NU9-2400MHZ230FSCargoLink Fuel Sensor (wireless)

Kit Bulletin KT40-1253-4 Date: September 16, 2014 Subject: CargoLink™ Fuel Sensor (wireless) Used on: Truck and Trailer Units Bulletin Location: TSA Info Central\Kit Bulletins ESA Info Central\Kit Bulletins Installation Instructions: See Truck and Trailer Edition CargoLink™ TK 55151-11-IM Description: This kit contains a new CargoLink™ wireless fuel level sensor, tank gauge float assembly, activation magnet & associated hardware. It requires installation of the CargoLink™ Coordinator available separately. The included tank gauge float assembly must be installed with any new wireless fuel sensor application. It can be used on a wide variety of Thermo King and other brands of tanks. The sensor is set from the factory for 22” diameter fuel tanks. The sensor is wirelessly configurable to other tank sizes using the available CargoLink™ service tool application, available separately. Applications: Transport Refrigeration unit controls & monitoring for fuel level. l Microprocessor control with digital fuel sensor requirements for a 1-4V signal (also configurable to 0-5V). l Analog Fuel Level alarm switch requirement for 12V system voltage at alarm activation (Fuel Level ≤ 15%). l Other telematics & unit control systems. Benefits: Warning: Use caution when working in or around the area of the diesel fuel tank. Diesel fuel vapors are potentially explosive. Do not smoke while working near the diesel fuel tank. Do not breath escaping fuel system fumes or vapors. Caution: Changes or Modifications not expressly approved by Thermo King could void the user's authority to operate the equipment Note: Always wear protective clothing, gloves and eye wear when working in or around diesel fuel. All personal protective equipment must be used in the manner specified by the manufacturer. Protection afforded by the equipment may be impaired if the equipment is used in a manner not specified by the manufacturer. IMPORTANT INSTALLATION NOTES: • The fuel level sensor must be paired to a properly installed CargoLink™ WPAN Coordinator prior to installation. See “Installation - Pairing Sensors”. • The Fuel Level Sensor – “FLS” (digital) or Fuel Level Alarm – “FLA” (analog alarm) wired output of the Coordinator should be wired into the corresponding controller device prior to pairing. See the wiring diagram figure 1 & 2. • The supplied fuel float assembly must be installed in the tank prior to installation of the fuel level sensor. • The existing tank fuel floats do not have a magnet drive strong enough to move the gauge used in the fuel level sensor and must be replaced. • The fuel level sensor attaches to the float arm assembly with an interference fit that will require light use of a rubber mallet to seat the sensor square on the float arm assembly. This is used to assure a strong mechanical resistance to the effects of road vibration. The gauge is secured to the float arm using two 6/32 x ½” Tri-lobe thread forming screws(included). l CargoLink™ Wireless Technology : No exposed wires to break. l Fast retrofit or new install on most tanks, no extra ports required. l Anti-slosh technology provides reliable level measurement at all tank volumes. l Durable, long-lasting construction. l Weather/waterproof to IP69K including diesel fuel and chemical wash down. 40-1253 Kit - Fuel Sensor (wireless) Part no. Description Qty 42-1473 Fuel Level Sensor - (wireless) 1 42-1192 Magnet disc CargoLink 1 NSS Fuel tank gauge float 2 51-2837 Screw (6-32 x .5 in long) 2 NSS Screw (1/4-28 x .885 in long) 4 41-2457 Socket terminal 1 Webiste is www.thermoking.com Fuel Level Alarm 4. Fuel Level Alarm wiring – applicable only to controllers with fuel level alarm input. a. For systems that have a system level voltage (12- 14V) fuel alarm input without a variable fuel level input, connect the Coordinator output wire labeled FLA to the alarm circuit. Pairing Pairing is the process of identifying the fuel sensor to the CargoLink network. Important: Keep all sensors away from the magnets for at least 60 seconds before beginning the pairing process. 1. Bring all sensors to be paired directly to the coordinator module. The pairing activity should occur within 10 feet of the coordinator module especially when multiple systems are being installed concurrently. 2. Verify the red PWR (Power) LED is illuminated on the Coordinator. See figure 3. 3. Press and release the switch on the Coordinator until the FUEL LED is illuminated. Note: Repeated presses of the switch will cycle through all selections before starting over at the top. 4. Once FUEL is selected, press and hold the switch again until the green PAR (Pairing) LED illuminates. a. One green and two redLED’swill now be illuminated on the module indicating it is in the pairing mode. NOTE: If no action is taken within 30 seconds, the green PAR LED on the module will begin flashing rapidly for 8 seconds and then go out. Repeat step 4 to restart the pairing procedures. 5. With the three LED's (PWR, FUEL & PAR) illuminated on the coordinator, bring the supplied magnet and sensor together quickly two times and then remove the magnet. Note: The correct orientation of the fuel sensor to the magnet must be followed or the pairing process will not work. See figure 5 for proper pairing target alignment. INSTALLATION PROCEDURE: SR-2 & SR-3 1. Wiring the Coordinator to SR-2 & SR-3 Fuel sensor input – if wiring to an SR-4, go to step 2, if wiring to a control that only accepts a fuel level alarm input, go to step 7. a. Locate the “FLL” wire at connector J3 pin 23 on the SR-2 or SR-3 controller. b. Cut FLL, leaving 102 mm (4”) of wire from the connector. Use a single sided crimp connector and cap the cut wire no longer connected to the controller. Go to Step 3. c. If no wire is connected to pin 23, use included terminal (41-2457) and crimp on FLS wire. Insert into J3 pin 23. Go to Step 3b. SR-4 2. Wiring the Coordinator to SR-4 fuel sensor input a. Locate the “FUEL-01” wire at the 3 wire option harness located a…

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IN D U STR IAL PRO DU CTS MARYVILLE, TENNESSEE

PRODUCT APPLICATION REFERENCE: DRAWING NUMBER REVZONEDESCRIPTION OF REVISION(S)DATE/ECNBY DATE DATE DATE DATE EXPERIMENTAL NUMBER DRAWING SCALE DESIGN CONTROL ENGINEERING APPROVED BY DESIGN APPROVED BY CHECKED BY DRAFTED BY CUSTOMER NAME MATERIAL PRODUCT MODEL DRAWING NUMBER SIZE DRAWING TITLE DRAWING AND/OR TECHNICAL INFORMATION NOTICE TO PERSONS RECEIVING THIS 3D PRO-E CAD DRAWING NO MANUAL CHANGES TOLERANCES UNLESS OTHERWISE SPECIFIED: 2 PLACE DECIMAL X.XX 0.02 IN. 3 PLACE DECIMAL X.XXX 0.010 IN. ALL ANGLES X 2 QUALITY SYMBOL DEFINITION A A B B C C D D E E F F G G H H J J K K L LMNPR 1 22 33 44 55 66 77 88 99 1010 1 THIRD ANGLE PROJECTION INCHES UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE SPECIFIED IN: ALL TECHNICAL AND OTHER INFORMATION PROVIDED HEREIN AND HEREWITH (COLLECTIVELY REFERRED TO AS "INVENSYS CONTROLS PROPERTY") ARE PROPRIETARY TO INVENSYS CONTROLS AND ARE HEREBY ISSUED AND/OR LOANED IN CONFIDENCE SOLELY AND EXCLUSIVELY FOR ENGINEERING EVALUATION AND/OR INFORMATIONAL PURPOSES. INVENSYS CONTROLS PROPERTY MAY NOT BE REPRODUCED OR USED FOR ANY PURPOSE WHATSOEVER WITHOUT PRIOR WRITTEN PERMISSION FROM AN AUTHORIZED REPRESENTATIVE OF INVENSYS CONTROLS AND MUST BE PROMPTLY RETURNED TO INVENSYS CONTROLS UPON COMPLETION OF THE SPECIFIC PURPOSE(S) FOR WHICH IT WAS LOANED. THIS SYMBOL DENOTES DIMENSIONS WHICH ARE CRITICAL TO QUALITY (CTQ). INTERPRETATION OF THESE SYMBOLS SHALL BE PER ES-10633. SPC OR OTHER METHODS MUST BE USED, AND RECORDS KEPT, TO PROVE PROCESS CAPABILITY. DO NOT SCALE THIS DRAWING MNPRT THIS DRAWING AND ALL SUPPORTING MODELS SHALL CONFORM TO ES-10653 AND ES-10654. 191 EAST NORTH AVENUE CAROL STREAM, ILLINOIS 60188-2000 U.S.A. A A .22 ABOVE PCB SURFACE POTTING TO COVER PCB, SCREWS, AND WIRES A. McLANE FUEL SENSOR CASE ASSEMBLY DN/A 086683A0001 1OF1 RAM JOE RMS 16MAY14 CONVERTED FROM DRAWING 086697B0001 A RAM JOE RMS 06JUN14 ITEM #5 WAS 1114028-003; ITEM#10 QTY WAS 'AS REQ'D'; ADDED ITEMS #16 AND #17; RELEASE, COS 97364 A10 C9 A8 B N/A 086683A0001 THERMO KING 13MAY14 R. SCHMURR13MAY14 E. HAFFNER13MAY14 R. SCHMURR 13MAY14 CAROL STREAM N/A 1.000 ITEMPART NUMBERDESCRIPTIONQTY 1100-01666-01PCB ASSY W/ CONFORMAL COATING1 2040276A0001LIGHT PIPE1 3040302B0001LEVEL GAUGE(FROM N6244-00678)1 4086696B0001FUEL SENSOR CASE1 5040349A00016-32 X .375 PAN HEAD SELF TAPPING3 6040306A0001PRODUCT LABEL - MODEL1 7040306A0002PRODUCT LABEL - FCC1 8040306A0003PRODUCT LABEL - MAC1 9040359A0001GAUGE RETENTION TAPE1 10040301C0003POTTING COMPOUND0.3 11022533A0005SOLDERAS REQ'D 12038418D0001SHIP LABEL0.025 13039984A0014BULK BOX0.025 14270KX111ATMEL APPLICATION FIRMWARE1 15270KX112FREESCALE RADIO FIRMWARE1 16040348A0001MIXING NOZZLE0.1 17040360A0001PINCH TUBE0.1 SEE NOTE 9 SEE NOTE 5 SEE NOTE 5 SEE NOTE 4 6 8 7 SEE NOTE 14 NOTES: 1. ENGINEERING APPROVAL OF SAMPLES IS REQUIRED PRIOR TO AUTHORIZATION OF PART PRODUCTION. 2. OPERATING TEMPERATURE: -40C TO 85C 3. POWERED BY AN INTERNAL NON-REPLACEABLE BATTERY. 4. USE ITEM 11 TO SOLDER ITEM 3 GAUGE WIRES TO PCB LOCATIONS X4 AND X5 AS SHOWN 5. SECURE ITEM 1 PCB ASSEMBLY TO ITEM 4 CASE WITH ITEM 5 MOUNTING SCREWS. TORQUE SCREWS TO BETWEEN 3 AND 5 IN LBS. 6. USE ITEM 10 TO COMPLETELY ENCASE CIRCUIT BOARD. 7. AFTER CURING, ENCAPSULANT TO MEET SPECIFIED HARDNESS AS NOTED IN WORK INSTRUCTION AUDIT PROCEDURE. 8. APPLY ITEMS 6, 7 AND 8 PRODUCT LABELS TO CURED ENCAPSULANT AS SHOWN AFTER UNIT HAS PASSED END OF LINE TEST. 9. PRESS ITEM 2 LIGHT PIPE INTO MATING HOLE IN ITEM 4 CASE. 10. THIS ASSEMBLY MUST BE COMPLIANT WITH THE EUROPEAN UNION DIRECTIVE 2002/95/EC (ROHS DIRECTIVE; 27 JANUARY 2003), AS AMENDED, AT THE TIME OF ORDER. 11. WIRES SHALL BE PRESSED FLUSH AGAINST THE PCB WITH A MINIMUM POTTING THICKNESS OF .010” COVERING THE WIRES. 12. REFERENCE CUSTOMER DRAWING 2E39731 AND CUSTOMER SPECIFICATION “WIRELESS FUEL SENSOR”. 13. LABELS TO BE PRINTED WITH FULL RESIN RIBBON RESISTANT TO SCRATCHES, SMEARS, AND MOST HARSH CHEMICALS. 14. PLACE GAUGE RETENTION TAPE CENTERED OVER GAUGE AND ADHERED TO CASE AS SHOWN. 2 3 4 5 WIRE SHOWN HOW THEY SHOULD BE ROUTED IN THE CASE FOR SOLDERING TO PCB BOARD. SEE NOTE 11 1 6 7 8 9 HOLES IN DIAL GAUGE AND CASE MUST BE ALIGNED. GAUGE RETENTION TAPE PLACED AFTER HOLES IN DIAL GAUGE ARE ALIGNED TO CASE A-ASECTION

Engineering Test Report No. 1400654-01 Measurement of RF Emissions from a Zigbee Battery Powered Fuel Level Sensor with Radio Module Transmitter For Invensys, Inc. 191 E. North Avenue Carol Stream, IL 60188 P.O. Number 140065401 Date Tested March 17, 2014 through March 24, 2014 Test Personnel Mark Longinotti Test Specification FCC "Code of Federal Regulations" Title 47, Part 15, Subpart C, Section 15.247 for Frequency Hopping Spread Spectrum Intentional Radiators or Digital Modulation Intentional Radiators Operating within the 2400-2483.5MHz band Industry Canada RSS-210 Industry Canada RSS-GEN Test Report By: Mark Longinotti EMC Engineer Requested By: Randy Schmurr Invensys, Inc. Approved By: Raymond J. Klouda Registered Professional Engineer of Illinois - 44894 Elite Electronic Engineering, Inc. 1516 Centre Circle Downers Grove, IL 60515 Tel : (630) 495-9770 Fax: (630) 495-9785 www.elitetest.com Engineering Test Report No. 1400654-01 TABLE OF CONTENTS PARAGRAPH DESCRIPTION OF CONTENTS PAGE NO. THIS REPORT SHALL NOT BE REPRODUCED, EXCEPT IN FULL, WITHOUT THE WRITTEN APPROVAL OF ELITE ELECTRONIC ENGINEERING INCORPORATED. Page 2 of 66 1. Introduction ................................................................................................................................................... 5 1.1. Scope of Tests ..................................................................................................................................... 5 1.2. Purpose ............................................................................................................................................... 5 1.3. Deviations, Additions and Exclusions .................................................................................................. 5 1.4. EMC Laboratory Identification ............................................................................................................. 5 1.5. Laboratory Conditions.......................................................................................................................... 5 2. Applicable Documents .................................................................................................................................. 5 3. EUT Setup and Operation ............................................................................................................................ 6 3.1. General Description ............................................................................................................................. 6 3.1.1. Power Input ................................................................................................................................. 6 3.1.2. Peripheral Equipment ................................................................................................................. 6 3.1.3. Signal Input/Output Leads .......................................................................................................... 6 3.1.4. Grounding ................................................................................................................................... 6 3.2. Operational Mode ................................................................................................................................ 6 3.3. EUT Modifications ................................................................................................................................ 6 4. Test Facility and Test Instrumentation ......................................................................................................... 6 4.1. Shielded Enclosure .............................................................................................................................. 6 4.2. Test Instrumentation ............................................................................................................................ 6 4.3. Calibration Traceability ........................................................................................................................ 6 4.4. Measurement Uncertainty ................................................................................................................... 6 5. Test Procedures ........................................................................................................................................... 7 5.1. Powerline Conducted Emissions ......................................................................................................... 7 5.1.1. Requirements .............................................................................................................................. 7 5.2. 6dB Bandwidth ..................................................................................................................................... 7 5.2.1. Requirement................................................................................................................................ 7 5.2.2. Procedures .................................................................................................................................. 7 5.2.3. Results ........................................................................................................................................ 7 5.3. Peak Output Power .............................................................................................................................. 7 5.3.1. Requirements .............................................................................................................................. 7 5.3.2. Procedures .................................................................................................................................. 8 5.3.3. Results ........................................................................................................................................ 8 5.4. Duty Cycle Factor Measurements ....................................................................................................... 8 5.…

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Engineering Test Report No. 1400654-01 Page 17 of 66 Figure 2 Test Setup for Radiated Emissions, 30MHz to 1GHz – Horizontal Polarization Test Setup for Radiated Emissions, 30MHz to 1GHz – Vertical Polarization Engineering Test Report No. 1400654-01 Page 18 of 66 Figure 3 Test Setup for Radiated Emissions, 1GHz to 18GHz – Horizontal Polarization Test Setup for Radiated Emissions, 1GHz to 18GHz – Vertical Polarization