Diesel Tank Management Installation

top-level wiring diagram like generator in case it’s straightforward for others? 230VAC, 12VDC, 24VDC diagrams - add shortcut links

1 - Configuration Selection

Select the configuration options that best match the installation requirements. The IoT Pro Diesel Tank Management system can be configured with different power supply, barcode scanner, and fuel level sensor options.

Power Supply

The system can be configured for 230VAC, 12VDC, or 24VDC operation.

  • 230VAC is typically used for fixed fuel dispensing installations.

  • 12VDC and 24VDC are typically used for portable fuel dispensing systems.

The system supply voltage must match the pump supply voltage. For example, a system using a 12VDC pump must also be configured for a 12VDC supply.

Barcode Scanner

The system supports either a Wired Barcode Scanner or Wireless Barcode Scanner.

The wired barcode scanner is supplied with a 5m cable and is generally the preferred option where the dispensing point can be conveniently reached. The wireless barcode scanner provides greater freedom of movement but has a few additional considerations:

  • The scanner can be misplaced or removed from the dispensing area

  • The scanner must be correctly placed in its charging cradle to ensure that it remains charged

Fuel Level Sensor

Two fuel level sensor options are available:

  • Submersible Pressure Sensor - Recommended for fixed fuel tank installations

  • Capacitive Level Sensor - Recommended for portable or mobile fuel tank installations

2 - Mechanical Installation

Main Panel Installation

Install the main panel close to the existing diesel fuel dispensing equipment to minimize cable lengths, while keeping the panel easily accessible for operation and maintenance.

When selecting the installation location:

  • Ensure sufficient space is available around the panel for access and cable routing

  • Allow additional space for the Wired Barcode Scanner holder or Wireless Barcode Scanner enclosure

If the panel is exposed to rain, install a suitable rainwater deflector (paraqua) above the enclosure

2 x Image: Wired and wireless barcode systems installed (show bolts or wall anchors inside)

Image: Rainwater deflector (paraqua)

Mount the main panel securely using suitable fixings for the installation surface:

  • Wall mounting: For typical installations, use four 6 x 45 mm wall plugs

  • Metal panel or structure: Use four M6 A2 stainless-steel bolts, washers and nuts

Cable Management

Route all field wiring to the main panel using one of the following methods:

  • Surface wiring: Use the cable glands at the bottom of the main panel where the cables are routed externally along the wall

  • Concealed wiring: Alternatively, drill an internal cable entry hole to bring the wiring directly into the rear or inside of the panel. This provides a neater installation and reduces the risk of cable tampering.

In both cases, use split flexible conduit where multiple cables follow the same route to keep the incoming wiring grouped, protected, and neatly organized.

image: vassallo for a mix of both

image: wall wiring (callus garden centre, piscopo)

image: hole inside panel for concealed wiring (tec + split conduit showing)

Barcode Scanner Installation

Wireless Barcode Scanner

  1. Mount the wireless barcode scanner enclosure next to the main panel, using:

    1. Wall mounting: For typical installations, use four 6 x 45 mm wall plugs

    2. Metal panel or structure: Use four M6 A2 stainless-steel bolts, washers and nuts

  2. Connect the DC barrel connector and RJ50 cable to the back of the wireless scanner. Secure the scanner holder inside the enclosure using its two mounting holes and suitable fixings.

  3. Insert the battery into the bottom of the wireless barcode scanner

  4. Select the preferred cable routing method:

    1. Surface wiring: Install suitable cable glands at the bottom of the scanner enclosure. Route the DC power cable and RJ50 cable through the fifth and sixth cable glands of the main panel, respectively.

    2. Concealed wiring: Drill a suitable cable entry hole to route the cables internally between the scanner enclosure and the main panel

image: wireless enclosure installed

image: cable gland wiring or concealed wiring hole (tec) - add labels

Wired Barcode Scanner

  1. Install the barcode scanner holder in a convenient location next to or below the main panel, using:

    1. Wall mounting: For typical installations, use two 6 x 45 mm wall plugs

    2. Metal panel or structure: Use two M6 A2 stainless-steel bolts, washers and nuts

  2. Route the scanner cable into the main panel through the fifth cable gland, ensuring that the gland is properly tightened

  3. Place the barcode scanner in its holder

image: holder installed

image: wired barcode scanner inside holder

Pulser Installation

Apply a suitable pipe sealant to all threaded fittings. Würth Pipe Sealant, Art. No. 0893 577 050, is recommended. Always allow the sealant to cure before pressurizing the system.

  1. Install the pulser as the last fitting before the dispensing pipe. The supplied pulser uses 1" BSP threaded connections. Select the appropriate fittings for the installation.

    1. image: common 1" BSP fittings - male-to-male and male-to-hose-tail (labelled)

  2. Ensure that the pulser is installed in the correct flow direction, as indicated by the arrow on its body

    1. image: Pulser showing the flow direction

  3. Route the pulser cable to the main panel. If an extension is required, use a suitable junction box with a 3-core, 0.5 mm² cable. Where cable glands are used, route the cable through the third gland from the left.

    1. image: typical installation

Fuel Level Sensor Installation

Capacitive Level Sensor

The Capacitive Level Sensor is recommended for moving, portable fuel tanks

  1. Choose the appropriate mounting method:

    1. BSP adapter: When a suitable threaded port is available

    2. Flange: When no suitable threaded port is available add which self-drill screws to use

refer to generator for more in-depth installation guide?

The required fittings for these installations can be ordered from the IoT Pro Product Selector, under IoT Pro Diesel Tank Module > Diesel Tank Module Accessories > Mechanical Adapter Selection.

image: vassallo portable tank installation

  1. Cut the sensor probe to approximately 3 mm shorter than the internal tank depth. Calibrate the sensor using the supplied calibration tool.

  2. Route the sensor cable to the main panel. If an extension is required, use a suitable junction box with a 3-core, 0.5 mm² cable. Where cable glands are used, route the cable through the fourth gland from the left.

Submersible Pressure Sensor

The Submersible Pressure Sensor is recommended for fixed, on-ground fuel tanks

  1. Choose the appropriate mounting method:

    1. BSP adapter: When a suitable threaded port is available

    2. Flange: When no suitable threaded port is available add which self-drill screws to use

See Diesel and Water Tank Installation for a more in-depth installation guide

The required fittings for these installations can be ordered from the IoT Pro Product Selector, under IoT Pro Level Submersible Module > Submersible Module Accessories > Mechanical Adapter Selection.

  1. Lower the sensor to the bottom of the tank, then raise it approximately 5cm to prevent contact with sediment. Secure the cable gland to hold the sensor in position.

  2. Route the sensor cable to the main panel. If an extension is required, use a suitable junction box with a 3-core, 0.5mm² cable. Where cable glands are used, route the cable through the fourth gland from the left.

  3. Where additional cable protection is required, use split flexible conduit and secure it with self-amalgamating tape.

image: vassallo and tec/piscopo/callus for typical installation

The submersible pressure sensor requires atmospheric pressure reference for accurate measurements. If a junction box is used, a 1-2mm hole may be drilled at the gland’s side or at the bottom of the enclosure (to protect opening from water ingress).

The submersible pressure sensor uses a blue wire for the GND connection

3 - Electrical Installation

Disconnect both the main system and pump power supplies before proceeding. Verify that all circuits are de-energized. Electrical installation must only be performed by a qualified electrician or authorized technician.

Refer to DIN-Rail Terminal Block Wiring for a better understanding of DIN numbering

link to refer to appendix for full wiring diagrams

Peripheral Wiring

Following the Mechanical Installation, the following peripheral cables should be routed into the main panel and ready for connection:

  • Barcode Scanner: One cable for the wired scanner, or two cables (DC power and RJ50) for the wireless scanner

  • Pulser: 3-core cable

  • Fuel Level Sensor: Cable from either the submersible pressure sensor or the capacitive level sensor

Connect each peripheral as described below, keeping the system and pump power supplies disconnected throughout the installation.

Barcode Scanner

Both barcode scanner configurations use the same communication and ground connections:

  1. Connect the Orange and Brown wires to Left Group/Yellow (terminal 7) and Left Group/Green (terminal 8), respectively

  2. Connect the Black wire to GND (terminal 6)

  3. Connect the Red supply wire according to the scanner configuration:

    • Wired Barcode Scanner: 5VDC (terminal 5)

    • Wireless Barcode Scanner: 12VDC (terminal 1 or 2)

Pulser

  1. Connect the Red wire to 12 VDC (terminal 1 or 2)

  2. Connect the Black wire to GND (terminal 3 or 4)

  3. Connect the Yellow wire to Left Group/White - Pulse Input (terminal 10)

Fuel Level Sensor

Both fuel level sensor configurations use the same supply and signal connections:

  1. Connect the Red wire to 12VDC (terminal 1 or 2)

  2. Connect the ground wire to GND (terminal 3 or 4)

  3. Connect the Yellow wire to Right Group/Grey – Fuel Level Input (terminal 14)

The ground wire differs between sensors:

  • Submersible Pressure Sensor: Blue wire

  • Capacitive Level Sensor: Black wire

Route the analogue fuel level sensor cable away from other electrical wiring, particularly power cables, to minimise electrical interference and ensure accurate, stable readings

Power Supply and Pump Connection

As outlined in Configuration Selection, the system supports 230VAC, 12VDC and 24VDC configurations.

12VDC - Conversion Method

add loom video with captions

24VDC - Conversion Method

add loom video with captions

230VAC - Standard Configuration

Connect the incoming mains supply and pump cables to the 6-way terminal block as illustrated below.

4 - System Commissioning

to continue

Ensure all connections are securely terminated and verified before restoring power. Power on the system and check that the barcode scanner lights up or beeps.

Device Setup

  1. Connect to the IoT Pro device using the mobile application

  2. Confirm that Peripherals is OK

  3. Activate the IoT Pro device according to the communication network being used:

    1. Activate the Device - Cellular

Platform Setup

  1. Setup Asset etc.

  2. Send Message

Verification

  1. Dispense fuel

  2. Check report

5 - Appendix

DIN-Rail Terminal Block Wiring

Connections are referred to left-to-right as seen when panel is open

Terminal Position

Internal (Top) Wire

Function

Connect To

1-2

Red

12V x 2

Submersible Pressure, Pulser, Capacitive Sensor, Wireless Barcode Scanner

3-4

Black

GND x 2

5

Red

5V

Wired Barcode Scanner

6

Black

GND

7

Left Group / Yellow

RS232 TX

Barcode Scanner (Orange)

8

Left Group / Green

RS232 RX

Barcode Scanner (Brown)

9

Left Group / Grey

DIN1: RFID/iButton 1-Wire

10

Left Group / White

DIN2: Pulse Input

Pulser (Yellow)

11

Left Group / Brown

DIN3: Manual Override

12

Right Group / Yellow

N/A

13

Right Group / Green

N/A

14

Right Group / Grey

AIN1: Fuel Level

Submersible Pressure or Capacitive Sensor (Yellow)

15

Right Group / White

OUT1: Pump Relay

16

Right Group / Brown

OUT2: Buzzer

Peripherals Specifications

Wired Barcode Scanner

  • Power Supply: 5VDC

  • Wiring

    • Red Wire: +5V

    • Black Wire: GND

    • Orange Wire: RS232 RX

    • Brown Wire: RS232 TX

Submersible Pressure Sensor

  • Power Supply: 10-30VDC

  • Wiring

    • Red Wire: +V

    • Yellow Wire: Analogue Output

    • Blue Wire: GND

Pulser

  • Power Supply: 5-24 VDC

  • Wiring

    • Red Wire: +V

    • Yellow Wire: Pulse Output

    • Black Wire: GND

Wireless Barcode Scanner

  • Power Supply: 12VDC

  • Wiring

    • Red Wire: +12VDC

    • Black Wire: GND

    • Orange Wire: RS232 RX

    • Brown Wire: RS232 TX

Capacitive Level Sensor

  • Power Supply: 10-32 VDC

  • Wiring

    • Red Wire: +V

    • Yellow Wire: Analogue Output

    • Black Wire: GND