OEM Controls ST511 ST-511 Radio Primary User Manual Contents

OEM Controls, Inc. ST-511 Radio Primary Contents

User Manual

User Guide Mobile GoPOD Secure Fueling System 10 Controls Drive, Shelton CT 06484 203.929.8431 www.oemdd.com
ii 10 Controls Drive, Shelton CT 06484 203.929.8431 www.oemdd.com WARNING: It is the purchaser’s responsibility to determine the suitability of any OEM Controls, Inc. product for an intended application and to ensure that it is installed and guarded in accordance with all federal, state, local and private safety and health regulations, codes and standards. We can advise you of the various features that are available, but we believe that our customer’s engineering departments should be qualified experts in their own product field. If the product will be used in a safety critical application, the customer must undertake appropriate testing and evaluation to prevent injury to the ultimate user. Should you have any questions or if any of the above warning is unclear, please contact OEM Controls, Inc. at 10 Controls Drive, Shelton, CT, 06484, FAX: 203.929.3867, TEL: 203.929.8431 WARNING: Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment complies with the FCC RF radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with a minimum distance of 20 centimeters between the radiator and your body. This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement.
iii Contents Section 1 1 Overview of the Mobile GoPOD Secure Fueling System .................... 1 The ST-542 Human Machine Interface (HMI) ....................................................................................................... 3 The Mobile STI GoPOD Assembly ........................................................................................................................ 3 Secure Fuel Bypass Controller STOB-100 ............................................................................................................. 4 Automated Ball Valve ............................................................................................................................................ 5 The Mobile GoPOD Secure Fueling Antennas ....................................................................................................... 6 Mobile GoPOD Complimentary Equipment .......................................................................................................... 7 Section 2 8 Installation Guidelines ........................................................................ 8 Mobile GoPOD Secure Fueling System ................................................................................................................. 8 Mobile GoPOD System Wiring Configuration....................................................................................................... 9 The GoPOD Electrical Connections ..................................................................................................................... 10 The Battery Cable for GoPOD ...................................................................................................................... 11 Power Supply Requirements ................................................................................................................................. 11 Installing the GoPOD CPU ................................................................................................................................. 12 ST-542 Outline Dimensions and Interface Connectors ........................................................................................ 13 Mounting the ST-542 (HMI) ................................................................................................................................ 14 Before starting: .............................................................................................................................................. 14 Installing the GPS Antenna .................................................................................................................................. 15 Electrical Wiring Termination for GPS Antenna .......................................................................................... 15 The Radio Antenna Installation Guidelines .......................................................................................................... 16 Installing the Secure By-Pass Controller .............................................................................................................. 17 Section 3 18 Testing and Troubleshooting ............................................................ 18 HMI (ST-542) Troubleshooting ........................................................................................................................... 18 Quick Check – For the STI GoPOD CPU ............................................................................................................ 18 IF – THEN: Using ST1-CPU LEDs to Diagnose the System ....................................................................... 19 Troubleshooting the Automated Ball Valve ......................................................................................................... 19 Using the Secure Fuel Controller to Troubleshoot ............................................................................................... 20 Section 4 21 Fueling with the HMI Touch Screen ................................................. 21 Selecting or Entering the Equipment Number ............................................................................................... 21 Using a Secure System Without a Service Tracker ....................................................................................... 21 Entering Data in a Secure System With a Service Tracker ........................................................................... 22 Mobile GoPOD Secure Fueling System Block Diagram ...................................................................................... 24 Section 5 25 Index ................................................................................................. 25 Figures Figure 1.- Mobile GoPOD Secure Fueling Modules .............................................................................................. 2 Figure 2.- ST-542(HMI) ......................................................................................................................................... 3 Figure 3.- STI GoPOD Assembly ........................................................................................................................... 4 Figure 4.- Automated Ball Valve ............................................................................................................................ 5
Contents –STIB 22637 Rev. A iv Figure 5.- The Mobile GoPOD Secure Fueling Antennas ...................................................................................... 6 Figure 6.- Installation Guidelines ........................................................................................................................... 8 Figure 7.- Mobile GoPOD System Harness Installation ......................................................................................... 9 Figure 8.- The GoPOD Electrical Installation ...................................................................................................... 10 Figure 9.- Battery Cable Connection Instructions ................................................................................................ 11 Figure 10.- Installing the GoPOD Assembly ........................................................................................................ 12 Figure 11.- ST-542 Outline and Dimensions ........................................................................................................ 13 Figure 12.- GPS Antenna Installation Instructions ............................................................................................... 15 Figure 13.- GoPOD Radio Antenna ST-511 Installation Instructions .................................................................. 16 Figure 14.- Secure Fueling Controller STOB-100 Installation Instructions ......................................................... 17 Figure 15.- Troubleshooting the Secure Fuel Controller and Automated Ball Valve ........................................... 20 Figure 16.- Using the HMI to Fuel ...................................................................................................................... 23 Figure 17.- Mobile GoPOD Secure Fueling System Block Diagram ................................................................... 24 Document Revision History OEM Controls Inc; All rights reserved. Disclaimer and Limitation of Liability Document Number: Revision: B Date of Release: 4/26/2011 About this guide: This guide provides basic instruction on the installation and use of the Mobile GoPOD Secure Fueling System.
| Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| | Section 1 1 Section 1 Overview of the Mobile GoPOD Secure Fueling System This document will serve the user of this equipment as a Manual of Operations and basic troubleshooting guide, thereby allowing for the proper installation and use of the of Mobile GoPOD Secure Fueling System. The Mobile GoPOD system contains a group of stand- alone modules built by OEM Data Delivery, Inc. that have been combined and engineered to provide the user with complete system of mobile product delivery and information gathering. In addition to controlled product dispensing, the system records information on location, equipment being maintained, date/time, type of work and the specific task or reason for service. The heart of system is the STI GoPOD CPU module. It operates wireless and hands-free to collect information passively, via drive-by, within a range of 200 ft. line of site, and transmits data via secure radio link. It is then formatted, downloaded into a web report each night, and made available on a password-protected website. The system will track disposition of equipment and indirect costs and can be configured for data management to generate e-mail alerts for specific events or benchmarks i.e. maintenance is due, warranty is about to expire. There is a Secure Fuel software option, visible to the operator at the ST-542 (HMI) (Human Machine Interface) display. This Password required option is designed for real-time tracking of dispensed product and will prevent theft or unauthorized use of the system. The By-Pass Key Controller module, in this system, is a hardwired option that serves as a failsafe measure in the case of a computer failure, or system miscue by switching to the system to battery power directly and allowing the operator to complete the required transaction. The system was designed to allow for user flexibility at the installation process. Modules that make up the system can be placed in the most convenient location, for the user, due to the flexible interconnecting wiring scheme and design philosophy. The system will allow for additional information gathering pieces or dispensing modules without compromising the basic design. This document provides coverage for the following components: ST-542 (HMI), STI GoPOD Assembly, ST-511 Radio Antenna, ST-560 GPS Antenna, and the Automated Ball Valve.
Contents –STIB 22637 Rev. A 2 Section 1 | Overview and Technical Specifications Figure 1.- Mobile GoPOD Secure Fueling Modules Mobile GoPOD Secure Fueling System Assembly PIN # Description OEM Part Number Qty 1 HUMAN MACHINE INTERFACE (HMI) ST-542 ST-542-103 1 2 GPS ANTENNA WITH CABLE ASSEMBLY ST-560-GPS 1 3 GPRS CELLULAR ANNTENA CBA-3KT 1 4 RADIO ANNTENA ST-511 1 5 GoPOD CPU ASSEMBLY STI 1 6 SECURE BY-PASS CONTROLLER STOB-100 1 7 AUTOMATED BALL VALVE & ACTUATOR DE305H 1 4 5 2 1 3 6 7
Contents –STIB 22637 Rev. A Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls Inc.| Section 1 3 The ST-542 Human Machine Interface (HMI)  Display Type QVGA TFT LCD  Colors 18 bits (256 k)  Resolution 320 x 240  Size (diagonal) 5.87” (4:3)  View Angle (H°, V°) H: 140°, V: 120°  Brightness 320 nits by LED backlight  Touchscreen 4-wire resistive  Contrast Ratio 500 The ST-542-200 is a rugged LCD touch screen display that allows the operator to directly interface, in real time with the operating Serial Pump Tracker GoPOD CPU, through an OEM Data Delivery, Inc. design feature called the Human Machine Interface (HMI). This four (4) line- twenty (20) character LCD display, built by OEM Data Delivery, Inc., is configured by the software and hardware links, to allow the operator to directly input to and view all of the processes’ for the selected pump, as they are happening, in real time. This rugged LCD display must be hardwired to its GoPOD CPU. It should be mounted as recommended, no more than 35 feet from the STI-GoPOD CPU with the harness supplied by OEM Data Delivery, Inc., at a height convenient for the operator. See the Block Diagram at Figure (2) for installation placement recommendations. Figure 2.- ST-542(HMI) The Mobile STI GoPOD Assembly This STI-GoPOD unit is the control center of the Serial Pump Tracker System. The GoPOD assembly houses a ruggedized CPU configured with 512 MB Memory, 1 GB CF, Windows XP Embedded for ease of use. The fan-less housing was designed to be installed in the cab of a lube or fuel truck, low boy truck, mechanics’ truck, or supervisor’s vehicle. It is easily installed under the dash in the cab or on the passenger side firewall or behind any seat. STI GoPOD is equipped with a GPS antenna, and a radio antenna. Information is collected passively, and “hands-free”. GPS coordinates are automatically stamped into the record as hourly data is collected. Information is collected via drive-by, within a range of 300 ft. line of site, and transmitted via that secure radio link. From its external modem data is then downloaded into a web report each night, via cellular WIFI connectivity and made available on a password-protected website. Information easily integrates with any major back office management system and
Contents –STIB 22637 Rev. A 4 Section 1 | Overview and Technical Specifications with dedicated ports on the CPU, for communication, there is never an interruption of equipment operation. At the GoPOD core is an Intel Celeron microprocessor that is equipped with (2x) RS-232/422/485 ports by BIOS selectable, and (4x) USB ports. The 600MHz CPU allows for real time updates when the operator is dispensing or capturing product. Figure 3.- STI GoPOD Assembly Secure Fuel Bypass Controller STOB-100 This key operated electro-mechanical controller option allows the user a second degree of security, when wired between the GoPOD CPU and the Automated Ball Valve. (See Figure 7.- Installation Guidelines) The Secure Fuel Bypass Controller sits in a passive state until the key switch is activated. At that point power is applied directly to the Automated Ball Valve, in this system, and the operator is able to complete the delivery manually. The controller serves as a failsafe measure in the case of a computer failure, or system miscue by switching to the battery power directly and allowing the operator to complete the required transaction. It should not be used as a convenient method of product delivery, from battery to pump, without computer control. This override system will not record the transaction; it only serves to complete the delivery in a timely manner. It allows for convenient testing of the system, when time allows and without the GoPOD CPU, without the stress of delivery schedules. Technical Specifications Environment • Temperature: -40 to +70°C operating Weather Resistance • Sealed and tested for dust and water resistance to IP-65 or greater GoPOD • Power Consumption: Typical wattage when operating 13.5W • Input Voltage: DC 9V ~ 35V Data Format • Comma-Separated Value (CSV), Extensible Markup Language (XML), Open Database Connectivity (ODBC), and others. Connectivity • Cellular • WiFi
Contents –STIB 22637 Rev. A Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls Inc.| Section 1 5 Automated Ball Valve The Automated Ball Valve in the Service Tracker Pump System operates as the computer driven, electronic controller between the product pump and the GoPOD CPU. It operates as a secure fueling station when used in conjunction with the Secure Fuel Bypass Controller. As configured in this system it operates with (+) 12VDC input voltage. This actuator can be mounted in any direction without consequence, however, determine that the actuator, open or closed, matches the position of the equipment to which it is mounted. Use the manual override to change the position, if necessary. Note: Wiring power to terminals 1 & 2 will cause the camshaft to rotate counter -clockwise. Rotating counter-clockwise opens the valve. Wiring power to terminals 1 & 3 will cause the camshaft to rotate clockwise. Rotating clockwise closes the valve. 1. Install the ball valve and actuator to a valve bracket or damper, ensuring that the base of the actuator is flush with the top plate. 2. Insert bolts but do not tighten. 3. Use the manual override to move the stem of the valve or damper slightly to correct for side thrust or misalignment. 4. Manually place the valve to either full travel positions and tighten the bolts using a cross pattern scheme and equally draw the bolts down to finish. Figure 4.- Automated Ball Valve Modulating Controls Accepts 0 - 5 VDC , or 0 - 12 VDC control signal to position the valve at various degrees of open/close. Fail-Safe Backup Battery backup system that allows normal operation of actuator with 120 Volt AC but converts battery DC to AC upon incoming AC power failure. Spring-Return Fail-Safe Fail-safe spring back-up system within the electric actuator takes over upon loss of power. MANUAL OVERRIDE
Contents –STIB 22637 Rev. A 6 Section 1 | Overview and Technical Specifications The Mobile GoPOD Secure Fueling Antennas Figure 5.- The Mobile GoPOD Secure Fueling Antennas
Contents –STIB 22637 Rev. A Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls Inc.| Section 1 7 Mobile GoPOD Complimentary Equipment 1. ST-550 Radio Service Tracker: In the operation mode, an ST-550 mounted on the dash board or on the top of a vehicle, has been logging in CMH (Cumulative Machine Hours), and compiling maintenance service times on the vehicle. Each maintenance procedure is assigned a Service Tracker number (up to seven different procedures can be tracked). The maintenance issues are displayed as service alerts. Each service alert has a designated identifier number (one through seven) that display on the “Power Box” of the ST-550. The number indicates that a particular maintenance procedure should be completed. When the service alert is satisfied the counter is reset with any supporting PDA (Personal Data Assistant). Retrieving the ST-550 data, such as the profile, service alerts, work/ idle/ run/ count/duration logs is accomplished with a supporting PDA. 2. ST-900 Service Tracker: is designed with GPS and cellular communications. It tracks equipment activity at utility construction sites and during service calls, so that PTO (Power Take-Off) credits can be obtained quickly for fuel used at the work site. The unit generates a range of customized data logs, including machine hours, location and idling vs. work. It also generates dump-load logs, seat belt logs, travel logs. It fully integrates with a fuel management system, and can be used for allocating equipment between jobsites and for job estimating. It is designed to communicate from remote areas to a drive by, line of sight cellular device or by using the OEM Data Delivery manufactured mobile CPU called GoPOD. 3. ST-570 Radio Frequency Identification Device (RFID) is mounted to a specific piece of equipment and is profiled with an equipment serial number that identifies that equipment piece. Transmitting data is accomplished via radio to a supporting PDA, or by using the OEM Data Delivery manufactured mobile CPU called GoPOD. It only requires the operator push the red transmit button. 4. Radio Pump Tracker: Is designed to work in conjunction with a supporting pulse flow-meter to tally fuel or consumables. It is profiled to identify and display the equipment piece to which it is mounted- with its location, specific equipment serial number and the amount of consumable dispensed to it. After the transaction is complete, data is retrieved and stored at the OEM Data Delivery mobile CPU called GoPOD , or to a hand-held supporting PDA device that captures equipment hours, mileage and gallons dispensed. 2 1 3 4
8 Section 2 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| Section 2 Installation Guidelines Mobile GoPOD Secure Fueling System Figure 6.- Installation Guidelines GPS ANTENNA INTERCONNECTION HARNESS TO THE GOPOD MODULE INSTALL THE STI GOPOD UNDER THE DASH IN THE CAB, OR ON THE PASSENGER SIDE FIREWALL, OR BE-HIND THE SEAT. INSTALL THE ST-542 TOUCH SCREEN DISPLAY ON THE BACK OF THE TRUCK WITHIN 35 FEET OF THE GOPOD. INSTALL THE GO POD RADIO ANTENNA MOUNT THE RAVEN X ANTENNA ON EITHER OF THE CAB SIDE MIRRORS INSTALL THE SECURE BY-PASS CONTROLLER ON ANY FLAT CONVENIENT LOCATION,THAT IS WITHIN 30 FEET OF THE FUEL DISPENSER ON THE TRUCK. WIRING TO BATTERY (+) (-) VOLTAGE DETECTOR AUTOMATED BALL VALVE AUTOMATED BALL VALVE TO PRODUCT PUMP
Contents –STIB 22637 Rev. A | Installation Guidelines| Section 2 9 Mobile GoPOD System Wiring Configuration Figure 7.- Mobile GoPOD System Harness Installation GOPOD RADIO ANTENNA ST-511 2’ MOLDED HARNESS STOB-100 SECURE BY-PASS CONTROLLER WITH E-STOP GPS ANTENNA ST-560-200 HMI DISPLAY AUTOMATED BALL VALVE 30’ MAX HARNESS LENGTH 35’ MAX LENGTH (SUPPLIED) SERVICE TRACKER/ PUMP TRACKER RS-232 CONNECTION 30’ MAX LENGTH (SUPPLIED) BATTERY CABLE (5) AMP SUPPLY (SUPPLIED) +12VDC SYSTEM POWER WIRING, (SUPPLIED ) 30’ MAX HARNESS LENGTH WIFI ANTENNA AND WIRING 30’ MAX LENGTH (SUPPLIED)
Contents –STIB 22637 Rev. A 10 Section 2 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| The GoPOD Electrical Connections Figure 8.- The GoPOD Electrical Installation ST-511-200 SIGNAL NAME -RADIO ANTENNA COM1 AT GOPOD RED +12VDC 1 BLUE TO RX1 2 WHITE FROM TXD 3 BLACK -12VDC 4 STI CPU SIGNAL NAME –RS-232 WITH I/O COM 2 AT GOPOD RED +12VDC 1 J2-33 RS 232 TXO 2 J2-22 RS 232 RXO 3 BLACK -12VDC 4 ST-560-200 SIGNAL NAME – GPS ANTENNA COM3 AT GOPOD BROWN +12VDC 1 BLUE TO GPS RX1 2 WHITE FROM GPS TXD 3 BLACK -12VDC 4 ST-542Q HMI DISPLAY COM4 AT GOPOD BROWN +12VDC 1 BLUE RS232 TXO 2 WHITE RS232 RXO 3 BLACK -12VDC 4 ST-511-200 GoPOD Radio Antenna RS-232 Interface with ST11-CPU ST-560-200 GPS Antenna ST-542-200 HMI Display Secure Pump Option splice connectors. See figure 13. COM 1 COM 2 COM 3 COM 4 Modem /WIFI Antenna +12VDC Power Battery cable
Contents –STIB 22637 Rev. A | Installation Guidelines| Section 2 11 The Battery Cable for GoPOD 1. Connect the battery harness ring terminal “RED” wire to the battery positive 12VDC or 24VDC post. 2. Connect the battery harness ring terminal “BLACK” wire to the ground source on the battery. 3. Run the battery cable back to the GoPOD enclosure and connect it to the power connector installed on the perforated cover. 4. Put a 15 Amp Fuse in the fuse holder and close the cap. A (Green) LED should be visible on the GoPOD CPU Figure 9.- Battery Cable Connection Instructions Power Supply Requirements Typical Supply Voltage: 8-15 VDC The OCI Modules can withstand the following conditions without any permanent damage;  Reverse Polarity: The V-Bat and Ground terminals can be INTERCHANGED  Short Circuit: Any Input or Output from the system can be shorted to V-Bat or Ground. GoPOD Power Connector
Contents –STIB 22637 Rev. A 12 Section 2 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| Installing the GoPOD CPU Figure 10.- Installing the GoPOD Assembly Note: For proper ventilation of system heat, the GoPOD module must be mounted in a place where it’s perforated cover is open to air movement. Recommend: Bulkhead mounting that will support at least 15 LBS. 8.50 10.50 10.0 12.0 Slide the Mounting Plate’s keyholes onto the pre-existing mounting hardware and tighten bolts Bulkhead, Flat washer and ¼-20 Nut. Mounting Plate, Flat washer, Lock washer, and ¼-20 Bolt. Mount with this End Up 3.58 Secure the GoPOD module as shown using the mounting plate’s pre-drilled keyholes as a template to position the mounting hardware properly.
Contents –STIB 22637 Rev. A | Installation Guidelines| Section 2 13 ST-542 Outline Dimensions and Interface Connectors Figure 11.- ST-542 Outline and Dimensions Note: All dimensions are in inches. ST-542-200 MECHANICAL SPECIFICATIONS ITEM DESCRIPTION MATERIAL ZINC IP67 MOUNTING HARDWARE 8-32 X LG (RECOMMENDED) VIEWING ANGLE H: 140°, V: 120° DISPLAY TYPE QVGA TFT LCD ENVIRONMENTAL TEMPERATURE -40°C +70°C OPERATING VOLTAGE 8 VDC to 24 VDC ALIGN MATING CONNECTOR KEYWAYS, BEFORE STARTING TO MATE CONNECTORS. Mounting Plate Dimensions Mount the ST-542 with four (4) 8-32 Pan Head or Round Head screws to a flat surface, usually on the back of a fuel truck with easy access for the equipment operator, using the mounting holes provided.
Contents –STIB 22637 Rev. A 14 Section 2 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| Mounting the ST-542 (HMI) Before starting: Record the ST-542 SERIAL NUMBER, located on the side of the HMI and the MACHINE NUMBER that you are installing the equipment on, for reference purposes. This information must be reported back to OEM Data Delivery for tracking purposes. 1. Turn off the engine and the master switch. 2. Visualize how to run the wires from the battery box and the engine to the GoPOD CPU. 3. Mount the ST-542 on a flat surface convenient to the operator’s reach and visibility. 4. If the ST-542 is mounted outside the vehicle, drill a hole (3) three inches below the ST-542, and 1/2inch in diameter. 5. Pull the pigtail harness through this hole and route the cable to the GoPOD CPU. This will protect the harness from the elements and road hazards. 6. Plug the connector (J1) from the pigtail on the ST-542 and push the cable through the 1/2 inch drilled hole. 7. Secure the harness using cable-ties, leaving adequate slack in the wires. Mobile radios and high power AC equipment or transmission lines are potential sources of interference. If interference is a problem a shielded cable which is connected to chassis ground is advised. Contact OEM Controls for further assistance.  Installing the ST-542 harness: Be aware of moving parts, provide adequate slack for wires around moving parts. Do not have unsecured or hanging wires.  When mounting the ST-542 (HMI), beware of compartments that open; Example: Where a radiator assembly lifts up, as in a bob cat or other skid steers. Choosing a secure location will prevent damaging the ST-542.  Before drilling check for obstructions and sensitive equipment (e.g. radiators, hydraulic tanks, fuse boxes etc.). Recommended: Plug the drilled hole with a recognized caulking compound (such as RTV) after routing the ST-542 harness through the opening.
Contents –STIB 22637 Rev. A | Installation Guidelines| Section 2 15 Installing the GPS Antenna Mount the Garmin GPS antenna on the roof, or highest flat non-operating surface of the equipment. Be sure the antenna is in a horizontal position, with an unobstructed view to the atmosphere. Electrical Wiring Termination for GPS Antenna Figure 12.- GPS Antenna Installation Instructions GPS ANTENNA 30’ HARNESS SIGNAL NAME GOPOD (M1) P-19779 RED +12VDC COM4 -1 GREEN TO GPS RX1 COM4 -2 WHITE FROM GPS TXD COM4 -3 BLACK -12VDC COM4 -4 NOTE: Align keyways of mating connectors before securing contacts
Contents –STIB 22637 Rev. A 16 Section 2 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| The Radio Antenna Installation Guidelines Figure 13.- GoPOD Radio Antenna ST-511 Installation Instructions
Contents –STIB 22637 Rev. A | Installation Guidelines| Section 2 17 Installing the Secure By-Pass Controller Turn off the engine and the master switch. Figure 14.- Secure Fueling Controller STOB-100 Installation Instructions For technical problems with the installation, contact OEM Data Delivery, and our support team will respond with advice and support. 10 Controls Drive, Shelton CT 06484 203.929.8431 www.oemdd.com J1 SIGNAL NAME BALL VALVE ACTUATOR BLACK HOT 1 WHITE NEUTRAL 2 GROUND GROUND 3 J2 GOPOD ASSEMBLY SPLICES WHITE +12VDC 1-WHITE WIRE SPLICE GREEN DIGITAL INPUT 2-GREEN WIRE SPLICE RED DIGITAL OUTPUT 3-RED WIRE SPLICE BLACK GROUND 4-BLACK WIRE SPLICE 1. Visualize how to run the wires from the battery box and the engine to the GoPOD CPU. (See figure 8.- for the suggested wiring scheme.) 2. Mount the Secure By-Pass Controller on a flat surface convenient to the operator’s reach and visibility. 3. If the By-Pass Controller is mounted outside the vehicle, drill a hole (3) three inches below the Controller, and 15/16 inch in diameter. 4. Pull the pigtail harnesses through this hole and route the bottom cable (J2) to the GoPOD CPU assembly and the top (J1) to the Ball Valve Actuator. This will protect the harnesses from the elements and road hazards. 5. Recommended: Plug the drilled hole with a recognized caulking compound (such as RTV) after routing the (2) harnesses through the opening. 6. Secure each harness using cable ties, leaving adequate slack in the wires.
18 Section 3 | | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| Section 3 Testing and Troubleshooting HMI (ST-582) Troubleshooting Once the installation is complete, either stationary or mobile, and the GoPOD CPU has power, the ST-542 (HMI) screen should have the entry screen visible with commands for the operator. If the system is configured as a secure system then a log-on screen will be visible, if it is non-secure then a Miscellaneous entry screen will be visible. If after the system is powered and the (HMI) remains blank, then a few possible causes need to be checked: 1. Check the HMI connection to the GoPOD assembly at COM 4, making sure the connector has been seated correctly and fastened securely. (See Figure 9. - for installation references) 2. Check for broken or crimped wires in the 35’ interconnection harness to the GoPOD CPU. 3. Ensure that software as shipped is correct, check for version number and contact OEM Data Delivery, Inc. for support. 4. Using a voltmeter check for full voltage (+12VDC) to the input side of the CoPOD CPU. The HMI is powered from the GoPOD. Quick Check – For the STI GoPOD CPU The GoPOD CPU is shown without the GoPOD shield assembly. The CPU side shown in the photo is visible and accessible through the opening in the GoPOD perforated cover. To see how the CPU is mounted in the GoPOD perforated cover: See Figure 3.- in the Overview Section 1. If a wiring problem is suspected refer to the GoPOD Wiring Installation, Section (2) for wiring information on this unit. Refer to Figures (7) and (8).
Contents –STIB 22637 Rev. A | Testing and Troubleshooting| Section 3 19 IF – THEN: Using ST1-CPU LEDs to Diagnose the System  IF - A (Green) LED is visible, marked PWR (See photo above for location). THEN - Good voltage and ground connections are in place.  IF – No (Green) LED . THEN – Look for incorrect wiring from power source or improper input voltage source. Voltage must be at least 3VDC at the CPU power. Also check Power Switch for ON/OFF status (See photo above for location.  IF - A flashing (Red) LED is visible marked HDD (See photo above for location). THEN – Hard disk and compact flash disc status is updating.  IF - No (Red) LED Check for secure connections at COM 1, 2,3 and 4 on the GoPOD perforated cover mounting plate. Troubleshooting the Automated Ball Valve PROBLEM CAUSE/ CORRECTIVE ACTION BALL VALVE STOPS WORKING INTERRUPTED POWER. CHECK FOR BROKEN OR LOOSE WIRES. BLOWN FUSES OR TRIPPED BREAKER. CHECK FOR CORRECT VOLTAGE. ACTUATOR TO VALVE MISALIGNMENT. DAMAGED HOUSING OR MOUNTING HARDWARE. WORN, LOOSE OR SHIFTED PARTS DUE TO SHOCK, VIBRATION, ETC. BALL VALVE IS OVERHEATING LOW VOLTAGE; MEASURE LINE VOLTAGE TO INSURE THAT ACTUATOR IS RECEIVING FULL RATED VOLTAGE. AMBIENT TEMPERATURE IS TOO HIGH AND HEAT IS BEING CONDUCTED THROUGH MOUNTING HARDWARE. MOTOR STALL. CHECK FOR FOREIGN OBSTRUCTION/ INCREASED LOAD DUE TO LINE PRESSURE. LOW TORQUE OUTPUT LOW VOLTAGE OR CURRENT, OVERHEATING INCORRECT OPERATION INCORRECT DURATION CYCLE, CHECK GOPOD SOFTWARE DISPLAY TIME, INCORRECT CAM ADJUSTMENT. Red LED Green LED Power On/Off Switch Power Connector
Contents –STIB 22637 Rev. A 20 Section 3 | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| Using the Secure Fuel Controller to Troubleshoot Use this controller with the key inserted and Bypass selected to check the system without computer control. Using the key select will directly link the battery power to the Ball Valve Actuator. If the Valve opens then the GoPOD CPU or the wiring from it is the problem. WARNING: To perform this test, remove any product from the system piping, and disconnect the ball valve from the product pump. This feature will also allow the actuator to be set if the operation of the valve is incorrect without use of the GoPOD CPU. This actuator can be mounted in any direction without consequence, however, determine that the actuator, open or closed, matches the position of the equipment to which it is mounted. Use the manual override to change the position, if necessary. Note: Wiring power to terminals 1 & 2 will cause the camshaft to rotate counter -clockwise. Rotating counter-clockwise opens the valve. Wiring power to terminals 1 & 3 will cause the camshaft to rotate clockwise. Rotating clockwise closes the valve. Figure 15.- Troubleshooting the Secure Fuel Controller and Automated Ball Valve A CRESCENT WRENCH WILL BE NEEDED TO CHANGE THE FACTORY SETTING ON THE MANUAL OVERRIDE.
| Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| | Section 4 21 Section 4 Fueling with the HMI Touch Screen Selecting or Entering the Equipment Number If the equipment being serviced is not equipped with any of the complimentary Service Trackers that communicate on command to the GoPOD CPU, then servicing information may be entered manually via the ST-542 (HMI) display. This unit (ST-542) operates as an adjunct to the GoPOD CPU and servicing information can be entered in the following manner. Using a Secure System Without a Service Tracker If the system is configured as a secure system, the user will need to enter a password to unlock it. When power is applied to the HMI display, the secure Main Menu screen will launch. Step 1. Tap UNLOCK to enter a password at the sign in screen. Step 2. Enter the assigned PIN number using the 1-2-3 screen and tap OK when complete. Step 3. Fuel the equipment. Once the password is accepted the Fueling screen will launch with the Equipment List selection box.
Contents –STIB 22637 Rev. A 22 Section 4 |Using the HMI| When the product is successfully dispensed, tap the Equipment List Box. Step 4. Enter the Equipment Number using the 123 keypad on the display and tap OK, or if previously entered select the Equipment Number from the list by tapping on it. The Equipment Number will be automatically entered into the S/N field. Step 5. Enter the Cumulative Machine Hours (CMH) in the Hours field (optional) and tap OK. Equipment Number and servicing data will be displayed. This real time data will be requested by GoPOD and transferred via the GoPOD radio antenna RT-511, to the home base as a permanent record of this transaction. Entering Data in a Secure System With a Service Tracker Start with Steps 1. and 2. To unlock the GoPOD, Then fuel the equipment piece. Step 6. When the Summary screen launches tap OK Tap OK The final part to the transaction will display the Equip/SN and the amount of product pumped at the bottom of the screen. When transaction is complete, tap LOGOUT. If there is no input to the HMI screen within (5) minutes the system will timeout and return to the UNLOCK screen.
Contents –STIB 22637 Rev. A | Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc|| Section 4 23 When the product is successfully dispensed the Equipment Number and servicing data will be displayed. This real time data will be requested by GoPOD and transferred via the GoPOD radio antenna RT-511, to Mobile mounted GoPOD. This data will be downloaded via the WIFI connectivity to the home base as a permanent record of this transaction. It is then formatted, downloaded into a web report each night. Information easily integrates with any major back office management system and with dedicated ports on the CPU, for communication, there is never an interruption of equipment operation. The operator is now free to select a new Equipment Number. Figure 16.- Using the HMI to Fuel Press and hold the “WAKE” button on the Service Tracker until the F appears in the POWER window. Tap “Fuel Complete” when the product is dispensed. The Equip/SN and gallons pumped will display at the bottom of the screen.
Contents –STIB 22637 Rev. A 24 Section 4 |Using the HMI| Mobile GoPOD Secure Fueling System Block Diagram Figure 17.- Mobile GoPOD Secure Fueling System Block Diagram GPS ANTENNA INTERNET ANTENNA GOPOD RADIO ANTENNA ST11 GoPOD CPU Assembly Auxiliary Service Tracker Modules ST-550 ST-900 ST570 Pump Tracker SECURE BY- PASS CONTROLLER AUTOMATED BALL VALVE PRODUCT PUMP ST-542 HMI Interface
| Confidential and Proprietary, Property of OEM Data Delivery a Division of OEM Controls, Inc| | Section 5 25 Section 5 Index A Automated Ball Valve, 6 B Battery cable, 12 C Cumulative Machine Hours, 8 E Electrical wiring scheme, 11 Entering data, 23 Equipment numbers, 25 G GoPOD mechanical specifications, 13 GoPOD Radio antenna mechanical installation, 18 GPS Mechanical Installation, 17 I Installation Guidelines, 10 O Overview of the the Serial Pump Tracker, 1 R Radio Pump Tracker, 8 Reverse polarity, 13 S Secure Fuel By-Pass Controller, 4 Serial Pump antennas, 7 Short Circuit, 13 ST-542 (HMI), 3 ST-550 Service Tracker, 8 ST-900 Service Tracker, 8 STI-GoPOD, 3 STI-GoPOD technical specifications, 4 Supply Voltage, 13 T Troubleshooting, 20 U Unlocking (HMI), 24 W WIFI, 4
Contents –STIB 22637 Rev. A 26 Section 5 |Using the HMI| If you have any questions regarding this product, we will be happy to assist you. Please contact us at: OEM Controls, Inc. 10 Controls Drive Shelton, CT 06484 (203) 929-8431 Fax: (203) 929-3867 www.oemdd.com

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