Stationary Diesel Tank Management

Installation Guide

This guide will walk you through installing the IoT Pro Submersible monitoring system on a stationary diesel tank. The process typically takes 1-2 hours for a standard installation.

This installation must be performed by a qualified electrician or authorized technician only due to high voltage hazards

Before you begin

Before your first installation, complete the IoT Pro Quick Start in the office to familiarize yourself with the process

Parts Needed

  • 1 x IoT Pro Submersible

  • 1 x Pressure Sensor (1m, 2m or 4m)

  • 1 x 12VDC 1A Power supply

  • As Necessary x 2 Core 0.75mm² cable for supply

  • 1 x 3d printed adaptor with a suitable thread + Nut

  • 1 x 12mm HSS drill bit

  • 1 x 32mm hole saw

  • 1 x M12 Grommet

Optional but Recommended

  • As Necessary x conduit

  • 1 x Bond and Seal (Wurth recommended)

  • M5 self drill A4 Stainless Steel screws

Installing Sensors

Start with installing the pressure sensor, before installing the IoT Pro. This allows you to position the IoT Pro device optimally, avoiding the need for junction boxes or cable extensions.

There are multiple ways to install a Pressure sensor into a diesel tank:

  • Option A:

    • Look at the top of the tank for any holes purposefully blanked out by the manufacturer

    • Find one larger than ¾ths inch with thread, on modern resin tanks you can usually find a 1.5 inch threaded blank to use.

    • Identify the thread size and choose a suitable adaptor

    • Pass the pressure sensor cable through the 3d printed adaptor and hand tighten the adaptor to the tank

  • Option B:

    • Look at the top of the tank for a mechanical dial gauge, these are usually float type sensors with a 1 or 1.5 inch thread

    • Identify the thread size and choose a suitable adaptor

    • Pass the pressure sensor cable through the 3d printed adaptor and hand tighten the adaptor to the tank

  • Option C:

    • If no blank or gauge is present then a fresh hole would need to be made

    • Look at the tank from the top and find a removable piece, usually the lid could be removed to fill with fuel or a patch would be removable so that accessories can be added

      • Remove the piece and drill the necessary sized hole (32mm recommended for a 1 inch adaptor)

    • If the tank is completely sealed and no piece, that’s large enough, can be removed then a hole in the tank would need to be made.

      • If the tank is made of metal then it would need to be emptied and left to vent before drilling as there is an explosion risk

      • If the tank is made of resin, plastic or fiber, you can drill slowly without emptying first but it is still a good safety precaution to do.

Installation Tips: If the sensor cable is to be left exposed, it is good practice to pass it through a conduit first to prevent any damage to the cable.

Installing The IoT Pro


  1. Locate the pump control panel, this is usually found on top of the tank in newer non-metal tanks or in front of the tank in a cabinet if it is made of metal.

  2. Choose a suitable place for the IoT Pro to be attached, but do not mount the device at this stage.

    1. It is important not to drill into any tanks that contain fuel unnecessarily, so for this we recommend you use bond and seal instead of screws

  3. Pass the connection end of the sensor to the IoT Pro

  4. open the panel and, with a multimeter check for a 240v supply.

  5. Using a multimeter check the main circuit breaker has correct supply (EU 240v) then turn it off and confirm visually that the voltage goes down to 0 and the pump does not work

  6. Drill a 12mm hole on the side or bottom of the control panel and add an M12 grommet

  7. Insert the sensor cable and supply cable into the IoT Pro

  8. Pass the supply cable into the control panel via the grommet attached in step 6


Electrical Connections

Turn off the main supply to the pump before proceeding

Note: A complete wiring diagram is available at the end of this guide for reference

Use a 0.75mm² 2-core cable for AC and DC supply but keep the AC supply cable as short as possible


Pass the sensor cable into the IoT Pro device and connect as follows:

  • DIN5: Yellow wire

  • DIN6: Black wire

  • 3V6: Red wire

  • GND: Blue wire

Power Supply

  1. Use a 2-core 0.75mm² cable

  2. Connect one end of the cable to the power board’s 2-pole terminal block

  3. Connect the other end to the 12VDC power supply

  4. Connect the 12VDC power supply after the circuit breaker you turned off to drill the hole

Tech Tips: Some pumps work on a DC 12V battery, this would mean that you can connect directly to the battery and not use the 12VDC power supply. (Check on the wiring diagram of the controller, or follow the wires going to the battery and confirm a 12VDC supply with a multimeter)


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


Conclusion

  1. Double-check all connections

  2. Switch the cold room controller circuit breaker back on

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

  4. Test the cold room operation

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

  6. Attach the IoT Pro in the chosen location

  7. Resume normal operation