Monitor fuel levels, receive power loss and recovery alerts, and automate test runs to ensure your generator is always ready when needed.

Installation Guide

Before you begin

Installing Sensors

Start with installing the sensors first, before installing IoT Pro. We'll begin with the fuel tank capacitive level sensor and engine temperature sensor. This allows you to position the IoT Pro device optimally for both sensor cable runs, avoiding the need for junction boxes or cable extensions. Refer to Reference Images for guidance.

Fuel Tank Capacitive Level Sensor

Preparation

The capacitive level sensor probe length can be adjusted according to the fuel tank depth. Up to 2/3 of the sensor can be cut (for example, if the probe is 300mm long, it can be shortened to 100mm). Make sure to account for the length of the adapter depending on the installation method.

Instructions for cutting the probe:

1. Mark the cutting position 3mm shorter than the tank depth (L)

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2. Cut the probe at the marked position with a saw blade - do not remove the bottom plug before cutting.

   1. To cut the probe, put the probe in a vice and make sure to hold it with a thick cloth or cardboard to not damage the paint on the probe, or the probe itself

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3. Debur with knife file the cut probe - inside of the tube should be kept clean, burrs dropped into the tube must be cleaned to remove risk of blockage.

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4. Remove the beige rubber plug from the cut-off section of the original probe and transfer it to the new probe. Ensure that the beige plug is firmly secured to the internal electrode. This maintains the proper gap between the inner and outer electrodes and allows fuel to smoothly enter the sensor probe. Finally, re-assemble the black bottom plug.

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Calibration

Prepare a plastic bottle (a regular 2L soft drink bottle with a wide cap works well) or diesel container which is deeper than the maximum calibration length.

Instructions for calibrating the probe with the provided calibrating tool:

1. Do not power on the probe

2. Remove the top Phillips head screws at the top of the sensor and connect the calibrator to the probe

3. Turn on the calibrator (ensure that this has a 12V A23 battery) and that the LED on the calibrator turns on

4. Insert the probe into the bottle so it is submerged to the same depth the probe will be submerged at when the fuel tank is full, taking into account the adapter height offset depending on the installation option, and wait for 30s

5. Press 'F' on the calibrator and release when the calibrator LED starts blinking

6. Wait for the blinking led to stop

7. Remove the probe and drain in free air for 30s in a well-ventilated area away from ignition sources. Clean off any excess fuel.

8. Leave your probe in free air for 30s (This way the empty position 0% level will be when no Diesel is touching the capacitive sensor)

9. Press 'E' on the calibrator and release when the calibrator LED starts blinking

10. Wait for the blinking led to stop

11. Turn off and remove calibrator

12. Close the top cover with screws again

13. The sensor may now be installed and wired to IoT Pro.

Installation Methods

Locate the fuel tank inside the generator and choose one of the following installation methods (listed in order of preference):

• Option A: Use an existing free inlet or replace the existing mechanical gauge sensor

  • Use the provided adapter with provided gasket and O-ring to ensure a proper seal

    • 1 inch to 3 inch BSP adaptors can be provided, get in touch with our team members from IoT Solutions Website - Contact Us for custom adaptors

  • Use the provided M5 stainless steel A4 self-drilling screws to attach the capacitive sensor to the provided adaptor

  
  
  

  
  

  
  

• Option B: Drill a hole into the lid of the tank or into a flat removable piece of the tank

  • First remove the lid or the removable piece

  • Identify the best hole location for the sensor - there should be no obstructions to the sensor once installed into the tank

  • Drill a pilot hole - use the appropriate drill bit material according to the lid or piece material

  • Enlarge the hole with a cone drill or hole drill depending on the material thickness to 34 mm diameter

  • Install the capacitive sensor as shown with the provided adaptor, nut, gasket and O-ring

    
    
    

    
    

• Option C: Install a 3D printed custom adapter fuel inlet (Get in touch with our team members from IoT Solutions Website - Contact Us)

  • The 3D print can be customized to your tank specifications

• Option D: Drill an additional hole directly into the tank (least preferred - tank must be emptied and fully ventilated before drilling to prevent fire hazard)

  • Identify the best hole location for the sensor - there should be no obstructions to the sensor once installed into the tank

  • Drill a pilot hole - use the appropriate drill bit material according to the tank material

  • Enlarge the hole with a cone drill or hole drill depending on the material thickness to 31 mm diameter

  • Use a 1 inch BSP tap to thread the drilled hole

  • Install the capacitive sensor as shown in Option A with the provided 1 inch adaptor, gasket and O-ring

Engine Block Temperature Sensor

1. Locate a suitable hole in the engine block near the cooling channels

2. Apply Bond and Seal adhesive (Wurth Article No. 089010011 or Article No. 0893236110)

3. Insert the temperature probe firmly into the hole

Electrical Connections

Use a separate multi-core cable for each connections. Mount the DIN relays securely inside the control panel.

AC External Input (DIN1)

Connect to the AC feed entering the generator, ideally before any protection devices:

• Preferred: Connect directly to the battery charger input

• Alternative: Wire from the control board where the generator receives its AC mains feed

Generator AC Output (DIN2)

Tap into a single phase of the generator output:

• Preferred: Connect directly after the MCBs (main circuit breakers) at the generator output

• Alternative: Tap from the control board if direct access is not possible

Fault Detection Input (DIN3)

1. Locate the dry contact relay on the generator control board that activates during fault conditions

2. Wire this contact to DIN3 and Ground

Fuel Tank Capacitive Sensor

Route the sensor cable to the IoT Pro device and connect as follows:

• AIN2: Blue wire

• 12V/24V: Red wire

• GND: Black wire

Engine Temperature

Route the sensor cable to the IoT Pro device and connect as follows:

• DIN4: Yellow wire

• 3V6: Red wire

• GND: Black wire

Power Supply

1. Use a 2-core 0.5mm² cable

2. Connect one end of the cable to the power board’s 2-pole terminal block (red = +V, black = GND)

3. Connect the other end directly to the generator's 12V/24V battery before any main switch

4. Terminate the cable using 6mm ring crimp connectors

5. Secure to the battery terminal lug nut

6. Inside the IoT Pro device, bridge the positive supply (+V) to AIN1 as required for battery voltage sensing

Cable Management

Internal/External Routing

• Route cables through the generator's soundproof insulation wherever possible

• This provides neater installation and protects cables from chafing

Cable Securing

• Apply fiber/duct tape to any cables on the generator exterior for additional security and safety

Wire Extensions

If you need to extend the pressure or temperature sensor cables:

• Use heated solder joints

  • Wire extensions should be done inside the generator for added environmental protection

Reference Images

Testing and Commissioning

Initial Verification

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

2. Confirm that Peripherals is OK

3. Verify the Application Data

Software Platform Configuration

1. Log In to your IoT Pro Software Platform

2. Navigate to Assets

3. Create a new asset whilst taking particular note of the following settings:

   1. Choose the Device ID based on the label on the device

   2. Asset Shape: Cuboid

   3. Enter tank dimensions (measure from inside the tank)

      
      

Conclusion

1. Double-check all connections

2. Switch the generator mode from STOP back to AUTO

3. Activate the IoT Pro Device and Send a Message as explained in IoT Pro Quick Start
   

4. Test the generator operation

5. Verify that all sensor readings appear correctly on the dashboard

6. Resume normal operation

Appendix

Wiring Diagram