day retention)
  • Graphical trend charts
  • MQTT integration

v2.0 (Future)

  • User accounts and role-based access control
  • Mobile app (iOS/Android)
  • Advanced analytics and reporting
  • Predictive maintenance alerts
  • Multi-tenancy support

📜 License

See LICENSE file for details.

🤝 Support

For technical support, bug reports, or feature requests, please open an issue on GitHub.

Common Resources

🏗️ Repository Structure

ArduinoSMSTankAlarm/
├── TankAlarm-112025-Client-BluesOpta/    # Remote monitoring client
├── TankAlarm-112025-Server-BluesOpta/    # Central server & dashboard
├── TankAlarm-112025-Viewer-BluesOpta/    # Read-only viewer
├── TankAlarm-112025-Common/              # Shared library
├── CODE REVIEW/                          # Code reviews & documentation
├── RecycleBin/                           # Archived versions
├── Tutorials/                            # Getting started guides
├── BillOfMaterials.md                    # Hardware BOM
└── README.md                             # This file

Built with ❤️ for industrial IoT applications

Last Updated: January 7, 2026

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Arduino GSM code that will send SMS alert of high tank sensor data

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