dp189 condense shipping guide

DATAONLINE LLC 10 COTTAGE ST. BERKELEY HEIGHTS NJ 07922 USA PHONE: 908-464-2646 FAX: 908-464-3891 WEB: WWW.DATAONLINELLC.COM

INSTALLATION GUIDE REV 2.0 23

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CONTACT THE DATAONLINE CUSTOMER SERVICE & TECHNICAL SUPPORT CENTRE ON: 1-866-M2M-TICKE(ET) OR 1-866-626-8425

DPW800 SERIES INSTALLATION GUIDE

REFLEX & GSM VERSIONS

Covering the installation of the following products:

♦ DPW811 Single Channel, Single Display.

♦ DPW821 Dual Channel, Single Display.

♦ DPW822 Dual Channel, Dual Display.



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INSTALLATION PROCEDURE The following instructions are designed to assist with the installation and configuration of the DataOnline DPW800 range of Telemetry products. The procedure aims to ensure that all of the information required for a successful installation is collected and preserved, such that the readings presented by the newly installed equipment may be verified as accurate before leaving site. At the back of this guide, you will find a copy of the "INSTALLATION INFORMATION SHEET". This makes an ideal place to make a note of important information as you work your way through the installation procedure. This information will then be readily available for use by the DataOnline Customer Service & Technical Support Center, or yourself, as you perform the Web Configuration of the system you are about to install.

The information contained within this document applies to units equipped with either GSM or REFLEX data communication devices.

The installation procedure itself is broken down into the following simple steps:

� RECORD SITE, TANK AND PRODUCT INFORMATION. � RECORD UNIT SERIAL NUMBER. � PHYSICALLY MOUNT THE UNIT. � CONNECT SENSOR WIRING (if required). � WAKE or POWER UNIT UP. � PERFORM TEST TRANSMISSION. � VERIFY ERROR FREE TRANSMISSION. � ALIGN SOLAR PANEL (if required). � CONNECT EXTERNAL POWER SOURCE (if required). � CONNECT SENSOR PIPEWORK. � ENTER "FILL" MODE. � VERIFY DISPLAYED READINGS. � ENTER "DEBUG" MODE. � PERFORM 2nd TEST TRANSMISSION. � VERIFY TRANSMISSION RECEIVED. � INITIALIZE WEB SERVICE. � CHECK AND CLOSE UNIT. � TRAIN CUSTOMER (if required).

A detailed description of each step above is contained in the following pages of this document. .



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RECORD SITE, TANK AND PRODUCT INFORMATION Make comprehensive notes of the details of the site, tank, and product being monitored, in order to simplify the Web Configuration process, or the configuration of your own company's internal logistics system. The site based information should be entered on the "INSTALLATION INFORMATION SHEET", within the "Site Details" section, and should include a full postal address, contact information, and the site time-zone. Complete the "Tank Details" section, and include internal physical tank dimensions, the tank type (flat, or dished ends etc), manufacturer, and orientation (horizontal or vertical). The "Product Details" section should also be completed. Include as much information about the product as possible including its Specific Gravity if it is known. Finally, and perhaps most importantly, make a note of the current product level, and any other parameter to be monitored, BEFORE you disconnect any existing monitoring equipment. Add this in the "Current Readings" section, along with the date and time that these readings were taken.

RECORD UNIT SERIAL NUMBER

Within this section, also make a note of the span of the sensor(s) fitted, and the proposed power source for the unit (Solar, or External Power Source).

PHYSICALLY MOUNT THE UNIT NOTE: If there is any doubt regarding coverage at the installation site, it would be good practice to perform the following three steps (Wake Unit Up, Perform Test Transmission, & Verify Error Free Transmission) prior to mounting the unit. This allows the unit to be relocated if a signal issue is discovered. Mount the unit to the existing tank gauge mounting tabs (if fitted), using the "U" bracket on the back of the mounting plate (see photograph on following page). The four hex cap head screws allow the "U" bracket to be secured tightly to the existing mounting tabs. If this unit is to replace an existing mechanical gauge, currently mounted on the gauge mounting tabs, then make sure that a tank level reading is taken, and noted, BEFORE this gauge is removed.

The serial number of the DPW800 series device is located on theunderside of the lid mounted circuit board. This is visible by looking through the side of the clear lid, on the right hand side near to the top. A unique serial number is clearly marked on each unit, as an 8 digit Hexadecimal number, which begins with "FF6" for GSM units, and "FF5" for REFLEX 25 and 50 units. Make a note of this number on the "INSTALLATION INFORMATION SHEET" in the space provided for the "Unit ID", under "Unit Details".



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If the unit is to be mounted on one of our optional stands, then the stand must first be bolted down to the mounting platform. Remove the "U" bracket from the mounting plate, and then mount the unit with the two bolts supplied with the stand.

CONNECT SENSOR WIRING (if required). Most DPW800 series products are supplied with pre-wired integral sensor assemblies. However as an option, they may be ordered without sensors. This allows them to be used with almost any two-wire 4-20mA sensor. If this is the case, then the external sensor loop wiring should be performed at this stage. Connect the sensor 4-20mA loop positive connection to the "+VE" terminal on the 3 way connector marked "INPUT 1" ("INPUT 2" for the second channel). Connect the sensor 4-20mA loop return connection to the "IP1" (or "IP2" for the second channel) terminal on the 3 way connector marked "INPUT 1" ("INPUT 2" for the second channel). If the 4-20mA signals are to be "shared" with other equipment, then a different wiring arrangement may be required, and a Signal Isolation Card may also be needed. Contact the DataOnline Customer Service & Technical Support Center at 1-866-626-8425 for further advice.

WAKE or POWER UNIT UP. DPW800 series products are either shipped with their internal battery disconnected, or the unit is placed into a special "low power shipping mode". Before the unit can be used, it must be either "powered up" or "woken up". If the display(s) on the front of the unit show the text "ASLEEP", then the unit has been delivered in "low power shipping mode". To "wake" the unit up, press and hold the FILL button until "ASLEEP" disappears from the display (this could take up to 20 seconds). If the display(s) on the front of the unit are completely blank, then the unit has been shipped with the internal battery disconnected. Remove the front cover from the unit by unscrewing the four Phillips screws at the corners of the lid. Connect the white battery connector to the mating white connector on the lid PCB marked "BATTERY". Ensure that the connector is fitted in the correct orientation, and is pushed in completly to engage the "latch".

If the unit is to be mounted onto some other existing bracket or mounting arrangement, then the "U" bracket on the rear of the mounting plate may be removed as required. In the picture to the left, the "U" bracket can be seen still attached to the mounting plate. You can also see the two 7/16" mounting holes, at the top and bottom on the center line of the mounting plate. These holes mate with standard DataOnline stands after removal of the “U” bracket. The optional stands come with bolts for attaching the unit to the stand.



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PERFORM TEST TRANSMISSION. Before any further installation work is completed, it is important to confirm that network coverage is available at the tank location. This is achieved by performing a test transmission, which will cause the radio to register with the GSM or REFLEX 25/50 network, perform a transmission, followed by a received message check. To perform the test, press the "FILL" and "MODE" buttons simultaneously until "DEBUG" appears on the display(s). As soon as "DEBUG" appears press the "FILL" button, until "TEST" appears on the top display. If two displays are fitted the bottom display will show "RADIO" during the rest of this process.

VERIFY ERROR FREE TRANSMISSION. The top display will show the message "LOG-ON" until network registration is achieved. On successful registration the display will show the signal strength, which should be noted for reference. The message "S.00" to "S.31" indicates the level of received network signal strength. (Reflex units with software prior to Version 3.1 , as displayed in Debug values, do not display the received signal strength) Each of the transmission, and reception tests which follow, will display "DONE" to indicate success, or "Err.nnn" to indicate failure. Make a note of any errors, in order to assist diagnosis. If registration is not possible the message "NO-REG" will appear after several minutes. In this case it is worth trying a second test transmission in order to confirm the lack of network coverage.

ALIGN SOLAR PANEL (if required). The standard DPW800 series product is fitted with a Solar Panel, which must be correctly aligned to give it an unobstructed view of the Southern sky, (in the Northern Hemisphere). This task is obviously best performed with the aid of a Compass.

CONNECT EXTERNAL POWER SOURCE (if required).

If there are large obstructions to the South, which will cast a shadow directly onto the unit, then it may be necessary to turn the Solar Panel towards the East or West to catch the morning or afternoon sun. When the Solar panel is correctly aligned, tighten the Hex Head Bolt on the Solar Panel angle bracket to prevent it from accidentally moving out of alignment. Finally, ensure that the wire from the Solar Panel is connected to the input marked "POWER" on the main PCB within the lid (see picture to the left).



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The DPW800 series of products may optionally be fitted with a 110V or 240V a.c. mains power supply, or indeed a 12V or 24V d.c supply. Before making any connection to the power supply within the unit, check that the power supply fitted, is compatible with the power source that you plan to connect.

CONNECT SENSOR PIPEWORK. The sensor assembly on the DPW800 series of products, is terminated in 1/4" NPT tapered threads as standard. Optionally it can be supplied with 1/4" or 6mm compression fittings.

The pilot tubing connections to the tank should be made such that the liquid leg (high pressure) is connected to the sensor assembly port marked "plus", and the gas leg (low pressure) is connected to the sensor assembly port marked "minus". IMPORTANT NOTE: The equalization valve should be fully open before the isolation valves are opened to connect the sensor assembly to the tank. If no equalization valve is fitted, then the liquid leg isolation valve should be opened first (very slowly). Then the gas leg isolation valve should be opened (again very slowly) in order to avoid unduly stressing the sensor assembly measuring elements.

The external line power must match the power supply module rating and is connected to the green screw connector on the Power Supply Module (see picture on left). This power should come from a switched and fused source, to allow the supply to be disconnected should it be necessary to work inside the equipment. The output of the supply is connected to the input terminal marked POWER on the main PCB within the lid (The red wire goes to +VE & the black wire to -VE terminals, see picture to the left).

The photograph to the left shows a unit equipped with both the Differential Pressure sensor, and the optional Pressure sensor. The high and low pressure ports on the Differential Pressure sensor are marked with "plus" and "minus" signs to assist with correct connection of the pilot tubing to the tank.



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ENTER "FILL" MODE. In order to verify the readings on the newly installed unit, you need to place the unit into "FILL" mode, where it will power the sensors in turn, take readings, and update the local display(s). To enter "FILL" mode, press and hold the "FILL" button until the display(s) show the message "FILL". At this point, release the button and wait for the display(s) to be updated with reading(s). If the unit is equipped with sensors which take some time to "settle", such as ultrasonic or radar sensors, then you may need to wait up to one minute, otherwise the first reading should appear within a few seconds.

VERIFY DISPLAYED READINGS. The reading(s) displayed on the DPW800 series unit should match the values that you noted earlier on the "INSTALLATION INFORMATION SHEET", before you removed the existing sensor/gauge arrangement. If they do not, then the most likely explanation is that the display is incorrectly spanned. By default the display(s) are spanned to match the calibrated sensor span (i.e. 0 to 600 in W.C. in the case of the standard Differential Pressure sensor). In order to resolve any such issue, you will need to contact the DataOnline Customer Service & Technical Support Center at 1-866-626-8425 for assistance. Before doing so, complete the following two steps (DEBUG & 2nd TEST), as this will provide you with information which the Customer Service staff will need to help resolve the issue.

ENTER "DEBUG" MODE. To enter "DEBUG" mode, press and hold both the "FILL" and "MODE" buttons simultaneously, until "DEBUG" appears on the display(s). At this point release both buttons. If the unit is still in "FILL" mode, then there may be a short delay, as the unit will need to complete the sensor measurement cycle which is currently in progress (remember the longer delays associated with ultrasonic & radar sensors). "DEBUG" mode will display a set of key system parameters in rotation, which will provide important information regarding the "health" of the unit, and the installation. Make a note of the value of each of these parameters on the "INSTALLATION INFORMATION SHEET", within the "DEBUG Values" section. A separate box is available for each parameter. The cycle will repeat 3 or more times before the unit reverts back to normal operation. If you have not made a note of all of the parameters at this point, then simply re-enter "DEBUG" mode again.



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PERFORM 2nd TEST TRANSMISSION. To perform the second test transmission, press the "FILL" and "MODE" buttons simultaneously until "DEBUG" appears on the display(s). As soon as "DEBUG" appears press the "MODE" button, until "DATA" appears on the top display. If two displays are fitted the bottom display will show "RADIO" during the rest of this process. This will now perform a test transmission just like before, which will cause the radio to register with the GSM or REFLEX 25/50 network, perform a transmission, followed by a received message check. Again check that each stage is completed successfully with a "DONE" message, and if any error messages appear, then make a note of the error number.

VERIFY TRANSMISSION RECEIVED. Contact the DataOnline Customer Service & Technical Support Center at 1-866-626-8425 in order to confirm that both of the test transmissions were received. This will provide the final confirmation of trouble free network coverage. Have the completed "INSTALLATION INFORMATION SHEET" available when you call, and provide them with your name, phone number and company name. They will then ask you for the ID of the unit that you are installing. You may be asked for information from the "INSTALLATION INFORMATION SHEET", such as the parameter values noted in "DEBUG" mode, as well as any error messages which appeared during the test transmissions. The DataOnline Customer Service & Technical Support Center will confirm that both test messages were received.

INITIALIZE WEB SERVICE. While you are on line to the DataOnline Customer Service & Technical Support Center, they will also be able to initialize the Web Service for you. To do this they will need all of the information on the "INSTALLATION INFORMATION SHEET", to allow them to completely configure the web site for this tank. If you have access to a fax machine, they will provide you with a fax number to send this sheet to. This will save you the time trouble of dictating all of the information over the telephone.

CHECK AND CLOSE UNIT. When the DataOnline Customer Service & Technical Support Center has completed their config-uration and verification tasks, you can finally close up and check the unit before leaving site. NOTE: Before tightening (hand tight) the four lid screws, ensure that all internal cabling is routed such that it is not trapped between the lid, and the battery bracket etc.

TRAIN CUSTOMER (if required).



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The very last task to complete before leaving site, is to give the customer an overview of their new DataOnline DPW800 Series Product. This overview should include a brief discussion regarding the following:

� The use of the "FILL" button by the driver when the tank is filled.

Explain that the driver must press the "FILL" button prior to filling the tank in order to ensure that the level reading(s) displayed are current and accurate. It will also cause the unit to transmit a "fill alarm" message at the end of the tank fill cycle, such that the tank graph on the web will be updated to show the new product level.

� The use of the "FILL" button to obtain an immediate display update.

Explain that the level shown on the display could be up to an hour old, and that if an absolutely up to date reading is needed, then it is possible to get one by using the "FILL" button. If the tank level remains the same, the unit will return to its normal operating mode after 15 minutes.

� The function, and scaling of each of the displays.

The function and scaling of the display(s) will be obvious in most installations. But where multiple tanks exist, or a level and pressure is being displayed it may be necessary to point out the actual function of each display. Equally it may be necessary to make the scaling clear, particularly if the old gauge which this unit replaces was scaled differently.

� Keeping the Solar Panel clean, and clear of site debris and dust.

Just about the only regular maintenance required on the unit is a periodic "wipe" of the Solar Panel (if fitted). Site dust and debris can collect on the Solar Panel, and if not cleared by rainfall or snow this can lead to a reduction in efficiency of the Solar Panel. A wipe with a clean damp cloth is all that is required.



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Optional Parts for Wireless Units.

DAP-BAT1034-189 6v re-chargeable battery for solar and 110v unit models FF4, FF5 & FF6.

DAP-TRFMA1012 Battery charger for 6v re-chargeable.

DAP_BP172-189 9v Alkaline battery packs for models FF4, FF5 and FF6.

DAP-BP296-189 7v lithium battery packs for models FF4, FF5 and FF6.

DPK-BAT1035/9139 Satellite battery pack.

DQ-ANT-GSM External antenna for GSM (cellular) unit.

DAP-FST3000 Fuse kit for RT124 wired/phone line unit.

DAP-FST4000 Fuse kit for Satellite unit.

DPA910 2ch Alarm relay board for Models FF4, FF5, FF6 and FF78.

DPA940 2ch isolation relay board for Models FF4, FF5, FF6 wireless units.

DPA444 4ch isolation relay unit for Model FF78 wireless unit.

DPA960 110vac supply for Models FF4, FF5, FF6 and FF78 wireless units.

Please call (908) 464-2646 ext 123

for ordering and price information.



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INSTALLATION INFORMATION SHEET

UNIT DETAILS: Unit ID: Sensor 1 Span:

Unit Type: Power Source: Sensor 2 Span:

Notes:

SITE DETAILS: Customer/Site Name:

Site Address:

Country: ZIP/Postcode: Time Zone:

Site Contact: Phone No:

Site Contact E-Mail Addresses:

Notes:

TANK DETAILS: Tank Name/ID:

Tank Type: Horizontal / Vertical Dished Ends: YES / NO Dish Depth:

Tank Height/Length: Tank Diameter: Manufacturer:

Notes:

PRODUCT DETAILS: Product: Specific Gravity:

Notes:

WEB-SITE SETUP: Preferred Units:

Re-Order Level: Critical Level: High Level:

Level Alarms: YES / NO Alarm Delivery Via: Email / SMS / Both

Email Address: Mobile No:

Auxiliary Channel: YES / NO Function: Preferred Units:

Notes:

LOCAL DISPLAY: Preferred Units:

Second Display: YES / NO Preferred Units:

Notes:

CURRENT READINGS: Level and or Pressure readings taken from existing sensors or gauges.

Current Product Level: Auxiliary Channel Reading:

Date & Time: Notes:

"DEBUG" VALUES: Note the value of the parameters listed here, as viewed in DEBUG mode.

C1: mA C2: mA bd: V bn: V



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Notes

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