TankAlarm v1.1.2 - Industrial Tank Monitoring System

Release Date: February 23, 2026
Version: 1.1.2
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.

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🎯 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)

       ┌─────────────┐                  ┌─────────────┐
       │   CLIENT    │                  │   SERVER    │
       │  (Remote)   │                  │ (HQ/Office) │
       │ • Monitors  │                  │ • Dashboard │
       │ • Sensors   │                  │ • Alerts    │
       └──────▲──────┘                  └──────▲──────┘
              │                                │
              │ Cellular                       │ Cellular
              ▼                                ▼
       ┌──────────────────────────────────────────────┐
       │            BLUES NOTEHUB (Cloud)             │
       │     (Data Exchange & Device Management)      │
       └──────────────────────┬───────────────────────┘
                              │
                              │ Cellular/WiFi
                              ▼
                       ┌─────────────┐
                       │   VIEWER    │
                       │ (Read-Only) │
                       └──────┬──────┘
                              │
                         Ethernet LAN
                        (User Display)

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✨ 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 with constant-time comparison and rate limiting
• Configuration Import/Export - JSON-based backup and templating
• Config Comparison - Visual diff before deploying changes
• Unsaved Changes Warning - Prevents accidental data loss
• Audit Log - Track configuration changes with timestamps
• Contextual Tooltips - Inline help for complex configuration options

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

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🔧 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

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📋 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)

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🚀 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 three fleets:
   • tankalarm-server - For server device(s)
   • tankalarm-clients - For all client devices
   • tankalarm-viewer - For viewer device(s)
4. Claim all Notecards into the product
5. Assign each Notecard to the appropriate fleet

Detailed Instructions:

• Client Setup: TankAlarm-112025-Client-BluesOpta/README.md
• Server Setup: TankAlarm-112025-Server-BluesOpta/README.md
• Fleet Configuration: TankAlarm-112025-Server-BluesOpta/FLEET_SETUP.md

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

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📊 Technical Specifications

Client Specifications

• Lines of Code: 5,488
• 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: 10,328
• 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: 763
• 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

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📡 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)         │                       │

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🛡️ Security Features

Authentication

• PIN-based Access Control - Protect configuration endpoints
• Constant-Time PIN Comparison - Prevents timing attack analysis
• Authentication Rate Limiting - Exponential backoff with lockout after 5 failures
• 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
• Client UID length validation with diagnostic logging
• Hash table bounds checking to prevent out-of-bounds access
• HTTP 400/401/429/500 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.

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📖 Documentation

Installation & Setup

• Client: TankAlarm-112025-Client-BluesOpta/README.md
• Server: TankAlarm-112025-Server-BluesOpta/README.md
• Fleet Setup: TankAlarm-112025-Server-BluesOpta/FLEET_SETUP.md

Advanced Features

• Relay Control: TankAlarm-112025-Client-BluesOpta/RELAY_CONTROL.md
• Unload Tracking: TankAlarm-112025-Client-BluesOpta/UNLOAD_TRACKING.md
• Device-to-Device API: TankAlarm-112025-Client-BluesOpta/DEVICE_TO_DEVICE_API.md
• Migration Guide: TankAlarm-112025-Client-BluesOpta/MIGRATION_GUIDE.md

Security & Architecture

• Security Fixes (Feb 2026): CODE REVIEW/SECURITY_FIXES_02062026.md
• Communication Architecture: CODE REVIEW/COMMUNICATION_ARCHITECTURE_VERDICT_02192026.md
• Data Usage Analysis: CODE REVIEW/DATA_USAGE_ANALYSIS_02192026.md
• Common Header Audit: CODE REVIEW/COMMON_HEADER_AUDIT_02192026.md

Code Reviews & Release History

• v1.1.1 Release Notes: CODE REVIEW/V1.1.1_RELEASE_NOTES.md
• v1.0 Release Summary: CODE REVIEW/V1.0_RELEASE_SUMMARY.md
• v1.0.1 Release Notes: CODE REVIEW/V1.0.1_RELEASE_NOTES.md
• Advanced Features (Feb 2026): CODE REVIEW/ADVANCED_FEATURES_IMPLEMENTATION_02052026.md
• Historical Data Architecture: TankAlarm-112025-Server-BluesOpta/HISTORICAL_DATA_ARCHITECTURE.md
• Console Restrictions: TankAlarm-112025-Server-BluesOpta/CONSOLE_RESTRICTIONS.md

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🧪 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 1.1.2 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 v1.1.2 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)

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🔮 Roadmap

v1.2 (Planned)

• Enhanced email formatting (HTML, attachments)
• Historical data logging (30-day retention)
• Graphical trend charts
• Common header consolidation (centralize duplicated constants)
• Event-driven Notecard polling (file.changes + change trackers)

v2.0 (Future)

• Advanced analytics and reporting
• Predictive maintenance alerts

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📜 License

See LICENSE file for details.

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🤝 Support

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

Common Resources

• Blues Wireless Documentation: dev.blues.io
• Arduino Opta Documentation: docs.arduino.cc
• Bill of Materials: TankAlarm-112025-BillOfMaterials.md

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🏗️ 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
├── TankAlarm-112025-BillOfMaterials.md    # Hardware BOM
└── README.md                             # This file

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📋 Changelog

v1.1.1 (February 20, 2026)

• Viewer Fleet: Viewer devices now join dedicated tankalarm-viewer fleet for fleet-scoped DFU and routing
• Relay Forwarding: New relay_forward.qo/.qi protocol for client-to-client relay commands via server
• Serial ACKs: Client emits serial_ack.qo processing/complete status during serial log requests
• Config ACK Enhancements: Config version hash (cv) tracked through dispatch → ACK cycle
• ArduinoJson v7: Full migration to auto-sizing JsonDocument in Server and Viewer (removed all capacity constants)
• Notecard Hardening: NULL-safe card.uuid handling across all three sketches
• Watchdog Fix: Corrected macro name to TANKALARM_WATCHDOG_AVAILABLE across all components
• Memory Safety: Use JDelete for unsent request cleanup; fix relay body allocation leak
• Dead Code Removal: ~300 lines of unused helpers removed from Common headers
• Documentation: 14 tutorial guides updated for three-fleet architecture

v1.1.0 (February 19, 2026)

• Security: Constant-time PIN comparison to prevent timing attacks
• Security: Authentication rate limiting with exponential backoff and lockout
• Security: Hash table bounds checking to prevent out-of-bounds memory access
• Security: Client UID length validation with diagnostic logging
• Security: Buffer boundary fix for FTP response parsing
• Server Console: Configuration import/export (JSON backup & templating)
• Server Console: Unsaved changes warning with browser prompt
• Server Console: Configuration comparison with visual diff before deploy
• Server Console: Audit log tracking last 50 configuration changes
• Server Console: Contextual tooltips for complex configuration fields
• Architecture: Communication architecture review and documentation
• Architecture: Data usage analysis for standard vs. proxy patterns
• Architecture: Common header audit identifying constants to centralize
• UI: Centralized CSS with browser caching for faster page loads
• Stability: JavaScript null-safety hardening across dashboard pages
• Stability: UTF-8 BOM and struct compilation fixes

v1.0.1 (January 13, 2026)

• Centralized CSS into single cached stylesheet
• UI header standardization (Action Bar layout)
• JavaScript null-safety hardening
• Compilation fixes (UTF-8 BOM, struct definitions)

v1.0.0 (December 2025)

• Initial production release
• Client, Server, and Viewer firmware
• Blues Wireless fleet-based routing
• Web dashboard with SMS/email alerts
• LittleFS persistent storage
• Remote client configuration

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Built with ❤️ for industrial IoT applications

Last Updated: February 20, 2026