Card Network Configuration Guide

# Compliance Protocol: Drop Tube & Spill Bucket Verification

**Category:** Compliance / Tank Hardware
**Source:** Field Note WO#56805 + Regulatory Guidelines (OCC/OPW/Franklin)
**Last Updated:** 11/27/2025

## 1. The Goal: Prevent Overfills (95% Rule)
State regulations (and manufacturers like OPW/Franklin Fueling) require that drop tubes shut off fuel flow before the tank exceeds 95% capacity.

### The "Field Tech" Math (Approximation)
*Note: Always verify with specific State Testing Forms and Tank Charts when available. The below is a field estimation method.*

1.  **Target:** 95% of Tank Volume.
2.  **Void Space Calculation:** We need to ensure the drop tube valve sits low enough to leave space for that last 5% of fuel.
3.  **Verification:** Measure the riser. Calculate the "Void" (Tank Top minus 95% liquid level). The drop tube shutoff valve must be positioned to trigger *before* the liquid hits that void.

### Pass/Fail Criteria
*   **PASS:** Drop tube shutoff valve is positioned *below* the calculated 95% liquid level height.
*   **FAIL:** Shutoff valve is too high, risking overfill.

## 2. Spill Bucket Integrity Test
**Method:** Hydrostatic Test (Water Level Monitoring)
*Standard regulatory requirement for most states.*

*   **D:** Depth of bucket
*   **W:** Width of bucket
*   **WL:** Water Level (Initial)

### Procedure
1.  Fill bucket to marked level (WL).
2.  Wait 1 hour (standard test duration).
3.  **PASS:** No change in WL.
4.  **FAIL:** Any decrease in WL indicates a leak (or loose drain valve).

## 3. Veeder-Root (VR) Tank Setup Verification
Ensure the tank monitor programming matches the physical tank dimensions.

*   **Critical Check:** Does the VR's "95% Volume" setting match the actual tank chart for that inch level?
*   **Common Error:** Using a generic 95% calculation instead of the manufacturer's specific tank chart (which accounts for tank curvature).

## 4. Regulatory Reference
*   **OCC (Oklahoma Corporation Commission):** Requires annual/tri-annual testing depending on installation date.
*   **Forms:** Use official State Testing Forms for final validation.


Compliance Protocol: Drop Tube & Spill Bucket Verification

# DEF Winterization Field Reference Guide

**Category:** Equipment Maintenance / Seasonal Operations
**Region:** All (Climate-Dependent)
**Last Updated:** 12/25/2024
**Cross-Reference:** [Error Codes Reference](./error-codes-diagnostic-reference.md), [STP Troubleshooting](./stp-troubleshooting-guide.md)

---

## Quick Reference

**DEF Freeze Point:** 12°F (-11°C)
**Expansion When Frozen:** ~7%
**Heat-ON Setpoint:** 35°F (2°C)
**Heat-OFF Setpoint:** 45°F (7°C)
**Max Winter Tank Fill:** 70-75%

**Gilbarco Technical Support:** 1-336-547-5000
**Benecor Support:** 1-844-BENECOR (1-844-236-3267)

---

## 1. DEF Chemistry Fundamentals

The **32.5% urea concentration** represents the eutectic point - both urea and water freeze simultaneously at the lowest possible temperature. Any concentration above or below this percentage has a *higher* freeze point.

**CRITICAL:** Additives are strictly prohibited. Anti-freeze or anti-gel products alter concentration and contaminate the fluid.

| Property | Value | Field Implication |
|----------|-------|-------------------|
| Freeze point | 12°F (-11°C) | Heat systems must maintain above this |
| Expansion rate | ~7% when frozen | Never fill tanks above 90% capacity |
| Specific gravity | 1.09 at 68°F | Slightly heavier than water |
| Density | 9.07-9.12 lbs/gallon | Important for tank weight calculations |
| pH range | 7.0-8.5 | Mildly corrosive to many metals |

### Shelf Life vs Temperature

| Storage Temp | Shelf Life |
|--------------|------------|
| ≤60°F | 36 months |
| 77°F | 18 months |
| 86°F | 12 months |
| 95°F | 6 months |

**Ideal maintenance temperature: 40-50°F** - warm enough to prevent freezing, cool enough to maximize shelf life.

---

## 2. Heat Trace Systems

Self-regulating heat trace cable is preferred over constant-wattage - it automatically adjusts output based on temperature and can be overlapped at valves and fittings without creating hot spots.

### Wattage Requirements by Climate

| Climate Condition | Required Wattage | Application |
|-------------------|------------------|-------------|
| Mild (above 20°F typical) | 3-5 W/ft | Basic freeze protection |
| Moderate (0-20°F) | 5-8 W/ft | Standard DEF installations |
| Severe (below 0°F) | 10-15 W/ft | Northern plains, mountain regions |

### Recommended Products

| Product | Specs | Application |
|---------|-------|-------------|
| Chromalox SRM/E 388210 | 10 W/ft, 120V, self-regulating | Most DEF applications |
| Chromalox SRM/E 388244 | 10 W/ft, 240V | 240V systems |
| Raychem WinterGard 196811-000 | 6 W/ft, 120V, max 200 ft | Lighter duty |
| Chromalox End Seal Kit 383574 | 5 per kit | Weatherproof terminations |
| Chromalox Splice/Tee Kit 383558 | - | Junction points and repairs |
| Chromalox Line-sensing Thermostat 389600 | 40°F preset, 22A, -40°F to 160°F | Temperature control |

### Installation Fundamentals

- Apply heat trace along pipe bottom (6 o'clock position for horizontal runs)
- Secure with aluminum tape every 12 inches
- Provide 2-3 feet of extra cable looped around valves, pumps, and fittings
- Install insulation OVER the heat trace - minimum 1" thickness (1.5-2" for severe cold)
- Always install weatherproof jacket over insulation for outdoor applications

---

## 3. Controller Programming

| Parameter | Setpoint | Purpose |
|-----------|----------|---------|
| Heat-ON activation | 35°F (2°C) | Maintains margin above freeze |
| Heat-OFF deactivation | 45°F (7°C) | Prevents excessive heating |
| Differential/deadband | 5-10°F | Prevents short cycling |
| Low temperature alarm | 20°F (-7°C) | Critical freeze risk warning |
| High temperature alarm | 65-85°F (18-30°C) | Degradation risk warning |

**Sensors:** Use PT100 RTDs (Resistance Temperature Detectors) for accuracy - ±0.15°C to ±0.3°C depending on class. Ensure sensors are attached to pipe surfaces, not suspended in air.

---

## 4. Material Compatibility

ISO 22241 specifies extremely tight contamination limits - as little as **0.2 ppm** of copper, zinc, or chromium can render DEF unusable and damage SCR catalysts.

**One tablespoon of table salt contaminates approximately 3 gallons of DEF.**

| Approved Materials | NEVER Use |
|-------------------|-----------|
| 316/304 Stainless Steel | Copper or brass |
| HDPE Polyethylene | Zinc (galvanized) |
| Polypropylene | Aluminum |
| PTFE (Teflon) | Carbon steel |
| Viton (FKM) elastomers | Chrome-plated fittings |
| EPDM rubber | Nickel-plated fittings |

**316 stainless steel** is preferred for all wetted metal components (contains molybdenum for superior corrosion resistance).

---

## 5. Pre-Winter Preparation Checklist

Complete before the first freeze of the season (September-October).

### System-Wide Inspection

- [ ] Inspect dispenser cabinet for damage, bent sheathing, missing door magnets
- [ ] Check all door seals and gaskets for proper closure
- [ ] Verify insulation is intact throughout system
- [ ] Clean crystallized DEF deposits from fittings and nozzle boots
- [ ] Inspect for leaks at all connections
- [ ] Verify tank level is 50-70% (allows for 7% freeze expansion)

### Heat Trace Testing Protocol

1. **De-energize and lock out** the circuit
2. **Continuity test**: Measure resistance between bus wires - should show 0.1-1.0 ohms typical
3. **Megger test**: Apply 2500 VDC between bus wires and ground braid - minimum **20 megohms** acceptable, **2000+ megohms** ideal
4. **Re-energize and measure amp draw**: Compare to specifications (cold startup draws 2-3x normal for self-regulating cable)
5. **Temperature verification**: Use contact thermometer or thermal imaging to verify pipe surface above 32°F throughout

### Electrical Verification

- [ ] Verify breaker status and sizing (account for inrush current)
- [ ] Check all power connections for corrosion or damage
- [ ] Verify ground fault protection is functional
- [ ] Confirm controller displays correct readings
- [ ] Test high/low temperature alarms

---

## 6. Filter Maintenance

DEF filters require **more frequent replacement** than fuel filters - SCR systems are extremely sensitive to particulate contamination.

### Specifications

| Parameter | Recommendation |
|-----------|----------------|
| Micron rating | 5 micron (absolute) - optimal balance |
| Alternative | 10 micron for longer intervals |
| Housing material | 316L stainless steel required |
| Efficiency | Beta 5000 (99.98% retention) |

### Replacement Indicators

- Decreased flow rate at dispenser (primary indicator)
- Longer customer fill times
- Visible crystallization on filter housing
- High differential pressure across filter
- Dispenser fault codes related to flow

### Recommended Products

- **PetroClear DEF-E5**: 5 micron absolute, 316L stainless, 7 GPM max
- **PetroClear DEF-E10**: 10 micron version
- **Cim-Tek D.E.F.-TEK**: Designed for DEF particulate and crystal removal

---

## 7. Safe Thawing Procedures

### Prohibited Heat Sources

- Open flame (propane torch, blowtorch)
- Kerosene or propane heaters directed at equipment
- Hair dryers on high heat settings
- Any direct high-heat application to plastic components
- **Additives of any kind** (destroys DEF permanently)

### Approved Thawing Methods (In Order of Preference)

1. **Built-in heating system**: Repair and activate if possible
2. **Cabinet/enclosure heating**: Raise ambient to 50-60°F
3. **Heat blankets/wraps**: Low wattage, thermostatically controlled
4. **Portable space heater**: Heat the area, not direct on equipment
5. **Hot towels**: Wrap and replace as they cool

### Expected Thaw Times

| Component | Thaw Time | Notes |
|-----------|-----------|-------|
| Nozzle/hose | 15-30 minutes | Usually first to thaw |
| Small lines (≤1") | 30-60 minutes | With proper heat application |
| Large lines (>1") | 1-3 hours | Depends on frozen volume |
| Pump assembly | 1-2 hours | Inspect carefully after |
| DEF tank/tote | 4-24+ hours | Do not rush |

### Post-Thaw Inspection

- [ ] Full flow restored at all points
- [ ] Visual inspection complete - no cracks, bulges, or leaks
- [ ] All connections verified tight
- [ ] No frost remaining on components
- [ ] Operating temperature reached throughout
- [ ] Heat trace system verified operational
- [ ] Dispense small test quantity to verify quality

---

## 8. Troubleshooting Winterization Failures

### Diagnostic Flowchart - Non-Flowing DEF Dispenser

```
System Not Dispensing
        │
        ├─► Check power at breaker
        │   └─► Tripped? → Check for ground fault, reset and monitor
        │
        ├─► Verify heat trace amperage
        │   └─► Zero amps? → Open circuit - locate break with megger
        │   └─► Low amps? → Damaged sections - thermal scan for cold spots
        │
        ├─► Check thermostat operation
        │   └─► Not calling for heat? → Verify setpoints, sensor location
        │   └─► Stuck on? → Replace controller or relay
        │
        └─► Inspect insulation
            └─► Wet or compressed? → Replace immediately (loses R-value)
```

### Heat Trace Failure Modes

| Symptom | Likely Cause | Solution |
|---------|--------------|----------|
| Breaker trips immediately | Short to ground | Megger test to locate, replace damaged section |
| Breaker trips at cold startup | Inrush exceeds rating | Verify circuit length, consider slow-trip breaker |
| No heat output | Open circuit | Continuity test, replace failed section |
| Uneven heating | Localized damage | Thermal scan, repair or replace affected area |
| Continuous operation | Controller/sensor failure | Replace thermostat, verify sensor attachment |

### Pump Damage Assessment After Freeze

Before attempting operation:
- Check for visible cracks in housing
- Look for fluid leaking from shaft seal
- Verify motor rotation (may be seized)
- Test flow rate against specification (>80% of rated = pass)
- Test pressure output against specification
- Listen for grinding, cavitation, or unusual noise

### Repair vs Replace Decision

**Replace when:**
- Repair cost exceeds 50-60% of new component cost
- Multiple damage points exist
- Megger readings fall below 1 megohm
- Safety-critical components damaged (pressure vessels, relief valves, emergency shutoffs)

**Repair when:**
- Damage is localized
- Parts are readily available
- Component is under 5-7 years old

---

## 9. Manufacturer-Specific Features

### Gilbarco Veeder-Root

**Encore DEF Dispensers:**
- Thermostat-controlled heated cabinets rated to **-22°F (-30°C)**
- Heated nozzle boots
- DEF recirculation systems (circulate product continuously)
- Red Jacket CoreDEF submersible pump (3/4 HP and 2 HP options)
- Integrates with TLS-450PLUS DEF Recirculation Software Feature

**Key advantage:** 4-year corrosion warranty - best in industry

**Support:** 1-336-547-5000 | gilbarco.com

### Wayne Fueling Systems (Dover)

**Ovation Series Model Designations:**
- **Ovation HD**: Diesel + Cold Climate DEF (insulated and heated)
- **Ovation HW**: Diesel + Warm Climate DEF (unheated - for temps always above 12°F)
- **Vista DEF**: Standalone dispenser with optional heater

**Patented Feature:** Self-closing nozzle and hose doors automatically close when not in use to prevent freezing.

**Model Codes:** "3" = cold-climate DEF module on right of A side; "4" = left side

### Gasboy (Gilbarco Veeder-Root)

**AtlasX DEF Dispensers:**
- **Cold Weather Models (8862G/9862G)**: Thermostatically controlled heated cabinet, internal hose storage, enclosed heated nozzle hang-up, rated to **-30°C (-22°F)**
- Part numbers: 9860KX-Z, 9862KX-Z, 8862KX-Z for cold weather

### OPW DEF Components

- **21Gu DEF Nozzle**: 19mm spout per ISO 22241, 50 PSI max, NEWGARD hand insulator
- **66SB Swivel Breakaway**: 360° rotation, 175-330 lb separation force

**Installation Note:** Use gas/oil-approved non-hardening thread sealant only - never PTFE tape on DEF connections. Torque to 25-30 ft-lbs.

**DEF Hose Part Numbers:**
- **21GU-H17G**: 17.4 ft for Gilbarco/Wayne dispensers
- **21GU-H11**: 11 ft for Bennett/Gasboy dispensers

### Benecor DEF Systems

- **KDH-100-120V (Standard)**: Freeze protection to **0°F (-17°C)**, 120V strip heater, insulated tank enclosure
- **KDH-100-24VX (Extreme)**: Freeze protection to **-40°F (-40°C)**, 24V enhanced heating

Systems available from 20 gallons to 20,000 gallons with in-house insulation foaming.

**Support:** 1-844-BENECOR (1-844-236-3267) | benecor.com

---

## 10. Regulatory Compliance

### ISO 22241 Requirements

| Parameter | Specification |
|-----------|---------------|
| Urea concentration | 32.5% ±0.7% (31.8-33.2% acceptable) |
| Maximum metals contamination | 0.2-0.5 ppm depending on element |

**Maximum Contamination Limits:**

| Contaminant | Limit | Contaminant | Limit |
|-------------|-------|-------------|-------|
| Calcium | 0.5 ppm | Copper | 0.2 ppm |
| Iron | 0.5 ppm | Zinc | 0.2 ppm |
| Aluminum | 0.5 ppm | Chromium | 0.2 ppm |
| Sodium | 0.5 ppm | Nickel | 0.2 ppm |
| Magnesium | 0.5 ppm | Phosphorus | 0.5 ppm |

### API Certification

Look for the **API certification mark** on all DEF products. Maintain Certificates of Analysis from suppliers documenting urea concentration, density, and metals analysis for each batch.

### Storage Tank Requirements

- Approved materials: HDPE (most common), cross-linked polyethylene, polypropylene, 316/304 stainless steel, fiberglass reinforced plastic
- Secondary containment: 100% of largest container plus freeboard
- Tank venting mandatory - position to avoid moisture infiltration

---

## 11. Maintenance Schedule

### Pre-Winter (September-October)

- Full system inspection per checklist
- Heat trace testing (continuity, megger, amp draw)
- Thermostat programming verification
- Insulation inspection and repair
- Filter replacement
- Tank level adjustment (50-70%)

### During Winter (Monthly)

- Visual inspection for freeze damage
- Heating system operation verification
- Flow rate monitoring
- Crystallization inspection at fittings
- Nozzle boot cleaning
- Tank level check

### Post-Winter (March-April)

- Full system inspection
- Tank cleaning if needed
- Filter replacement
- Thermostat adjustment or heating system shutdown
- Documentation of any winter issues for following season

---

## 12. Quick Reference Specifications

| Parameter | Specification |
|-----------|--------------|
| DEF freeze point | 12°F (-11°C) |
| DEF expansion when frozen | ~7% |
| DEF composition | 32.5% urea, 67.5% deionized water |
| Heat-ON setpoint | 35°F (2°C) |
| Heat-OFF setpoint | 45°F (7°C) |
| Max tank fill level (winter) | 70-75% |
| Min tank level (winter) | 50% |
| Filter micron rating | 5-10 micron absolute |
| Heat trace wattage | 5-10 W/ft typical |
| Megger test minimum | 20 megohms |
| Pressure test | 1.5× operating pressure, 10 min hold |
| Shelf life (≤60°F storage) | 36 months |
| Shelf life (≤77°F storage) | 18 months |

---

## Related Documentation

- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md) - DEF dispenser error codes
- [STP Troubleshooting Guide](./stp-troubleshooting-guide.md) - Pump-related diagnostics
- [Wayne Dispenser Troubleshooting](./wayne-dispenser-troubleshooting.md) - Wayne-specific procedures

---

*Field reference guide for DEF winterization procedures. The 12°F freeze point, 7% expansion rate, and extreme contamination sensitivity drive every equipment and procedural requirement. Pre-winter preparation in September/October prevents emergency service calls in January.*


DEF Winterization Field Reference Guide

# Eastern Oklahoma Service Territory: Tahlequah-to-Tulsa Corridor

**Category:** Territory / Market Research
**Region:** Eastern Oklahoma, Tulsa Metro to Arkansas Border
**Last Updated:** 12/25/2024
**Cross-Reference:** [Western Oklahoma Analysis](./western-oklahoma-market-analysis.md), [I-44 Corridor Research](./i44-corridor-analysis.md)

---

## Quick Reference

**D&H United Tulsa:** 4373 S 93rd East Avenue, Tulsa | (918) 627-3333
**Nwestco Springdale:** 4725 N Oak Street, Springdale, AR | (479) 751-4867
**Guardian Fueling Tulsa:** 1515 W 36th, Tulsa | guardianfueltech.com

---

## Executive Summary

**The service territory boundary between Arkansas and Tulsa petroleum equipment companies falls near Park Hill/Tahlequah** - significantly further east than expected. Muskogee, initially hypothesized as contested territory, is firmly within Tulsa's commercial sphere due to QuikTrip's established presence and D&H United's 40-mile proximity advantage.

**Key Finding:** Tulsa-based companies dominate approximately **75% of the corridor** from Broken Arrow to the Muskogee-Fort Gibson line.

---

## 1. Territory Classification Summary

| Location | ZIP | Classification | Confidence | Distance to Tulsa |
|----------|-----|----------------|------------|-------------------|
| Owasso | 74055 | Tulsa Core | 95%+ | 15 miles |
| Broken Arrow | 74012 | Tulsa Core | 95%+ | 15 miles |
| Coweta | 74429 | Tulsa Metro | 95% | 25 miles |
| **Muskogee** | 74403 | **Tulsa Dominated** | 85% | 50 miles |
| Fort Gibson | - | Transition Zone | 70% | 60 miles |
| **Park Hill** | 74451 | **Arkansas Dominated** | 95% | 65 miles |
| Tahlequah | - | Arkansas Territory | 90% | 70 miles |

---

## 2. Territory Boundary Map

```
WEST ←──────────────────────────────────────────────────────────→ EAST

TULSA TERRITORY                    │                ARKANSAS TERRITORY
                                   │
Owasso ─── Broken ─── Coweta ─── MUSKOGEE ─── Fort ─── PARK HILL ─── Tahlequah
(74055)    Arrow      (74429)    (74403)      Gibson   (74451)
           (74012)                             ▲
                                              │
                                    ═══ BOUNDARY LINE ═══

TULSA PROVIDERS:                           ARKANSAS PROVIDERS:
• D&H United (dominant)                    • Nwestco/Arkoma (primary)
• Seneca Companies                         • Ark-O Petroleum
• Guardian Fueling                         • B&B Equipment (local)
• P.B. Hoidale
```

---

## 3. Distance Analysis

The boundary is determined by **service response time economics**:

| Location | D&H United (Tulsa) | Nwestco (Fort Smith) | Advantage |
|----------|-------------------|---------------------|-----------|
| Owasso | 15 mi | 120 mi | Tulsa +105 mi |
| Broken Arrow | 15 mi | 115 mi | Tulsa +100 mi |
| Coweta | 25 mi | 100 mi | Tulsa +75 mi |
| **Muskogee** | **50 mi** | **90 mi** | **Tulsa +40 mi** |
| Fort Gibson | 60 mi | 75 mi | Tulsa +15 mi |
| **Park Hill** | **65 mi** | **65 mi** | **Neutral** |
| Tahlequah | 70 mi | 60 mi | Arkansas +10 mi |

The **distance equilibrium point** falls near Park Hill/Fort Gibson.

---

## 4. Muskogee Market Detail

### Classification: TULSA DOMINATED (85% confidence)

**Key Evidence:**
- 2 QuikTrip locations (Tulsa-HQ chain only expands into its own market)
- D&H United 50-mile proximity vs Arkansas 90+ miles
- 7+ Casey's locations (Gilbarco equipment, likely D&H service)
- Love's Travel Stop #166 (OKC-based, internal maintenance)
- Pilot Travel Center #259 (national contracts)

### Station Inventory (~30 stations)

| Brand | Count | Service Notes |
|-------|-------|---------------|
| Casey's | 7 | Gilbarco equipment - D&H United likely |
| QuikTrip | 2 | Tulsa-based corporate contracts |
| Phillips 66/Conoco | 4 | Regional brand, Tulsa providers |
| Shell | 3 | Brand network contracts |
| Sinclair | 2 | Variable - could be either |
| Love's | 1 | Internal/national contracts |
| Pilot | 1 | National contracts |
| Independents | ~9 | Mixed providers |

### Primary Service Companies

**D&H United Fueling Solutions** (Dominant)
- Branch: 4373 S 93rd East Avenue, Tulsa
- 50 miles to Muskogee
- OCC Licensed Installers: Kenneth Sowers, Paul Custer, Dustin McManus, Michael Wilson
- Gilbarco Veeder-Root authorized distributor
- Acquired Petroleum Marketers Equipment Company (July 2021)

**Seneca Companies**
- Branch: 6947 East 13th Street, Tulsa
- 50 miles to Muskogee
- Claims OK, AR, N. Texas, S. Missouri territory
- Tulsa branch since 2011

**Guardian Fueling Technologies** (New 2024)
- Branch: 1515 W 36th, Tulsa
- Licensed installer in Chouteau (30 miles from Muskogee)
- Entered Oklahoma market February 2024

---

## 5. Park Hill / Cherokee County Detail

### Classification: ARKANSAS DOMINATED (95% confidence)

**Key Evidence:**
- Zero QuikTrip presence in Cherokee County
- Nwestco Springdale 55-60 miles vs Tulsa 65+ miles
- Local contractor B&B Equipment coordinates with Arkansas providers
- Tahlequah hosts 2 Casey's (typically Nwestco/Gilbarco relationships)

### Station Inventory (3 stations)

| Name | Address | Brand | Likely Provider |
|------|---------|-------|-----------------|
| Sinclair | 25436 State Highway 82 | Sinclair | Nwestco/Ark-O |
| Oklahoma Station | 28455 Highway 82 | 76 | Unknown - 40+ yr local |
| Sinclair Oil | 25148 Highway 82 | Sinclair | Nwestco/Ark-O |

### Primary Service Companies

**Nwestco LLC (Hooten Equipment)**
- Branch: 4725 N Oak Street, Springdale, AR
- 55 miles to Park Hill
- OCC Licensed Installers: Justin Burkes, Tony Ward (expires 12/31/2025)
- Acquired Arkoma Services March 2024
- "Representing Gilbarco for over 15 years"

**Ark-O Petroleum Equipment Inc**
- Location: 441 Jean Mary Ave, Tontitown, AR
- 55 miles to Park Hill
- Wayne/Tokheim equipment specialist
- Website states MO, AR, OK service territory

**B&B Equipment (Local)**
- Location: 24849 East Cobbs Corner Road, Tahlequah
- 10 miles to Park Hill
- OCC Licensed Installer: Larry Bradham
- UST installation focus

---

## 6. Tulsa Metro Baseline (Core Territory)

### Broken Arrow (74012) - 95%+ Confidence

| Metric | Value |
|--------|-------|
| Total Stations | ~25 |
| QuikTrip Locations | 9+ |
| Maverik (ex-Kum & Go) | 7 |
| Casey's | 4 |
| Distance to D&H United | 15 miles |

### Owasso (74055) - 95%+ Confidence

| Metric | Value |
|--------|-------|
| Total Stations | ~15 |
| QuikTrip Locations | 5+ |
| Maverik | 3 |
| Casey's | 2 |
| Distance to D&H United | 15 miles |

**Key Evidence:** D&H United installer Michael Wilson resides in Broken Arrow.

---

## 7. Market Consolidation (2021-2024)

Three acquisitions reshaped Oklahoma's petroleum equipment landscape:

### D&H United + Petroleum Marketers Equipment (July 2021)
- Consolidated Tulsa's largest petroleum equipment operations
- 35+ branch offices, 1,400+ employees nationwide
- Comprehensive OCC licenses through multiple installers
- Now dominant Tulsa-area provider

### Nwestco + Arkoma Services (March 2024)
- Combined Fort Smith operations with Springdale (Hooten Equipment)
- Creates Arkansas's strongest petroleum equipment network
- Licensed Oklahoma installers: Brent Loyd, Justin Burkes, Tony Ward

### Seneca Companies + Titan Fuel Systems
- Expanded Oklahoma footprint from 2011 Tulsa branch
- Added 2021 OKC operations
- Claims coverage across "Oklahoma, Northern Texas, Southern Missouri and Arkansas"

---

## 8. Gilbarco Authorization Overlap

Multiple companies hold Gilbarco Veeder-Root authorized distributor status:

| Company | Territory | Competitive Position |
|---------|-----------|---------------------|
| D&H United | Tulsa-dominant | 50-mile advantage at Muskogee |
| Nwestco | Arkansas-dominant | 60-mile reach from Springdale |
| Seneca Companies | Regional | Stocks Gilbarco/VR parts |
| Guardian Fueling | Expanding | 2020 Gilbarco Distributor of Year |

**Implication:** Casey's locations (typically Gilbarco) could theoretically be serviced by multiple providers. Geographic proximity becomes the deciding factor.

---

## 9. Data Gaps & Verification Needs

### High Priority
1. **Casey's Corporate Contracts** - 7+ Muskogee locations represent significant uncertainty
2. **OCC Permit Records** - Recent UST permits in Muskogee/Cherokee counties would confirm active contractors

### Medium Priority
3. **Independent Station Surveys** - 10+ Muskogee independents may have varied arrangements
4. **Guardian Chouteau Coverage** - Contact Les Atchley for eastern Oklahoma service radius

### Low Priority (Confirmed)
5. Travel centers (Love's, Pilot) use internal/national contracts
6. Tulsa metro baseline established - no additional verification needed

---

## 10. Strategic Implications

### For Tulsa-Based Providers
- Muskogee is accessible territory despite 50-mile distance
- Fort Gibson represents practical eastern limit
- QuikTrip presence validates market investment
- Guardian's 2024 entry adds competitive pressure

### For Arkansas-Based Providers
- Focus resources on Cherokee County and border areas
- Tahlequah, Park Hill are natural territory
- 90+ mile distance to Muskogee limits competitiveness
- Nwestco/Arkoma consolidation strengthens position

### For Fuel Retailers
- **Muskogee & West:** Expect faster response from Tulsa contractors
- **Tahlequah & East:** Arkansas contractors may offer competitive pricing due to lower market density
- **Casey's locations:** Likely D&H United despite corporate uncertainty

---

## Related Documentation

- [Western Oklahoma Market Analysis](./western-oklahoma-market-analysis.md)
- [I-44 North Corridor Analysis](./i44-corridor-analysis.md)
- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md)

---

*Research conducted December 2024. Territory classifications based on QuikTrip presence, distance analysis, and OCC licensing records. Field verification recommended for station-level contract confirmation.*


Eastern Oklahoma Service Territory: Tahlequah-to-Tulsa Corridor

Field Technician Tools for Petroleum Equipment Service

# Fuel Retail POS Integration: Technical Field Guide

**Category:** Equipment / POS Systems / Integration
**Equipment:** Gilbarco Passport, Wayne Nucleus, Verifone Commander
**Last Updated:** 12/25/2024
**Difficulty:** Intermediate to Advanced
**Cross-Reference:** [Error Codes Reference](./error-codes-diagnostic-reference.md), [Wayne Dispenser Troubleshooting](./wayne-dispenser-troubleshooting.md)

---

## Quick Reference

**Gilbarco Passport Support:** 800-800-7498
**Wayne/Dover Support:** Contact authorized service center
**Verifone Commander Support:** 800-837-4366

---

## 1. Major POS Platform Architectures

### 1.1 Gilbarco Passport

Windows-based architecture on the **PX60 platform** (Intel Core i3-2120, 4GB DDR3, SSD).

**Key Component:** Enhanced Dispenser Hub (EDH/EDH2)
- Separate controller handling all dispenser communications and modem interfaces
- Segregated architecture isolates payment from POS application
- Keeps POS free from PCI scope

**Specifications:**
- 120+ certified back-office partners
- Communicates with dispensers via current loop through EDH
- Competitive pump control requires D-Box converters:
  - PA0338X000 for Wayne
  - PA0338X001 for Tokheim
- Different protocols must run on **separate loops**

### 1.2 Wayne Nucleus

Separates forecourt control from POS through the **Fusion automation platform**.

**Fusion Controller Variants:**
| Model | Capabilities |
|-------|-------------|
| Fusion 1000 | Basic forecourt control |
| Fusion 3000 | Mid-range with expanded protocol support |
| Fusion 6000 | Electronic payment processing separate from POS |

**Key Facts:**
- Supports 40+ different dispenser types out-of-box (including Gilbarco)
- ~25% of Nucleus installations interface with non-Wayne dispensers
- Default IP: **192.168.150.1**
- File access: WinSCP with PPK key authentication

### 1.3 Verifone Commander

Runs on **Secure Real-Time Linux** with virtualized architecture.

**Four Virtual Cores:**
1. **Store Controller** - POS application (up to 32 terminals)
2. **Forecourt Controller** - Dispenser interface
3. **Payment Controller** - VIPER EPS with dedicated NIC for network segmentation
4. **V950 Services** - Remote diagnostics

**Specifications:**
- Supports up to **64 fueling positions**
- Forecourt Control Interface (FCI) box with up to 4 interface boards
- Any combination of current loop and RS-485
- Web-based Commander Console for remote configuration

### Platform Comparison

| Platform | OS | Payment Isolation | Multi-Vendor Approach |
|----------|-----|------------------|----------------------|
| Gilbarco Passport | Windows (PX60) | Segregated via EDH | Separate D-Box per protocol |
| Wayne Nucleus | IBM retail-hardened | Fusion 6000 optional | Fusion controller 40+ protocols |
| Verifone Commander | Secure Linux | Dedicated VIPER core | FCI box with mixed boards |

---

## 2. Communication Protocols

### 2.1 Industry Standards

#### IFSF (International Forecourt Standards Forum)
- Developed 1992 by major oil companies and pump manufacturers
- Two-layer architecture: device application + transport layer
- Transport: LON (LonWorks) or TCP/IP
- Messages use Type-Length-Value (TLV) format

**IFSF Dispenser State Machine:**
```
Inoperative → Closed → Idle → Calling → Authorized →
Started → Suspended Started → Fuelling → Suspended Fuelling
```

#### Conexxus FDC (North America)
- Forecourt Device Controller Specification V2.1.2
- XML-based messaging adapted from IFSF

### 2.2 Gilbarco Two-Wire Protocol

| Parameter | Value |
|-----------|-------|
| Architecture | Master-slave |
| Baud Rate | 9600 bps |
| Physical Layer | 2-wire current loop |
| Data Format | 8 data bits, 1 start/stop, NO parity |
| Max Distance | 1200 meters |
| Current Levels | 20mA, 40mA, or 60mA (jumper selectable) |

**Message Structure:** Header-Body-Checksum with DLE character delimiting

### 2.3 Wayne DART Protocol

| Parameter | Value |
|-----------|-------|
| Physical Layer | RS-485 (2-wire half-duplex) |
| Baud Rate | 9600 bps |
| Parity | **ODD** (critical difference from Gilbarco) |
| Data Format | 8 data bits, 1 stop bit |

**DART Frame Structure:** START → PUMP_ID → TRANS_CODE → LENGTH → DATA → CHECKSUM

### 2.4 Physical Layer Specifications

| Protocol | Physical Layer | Max Distance | Topology |
|----------|---------------|--------------|----------|
| RS-232 | 3-wire (TxD, RxD, GND) | 15 meters | Point-to-point |
| RS-422 | 4-wire differential | 1200 meters | Multi-drop |
| RS-485 | 2-wire half-duplex | 1200 meters | Multi-drop (daisy chain only) |
| Gilbarco 2-Wire | Active current loop | 1200 meters | Multi-drop |
| Wayne DART | RS-485 based | Site-wide | Multi-drop |

### 2.5 Protocol Converters

**PTS Controller (Technotrade):**
- Supports 120+ dispenser brands
- Four independent ports, each programmable for different protocol/baud

**Gilbarco Epsilon Controller:**
- Handles ATCL, WCL, Gilbarco TwoWire, Wayne DART
- Up to 64 pumps using IFSF FDC POS protocol

**Allied Controller (Wayne-to-Gilbarco):**
- Channels 5-7: Wayne dispensers
- Channel 8: Wayne CATs

---

## 3. Communication Parameter Reference

### 3.1 Standard Configurations

| Controller/POS | Protocol | Baud Rate | Parity | Data/Stop Bits |
|----------------|----------|-----------|--------|----------------|
| Passport/EDH | Gilbarco EDIM | 1200 | Even | 7/1 |
| Commander, Allied, NCR | VR Protocol DIM | 9600 | Odd | 7/1 |
| Gilbarco Two-Wire | Native | 9600 | None | 8/1 |
| Wayne DART | Native | 9600 | **Odd** | 8/1 |

**CRITICAL:** Gilbarco uses NO parity; Wayne uses ODD parity. Mixing these guarantees failure.

---

## 4. Common Failure Patterns

### 4.1 RS-485 Wiring Errors (Most Common)

Despite being called "2-wire," RS-485 requires **three conductors**:
1. Two data lines (differential pair A/B)
2. Signal ground for zero-volt reference

**Cable shield does NOT provide signal ground** - this misconception causes more failures than any other.

**Common RS-485 Mistakes:**
| Issue | Symptom | Fix |
|-------|---------|-----|
| Missing signal ground | Intermittent comm | Add dedicated ground wire |
| A/B polarity reversed | No communication | Swap A/B (causes no damage) |
| Star topology | Intermittent comm | Rewire to strict daisy chain |
| Missing termination | Reflections, errors | Add 120Ω at both line ends |
| Inadequate line bias | False start bits | Add bias resistors |

**Correct RS-485 Installation:**
- Shielded twisted pair (10-12 twists/foot minimum)
- #18 AWG minimum (#14 AWG for long runs)
- Shield drain wire bonded to ground at **ONE end only**
- Keep stubs extremely short

### 4.2 Current Loop Errors

Gilbarco's 2-wire current loop permits only **one "active" device** supplying current—all others must be "passive."

**Failure Mode:** Connecting two active controllers to same loop causes communication collision.

**Diagnosis:**
1. Verify active/passive configuration
2. Check current flow with ammeter

### 4.3 Address Conflicts

**Symptom:** "Offline" or "No Communication" errors

Each fueling position requires a unique address.

**Gilbarco-Specific Issue:**
- Network ID stores on Passport server
- Grade ID stores on pump
- If POS-dispenser connection drops, pump retains Grade ID instead of Network ID
- Complicates recovery—may need to reprogram pump

### 4.4 Tank Gauge Integration (Veeder-Root TLS)

| Alarm | Meaning | Action |
|-------|---------|--------|
| Probe Out | Hardware failure | Inspect probe and wiring |
| E1 Comm Alarm | No EDIM-POS communication | Verify port, cable, programming |
| PLLD Shutdown | Failed line leak test | Investigate leak source |

**EDIM Diagnostics:** Menu → Diagnostics → Module → Comm
- Monitor Rx/Tx byte counts
- Both should show similar, increasing numbers
- No errors should display

### 4.5 Environmental Factors

| Factor | Risk | Prevention |
|--------|------|------------|
| Lightning/surges | Destroyed boards | UPS/surge protection on all controllers |
| Underground cable damage | Intermittent/complete loss | Proper burial depth, conduit |
| Connector corrosion | Signal degradation | Weather-sealed connections |
| Vibration | Loose connections | Locking connectors, strain relief |
| Temperature cycling | Component stress | Rated equipment for environment |
| Power quality | Communication errors | Proper grounding per NEC 514 |

**Power Quality:** Voltage drop to pumps must be under 5% from panel.

### 4.6 Quick Error Code Reference

| Code | Platform | Meaning |
|------|----------|---------|
| 11 | Gilbarco Encore | Communication problem |
| 50 | Gilbarco Encore | Communication loss with POS |
| E01 | Wayne iGEM | Sapphire/POS sync issue |

---

## 5. Troubleshooting Sequence

**Universal Fault Isolation:**

1. **Verify power** - Check voltage at controller and dispensers
2. **Check wiring continuity** - Test all conductors end-to-end
3. **Verify polarity** - Especially A/B on RS-485
4. **Check termination** - 120Ω at both ends of RS-485
5. **Confirm addresses** - Each position unique
6. **Match parameters** - Baud, parity, data bits must match exactly
7. **Test with loopback** - Isolate controller from network
8. **Substitute known-good equipment** - Final step

---

## 6. EMV Migration Status

### 6.1 Timeline & Compliance

**Final Liability Shift Dates:**
- April 17, 2021 (Visa)
- April 16, 2021 (Other networks)

**Current Status (as of April 2021):**
- Only **48% of major fuel merchants** fully EMV compliant
- Non-compliant merchants: **$13,000+/year** estimated fraud exposure

### 6.2 Terminal Generations

| Generation | Features | Certification |
|------------|----------|--------------|
| Gen 1 (pre-2015) | Mag-stripe only, RS-485, dial-up | None |
| Gen 2 (2015-2019) | Hybrid (mag+chip), transitioning to Ethernet | PCI PTS 3.x |
| Gen 3 (2019+) | NFC contactless, TCP/IP required, touchscreen | PCI PTS 4.x-6.x |

### 6.3 Platform-Specific EMV Solutions

**Gilbarco FlexPay:**
| Version | PCI Level | Notes |
|---------|-----------|-------|
| FlexPay II | PTS 3.x | Legacy EMV |
| FlexPay IV | PTS 4.x | First U.S. fuel terminal (2017) |
| FlexPay 6 | PTS 5.x/6.x | 9" all-in-one or 15.6" modular |

**FlexPay Connect System:**
- Backroom Communications Module (BRCM) supports 8 dispensers
- Dispenser Communications Module (DCM) at each unit
- Converts existing 2-wire to Ethernet

**Wayne iX Pay:**
| Version | Display | Certification |
|---------|---------|--------------|
| iX Pay | Original | PCI PTS 2.x |
| iX Pay 2 | First PTS 3.0 certified | |
| iX Pay T5 | 5.7" | Current |
| iX Pay T7 | 7" WVGA touchscreen | Media capable |

**Wayne Connectivity Requirements:**

| Connection Type | EPP Mode | EMV | Media |
|----------------|----------|-----|-------|
| Direct RS-485 | Yes | NO | NO |
| Wayne Connect | Yes | Yes | Yes |
| Ethernet | NO | Yes | Yes |

### 6.4 EMV Certification Levels

| Level | What It Certifies | Who Needs It |
|-------|-------------------|--------------|
| L1 | Physical hardware (electrical/mechanical) | Terminal manufacturer |
| L2 | EMV payment kernel software | Software provider |
| L3 | Complete terminal-to-host integration | **MERCHANT** |

**CRITICAL:** Installations without L3 certification leave merchants liable despite having EMV hardware. The POS must be L3 certified with the **specific payment processor**.

### 6.5 Network Infrastructure for EMV

**Pre-EMV:**
- RS-485 serial at 9.6-115 Kbps
- Two-wire twisted pair
- Dial-up connections

**EMV Requirements:**
- TCP/IP Ethernet (minimum 1 Mbps)
- CAT5e/CAT6 wiring (or Ethernet extenders)
- PCI-compliant network segmentation
- VLAN capability for payment isolation

**Field Solutions:**
| Solution | Pros | Cons |
|----------|------|------|
| New CAT6 conduit | Best performance | Expensive, disruptive |
| Ethernet extenders | Uses existing wire | Distance limits |
| Secure wireless | No trenching | UL listing required |

---

## 7. Emerging Technologies

### 7.1 Contactless Payment Adoption

- **61%** of consumers prefer contactless-enabled merchants
- **84%** find smartphone payments more convenient
- Major brands deployed: ExxonMobil, Shell, Chevron mobile apps

### 7.2 Future Payment Technologies

| Technology | Status | Notes |
|------------|--------|-------|
| Vehicle-to-pump (Car IQ Pay) | Rolling out 2024 | ExxonMobil first |
| Voice payments | Emerging | "Alexa, pay for gas" |
| In-vehicle integration | Development | Built into infotainment |

---

## Related Documentation

- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md)
- [Wayne Dispenser Troubleshooting](./wayne-dispenser-troubleshooting.md)
- [Veeder-Root CSLD Failures](./veeder-root-csld-failures.md)
- [Verifone Connectivity Troubleshooting](./troubleshooting-verifone-connectivity.md)

---

*This guide synthesizes field technician reference materials for Gilbarco Passport, Wayne Nucleus, and Verifone Commander platforms. Always verify against current manufacturer documentation for your specific equipment revision.*


Fuel Retail POS Integration: Technical Field Guide

# Gas Station Parts Cross-Reference Guide

This guide provides cross-reference information for common gas station parts. Use this to find equivalent parts across manufacturers.

## Nozzle Cross-Reference

| Size | OPW | Husky | Catlow | Application |
|------|-----|-------|--------|-------------|
| 3/4" | 11BP | 159559 XS | NEPNL | Unleaded prepay |
| 3/4" | 11B | 159503 XS | NEPL | Diesel prepay |
| 3/4" | 11AP | 159404 X | NEL | Standard full-service |

**Field Note:** OPW/Catlow > Husky - Husky equipment causes more intermittent issues.

## Breakaway Cross-Reference

| Size | OPW | Husky | Catlow | Type |
|------|-----|-------|--------|------|
| 3/4" | 66V-0300 | 2273 | CTM75 | Single-use |
| 1" | 66V-1300 | 2274 | CTM100 | Single-use |
| 3/4" | 66RB-1000 | 3360 | CTM75 | Reconnectable |
| 1" | 66RB-2000 | 2276 | CTM100 | Reconnectable |

**CRITICAL SAFETY:** NEVER attempt to reset a single-use breakaway after activation. OPW 66V, Husky 2273/2274 = ALWAYS REPLACE. Reconnectable breakaways (66RB, 3360, CTM) can be reused if undamaged - inspect O-rings before reuse.

## Swivel Cross-Reference

| Size | OPW | Husky | Catlow |
|------|-----|-------|--------|
| 3/4" MxF | 45-5060 | 000350 | C720 |
| 1" MxF | 45-5075 | 000087 | C720 1"x1" |
| 3/4" E85 | 241TPS-0492 | - | C720-E85 |

## Filter Cross-Reference

| PetroClear | Cim-Tek | Gilbarco OEM | Application |
|------------|---------|--------------|-------------|
| 40510P | 70010 | R18189-10 | Standard 10um (1"-12) |
| 40530P | 70012 | R18189-30 | Standard 30um (1"-12) |
| 40510P-AD | 70015 | Native | Gilbarco 10um (1.5"-16) |
| 40530P-AD | 70016 | Native | Gilbarco 30um (1.5"-16) |
| 40510W-AD | 70060 | - | Water sensing 10um |
| 40530W-AD | 70065 | - | Water sensing 30um |

**Filter Storage:** Store in cool, dry place. Check monthly, replace when flow drops.

## Thermal Receipt Paper Cross-Reference

| Size | Gilbarco Dispensers | Wayne Dispensers | Other Equipment |
|------|---------------------|------------------|-----------------|
| 2-5/16" x 209' | Encore 300, 500, 500S, Advantage | - | Tokheim, Unitec |
| 2-5/16" x 400' | Encore 700S | Ovation, Vista, Helix, DW-10/12/14 | DRB Car Wash |
| 2-3/8" x 212' | EMC, Ruby Journal | - | Veeder-Root TLS 350 |

**Paper Handling:** Thermal paper is heat-sensitive. Store away from heat sources. Shelf life: 5 years.

## ATG Probe Length Cross-Reference (Veeder-Root MAG Plus)

| Suffix | Length | Tank Depth | Notes |
|--------|--------|------------|-------|
| -103 | 5'4" | 6-7 ft | Shallow tanks only |
| -107 | 8' | 8-9 ft | Most common - standard 8ft tanks |
| -109 | 10' | 10-11 ft | Large capacity tanks |
| -110 | 10'6" | 11-12 ft | Commercial tanks |
| -112 | 12' | 12+ ft | Large commercial tanks |

## Stocking Tiers

### Tier 1 - Emergency/High-Failure (Always Stock)
- Breakaways (OPW 66V-0300, 66V-1300)
- Fuel filters (40510P, 40530P)
- Receipt paper (appropriate size for your dispensers)
- Nozzle splash guards
- Hose swivels

### Tier 2 - Common Replacement (Order as Needed)
- Nozzles (11BP, 11B)
- Hose assemblies
- Dispenser filters
- Printer head assemblies
- Card reader bezels

### Tier 3 - Specialty/Situational
- E85-compatible parts
- Cold weather seals (Viton)
- ATG probes
- Vapor recovery components

## Amazon Purchase Links

Parts are available on Amazon with affiliate tag. Search for:
- "OPW 66V breakaway" - Single-use breakaway
- "PetroClear 40510P" - Standard fuel filter
- "Gilbarco receipt paper" - Thermal paper rolls
- "OPW 11BP nozzle" - Standard unleaded nozzle

For verified product links, visit: https://vigilith.ai/knowledge/parts/catalog

## Important Notes

1. **Meter/Pulser Replacement:** Requires Weights & Measures calibration inspection.
2. **Shear/Fire Valves:** NEVER bypass. Contact authorities if activated.
3. **Seal Materials:**
   - Viton: Best for E85, cold weather, and harsh fuels
   - Buna-N: Standard, economical option
   - Fluorosilicone: Extreme temperature range
4. **UL Listing:** Always verify parts are UL 330 listed for fuel dispensing.

---
*Reference compiled December 2024. Sources: OPW Global, Husky Corporation, Catlow/Dover, PetroClear, Cim-Tek Filtration, manufacturer technical bulletins, PEI RP500, UL 330, NFPA 30A.*

*For the complete parts catalog with purchase links, visit: /knowledge/parts/catalog*


Gas Station Parts Cross-Reference Guide

# Gilbarco CRIND and FlexPay Systems Guide

**Last Updated:** December 2024  
**Applies To:** FlexPay II, FlexPay IV, FlexPay 6, Encore 300/500/500S/700S  
**Audience:** Field Service Technicians (5+ years experience)

---

## Quick Reference

| Emergency | Phone |
|-----------|-------|
| Gilbarco Technical Support | 1-800-800-7498 |
| Installation Issues | 1-800-743-7501 |
| RAS/Feature Activation | 1-800-800-7498 |
| GOLD Library | docs.gilbarco.com/gold |

---

## 1. FlexPay Terminal Generations

### Generation Comparison

| Specification | FlexPay II | FlexPay IV | FlexPay 6 |
|---------------|------------|------------|-----------|
| **Status** | **EOL Dec 31, 2024** | Current | Current (Oct 2023+) |
| PCI PTS Certification | v3.x (expired Apr 2021) | v4.x/PED 5 | v5.x SRED (6.x upgradeable) |
| Display | 5.7" or 10.4" non-touch | 5.7" VGA or 10.4" color | 9" HD touchscreen (A2-09) |
| EMV Support | Via HCR upgrade kit | Native | Native |
| Contactless | No | Via upgrade | Native |
| Manufacturer | Gilbarco | Gilbarco | Invenco by GVR |
| Spare Parts | **Unavailable** | Available | Available |

### FlexPay II End-of-Life Details

| Milestone | Date |
|-----------|------|
| PCI PTS v3.x expiration | April 2021 |
| Sales end | December 2023 |
| Support end | December 31, 2024 |
| Spare parts availability | Discontinued |

**CRITICAL:** FlexPay II sites must upgrade to FlexPay IV or FlexPay 6 for continued EMV compliance.

### FlexPay IV Specifications

| Specification | Value |
|---------------|-------|
| Installed base (North America) | ~400,000 units |
| Launch date | May 2016 |
| First US dispenser EMV terminal | Yes |
| UPM firmware requirement | 42.11.XX+ for Omnia |
| Omnia web interface | http://172.20.100.254:3000 |

### FlexPay 6 Model Options

| Model | Display | Resolution | Processor | Operating Temp |
|-------|---------|------------|-----------|----------------|
| **A2-09** | 9" HD touchscreen | 1280×720 | i.MX8 Quad A53 1.6GHz | -30°C to +70°C |
| M1-15 | 15.6" HD touchscreen | Full HD | Modular | Extended |
| M2-15 | 15" touchscreen | HD | Modular | Extended |

FlexPay 6 Features: Native contactless, 2D barcode, 1200 nits brightness, IPX6/IK10 rated, cloud-native via "The Hub"

---

## 2. Communication Infrastructure

### Architecture Overview

```
┌─────────────────────────────────────────────────────────────────┐
│              CRIND COMMUNICATION ARCHITECTURE                    │
├─────────────────────────────────────────────────────────────────┤
│                                                                 │
│  PASSPORT/                                                      │
│  COMMANDER                                                      │
│      │                                                          │
│      │ Ethernet                                                 │
│      ▼                                                          │
│  ┌────────┐                                                     │
│  │  EDH   │                                                     │
│  └───┬────┘                                                     │
│      │                                                          │
│      ├──────────────────────┐                                   │
│      │                      │                                   │
│      ▼                      ▼                                   │
│  ┌────────┐            ┌────────┐                              │
│  │ D-BOX  │            │ BRCM2  │ (FlexPay Connect)            │
│  └───┬────┘            └───┬────┘                              │
│      │                     │                                    │
│      │ Two-Wire            │ VDSL                              │
│      │ Current Loop        │                                    │
│      │                     ▼                                    │
│      │                 ┌────────┐                              │
│      │                 │ DCM2/3 │                              │
│      │                 └───┬────┘                              │
│      │                     │                                    │
│      ▼                     ▼                                    │
│  ┌─────────────────────────────────────────┐                   │
│  │              DISPENSER                   │                   │
│  │  ┌─────────────┐    ┌─────────────────┐ │                   │
│  │  │  Hydraulics │    │   FlexPay IV/6  │ │                   │
│  │  │    Node     │    │     CRIND       │ │                   │
│  │  └─────────────┘    └─────────────────┘ │                   │
│  └─────────────────────────────────────────┘                   │
│                                                                 │
└─────────────────────────────────────────────────────────────────┘
```

### BRCM (Backroom Communications Module)

| Part Number | Description | Capacity |
|-------------|-------------|----------|
| **PA04222000002B** | BRCM2 | 8 dispensers |
| **PA0435200002** | BRCM2.64 Universal | 32 dispensers |

### BRCM2 Jumper Settings

| Jumper | Position | Purpose |
|--------|----------|---------|
| JP_POS_A/B | Per config | RS-422 vs two-wire selection |
| JP24A/B | Per config | High-speed distribution |
| JP1C | Per config | 35mA or 45mA current |

### DCM (Dispenser Communications Module)

| Part Number | Description | Application |
|-------------|-------------|-------------|
| **M14576A001** | DCM2 | Encore 300/500 |
| **M15399A001** | DCM2.1 (integrated SSoM) | Encore 300/500 |
| **M15737A001** | DCM2.2 (integrated CCP) | Encore 500S/700S |
| **M15724A001** | DCM3 (Omnia only) | Encore 700S only, BRCM2 required |
| M11071A001R | 700S DCM VDSL | Encore 700S |

### DCM3 LED Diagnostics

| LED | Color | State | Meaning |
|-----|-------|-------|---------|
| D1 | Green | ON | 1.2VDC good |
| D8 | Green | ON | 24VDC good |
| D9 | Green | ON | 3.3VDC good |
| D6 | Yellow | ON | High-speed link established |
| D6 | Yellow | Blink | TX/RX activity |
| D7 | Green | ON | BRCM2 connected |

---

## 3. EMV Upgrade Paths by Dispenser Model

### Decision Matrix

| Dispenser Model | Age | Recommendation | Components Required |
|-----------------|-----|----------------|---------------------|
| Encore 300 pre-2005 | 20+ years | **REPLACE** | Retrofit not cost-effective |
| Encore 300 post-2005 | 15-20 years | RETROFIT | FlexPay IV, E-CIM insert, UPM, UX300, DCM2.2, Ethernet/FlexPay Connect |
| Encore 500 non-S | 15+ years | **REPLACE** | Older architecture unviable |
| Encore 500S E-CIM | 10-15 years | RETROFIT | FlexPay IV or 6, DCM2.2/DCM3, Ethernet/FlexPay Connect |
| Encore 700S | <10 years | Native/UPGRADE | FlexPay IV factory option, FlexPay 6 retrofit, Omnia upgrade |

**Gilbarco Recommendation:** Dispensers older than 8-10 years should be evaluated for replacement rather than retrofit due to hydraulic wear, parts availability, and ROI considerations.

### FlexPay IV Retrofit Components

| Part Number | Description | Required For |
|-------------|-------------|--------------|
| **M13888K901** | UPM Kit (current) | All FlexPay IV installs |
| M13888A901 | UPM Kit (superseded) | Legacy—use K901 |
| **M14330A001** | UX300 EMV Card Reader | EMV capability |
| **M16183K001** | Omnia Upgrade Kit | Insite360, Ethernet/IP |
| M15315K005 | Previous Omnia kit | Superseded by M16183K001 |
| M13987A002 | PIP3 FCB (10.4") | Display upgrade |
| M13987A004 | PIP3 FCB (5.7") | Display upgrade |

### Omnia Upgrade Details

| Specification | Value |
|---------------|-------|
| Kit part number | M16183K001 |
| Estimated cost | $4,700-$4,900 |
| Adds | Ethernet/IP router + Insite360 |
| UPM requirement | 42.11.XX or higher |
| Web interface | http://172.20.100.254:3000 |

### Encore 700S Omnia Components

| Part Number | Description |
|-------------|-------------|
| M16183K001 | Omnia Upgrade Kit |
| M15724A001 | DCM3 |
| M15649A001 | PIP (5.7") |
| M15649A002 | PIP (10.4") |

---

## 4. LON Bus Architecture (Encore S-Series)

### Protocol Overview

| Specification | Value |
|---------------|-------|
| Standard | Echelon LonWorks |
| Channel | FT-10 |
| Speed | 78 kbps standard (up to 1.25 Mbps capable) |
| Topology | Free (star/bus/daisy-chain/loop) |
| Control type | Peer-to-peer distributed |

### Neuron Chip Specifications

| Chip | Memory | I/O | Usage |
|------|--------|-----|-------|
| Neuron 3120 | 10KB ROM, 512B EEPROM, 1KB RAM | 11 | Simple nodes |
| Neuron 3150 | External memory bus (64KB) | Network port | Complex nodes (CRIND) |

### Node Addressing

| Component | Bits | Maximum |
|-----------|------|---------|
| Neuron ID | 48 bits | Unique per chip |
| Domain ID | 0-6 bytes | Varies |
| Subnet | 8 bits | 255 |
| Node | 7 bits | 127 |

### LON Error Codes

| Code | Description | Severity |
|------|-------------|----------|
| E3 | LON configuration | SUPERMAJOR |
| 5111 | Door node | MAJOR |
| 5174 | Totalizer | MAJOR |
| 5091 | ATC | MEDIUM |

### LON Troubleshooting

```
LON BUS TROUBLESHOOTING SEQUENCE
────────────────────────────────
1. Verify twisted-pair connections at all nodes
2. Check power: 24VDC main, 5VDC logic
3. Observe service LED on each node
4. Verify termination:
   - Free topology: 1 terminator
   - Bus topology: 2 terminators (ends)
5. Isolate nodes one at a time to find fault
6. Check for EMI sources (VFDs, motors)
7. Verify firmware compatibility across nodes
```

---

## 5. Two-Wire Current Loop

### Protocol Specifications

| Parameter | Value |
|-----------|-------|
| Type | Gilbarco proprietary multi-drop master/slave |
| Baud rate | 5,700 baud (up to 19.2 kbps) |
| Data format | 11-bit |
| Maximum devices | 16 per loop |
| Maximum cable length | 1,200m (3,937 ft) |

### Wiring Requirements

| Specification | Requirement |
|---------------|-------------|
| Standard gauge | 14 AWG stranded copper |
| Short runs | 18 AWG acceptable |
| Jacket | Gas/oil resistant underground rated |
| Classification | NEC Class 1 |
| Conduit sharing | May share with main power conduit |

### Cable Part Numbers

| Part Number | Description |
|-------------|-------------|
| **M11961A003** | Two-wire cable MOC |
| **M11961A004** | Two-wire cable Generic |
| M14080A004 | Ethernet cable FlexPay Connect v1 to DCM |
| M02993A006 | Dedicated high-speed cable DCM2.2 P333 |
| M02993A005 | Omnia cable P300 |
| M07793A001 | Serial Interface PCB (SIP) FlexPay CRIND |

---

## 6. Passport EMV Configuration

### Connection Model

**CRITICAL DIFFERENCE FROM WAYNE:**

| System | Role | Connection |
|--------|------|------------|
| Gilbarco CRIND | TCP SERVER | Waits for connection |
| Passport POS | TCP CLIENT | Initiates connection to CRIND |
| Wayne CAT | TCP CLIENT | Initiates connection to POS |
| Wayne/Commander | TCP SERVER | Waits for connection |

### EMV Port Configuration

| Parameter | Value |
|-----------|-------|
| EMV port | 4871 (TLS) |
| Default outdoor EMV DCR traffic | 192.168.31.31 |
| CRIND IP restriction | Cannot be on Verifone subnet |
| All DCR positions | Single channel for Auto-Upgrade |

### MWS Configuration Path

**MWS → Set Up → Network Menu → [Network Name] → Network Site Configuration**

### PIP3 Loopback Jumper

**CRITICAL:** Install PIP3 loopback jumper on **Side B** BEFORE power-up during installation.

---

## 7. Error Code Reference

### Communication Errors

| Code | Description | Cause |
|------|-------------|-------|
| 50 | POS lost | Network/EDH issue |
| 5075-5078 | Two-wire port errors | Current loop wiring |
| CR 02 | Card reader disconnected | CRIND cable/connection |

### EMV/Security Errors

| Code | Description | Cause |
|------|-------------|-------|
| 8025 | Encrypted pulser serial mismatch | Security key mismatch |
| 8041 | Pulser missing data | Pulser failure |
| 8046 | Pulser tamper | Security alert |

### System SUPERMAJOR Errors

| Code | Description | Cause |
|------|-------------|-------|
| E1 | W&M RAM corrupt | Memory failure |
| E2 | Application RAM corrupt | Memory failure |
| E3 | LON config | LON bus configuration |
| E6 | NV data mismatch | NVRAM issue |

---

## 8. LED Diagnostic Patterns

### BRCM LEDs

| LED | State | Meaning |
|-----|-------|---------|
| High-Speed Active | ON | ≥1 dispenser connected |
| COMM | Blink | Units online on current loop |
| Green field wiring | ON | Power established |

### DCM3 LEDs

| LED | Color | State | Meaning |
|-----|-------|-------|---------|
| D1 | Green | ON | 1.2VDC good |
| D8 | Green | ON | 24VDC good |
| D9 | Green | ON | 3.3VDC good |
| D6 | Yellow | ON | High-speed link |
| D6 | Yellow | Blink | TX/RX activity |
| D7 | Green | ON | BRCM2 connected |

### Omnia PCB LEDs

| LEDs | Pattern | Meaning |
|------|---------|---------|
| D32 RED + D30 slow blink + D31 GREEN | Steady | USB success |
| D32 RED + D30 slow blink + D32 fast RED | Alternate | USB fail |

### Connection Board (FlexPay IV Omnia)

| LED | State | Meaning |
|-----|-------|---------|
| Yellow CRIND 2W | Not lit/solid | CoIP/EMV mode |
| Yellow CRIND 2W | Blinks | POS transmitting on two-wire |
| Green/Yellow | Active | CRIND to SIP M07793A001 |

---

## 9. FlexPay 6 Retrofit Compatibility

### Compatible Dispenser Models

| Manufacturer | Models |
|--------------|--------|
| Gilbarco | Encore 300, Encore 500S, Encore 700S |
| Wayne | Select models |
| Tokheim | Select models |
| Vista | Select models |

### A2-09 Specifications

| Specification | Value |
|---------------|-------|
| Display | 9" HD |
| Resolution | 1280×720 |
| Brightness | 1200 nits |
| Processor | i.MX8 Quad A53 1.6GHz |
| Memory | 1GB RAM / 4GB storage |
| Operating temperature | -30°C to +70°C |
| Ingress protection | IPX6 |
| Impact protection | IK10 |
| Power | 24V |

---

## 10. Wayne iX Pay Comparison

For technicians working both platforms:

| Gilbarco Term | Wayne Equivalent |
|---------------|-----------------|
| CRIND | CAT (Card Accepting Terminal) |
| FlexPay | iX Pay |
| Passport | NUCLEUS/Topaz/Commander |
| UPM | (No direct equivalent) |
| Two-wire (45mA) | Two-wire (34mA) |

### Architectural Differences

| Aspect | Gilbarco | Wayne |
|--------|----------|-------|
| CRIND connection model | SERVER | CLIENT |
| POS connection model | CLIENT | SERVER |
| EMV port | 4871 TLS | 9700 TLS |
| Connection direction | POS→CRIND | CAT→Commander |
| Current loop | 45mA | 34mA |

---

## 11. Common Mistakes

### Installation Mistakes

| Mistake | Consequence | Prevention |
|---------|-------------|------------|
| Using superseded UPM M13888A901 | May not have latest features | Use M13888K901 |
| Forgetting PIP3 loopback jumper | Boot failure | Install Side B jumper before power-up |
| Wrong DCM for dispenser model | Communication failure | DCM3 for 700S Omnia only |
| CRIND IP on Verifone subnet | EMV fails | Use separate subnet |
| Not checking UPM firmware version | Omnia features unavailable | Verify 42.11.XX+ for Omnia |

### Configuration Mistakes

| Mistake | Consequence | Prevention |
|---------|-------------|------------|
| Single channel not selected for DCR | Auto-Upgrade fails | Set all DCR positions to single channel |
| Wrong EMV port | Connection failure | Gilbarco: 4871, Wayne: 9700 |
| Confusing TCP client/server roles | EMV handshake fails | Gilbarco CRIND = SERVER |

### Troubleshooting Mistakes

| Mistake | Consequence | Prevention |
|---------|-------------|------------|
| Assuming CRIND failure for 8025 | Replacing wrong component | 8025 = security key mismatch, not hardware |
| Ignoring LON E3 error | Multiple node failures | Address LON config before other diagnostics |
| Not checking all DCM LEDs | Missing power/communication issue | Check D1, D8, D9, D6, D7 systematically |

---

## 12. Part Number Quick Reference

### FlexPay II (EOL - Reference Only)

| Part Number | Description |
|-------------|-------------|
| M11930K001 | FlexPay II FCB |
| M10661K001 | Keypad |
| M10662K001 | Keypad (alternate) |
| M12492B002 | EMV HCR2 Upgrade Kit |
| K003 | HCR Kit variant |
| K903 | HCR Kit variant |

### FlexPay IV

| Part Number | Description |
|-------------|-------------|
| **M13888K901** | UPM Kit (current) |
| M13888A901 | UPM Kit (superseded) |
| **M14330A001** | UX300 EMV Card Reader |
| **M16183K001** | Omnia Upgrade Kit |
| M15315K005 | Previous Omnia kit (superseded) |
| M13987A002 | PIP3 FCB (10.4") |
| M13987A004 | PIP3 FCB (5.7") |

### FlexPay 6

| Part Number | Description |
|-------------|-------------|
| A1-05 | 5" touchscreen All-in-One |
| **A2-09** | 9" HD touchscreen All-in-One |
| M1-15 | 15.6" HD touchscreen Modular |
| M2-15 | 15" touchscreen Modular |

### DCM

| Part Number | Description |
|-------------|-------------|
| M14576A001 | DCM2 (Encore 300/500) |
| M15399A001 | DCM2.1 (Encore 300/500) |
| **M15737A001** | DCM2.2 (Encore 500S/700S) |
| **M15724A001** | DCM3 Omnia (Encore 700S only) |
| M11071A001R | 700S DCM VDSL |

### BRCM

| Part Number | Description |
|-------------|-------------|
| **PA04222000002B** | BRCM2 (8 dispensers) |
| **PA0435200002** | BRCM2.64 Universal (32 dispensers) |

### Cables

| Part Number | Description |
|-------------|-------------|
| M11961A003 | Two-wire cable MOC |
| M11961A004 | Two-wire cable Generic |
| M14080A004 | Ethernet cable FlexPay Connect v1 |
| M02993A006 | DCM2.2 P333 cable |
| M02993A005 | Omnia P300 cable |
| M07793A001 | SIP FlexPay CRIND |

---

## 13. Documentation References

### GOLD Library Documents

| Document ID | Description |
|-------------|-------------|
| MDE-5220H | FlexPay IV CRIND Retrofit Kit Installation |
| MDE-5221 | FlexPay IV CRIND Start-up Manual |
| MDE-5223 | FlexPay IV CRIND Service/Troubleshooting |
| MDE-5265E | BRCM2.x Installation and Upgrade |
| MDE-5359 | FlexPay IV CRIND (Omnia) Retrofit Encore 500S |
| MDE-5369G | FlexPay IV (Omnia V04.07) Programming and Service |
| MDE-5402B | FlexPay IV Applause Media Kit with Omnia |
| Doc ID 11436 | FlexPay 6 Hardware Connectivity Third-party POS (EMV) |
| Doc ID 11552 | FlexPay 6 Outdoor Payment Terminals datasheet |

---

## Support Contacts

| Issue Type | Phone |
|------------|-------|
| Technical Support | 1-800-800-7498 |
| Installation Issues | 1-800-743-7501 |
| RAS/Feature Activation | 1-800-800-7498 |

---

*Confidence Note: FlexPay generation specifications and PCI PTS certification dates verified through official Gilbarco documentation and authorized distributor catalogs. Part numbers current as of December 2024—verify availability through GOLD Library or distributor before ordering. EMV configuration procedures may vary by software version.*


Gilbarco CRIND and FlexPay Systems Guide

Gilbarco Encore Dispenser Complete Technical Reference

Gilbarco Passport POS Networking Guide

# Hydrogen Fuel Infrastructure: Oklahoma Future-Proofing Guide

**Category:** Emerging Technology / Alternative Fuels
**Region:** Oklahoma, Regional Hydrogen Corridor Planning
**Last Updated:** 12/25/2024
**Status:** Future Technology - No Oklahoma Stations Before 2030
**Cross-Reference:** [Western Oklahoma Analysis](./western-oklahoma-market-analysis.md)

---

## Quick Reference

**Oklahoma Clean Cities:** okcleancities.org
**Tulsa Clean Cities:** tulsacleancities.com
**Oklahoma Secretary of Energy:** hydrogen@ee.ok.gov
**DOE Hydrogen Tools Portal:** h2tools.org

---

## Executive Summary

**No public hydrogen stations currently operate in Oklahoma**, and no confirmed stations are planned before 2030. However, Oklahoma has built one of the nation's strongest legislative frameworks for hydrogen with **nine hydrogen-related laws passed in 2022**, including a 45% tax credit for commercial fueling infrastructure.

**Key Reality Check:**
- Woodside Energy's H2OK facility (Ardmore) was canceled August 2025
- HALO Hydrogen Hub proposal ($1.25B) was not selected by DOE
- Texas Triangle project (DFW by 2027-2028) represents nearest emerging infrastructure
- Light-duty FCEV market is declining; heavy-duty shows promise

**For Station Owners:** This is preparation time. Understand the technology, evaluate site suitability, and position for eventual corridor expansion from Texas.

---

## 1. Oklahoma's Hydrogen Policy Framework

### Available Incentives (Through December 2028)

| Incentive | Benefit | Notes |
|-----------|---------|-------|
| Commercial Infrastructure Tax Credit | **45%** of installation cost | New installations only |
| Alternative Fuel Vehicle Tax Credit | Up to **$50,000** | Purchasing or converting FCEVs |
| C-PACE Financing | Property-assessed clean energy | County-enabled programs |
| Workforce Development Credit | **50%** of tuition | Hydrogen engineering degrees |

### Active Production Projects

| Project | Location | Status | Target |
|---------|----------|--------|--------|
| CF Industries + NextEra | Verdigris Complex | MOU signed | 100 MW electrolysis, green ammonia |
| LSB Industries | Pryor | Development | Largest green ammonia site in NA |

*Neither project targets retail fuel supply directly, but both establish Oklahoma production capacity.*

---

## 2. Timeline Reality

### Oklahoma Hydrogen Station Outlook

| Timeframe | Expectation |
|-----------|-------------|
| 2024-2027 | **No retail stations** - Preparation phase |
| 2027-2030 | Monitor Texas corridor expansion |
| 2030+ | First stations possible if fleet demand materializes |

### Nearest Emerging Infrastructure

**Texas Triangle Project:**
- Five medium/heavy-duty hydrogen stations
- Dallas-Fort Worth coverage by 2027-2028
- Most realistic pathway to Oklahoma expansion

---

## 3. Storage Technology Overview

### Compressed Gaseous Hydrogen (CGH2)

| Parameter | Value |
|-----------|-------|
| Vehicle Pressure (Light-Duty) | 700 bar (10,000 psi) |
| Station Storage Pressure | 875-950 bar |
| Heavy-Duty Vehicle Pressure | 350 bar |
| Storage Type | Type I steel or Type III carbon fiber |
| Cost | ~$1,000/kg hydrogen stored |
| Delivery | ~100 kg max per tube trailer |

### Liquid Hydrogen (LH2)

| Parameter | Value |
|-----------|-------|
| Temperature | -253°C (-423°F) |
| Energy Density | 71 kg/m³ (vs 40 kg/m³ for 700-bar) |
| Delivery Capacity | ~4,000 kg per cryogenic tanker |
| Boil-off Rate | 0.5-1% of stored volume daily |
| Application | High-capacity stations (1,000+ kg/day) |

**Note:** Underground hydrogen storage does not exist at retail stations. NFPA 2 requirements and hydrogen embrittlement concerns make above-ground installation universal.

---

## 4. NFPA 2 Setback Requirements

These distances often determine site feasibility before any other factor.

### Bulk Gaseous Hydrogen

| From | Distance |
|------|----------|
| Air intakes/ventilation | 50-75 feet |
| Non-fire-resistive buildings | 25-75 feet |
| Concentrations of people | 50-75 feet |
| Flammable liquid storage (above ground) | 25-50 feet |
| Open flames/ignition sources | 25-50 feet |

### Liquid Hydrogen (3,500-15,000 gallons)

| From | Distance |
|------|----------|
| Air intakes | 75 feet |
| Occupied areas | 75 feet |
| Liquid oxygen/oxidizers | 100 feet |
| Non-fire-resistive buildings | 50-75 feet |

**Critical:** Pre-application meetings with your local fire marshal are essential before any serious investment consideration.

---

## 5. Equipment & Dispensing

### Major Manufacturers

| Company | Products |
|---------|----------|
| Nel ASA | H2Station product line |
| Linde | Ionic Compressor, Cryo Pump systems |
| Air Products | Complete station solutions |
| Chart Industries | Heavy-duty (HYLA/Nikola partner) |
| PDC Machines | Diaphragm compressors (900+ installed globally) |
| WEH GmbH | TK17 series nozzles |

### SAE J2601 Dispensing Protocols

| Protocol | Pressure | Application | Fill Time |
|----------|----------|-------------|-----------|
| H70 | 700 bar | Passenger FCEVs | 3-5 minutes |
| H35 | 350 bar | Transit buses, trucks | Longer |

### Pre-Cooling Requirement

Compressing hydrogen generates heat; composite tank liners cannot exceed 85°C. Fast fills require pre-cooling to **-40°C before dispensing**.

| Specification | Equipment Cost | Notes |
|---------------|----------------|-------|
| T40 (-40°C) | ~$70,000 | Full-speed fills |
| T20 (-20°C) | Less | Slower fills |

---

## 6. Capital Costs

### Station Types

| Configuration | Daily Capacity | Cost Range |
|---------------|----------------|------------|
| Gaseous tube trailer | 180-400 kg | $1.5-2M |
| Liquid hydrogen | 400-1,200 kg | $2-3.5M |
| Site preparation/permitting | - | $200-400K additional |

### Component Costs

| Component | Cost Range |
|-----------|------------|
| Compressors | $50,000-$140,000 each |
| High-pressure storage | $200,000-$500,000 |
| Dispensers | $45,000-$75,000 each |
| Chiller systems | $50,000-$100,000 |

*Historical costs have declined 77-88% since 2012 due to larger capacities and economies of scale.*

---

## 7. Maintenance Requirements

### Annual Maintenance Costs

**$100,000-$200,000** at typical utilization levels - far exceeding gasoline station requirements.

### Inspection Schedule (NFPA 2)

| Frequency | Tasks |
|-----------|-------|
| Daily | Visual inspection, emergency stop verification, alarm status |
| Weekly | Leak detection sensor verification, hose/nozzle check, log review |
| Monthly | Comprehensive inspection, calibration checks, filter replacement |
| Quarterly/Annual | Full performance evaluation, ASME pressure vessel inspection |

### Compressor Service

| Type | Service Interval | Typical Procedure |
|------|------------------|-------------------|
| PDC Machines diaphragm | 10,000-40,000 hours | 4-8 hours |
| Linde ionic liquid | ~10x longer | Specialized training required |

---

## 8. Economics Reality Check

### Current Retail Prices

| Metric | Value |
|--------|-------|
| National range | $29-36/kg |
| Price increase (since 2021) | +112% (California) |

### Per-Mile Cost Comparison

| Vehicle Type | Cost Per Mile |
|--------------|---------------|
| FCEV | $0.53-$0.60 |
| Gasoline hybrid | $0.12-$0.15 |
| Conventional gasoline | $0.15-$0.18 |

**FCEVs cost 3-4.5x more per mile than gasoline vehicles at current prices.**

### Market Trends

**Light-Duty FCEV (Declining):**
- Global sales: -21.6% YoY (2024)
- US Q2 2024: 99 vehicles sold (-91%)
- Major Shell stations closed, returned grant money
- California 2030 projection revised to ~20,500 vehicles

**Heavy-Duty Hydrogen (Growing):**
- Global truck market: $4.3B (2024) → $15-16B (2030)
- Transit buses: 46% of commercial FCEV deployments
- Hyundai XCIENT, Nikola TRE FCEV, Toyota/Kenworth Class 8 trucks active

### Breakeven Requirements

- 70%+ utilization
- Hydrogen priced at $8-10/kg minimum
- Volumes exceeding 400 kg daily
- **No stations operate profitably without subsidies**

---

## 9. Available Incentives

| Program | Benefit |
|---------|---------|
| Federal 30C Alt Fuel Infrastructure Credit | 30% of installation (up to $100K) |
| IRA Section 45V Production Credit | Up to $3/kg (for producers) |
| Oklahoma State Tax Credit | **45%** of commercial infrastructure |
| California LCFS Credits | ~$6.20/kg revenue (qualifying stations) |
| CA Energy Commission Grants | 70-85% of capital costs (approved projects) |

---

## 10. Site Suitability Checklist

### Minimum Requirements

| Factor | Requirement |
|--------|-------------|
| Lot size | 10,000+ sq ft (equipment + setbacks) |
| Electrical service | 150-400 kW (typical stations have 50-100 kW) |
| Delivery access | Ingress/egress for 40-foot trailers |
| Terrain | Flat for equipment pad |
| NFPA 2 setbacks | **Critical - must be satisfied** |

### Disqualifying Factors

- Insufficient space for code-required setbacks
- Poor electrical access with costly upgrade paths
- Underground utility conflicts
- Landlord deed restrictions
- Traffic flow preventing delivery truck access
- Dense urban sites (often cannot meet setback requirements)

### Electrical Upgrade Costs

| Current Service | Upgrade Cost |
|-----------------|--------------|
| 50-100 kW → 150-400 kW | $50,000-$300,000+ |

---

## 11. Permitting Timeline

| Phase | Duration (Typical) |
|-------|-------------------|
| Pre-application outreach | 1-3 months |
| Planning review | 1-6 months |
| Building review | 1-6 months |
| Construction | 3-9 months |
| Commissioning/testing | 1-3 months |
| **Total (Experienced Jurisdiction)** | **15-18 months** |
| **Total (Typical)** | **2-2.5 years** |
| **Complex Projects** | 3-4 years |

### Required Approvals

- Local planning
- Building department
- Fire marshal
- Air quality management
- Weights/measures certification

---

## 12. Safety Comparison: Hydrogen vs Gasoline

| Property | Hydrogen | Gasoline |
|----------|----------|----------|
| Flammability range | 4-75% in air | 1.4-7.6% in air |
| Auto-ignition temp | 575°C | 500°C |
| Minimum ignition energy | 0.02 mJ | 0.24 mJ |
| Dispersion | Rises at ~20 m/s | Pools |
| Fire behavior | Burns away from structure | Prolonged pooling |

**Key Safety Advantage:** Hydrogen rises and disperses rapidly outdoors rather than pooling. DOE studies show hydrogen flames burn away from vehicle structures and extinguish quickly.

**Response:** Most effective hydrogen fire response is **shutting off the supply**. Water cools surrounding structures but does not directly extinguish hydrogen flames.

---

## 13. Recommended Strategy for Oklahoma Station Owners

### Now Through 2027

1. **Assess site hydrogen suitability:**
   - Measure setback distances
   - Evaluate utility upgrade costs
   - Determine if NFPA 2 requirements can be met

2. **Build relationships:**
   - Oklahoma Clean Cities (okcleancities.org)
   - Tulsa Clean Cities (tulsacleancities.com)

3. **Monitor developments:**
   - Texas Triangle hydrogen station development
   - LSB Industries and CF Industries Oklahoma projects

### 2027-2030

1. Watch for commercial fleet hydrogen vehicle deployments (transit buses, port drayage trucks)
2. Evaluate grants requiring 70%+ cost coverage - without subsidies, economics do not support investment
3. Consider CNG infrastructure as bridge strategy (similar operational competencies transfer)
4. Attend first responder coordination meetings if considering future hydrogen

### Evaluate Investment ONLY If:

- Located on I-35 or I-40 corridors with heavy-duty truck traffic potential
- Positioned to serve transit bus depots or predictable fleet operations
- Can access grants covering 70%+ of capital
- Accept 10+ year investment horizon with 5+ years potential operating losses
- Site satisfies NFPA 2 setbacks with confirmed fire marshal pre-approval

---

## Related Documentation

- [Western Oklahoma Market Analysis](./western-oklahoma-market-analysis.md)
- [POS Integration Field Guide](./pos-integration-field-guide.md)

---

*This guide synthesizes current technical requirements, regulatory frameworks, and market conditions as of December 2024. Hydrogen fueling infrastructure represents emerging technology with evolving specifications, costs, and regulations. Verify current requirements with relevant authorities before any investment decisions.*

*Note: H2OK project cancellation (August 2025) and declining light-duty FCEV market signal caution. Heavy-duty applications may drive eventual Oklahoma infrastructure development.*


Hydrogen Fuel Infrastructure: Oklahoma Future-Proofing Guide

# I-44 North Corridor: Tulsa to Joplin Territory Analysis

**Category:** Territory / Market Research
**Region:** I-44 from Tulsa to Joplin, Missouri
**Last Updated:** 12/25/2024
**Cross-Reference:** [Eastern Oklahoma Analysis](./eastern-oklahoma-territory-analysis.md), [Western Oklahoma Analysis](./western-oklahoma-market-analysis.md)

---

## Quick Reference

**D&H United Tulsa:** 4545 S Mingo Road, Tulsa | (918) 627-3333
**Guardian Fueling Tulsa:** 1515 W 36th Pl, Tulsa | guardianfueltech.com
**Show Me Petroleum (D&H):** 3440 W Division St, Springfield, MO

---

## Executive Summary

**Tulsa's effective petroleum equipment service territory extends approximately 70 miles on the I-44 corridor** to Vinita. QuikTrip (Tulsa's commercial boundary indicator) maintains presence only to Chouteau (50 miles) for standard stores, though Travel Center formats extend to Joplin (120 miles).

**D&H United dominates the entire corridor** through strategic acquisitions: Petroleum Marketers (Tulsa), Show Me Petroleum (Springfield, MO), and Double Check Company (Kansas City).

**Key Clarification:** Froman Oil & Propane is NOT a petroleum equipment competitor - they focus exclusively on propane and fuel delivery.

---

## 1. Corridor Distance Summary

| Location | Distance | QuikTrip | Classification | Primary Servicer |
|----------|----------|----------|----------------|------------------|
| Claremore | 30 mi | 3 stores | Tulsa Core | D&H / Guardian / Seneca |
| Chouteau | 50 mi | Travel Center | Tulsa Outer | Guardian (local installer) |
| **Vinita** | **70 mi** | **None** | **Transition Zone** | D&H United (outer range) |
| Grove | 90 mi | None | Contested | Unknown - tourism market |
| Miami | 90 mi | Announced | Transition Zone | D&H / Seneca (overlap) |
| Joplin, MO | 120 mi | Travel Center | Missouri Territory | D&H (via Show Me) |

---

## 2. Territory Details

### Claremore (74017) - Tulsa Metro Core

**30 miles from Tulsa | Tulsa Dominated | 95% Confidence**

| Metric | Value |
|--------|-------|
| Total Stations | 14 |
| QuikTrip Locations | 3 (#20, #40, #66) |
| Casey's | 2 |
| Sinclair | 2 |
| Phillips 66 | 2 |

**Service Companies:**
- D&H United - OCC installers: Kenneth Sowers, Dustin McManus, Michael Wilson
- Guardian Fueling - Installer Tyler Mills
- Seneca Companies - Installers Justin Jackson, Andrew Jauregui
- P.B. Hoidale (OKC) - 115 miles, limited presence

---

### Chouteau (74337) - Tulsa Outer Reach

**50 miles from Tulsa | Tulsa Dominated | 90% Confidence**

**Critical Finding:** Guardian Fueling Technologies employs **Les Atchley**, OCC-licensed UST installer **physically located in Chouteau** (12769 S 430 Road). License valid through 12/31/2025.

| Station | Brand | Notes |
|---------|-------|-------|
| QuikTrip Travel Center #43 | QuikTrip | Truck diesel, DEF, scales |
| Shell/E-Z Mart | Shell | Convenience |
| Sinclair | Sinclair | Local |
| Love's Travel Stop | Love's | 4564 W 590 |
| Froman Propane | - | Propane only |

**Guardian's local installer presence is strongest evidence of active Tulsa-based service at 50-mile range.**

---

### Vinita (74301) - TRUE TRANSITION ZONE

**70 miles from Tulsa | 50 miles from Joplin | Transition Zone**

**QuikTrip Boundary Confirmed:** No QuikTrip operates in Vinita or Craig County. QuikTrip's northernmost I-44 locations terminate around Claremore/Bartlesville (~40-50 miles).

| Stations | Count | Notes |
|----------|-------|-------|
| Maverik (ex-Kum & Go) | 2 | Will Rogers Turnpike plazas |
| Love's Travel Stop #727 | 1 | Big Cabin (5.5 mi south) |
| Big Cabin Truck Plaza | 1 | 150 truck parking |
| Murphy Express | 1 | National brand |
| Circle K | 1 | National brand |
| Shell | 1 | National brand |
| Phillips 66 | 1 | National brand |
| Independents | 3 | Including Woodshed (26 yrs) |

**Service Territory:** D&H United and Seneca Companies (Tulsa branches) service as outer territory limit. 70-mile distance = ~1 hour drive time - viable for scheduled maintenance, challenging for emergency response.

---

### Grove (74346) - Contested Tourism Market

**90 miles from Tulsa | 60 miles from Joplin | Contested**

Unique dynamics as **Grand Lake tourism destination** serving boaters from OK, MO, AR, KS.

**Key Indicators:**
- Casey's General Store present (Midwest chain influence)
- No QuikTrip in Grove or Delaware County
- Multiple marina fuel operations (specialized equipment needs)

**Marina Fuel Operations:**
- Honey Creek Landing Marina
- Cedar Port Marina
- Serenity Point Marina
- Hammerhead Marina
- Cherokee Yacht Club

**Service Territory:** Unknown - requires field verification. 90 miles approaches outer Tulsa service limit. Arkansas companies (~50 miles to Bentonville) may compete.

---

### Miami (74354) - Northern Oklahoma Boundary

**90 miles from Tulsa | 30 miles from Joplin | Transition Zone**

**QuikTrip History:** Former store #30 closed. **New QuikTrip announced** in partnership with Peoria Tribe of Indians - QuikTrip's first-ever tribal partnership.

**Tribal Operations:**
- Adawe Travel Plaza (tribal-owned, non-ethanol gas, 150 truck parking)
- O-Gah-Pah Convenience Store

**Service Territory Overlap:**
Both Tulsa and Kansas City companies viable:
- Seneca Companies Tulsa branch claims "Southern Missouri" coverage
- Seneca's Kansas City branch (Independence, MO) at equal distance
- D&H United reaches via Tulsa (90 mi) or Show Me Petroleum Springfield (~120 mi)

---

### Joplin, MO (64801) - Missouri Territory

**120 miles from Tulsa | Missouri Dominated**

**Casey's Dominance:** 10+ locations plus $62 million distribution center (2019) serving 400-600 stores across MO, OK, KS, AR.

**Surprising QuikTrip Presence:** Travel Center #7061 at 6601 E 32nd Street (8 truck lanes, DEF, scales). Demonstrates QuikTrip's commercial territory extends further for strategic highway formats.

**D&H United's Missouri Consolidation:**

| Acquisition | Location | Date | Joplin Distance |
|-------------|----------|------|-----------------|
| Show Me Petroleum | Springfield, MO | Aug 2024 | 70 miles |
| Double Check Company | Kansas City, MO | Dec 2022 | 150 miles |
| Tanknology | National | Jul 2023 | N/A |

**Show Me Petroleum at Springfield is the closest service provider to Joplin.**

---

## 3. The 70-Mile Rule

Tulsa's effective petroleum equipment service territory extends approximately **70 miles on I-44**, beyond which response times become challenging for emergency service.

However, D&H United's acquisition strategy has eliminated this limitation - Show Me Petroleum in Springfield can service Joplin (70 miles) as readily as Tulsa services Vinita (70 miles).

---

## 4. QuikTrip as Commercial Indicator

| Distance | QuikTrip Status | Territory Type |
|----------|-----------------|----------------|
| 30-50 mi | Standard stores present | Strong Tulsa metro |
| 70-90 mi | Absent | Transition territory |
| 120+ mi | Travel Center format only | Strategic highway locations |

---

## 5. Froman Oil & Propane - NOT a Competitor

**Critical Clarification:** Froman Oil is NOT a petroleum equipment service company.

| Attribute | Detail |
|-----------|--------|
| Headquarters | 17951 S Highway 66, Claremore |
| Founded | 1962 (63 years) |
| Employees | 11-50 |
| BBB Rating | A+ |
| Office Locations | 8 (Claremore, Broken Arrow, Skiatook, Chouteau, others) |

**Services (NOT Petroleum Equipment):**
- Residential/commercial propane delivery
- Bulk diesel and gasoline delivery
- Propane autogas
- 30,000 gallon tank installations (propane only)
- Generator service
- 24-hour retail fuel pumps

**Key Finding:** Froman Oil holds NO Oklahoma Corporation Commission UST/AST installer licenses. They do not compete with D&H United, Guardian Fueling, or Seneca Companies.

---

## 6. Missouri Service Company Directory

| Company | Location | Joplin Distance | Status |
|---------|----------|-----------------|--------|
| Show Me Petroleum | Springfield, MO | 70 mi | D&H United subsidiary |
| Double Check Company | Kansas City, MO | 150 mi | D&H United subsidiary |
| Petroleum Equipment, Inc. | Kansas City, MO | 150 mi | Independent (30+ yrs) |
| Seneca Companies | Independence, MO | 150 mi | Independent |
| Midwest Petroleum Equipment | Kansas City, KS | 150 mi | Independent |
| Mid-State Petroleum Equipment | Columbia, MO | 180 mi | Independent |

---

## 7. Regulatory Implications

| State | Regulator | Notes |
|-------|-----------|-------|
| Oklahoma | OCC | Individual UST installer licenses |
| Missouri | DNR | Separate registration/compliance |

Companies servicing both states need dual compliance programs. D&H United's acquisitions provide unified compliance capability across both states.

---

## 8. I-44 vs. US-69 Comparison

| Factor | I-44 North | US-69 East (Tahlequah) |
|--------|------------|------------------------|
| Boundary Distance | ~70 miles | ~70 miles |
| QuikTrip Terminus | Chouteau (50 mi) | Limited presence |
| Station Mix | National travel centers | Local/independent |
| Competitor Region | Missouri (DNR) | Arkansas (DEQ) |
| D&H Position | Dominates via acquisitions | Competes with AR providers |

---

## 9. Strategic Implications

### For Service Companies
- D&H United is only company with verified presence at every distance point
- Guardian's Chouteau installer demonstrates local positioning strategy
- Seneca maintains competitive presence via Tulsa + Kansas City branches

### For Fuel Retailers
- **0-50 miles:** Multiple Tulsa providers competitive
- **50-70 miles:** Response time becomes factor - Guardian local advantage
- **70-90 miles:** Consider travel center national contracts
- **90+ miles:** Missouri providers may offer better response

### Key Account Notes
- Love's and Pilot use internal/national maintenance contracts
- Casey's (10+ Joplin locations) major Gilbarco account
- Tribal stations (Miami) may have unique service arrangements

---

## Related Documentation

- [Eastern Oklahoma Territory Analysis](./eastern-oklahoma-territory-analysis.md)
- [Western Oklahoma Market Analysis](./western-oklahoma-market-analysis.md)
- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md)
- [POS Integration Field Guide](./pos-integration-field-guide.md)

---

*Research conducted December 2024. Territory classifications based on QuikTrip presence, OCC licensing records, and company acquisition history. D&H United's Show Me Petroleum acquisition (August 2024) significantly extends their Missouri coverage.*


I-44 North Corridor: Tulsa to Joplin Territory Analysis

# Knowledge Base Articles Index

**Last Updated:** 12/27/2024
**Total Articles:** 25
**Audience:** Field Technicians, Station Owners, Compliance Officers

---

## Core Technical References

| Article | Lines | Coverage |
|---------|-------|----------|
| [gilbarco-encore-complete-reference.md](./gilbarco-encore-complete-reference.md) | 346 | X+Y nomenclature, hydraulics, D-Box, LON, calibration, error codes |
| [leak-detection-systems-guide.md](./leak-detection-systems-guide.md) | 494 | PLLD/CSLD, part numbers, EPA 40 CFR 280, OK/TX/KS compliance |
| [stp-troubleshooting-guide.md](./stp-troubleshooting-guide.md) | 364 | Franklin/Red Jacket fault codes, motor testing, flowcharts |
| [veeder-root-atg-alarm-reference.md](./veeder-root-atg-alarm-reference.md) | 349 | TLS-350/450/4 alarms, compliance checklists |
| [service-truck-build-guide.md](./service-truck-build-guide.md) | 175 | 2025 chassis/body/crane pricing, OK dealers |

---

## Equipment Troubleshooting

### Dispensers

| Article | Equipment |
|---------|-----------|
| [gilbarco-encore-complete-reference.md](./gilbarco-encore-complete-reference.md) | Gilbarco Encore series |
| [wayne-dispenser-troubleshooting.md](./wayne-dispenser-troubleshooting.md) | Wayne Ovation/Helix |
| [gilbarco-crind-flexpay-guide.md](./gilbarco-crind-flexpay-guide.md) | FlexPay CRIND payment terminals |

### Tank Monitoring & Leak Detection

| Article | Equipment |
|---------|-----------|
| [veeder-root-atg-alarm-reference.md](./veeder-root-atg-alarm-reference.md) | Veeder-Root TLS consoles |
| [veeder-root-csld-failures.md](./veeder-root-csld-failures.md) | CSLD system issues |
| [leak-detection-systems-guide.md](./leak-detection-systems-guide.md) | PLLD, CSLD, mechanical LLD |

### Pumps & Flow

| Article | Topic |
|---------|-------|
| [stp-troubleshooting-guide.md](./stp-troubleshooting-guide.md) | Submersible turbine pumps |
| [troubleshooting-slow-flow-nozzles.md](./troubleshooting-slow-flow-nozzles.md) | Slow flow diagnosis |
| [slow-flow-cold-weather-programming.md](./slow-flow-cold-weather-programming.md) | Winter flow issues |

### POS & Networking

| Article | Equipment |
|---------|-----------|
| [passport-pos-networking-guide.md](./passport-pos-networking-guide.md) | Gilbarco Passport |
| [commander-pos-networking-guide.md](./commander-pos-networking-guide.md) | Verifone Commander |
| [pos-integration-field-guide.md](./pos-integration-field-guide.md) | General POS integration |
| [card-network-configuration-guide.md](./card-network-configuration-guide.md) | Payment network setup |
| [troubleshooting-verifone-connectivity.md](./troubleshooting-verifone-connectivity.md) | Verifone network issues |
| [troubleshooting-verifone-datawire.md](./troubleshooting-verifone-datawire.md) | Datawire connectivity |

### DEF Systems

| Article | Topic |
|---------|-------|
| [troubleshooting-def-error-20.md](./troubleshooting-def-error-20.md) | DEF Error 20 resolution |
| [def-winterization-field-guide.md](./def-winterization-field-guide.md) | Cold weather DEF |

---

## Compliance & Reference

| Article | Coverage |
|---------|----------|
| [compliance-drop-tube-verification.md](./compliance-drop-tube-verification.md) | Tank drop tube inspection |
| [error-codes-diagnostic-reference.md](./error-codes-diagnostic-reference.md) | Multi-manufacturer error codes |

---

## Territory & Market Analysis

| Article | Region |
|---------|--------|
| [western-oklahoma-market-analysis.md](./western-oklahoma-market-analysis.md) | Western OK market |
| [eastern-oklahoma-territory-analysis.md](./eastern-oklahoma-territory-analysis.md) | Eastern OK territory |
| [i44-corridor-analysis.md](./i44-corridor-analysis.md) | I-44 corridor stations |
| [hydrogen-infrastructure-oklahoma.md](./hydrogen-infrastructure-oklahoma.md) | Future hydrogen infrastructure |

---

## Technician Resources

| Article | Purpose |
|---------|---------|
| [service-truck-build-guide.md](./service-truck-build-guide.md) | Service truck specifications |
| [field-technician-tools-guide.md](./field-technician-tools-guide.md) | Tool requirements |

---

## Related Documentation

- [FUEL_TECH_INSIDER_KNOWLEDGE.md](../FUEL_TECH_INSIDER_KNOWLEDGE.md) - 8 years field experience
- [SERVICE_COMPANY_ACCOUNTABILITY.md](../SERVICE_COMPANY_ACCOUNTABILITY.md) - Station owner guide
- [Oklahoma Compliance](../../compliance/oklahoma/README.md) - State-specific requirements

---

*This index is maintained as articles are added. See individual articles for detailed content.*


Knowledge Base Articles Index

Leak Detection Systems Field Technician Reference Guide

Petroleum Equipment Error Codes: Complete Diagnostic Reference

# Petroleum Service Truck Build Costs: Complete 2025 Guide

Building a service truck for petroleum equipment field work requires **$80,000–$160,000** total investment, with the configuration varying dramatically based on lifting capacity needs, integrated power systems, and chassis selection. The critical decision for fuel equipment technicians centers on crane capacity—extracting submersible turbine pumps demands **minimum 2,000 lb capacity at 10-foot reach**, a specification that eliminates entry-level crane options entirely.

This guide covers chassis options from Ford, RAM, Isuzu, and Chevrolet; service bodies from Reading, Knapheide, Royal, and Harbor; crane systems from AutoCrane, Stellar, and IMT; plus air compressors, welder/generators, and accessory systems. All pricing reflects 2024-2025 MSRP and dealer quotes with Oklahoma regional upfitter contacts included.

## Chassis selection drives payload and budget constraints

The foundation of any petroleum service truck is a Class 4-5 chassis cab with **14,000–19,500 lb GVWR**—necessary to support crane bodies weighing 2,000+ lbs plus equipment, tools, and the crane system itself. Four manufacturers dominate this segment with distinct advantages.

**Ford F-450/F-550 Chassis Cab** remains the most popular choice among Oklahoma petroleum contractors. The 2025 F-450 XL starts at **$55,000–$58,000** (regular cab, DRW) while the F-550 ranges **$58,000–$62,000**. The 6.7L Power Stroke diesel adds **$12,495** to base price but delivers **950 lb-ft torque** critical for field operations. Ford's clean top-of-rail frame design simplifies body mounting, and the 10-speed TorqShift transmission includes standard PTO provisions. Bob Moore Ford Pro in Oklahoma City (405-349-5672) maintains upfit partnerships with Knapheide and Reading for turnkey builds.

**RAM 4500/5500 Chassis Cab** offers the most competitive starting MSRP: the 4500 at **$55,660** and 5500 at **$56,770** for 2025 Tradesman trim. The 6.7L Cummins diesel provides **800 lb-ft torque** with legendary reliability, though the new 2025 models now include left and right-side PTO operation. Maximum payload reaches **11,960 lbs** on the 5500—sufficient for heavily equipped crane service bodies.

| Chassis Model | 2025 Starting MSRP | GVWR | Max Payload | Engine Options |
|--------------|-------------------|------|-------------|----------------|
| Ford F-450 XL | $55,000–$58,000 | 16,500 lb | ~9,500 lb | 7.3L Gas, 6.7L Diesel (+$12,495) |
| Ford F-550 XL | $58,000–$62,000 | 19,500 lb | ~12,000 lb | 7.3L Gas, 6.7L Diesel (+$12,495) |
| RAM 4500 Tradesman | $55,660 | 16,500 lb | ~10,500 lb | 6.4L HEMI, 6.7L Cummins |
| RAM 5500 Tradesman | $56,770 | 19,500 lb | ~11,960 lb | 6.4L HEMI, 6.7L Cummins |
| Chevy 5500HD WT | $60,685 | 19,500 lb | ~12,000 lb | Duramax Diesel only |
| Isuzu NRR | $58,000–$65,000 | 19,500 lb | ~13,500 lb | 5.2L Diesel |

**Isuzu NPR-HD/NRR cabover** configurations deserve consideration for operators frequently working in congested petroleum facilities. The forward cab position provides superior visibility, and the **50-degree wheel cut** enables tight maneuvering impossible with conventional chassis. The 2025 NRR diesel starts around **$58,000–$65,000** with payload capacity exceeding 13,000 lbs.

## Service body selection determines storage and crane mounting capability

Petroleum field work demands extensive compartmentalized storage plus reinforced substructure for crane mounting. Four manufacturers dominate the commercial market with 11-foot bodies designed for 84" cab-to-axle configurations.

**Reading Truck Body** produces the most crane-focused designs. Their **Master Mechanic MM 25-Series** handles cranes up to **5,000 lbs (25,000 ft-lb rating)** with integrated CABLOC drawer units and tread plate surfaces throughout—essential for petroleum work where spills are inevitable. The **RM-78 Series** supports crane ratings up to **78,000 ft-lb** for 8,000–12,500 lb hydraulic cranes, featuring torsion box understructure and full-power hydraulic outriggers. Pricing for crane bodies ranges **$15,000–$25,000** body-only, with the aluminum Classic II standard service body starting around **$10,000–$14,000** for 11-foot lengths.

Reading's Oklahoma City location (1401 Enterprise Ave, 405-681-6503) provides full upfitting, body mounting, and preventative maintenance services with retail parts counter access.

**Knapheide** offers the broadest distribution network and a **6-year warranty** on steel bodies (10-year on aluminum). Their steel KS Series uses 14-gauge A-40 galvanneal construction with 12-step E-coat finish. Compartment configurations include 500 Series (front vertical + lower rear), 600 Series (full-height vertical front and rear), and 700 Series combination layouts. The crane service body with torsion box floor option handles ratings up to **66,000 ft-lb**. Steel service bodies run **$7,000–$11,000** while crane bodies reach **$14,000–$22,000**.

**Royal Truck Body** (now part of Aebi Schmidt Group) manufactures premium steel bodies featuring **Axalta Imron Elite automotive grade paint** and **22-inch compartment depth** on DRW configurations—deeper than most competitors. Their 11-foot standard body weighs **1,910 lbs** with 106 cubic feet of storage. Pricing aligns with Reading at **$8,000–$12,000** for standard steel bodies.

| Manufacturer | 11' Steel Body | 11' Aluminum Body | 11' Crane Body | Warranty |
|-------------|---------------|-------------------|----------------|----------|
| Reading | $8,000–$12,000 | $10,000–$14,000 | $15,000–$25,000 | Varies |
| Knapheide | $7,000–$11,000 | $9,000–$13,000 | $14,000–$22,000 | 6-Year (10-Year Aluminum) |
| Royal | $8,000–$12,000 | Contact dealer | Contact dealer | Contact dealer |
| Harbor | $6,500–$10,000 | Limited | $13,000–$20,000 | Contact dealer |

Installation costs add **$1,500–$3,500** for standard bodies and **$3,000–$5,000** for complex crane body installations including electrical integration.

## Crane systems for STP extraction require careful capacity matching

Extracting submersible turbine pumps—weighing **1,500–3,000 lbs** and requiring **8–12 foot reach** over tank sumps—eliminates entry-level cranes from consideration. The critical specification is capacity at extended reach, not maximum rating at minimum boom length.

**AutoCrane** dominates the petroleum service market with proven reliability. The **5005H** provides the sweet spot for STP work: **5,000 lb capacity at 5-foot reach** degrades to **2,500 lb at 10 feet** and **2,080 lb at 12 feet**—meeting all STP requirements with margin. The **6006EH** offers additional headroom with **3,600 lb capacity at 10 feet** and **3,000 lb at 12 feet**. Standard features include 370° power rotation, automatic overload protection, and ANSI B30.5 compliance.

| Model | Crane Rating | Capacity @ 10' | Capacity @ 12' | Max Reach | MSRP Range |
|-------|-------------|----------------|----------------|-----------|------------|
| AutoCrane 3203H | 10,500 ft-lb | 1,050 lb | - | 15' | $8,000–$11,000 |
| AutoCrane 5005H | 25,000 ft-lb | **2,500 lb** | **2,080 lb** | 20' | $14,000–$18,000 |
| AutoCrane 6006EH | 36,000 ft-lb | **3,600 lb** | **3,000 lb** | 20' | $18,000–$22,000 |
| Stellar EC4000 | 16,000 ft-lb | ~2,000 lb | ~1,700 lb | 20' | **$20,210** |
| Stellar EC5000 | 25,000 ft-lb | ~2,500 lb | ~2,100 lb | 20' | $23,000–$25,000 |
| IMT 3203i | 12,000 ft-lb | ~1,200 lb | - | 15' | $12,000–$15,000 |
| IMT 4004i | 18,000 ft-lb | ~1,800 lb | - | 16' | $14,000–$17,000 |

**Stellar Industries EC Series** electric cranes eliminate hydraulic system requirements, enabling installation on gas-powered chassis without PTO infrastructure. The **EC4000** at **$20,210** (confirmed dealer pricing) provides 4,000 lb capacity with 20-foot reach and significantly quieter operation for residential-area work. Electric cranes require less maintenance and allow engine-off operation—advantageous for extended lift operations.

Complete installed costs (crane + mounting + outriggers + controls) range from **$15,000–$25,000** for mid-range models suitable for STP work, reaching **$40,000–$55,000** for heavy-duty 10,000+ lb systems.

## Air compressor selection balances CFM requirements against installation complexity

Petroleum field service demands minimum **30 CFM at 100 PSI** for 1-inch impact wrenches used on piping connections, with **70+ CFM** required for sandblasting applications. Three mounting approaches exist: underhood (vehicle engine-driven), standalone (deck-mounted with dedicated engine), and hydraulic-driven (using existing crane hydraulics).

**VMAC UNDERHOOD systems** represent the most elegant solution for petroleum service. The **UNDERHOOD70** delivers **70 CFM at 100 PSI** with **100% duty cycle**—no waiting for tank refill—while consuming zero deck space. The system integrates with the truck's cooling system via liquid-to-liquid cooler and includes digital throttle control through OBD2 CAN bus. Installed costs run **$8,000–$12,000** including 16–21 hours installation labor. The **UNDERHOOD150** provides **90–110 CFM** for sandblasting at **$10,000–$15,000** installed.

For trucks without underhood capacity, the **VMAC G30** standalone unit at **$5,728** provides 30 CFM with Honda GX390 engine—the minimum threshold for most petroleum work. The stacked configuration at **$6,604** reduces footprint for service body mounting.

**Vanair Viper Series** offers higher CFM in standalone packages. The diesel **Viper D80** delivers **80 CFM at 100 PSI** with Kubota Tier 4 Final engine and Smart Start Technology (auto-sensing air demand). Pricing runs **$18,303–$18,727**—significantly higher than VMAC but fully portable between trucks.

| System | CFM @ 100 PSI | Drive Type | Weight | Price |
|--------|--------------|-----------|--------|-------|
| VMAC G30 | 30 | Gas engine | 205 lbs | **$5,728** |
| VMAC UNDERHOOD70 | 70 | Vehicle engine | ~136 lbs | $8,000–$12,000 installed |
| VMAC UNDERHOOD150 | 90–110 | Vehicle engine | ~206 lbs | $10,000–$15,000 installed |
| Vanair Viper G80 | 80 | Gas engine | 473 lbs | **$11,909** |
| Vanair Viper D80 | 80 | Diesel engine | 735 lbs | **$18,303** |
| BOSS Infinity 80 | 80 | Hydraulic | - | **$8,800** |

**BOSS Industries Infinity Series** hydraulic-driven compressors integrate with existing crane hydraulic systems—an efficient approach when cranes are already installed. The **Infinity 80** at **$8,800** delivers 80 CFM using the truck's hydraulic pump, eliminating dedicated compressor engine weight and fuel consumption.

## Generator and welding systems determine field repair capability

Petroleum service requires **200–300 amp welding** for structural repairs and **5–10 kW generator output** for power tools and lighting. Multi-function systems combining air, power, and welding have become standard on fully-equipped service trucks.

**Miller Electric EnPak A60 systems** represent the integration benchmark. The **A60GBHW** provides 60 CFM rotary screw air, 7 kW generator, **325 amp welder**, 16 GPM hydraulic pump, and battery charging—all from a single 736 lb package powered by Kubota D902 diesel. Operating with truck engine off reduces fuel consumption by 30% and extends truck drivetrain life. Pricing ranges **$18,000–$25,000** unit-only plus **$3,000–$8,000** installation.

**Lincoln Electric Ranger Series** offers the most cost-effective standalone welder/generators. The **Ranger 305 G** at approximately **$8,000–$12,000** delivers 300 amp DC welding with 9,500 watt continuous generator output—meeting typical petroleum service requirements without the weight penalty of air compressor integration.

For heavy-duty applications, the **Miller Big Blue 600 Air Pak** provides 600 amp welding, 20 kW generator, and 60 CFM Ingersoll Rand compressor in a single trailer-mounted or truck-mounted package. This supports arc gouging with 3/8" carbons and powers multiple welding stations simultaneously—overkill for typical petroleum service but essential for pipeline or heavy equipment work. Pricing reaches **$45,000–$55,000**.

| System | Weld Amps | Generator | Air CFM | Hydraulics | Price Range |
|--------|----------|-----------|---------|------------|-------------|
| Lincoln Ranger 305 G | 300 | 9.5 kW | - | - | $8,000–$12,000 |
| Miller Trailblazer 330 | 330 | 10.5 kW | - | - | $7,500–$11,000 |
| VMAC 6-in-1 Kubota | 250 | 8 kW | 45 | PTO | **$21,803** |
| Miller EnPak A60GBHW | 325 | 7 kW | 60 | 16 GPM | $18,000–$25,000 |
| Miller Big Blue 600 Air Pak | 600 | 20 kW | 60 | - | $45,000–$55,000 |

**VMAC 6-in-1 systems** at **$21,803** (Kubota diesel) provide the best value multifunction package for petroleum service: 250 amp welding, 8 kW generator, 45 CFM compressor, battery boost/charge, and PTO output—all in a package 410 lbs lighter than Miller equivalents with smaller footprint.

## Tool organization and lighting complete the build

Professional petroleum service demands organized storage that survives constant vibration and frequent access. **Weather Guard Pack Rat systems** lead the market with **750 lb top/sides capacity** and **425 lb per drawer rating** using 14-gauge steel construction. Model 308-3 (48"×39.75"×9.5" with 4 compartments) runs **$1,119–$1,574**. The ARMOR-TUF powder coat resists petroleum products while the One-Touch latch enables single-hand operation.

**Adrian Steel** offers budget alternatives starting at **$266** (AS-19 2-drawer unit) with Lock n Latch systems providing open/retained/locked positions. Drawer capacity drops to **25 lbs per drawer**—adequate for hand tools but not heavy equipment.

Ladder racks from **System One** provide **1,250 lb capacity** in rust-free aluminum construction at **$1,000–$1,400** for Heavy Duty Contractor Rig configurations. The aluminum construction outlasts steel in petroleum environments where fuel exposure accelerates corrosion.

**Whelen Engineering** dominates warning and scene lighting with SAE Class 1 certified LED products. Mini LED bars in 16-23" lengths run **$305–$569** with 20+ flash patterns. For work lighting, **SoundOff Signal mPower 9×7** delivers **8,600 lumens** with 500-foot visibility and 5-year warranty—essential for night service calls at fuel facilities. Complete lighting packages range **$1,500–$4,000** depending on warning light configuration.

## Complete build cost estimates for three equipment levels

**Entry-level petroleum service truck** suitable for dispenser service and light pump work:

| Component | Specification | Cost |
|-----------|--------------|------|
| Chassis | RAM 3500 Chassis Cab Tradesman Diesel | $53,000 |
| Service Body | Knapheide Steel 11' KS Series | $9,000 |
| Crane | AutoCrane 3203H installed | $12,000 |
| Air Compressor | VMAC G30 | $6,500 |
| Welder/Generator | Lincoln Ranger 225 | $6,000 |
| Tool Organization | Adrian Steel drawer set | $1,200 |
| Lighting | Basic LED work/warning package | $1,500 |
| **Total Entry Build** | | **$89,200** |

**Mid-range petroleum service truck** equipped for STP extraction and moderate welding:

| Component | Specification | Cost |
|-----------|--------------|------|
| Chassis | Ford F-450 Chassis Cab XL 6.7L Diesel | $68,000 |
| Service Body | Reading Master Mechanic MM25 11' | $18,000 |
| Crane | Stellar EC5000 installed | $28,000 |
| Air Compressor | VMAC UNDERHOOD70 installed | $10,000 |
| Welder/Generator | Miller Trailblazer 330 Diesel | $12,000 |
| Tool Organization | Weather Guard Pack Rat system | $3,500 |
| Lighting | Whelen scene + warning package | $2,500 |
| Ladder Rack | System One HD Contractor | $1,200 |
| **Total Mid-Range Build** | | **$143,200** |

**Fully-equipped petroleum service truck** for comprehensive field capability:

| Component | Specification | Cost |
|-----------|--------------|------|
| Chassis | Ford F-550 Chassis Cab Crew XL 6.7L Diesel | $78,000 |
| Service Body | Reading RM-78 Heavy Duty Crane Body | $25,000 |
| Crane | AutoCrane 6006EH with radio remote installed | $28,000 |
| Multifunction | Miller EnPak A60GBHW installed | $28,000 |
| Tool Organization | Weather Guard + Sortimo modular | $5,500 |
| Lighting | Whelen full LED package | $4,000 |
| Ladder Rack | System One I.T.S. Utility with Work Winch | $1,500 |
| Additional Accessories | Vise plate, tank storage, specialty mounts | $3,000 |
| **Total Full Build** | | **$173,000** |

## Oklahoma regional upfitters and typical lead times

**Reading Truck Oklahoma City** (1401 Enterprise Ave, 405-681-6503) provides comprehensive upfitting including crane body installation, accessory mounting, and preventative maintenance. Standard upfits complete in **2–4 weeks** when bodies are in stock; complex crane builds extend to **10–12 weeks**.

**Oklahoma Upfitters** (Oklahoma City, 405-606-8065) handles flatbeds, service bodies, cranes, liftgates, and specialty equipment with competitive regional pricing. **Truck Van Fleet Upfitters** (Tulsa, truckvanfleetupfitters.com) provides shelving, ladder racks, and lighting installation with spray-on bedliner services.

For faster turnaround, **Service Truck Depot** (Texas, servicetruckdepot.com) maintains **100+ work-ready custom upfits in stock** with average **2-week turnaround** on custom builds—valuable for urgent fleet additions. The Knapheide Truck Equipment Center in Red Oak (Dallas-Fort Worth area) serves Oklahoma customers with full crane body capability.

**Key planning recommendation**: Order service bodies when chassis is ordered or in transit, not after arrival. The industry-standard 10–12 week lead time for custom crane bodies can otherwise idle expensive chassis for months. Ford's Delayed Start Warranty extends coverage up to 24 months from production to accommodate upfit time.

## Conclusion

Petroleum service truck investment ranges from **$89,000 for entry-level** through **$173,000 for fully-equipped** builds, with the mid-range **$140,000–$150,000** configuration meeting most STP extraction and field welding requirements. The most consequential decisions involve crane capacity (minimum 5,000 lb rating for comfortable STP margins) and power system integration (EnPak or VMAC multifunction systems eliminate separate component weight and space penalties).

Oklahoma operators benefit from Reading Truck's local presence for warranty service and preventative maintenance, though Texas upfitters like Service Truck Depot offer faster turnaround when speed matters more than proximity. The 2025 chassis market favors RAM's competitive MSRP and Cummins reliability, though Ford's broader upfitter support network may justify the $3,000–$5,000 premium for organizations prioritizing service access across the region.

Petroleum Service Truck Build Costs: Complete 2025 Guide

# Slow Flow in Cold Weather: The Programming Fix

**Last Updated:** 12/09/2025  
**Category:** Dispensers / Troubleshooting  
**Difficulty:** Intermediate  
**Impact:** HIGH - Fixes issues that cost $10k+ in wasted parts

---

## 🎯 The $10,000 Mistake

> *"I've seen $10k bills of parts and labor over 6 months for slow flow that wouldn't go away. I came out, checked the programming - lamp test was set to 3 instead of 6+, no prestart enabled. Free fix."*

**The Pattern:**
- Slow flow every morning
- Worse in cold weather
- Multiple techs, multiple parts replaced
- Problem keeps coming back

**The Cause:** Dispenser programmed for electronic leak detector, but station has mechanical.

---

## 🔧 Electronic vs Mechanical Leak Detectors

### Electronic Leak Detector
- Monitors STP electronically
- No high prime needed
- Dispenser settings: Lamp test LOW, prestart OFF

### Mechanical Leak Detector
- Uses physical pressure/flow sensing
- Needs higher prime pressure
- Dispenser settings: Lamp test HIGH (6+), prestart ON

---

## ⚠️ The Problem

**New dispensers come pre-programmed for ELECTRONIC leak detectors.**

If your station has MECHANICAL leak detectors and no one changes the programming:
- Dispenser doesn't prime the STP properly
- Low initial flow, especially in cold
- Appears to be STP/check valve issue
- Parts get thrown at it
- Problem persists

---

## 🛠️ The Fix (Gilbarco)

### Step 1: Determine Leak Detector Type

**At the STP/Tank:**
- Electronic: Has wiring to control box, digital display
- Mechanical: Physical float/valve mechanism, no electronics

**If unsure:** Look at existing dispensers that work properly, check their settings.

### Step 2: Access Dispenser Programming

**Gilbarco Encore:**
1. Enter diagnostic mode
2. Navigate to Configuration
3. Find Pump/STP settings

### Step 3: Check/Adjust Settings

| Setting | Electronic LD | Mechanical LD |
|---------|---------------|---------------|
| Lamp Test | 3 (low) | 6+ (high) |
| STP Prestart | OFF | ON |

### Step 4: Test

1. Complete a transaction
2. Start another immediately
3. Flow should be normal from start
4. Test in cold conditions if possible

---

## 🧪 Why Cold Weather Makes It Worse

- Fuel is thicker when cold
- Mechanical LD needs more prime pressure to open
- Without prestart, STP doesn't run until handle lifted
- First second of flow is slow (waiting for prime)
- Customer complains, tech gets called

---

## 💡 Diagnostic Questions

**Before replacing ANY parts for slow flow:**

1. Is it worse in the morning/cold?
2. Does it improve after a few gallons?
3. Have other techs tried to fix this?
4. What type of leak detector does this site have?
5. What are the current lamp test/prestart settings?

**If answers are:** Morning/cold, yes improves, yes multiple attempts, mechanical, low/off

**Solution:** Change programming, not parts.

---

## 📋 Pre-Visit Checklist

- [ ] Ask: When does slow flow occur?
- [ ] Ask: Is it the first transaction of the day?
- [ ] Ask: What parts have already been replaced?
- [ ] Determine: Leak detector type (electronic/mechanical)
- [ ] Check: Lamp test setting
- [ ] Check: STP prestart setting

---

## 📊 Cost Comparison

| Approach | Cost | Success Rate |
|----------|------|--------------|
| Check programming first | $100-200 (1 hour labor) | ~30% of slow flow calls |
| Replace STP check valve | $400-600 | Only if actually bad |
| Replace nozzle/breakaway | $200-300 | Only if actually bad |
| Replace STP | $2,000+ | Last resort |

**Always check programming before replacing parts.**

---

## 🚨 Red Flag History

If service records show:
- Multiple slow flow visits
- Various parts replaced
- Problem keeps returning
- Especially in cold months

**CHECK THE PROGRAMMING.**

---

## 📝 Field Notes

```
Date: ___________
Site: ___________

Symptom: Slow flow in cold/morning

Leak Detector Type: [ ] Electronic [ ] Mechanical

Current Settings:
- Lamp Test: _____
- STP Prestart: [ ] ON [ ] OFF

Correct Settings Applied:
- Lamp Test: _____  
- STP Prestart: [ ] ON [ ] OFF

Test Results:
___________
```

---

*"99% of techs don't know the difference between electronic and mechanical leak detectors in terms of dispenser programming. This fact alone probably causes slow flow issues constantly."*



Slow Flow in Cold Weather: The Programming Fix

# Submersible Turbine Pump (STP) Troubleshooting Guide

**Category:** Equipment / Tanks / STP
**Equipment:** Franklin FE Petro, Red Jacket, Veeder-Root
**Last Updated:** 12/25/2024
**Difficulty:** Intermediate to Advanced
**Cross-Reference:** [Error Codes Reference](./error-codes-diagnostic-reference.md), [Slow Flow Troubleshooting](./troubleshooting-slow-flow-nozzles.md)

---

## Quick Reference

**Franklin FE Petro Support:** 800-348-2420
**Veeder-Root Support:** 800-323-1799

---

## 1. STP Types & Configurations

### 1.1 Pump Categories

#### Fixed Speed Pumps

- Run at constant speed regardless of demand; flow controlled by system back-pressure
- Available in 1/3 HP, 3/4 HP, 1-1/2 HP, 2 HP, 3 HP, and 5 HP configurations
- Single-phase (1/3-2 HP) or three-phase (3-5 HP) motors
- Controller: Guardian Series (Franklin) or Isotrol/IQ (Red Jacket)
- Prone to hydraulic hammer on sudden flow stoppage

#### Variable Frequency Drive (VFD) Pumps

- Adjust motor speed in real-time to maintain consistent pressure/flow
- Available in 2 HP and 4 HP only (Franklin MagVFC)
- Selectable deadhead pressure: 24-42 psi
- Max flow: 2 HP = 110 GPM, 4 HP = 140 GPM
- Minimizes hydraulic hammer and reduces component wear
- RS485 communication for remote monitoring

### 1.2 Installation Configurations

| Configuration | Description | Troubleshooting Notes |
|---------------|-------------|----------------------|
| **Single Dispenser** | One STP serves one dispenser | Simplest - issues isolated to single pump/dispenser |
| **Multi-Dispenser** | One STP serves 2-4 dispensers via manifold | Check shear valves and filters at each dispenser independently |
| **Tandem/Master-Slave** | Two STPs share load | MagVFC shows "Sr" status; phase matching critical for 3-phase |

---

## 2. Controller Fault Codes

### 2.1 Franklin Guardian Series (Fixed Speed)

The Guardian controller features a 3-1/2" LCD display, automatic calibration, and logs the last 5 abnormal conditions in non-volatile memory.

| Code | Condition | Diagnosis & Action |
|------|-----------|-------------------|
| **UL** | Underload | Tank empty, clogged intake screen, or incorrect HP setting. Check fuel level first, then inspect intake filter screen (IFS). |
| **LI** | Low Voltage | Incoming voltage <185V. Resets automatically when voltage >200V. Check utility supply, transformer tap settings, wire gauge for voltage drop. |
| **HI** | High Voltage | Incoming voltage >260V. Resets when <245V. Contact utility or check transformer settings. |
| **OL** | Overload (Running) | Motor drawing excessive current while running. Check for clogged impeller, debris in pump, or mechanical binding. Test motor winding resistance. |
| **Lr** | Locked Rotor | Motor cannot start - drawing locked rotor amps. Check for foreign material, corrosion (especially water-ballasted tanks), or defective motor. Verify shaft spins freely. |
| **OC** | Open Circuit | Broken wiring or thermal overload tripped. Check motor pigtail connections, junction boxes, and motor winding continuity. |
| **Er** | Extended Run | Pump running beyond normal cycle time. Check for stuck dispenser nozzle, failed solenoid valve, or leak in product line. |
| **rEL** | Relay Fault | Internal relay failure in controller. Replace controller. |
| **unc** | Uncalibrated | Controller has not learned STP electrical characteristics. Press calibration button to auto-calibrate. |

### 2.2 Franklin MagVFC (Variable Speed)

Dual 7-segment display shows running status and fault codes. Fault history stores last 3 faults (F0, F1, F2).

| Code | Condition | Diagnosis & Action |
|------|-----------|-------------------|
| **UL** | Underload/Tank Empty | Check SW3 Pole 6 HP setting, verify fuel level, inspect intake for obstruction. |
| **LI** | Low Voltage | Input voltage outside 200-250VAC range. Check utility supply. |
| **LU** | Locked Rotor (Startup) | Foreign material in pump or defective PMA (permanent magnet assembly). Verify shaft rotation. |
| **OC** | Open Circuit | Wiring break or motor winding failure. Test continuity from controller to motor. |
| **OL** | Overload | Excessive current draw. Check for mechanical binding or debris. |

#### MagVFC Status Codes (Not Alarms)

- **ID** - Idle, no hook signal from dispenser
- **Pr:NN** - Pressure regulating at NN psi (flashes when running)
- **PL** - Power limit, operating beyond pressure regulate point
- **Sr** - Slave running (master/slave configuration)

---

## 3. Motor Electrical Testing

### 3.1 Testing Procedure

1. Disconnect power and lock-out/tag-out the controller
2. Remove motor control outputs (M1, M2) from controller terminals
3. Set ohmmeter to appropriate scale for expected resistance
4. Measure between motor wires per tables below (should match specs +/-5%)
5. Test any motor wire to ground - should be open circuit (infinite resistance)
6. For three-phase: resistance unbalance >5% from average indicates connection issues

### 3.2 Franklin FE Petro Winding Resistance (60 Hz Single-Phase)

| Model | R-B (Ohms) | R-O (Ohms) | B-O (Ohms) | SF Amps | LRA |
|-------|------------|------------|------------|---------|-----|
| STP 33 (1/3 HP) | 27 | 19 | 8 | 3.1 | 11 |
| STP 75 (3/4 HP) | 20 | 17 | 3 | 6.1 | 27 |
| STP 150 (1-1/2 HP) | 15 | 13 | 2 | 10.5 | 39 |
| STP 200 (2 HP) | 4.6 | 3 | 1.8 | 11.4 | 41 |

*R = Red, B = Black, O = Orange wire. All values +/-5%. 208-230V motors.*

### 3.3 Three-Phase Motors (60 Hz, Lead-to-Lead)

| Model | Resistance (Ohms) | SF Amps | LRA |
|-------|-------------------|---------|-----|
| STP 3 (3 HP, 208-230V) | 2 | 11.0 | 63 |
| STP 5 (5 HP, 208-230V) | 1 | 17.7 | 91 |
| STP 5H (5 HP, 460V) | 4 | 8.6 | 52 |
| STP 5G (5 HP, 575V) | 6 | 6.9 | 36 |

### 3.4 Variable Speed Motors

- **VS2 (2 HP):** 2.5 +/-1 ohms lead-to-lead
- **VS4 (4 HP):** 1.2 +/-1 ohms lead-to-lead

### Interpretation Guide

| Reading | Meaning | Action |
|---------|---------|--------|
| **0 ohms** | Shorted winding | Replace motor |
| **Infinite/OL** | Open winding | Replace motor |
| **Any wire to ground shows continuity** | Ground fault | Replace motor |
| **>5% variance from spec** | Connection issue or winding degradation | Investigate connections first |

---

## 4. Common Failure Modes

### 4.1 Motor Failures

| Failure Mode | Symptoms | Root Cause |
|--------------|----------|------------|
| Overheating | Thermal overload trips, OL fault, reduced life | Insufficient cooling, overloading, low liquid level covering motor, blocked intake |
| Seal Failure | Water in motor housing, bearing noise, shorts | Water intrusion, abrasive particles, thermal shock from hot/cold cycles |
| Electrical Faults | Intermittent operation, tripped breakers | Phase imbalance, low/high voltage, transient surges, phase loss |
| Locked Rotor | Lr/LU fault, motor hums but won't start | Foreign material, corrosion (especially water-ballasted tanks), seized bearings |
| Wrong Rotation | Very low flow, polished impeller | Miswired three-phase - swap any two phases to correct |

### 4.2 Mechanical Failures

| Failure Mode | Symptoms | Root Cause |
|--------------|----------|------------|
| Clogged Impeller | High amperage, reduced flow, OL faults | Debris, rags, solids from tank bottom |
| Check Valve Failure | Pressure loss, slow flow, air in lines | Debris preventing proper seating, worn seal |
| Intake Obstruction | UL fault, cavitation noise, erratic flow | Tank bottom debris, rag/absorbent pad blocking inlet |
| Cavitation | Impeller/diffuser damage, seal deterioration | Running with low fuel level, restricted intake |

### 4.3 System-Level Issues

| Issue | Symptoms | Root Cause |
|-------|----------|------------|
| Air in Lines | Sputtering flow, vapor lock, slow startup | Leaking pipes, low fuel level, thermal contraction overnight |
| Hydraulic Hammer | Banging in pipes, component wear, leaks at fittings | Fixed-speed pump with sudden flow stoppage (nozzle snap-off) |
| Slow Flow | Long fueling times, customer complaints | Clogged filters, dirty tank, mechanical LLD in slow-flow mode, check valve issues, high-point air traps |
| No Flow | Pump runs but no fuel delivery | Airlock, closed shear valve, failed check valve, empty tank |

---

## 5. Pressure Testing & Line Leak Detection

### 5.1 EPA Requirements

Pressurized piping systems must meet three leak detection thresholds:

| Test Type | Leak Rate | Requirements |
|-----------|-----------|--------------|
| Gross (Catastrophic) | 3.0 GPH | 1-hour detection, automatic shutdown or slow-flow restriction |
| Periodic/Monthly | 0.2 GPH | Monthly test, statistical or precision method |
| Annual | 0.1 GPH | Annual line tightness test, precision method required |

### 5.2 Mechanical vs Electronic Line Leak Detection

#### Mechanical LLD (3.0 GPH only)

- Detects gross leaks via pressure-activated piston mechanism
- Slow-flow indication (1-3 GPM) when leak detected
- Requires separate annual 0.1 GPH precision test
- **False trips:** Malfunctioning check valve, thermal contraction, air in lines
- **Can miss leaks:** Continuously running pumps, excessive head pressure

#### Electronic LLD (All Thresholds)

- Performs all three tests (3.0, 0.2, 0.1 GPH) automatically
- Pressure transducer monitors line pressure continuously
- Statistical analysis or precision pressure decay methods
- **Franklin EVO:** AUTO-LEARN calibration, Statistical LLD (SLLD)
- **Veeder-Root DPLLD:** Precision testing at full pump pressure, up to 1,178 gal capacity

### 5.3 Manual Pressure Test Procedure

1. Close all dispenser shear valves
2. Activate pump and record running pressure (Pon) - typically 25-35 psi
3. Deactivate pump and immediately record pressure (P1)
4. Wait 5 minutes and record pressure (P2)
5. **PASS:** Pressure remains >12 psi with minimal decay (<2 psi)
6. **FAIL:** Pressure drops below 12 psi or decays rapidly - isolate leak source

#### Leak Isolation

- Close shear valves one at a time and repeat pressure test
- When leak rate decreases, last valve closed isolates the leaking run
- Check dispenser sumps, STP sump, and visible piping for product

---

## 6. Troubleshooting Flowcharts

### 6.1 No Flow Condition

**Symptom:** Customer lifts nozzle, no fuel delivery. Pump may or may not run.

1. **Check controller display** - Note any fault codes (see Section 2)
2. **Verify power supply** - Measure voltage at panel (185-260V acceptable)
3. **Check hook signal** - Verify dispenser is sending pump request
4. **Verify fuel level** - ATG reading or manual stick measurement
5. **Check shear valve** - Ensure open position
6. **Test motor winding** - Resistance per Section 3 specifications
7. **Check shaft rotation** - Should spin freely by hand (pump removed)
8. **Inspect intake** - Remove and check for debris/obstruction

### 6.2 Slow Flow Condition

**Symptom:** Fuel dispenses but flow rate is below normal (<8 GPM at nozzle).

1. **Check/replace fuel filters** - Change yearly, or 6 months if >100K gal/month
2. **Test mechanical LLD** - Re-pressurize system to reset; if flow improves, LLD detected issue
3. **Check for air in lines** - Thermal contraction overnight can introduce vapor
4. **Verify check valve operation** - Debris can prevent full opening
5. **Inspect for visible leaks** - Sumps, dispensers, fittings
6. **Check tank cleanliness** - Debris at intake restricts flow
7. **Review pipeline configuration** - High points trap air/gas and restrict flow

### 6.3 Controller Alarm Condition

**Symptom:** Controller displays fault code, pump disabled.

1. **Note fault code** - Record for diagnosis per Section 2 tables
2. **Check fault history** - Guardian stores last 5; MagVFC stores F0, F1, F2
3. **Verify incoming voltage** - 185-260V range for Guardian, 200-250V for MagVFC
4. **Test motor winding resistance** - Per Section 3 specifications
5. **Check calibration** - "unc" requires auto-calibration sequence
6. **Inspect wiring connections** - Junction boxes, pigtail, controller terminals
7. **Test capacitor** - Single-phase motors only; failed capacitor causes Lr fault

### 6.4 Pressure Loss / LLD Alarm

**Symptom:** Line leak detector alarm, slow flow mode, or pressure decay.

1. **Run gross pressure test** - See Section 5.3 procedure
2. **Check for visible leaks** - STP sump, dispenser sumps, exposed piping
3. **Close shear valves to isolate** - Test each dispenser run independently
4. **Test check valve** - Debris or wear prevents proper seating
5. **Consider thermal effects** - Temperature changes cause pressure variation (not a leak)
6. **Verify LLD operation** - Faulty sensor or solenoid can cause false alarms

---

## 7. Manufacturer Comparison

| Feature | Franklin FE Petro | Red Jacket | Veeder-Root |
|---------|-------------------|------------|-------------|
| Controller | Guardian (fixed), MagVFC (VFD) | Isotrol, IQ Control Box | TLS-450PLUS/350 integration |
| Display | 3-1/2" LCD (Guardian), Dual 7-seg (MagVFC) | LED indicators, basic display | ATG console display |
| Calibration | Auto-calibration (single button) | DIP switch configuration | ATG-based configuration |
| Fault History | Last 5 (Guardian), Last 3 (MagVFC) | Limited LED indication | Full ATG event logging |
| VFD Option | Yes (2 HP, 4 HP) | Limited availability | Via third-party |
| Special Features | MagShell, Active Air Eliminator, TPI network | Adjustable column (RJ1/2/3), yoke disconnect | DPLLD precision LLD, full system integration |
| Key Document | Guardian/MagVFC Installation Manual | UMP Quick Troubleshooting (577014-053) | Annual Checklist procedures |

---

## 8. Annual Maintenance Checklist

Complete annually or per manufacturer recommendations. Document all findings.

### 8.1 Electrical

- [ ] Lock-out/tag-out power supply
- [ ] Inspect conduits and junction boxes for water intrusion
- [ ] Test motor winding resistance (record values)
- [ ] Verify incoming voltage at panel
- [ ] Observe current draw at shut-off pressure (compare to max amp value)
- [ ] Check controller fault history
- [ ] Test capacitor (single-phase motors)

### 8.2 Mechanical

- [ ] Inspect external pressure seals for leakage
- [ ] Check check valve seating and operation
- [ ] Inspect line leak detector port
- [ ] Verify riser seals integrity
- [ ] Check O-ring sealing surfaces for corrosion
- [ ] Inspect packer/manifold fasteners
- [ ] Clean or replace intake filter screen (IFS)

### 8.3 Performance

- [ ] Record running pressure with no dispensing
- [ ] Measure flow rate at each dispenser nozzle
- [ ] Replace dispenser filters (or 6 months if >100K gal/month)
- [ ] Check for obstructions in dispenser lines
- [ ] Run pressure decay test per Section 5.3
- [ ] Perform 0.1 GPH annual line tightness test

### 8.4 Documentation

- [ ] Record all test values in maintenance log
- [ ] Note any fault codes observed during service period
- [ ] Document parts replaced and serial numbers
- [ ] Update equipment inventory as needed
- [ ] File compliance records per EPA/state requirements

---

## 9. When to Pull the STP

Only pull the pump if:
- Motor windings are bad (confirmed by testing)
- Check valve inside column is bad
- Physical damage to pump
- Contamination in tank requires extraction

### Equipment Needed for STP Pull

- Crane (truck-mounted, minimum 2,000 lb @ 10')
- Chain hoist backup
- Pipe wrenches (18", 24", 36" - offset preferred)
- Cheater pipes
- Containment for fuel
- Safety barriers
- 4-gas monitor (LEL, O2, CO, H2S)

### Safety Requirements (OSHA 1910.146)

- 2+ people minimum
- Confined space training
- Continuous air quality monitoring
- Proper PPE (FR clothing, nitrile gloves)
- Fire extinguisher within reach
- Sump lid lifter (never lift by hand)

---

## Related Documentation

- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md)
- [Slow Flow Troubleshooting](./troubleshooting-slow-flow-nozzles.md)
- [Veeder-Root CSLD Failures](./veeder-root-csld-failures.md)
- [Wayne Dispenser Troubleshooting](./wayne-dispenser-troubleshooting.md)

---

*This guide synthesizes Franklin FE Petro service documentation, Red Jacket UMP troubleshooting guide (577014-053), and Veeder-Root annual checklist procedures. Always verify against current manufacturer documentation for your specific equipment.*

**[Download Printable Version (Word)](https://firebasestorage.googleapis.com/v0/b/alucard-475702.firebasestorage.app/o/STP_Troubleshooting_Guide_v1.docx?alt=media&token=2a18c203-b581-4016-a0a5-09d95aa9f5ee)** - Field-ready reference for service trucks


Submersible Turbine Pump (STP) Troubleshooting Guide

# Troubleshooting Guide: DEF Dispenser Error 20 & Leaks

**Context:** Troubleshooting recurring Error 20 on DEF dispensers and resolving leaks.
**Source:** Technician Field Note (Verified)

## Symptoms
*   **Error Code 20** (DEF side).
*   Leaking breakaway or nozzle.
*   Nozzle not engaging or maintaining flow.

## Diagnosis & Repair Steps

1.  **Inspect Electrical Connections:**
    *   Check for corrosion on cables.
    *   Re-secure all connections.

2.  **Clear Error 20 (Software):**
    *   Go to Programming Mode.
    *   Put dispenser into **Standalone Mode**.
    *   This often clears the Error 20 latch.

3.  **Inspect Mechanicals (Leak Source):**
    *   **Breakaway:** Check for leaks or separation. If it won't hold pressure or stays separated, replace it.
    *   **Nozzle:** If nozzle won't stay engaged or maintain flow, replace it.

## Parts Reference
*   **DEF Breakaway:** #21GUSSB
*   **DEF Nozzle:** #21GU040G

## Verification
*   Test dispense after clearing error.
*   Verify no leaks at breakaway or nozzle connection.
*   Confirm flow rate is normal.



---
## 🧠 Vigilith Deep Research (AI Generated)

### AI Research: Gilbarco DEF Error Codes
*   **Error 20:** "Communication Error with DEF Module"
*   **Tech Tip:** Often caused by loose CAN bus connection on the DEF heater module.
*   **Parts:** Heater Module Kit (M12345-K).


Troubleshooting Guide: DEF Dispenser Error 20 & Leaks

# Troubleshooting Guide: Slow Flow & Nozzle Issues

**Context:** Resolving slow flow complaints and leaking/bagged-off nozzles.
**Source:** Technician Field Note (Verified)

## Symptoms
*   Slow flow on Diesel (Auto or Truck side).
*   Nozzle not stopping (overflow risk).
*   Leaking hose assembly (whip hose, breakaway).

## Diagnosis & Repair Steps

1.  **Slow Flow:**
    *   **Step 1:** Replace Filters. (Check for "DOA" or leaking new filters).
    *   **Step 2:** Inspect Nozzle/Swivel. Debris can clog screens.
    *   **Verification:** Put dispenser in Standalone Mode to test flow rate.

2.  **Leaking Hose Assembly:**
    *   **Tighten:** Try tightening connections first.
    *   **Replace:** If tightening fails or leak is from crimping, replace the affected segment (Whip Hose, Breakaway, Main Hose, Swivel, or Nozzle).
    *   **Full Rebuild:** In severe cases (multiple leaks), replace the entire hanging hardware assembly.

## Parts Reference
*   **Nozzle:** #7HB0100 (High Flow)
*   **Swivel:** #455075
*   **Hose:** 1" x 9' (#PH1"x9') or 3/4" x 9' (#PH3/4"x9")
*   **Breakaway:** #CTM100 or #88EZR7575
*   **Filter:** #51130P or #70020

## Verification
*   Test for full flow.
*   Verify nozzle "click-off" (stopping) function.
*   Inspect all connection points for weeping or leaks under pressure.



---
## 🧠 Vigilith Deep Research (AI Generated)

### AI Research: Flow Rate Standards
*   **Standard:** 10 GPM (Gallons Per Minute) for standard dispensers.
*   **High Flow:** Up to 22 GPM (Satellite/Master).
*   **Compliance:** EPA requires < 10 GPM for light-duty vehicles.


Troubleshooting Guide: Slow Flow & Nozzle Issues

# Troubleshooting Guide: VeriFone Commander Connectivity (Buypass/Acumera)

**Category:** Network / POS Configuration
**Source:** Field Note WO#56798 (Strayhorn Marina)
**Last Updated:** 11/27/2025

## 🚨 The "Loop of Death" Scenario
**Symptoms:**
*   Dispensers show "No Communication".
*   Merchant ID (MID) change requested but fails to resolve.
*   Prepay fails or Pin Pad will not initialize.
*   Conflicting info from vendors (Acumera says IP, Buypass says URL).

## 🔍 Critical Checkpoints

### 1. The Physical Layer (The "Hidden" Fix)
*   **Issue:** Pin Pad initialization fails even with correct programming.
*   **The Fix:** The Pin Pad **MUST** be in the **VeriFone Zone** (Secure Ports 2 & 3).
*   **Workaround:** If ports are full, use a **5-Port Switch** to expand the Secure Zone.
    *   *Field Note:* Pin Pad began taking updates immediately after moving to the switch on Port 2/3.

### 2. Data Wire Configuration: IP vs. URL
*   **Confusion:** Acumera may provide an IP address that is actually for the Passport system, or a VeriFone IP that doesn't work.
*   **Resolution:** For Buypass integrations, Data Wire often requires a **URL**, not a static IP.
*   **Step:** Verify with Buypass Level 2 support specifically if they need a URL connection string.

### 3. The "Merchant ID" Trap
*   **Scenario:** You change the MID, reboot, and nothing happens.
*   **Check:** Is **Data Wire** enabled?
    *   *Lesson:* Changing MID often breaks the connection if Data Wire isn't re-handshaked.
    *   *Twist:* Sometimes the "New" MID is wrong, and you have to revert to the "Old" MID but with new Data Wire settings.

## 🛠 Triage Flowchart (When Stuck)

1.  **Secure Connections:** Reseat all Ethernet cables. (Fixed Card Readers in WO#56798).
2.  **Pin Pad Isolation:** Is the Pin Pad in the Secure Zone (Port 2/3)?
    *   *No?* Move it or add a switch.
3.  **Data Wire Toggle:** Enable Data Wire -> Reboot.
4.  **Vendor Conference:** Get Acumera AND Buypass on the line simultaneously.
    *   *Ask:* "Does this MID require an IP or a URL for Data Wire?"
5.  **Unattended Mode:** If all else fails, **Turn OFF Unattended Mode**.
    *   *Result:* Site can at least accept Prepays inside, even if CRIND is down.

## 📦 Parts Required
*   **5-Port Switch (GS305100PAS):** Keep one on the truck for expanding Secure Zones.



Troubleshooting Guide: VeriFone Commander Connectivity (Buypass/Acumera)

# Troubleshooting Guide: Verifone Commander Datawire & Payment Errors

**Context:** Dealing with "No Communication" errors, Prepay failures, and Pin Pad update loops.
**Source:** Technician Field Note (Verified)

## Symptoms
*   "No Communication" error on dispenser.
*   Prepay not working on dispenser with card reader.
*   Pin Pad stuck on "Starting Application" or update loop.
*   Processor offline despite network connectivity.

## Diagnosis & Repair Steps

1.  **Check Merchant ID (MID):**
    *   Incorrect MID can cause communication failures.
    *   **Action:** Verify and update Merchant ID in Commander settings. Reboot.

2.  **Inspect Physical Connections:**
    *   Loose Ethernet cables can drop card readers offline.
    *   **Action:** Secure all Ethernet connections at the switch and dispenser.

3.  **Datawire Configuration (Critical):**
    *   **Issue:** Datawire not enabled or configured incorrectly after MID change.
    *   **Action:** Enable Datawire. Ensure it is connected via **URL** (not just IP).
    *   **Note:** Acumera or Buypass support may be needed to confirm specific IP/Port/URL settings.

4.  **Pin Pad (VeriFone) Connectivity:**
    *   **Requirement:** Pin Pad must be connected to the correct **VeriFone Zone** (often Port 2 or 3 on the secure switch).
    *   **Troubleshooting:**
        *   If ports are full, use a switch (e.g., 5-port GS305100PAS) to create space.
        *   Verify Pin Pad takes updates after connection.

5.  **Unattended Mode:**
    *   **Symptom:** Dispensers not calling in when handle is lifted.
    *   **Action:** Turn **OFF** Unattended Mode to restore normal handle-lift communication.

## Verification
*   Reboot Commander after major setting changes.
*   Test handle lift on all grades.
*   Confirm Prepay acceptance.
*   Verify Processor comes online (may require Level 2 support if stubborn).



---
## 🧠 Vigilith Deep Research (AI Generated)

### AI Research: Verifone Commander Specs
*   **Manual Reference:** VeriFone Commander Site Controller Installation Guide (VFI P/N 24356)
*   **Datawire Ports:** Standard ports are 443 (HTTPS) and 80 (HTTP).
*   **Note:** Ensure firewall allows outbound traffic to `xml.buypass.com`.


Troubleshooting Guide: Verifone Commander Datawire & Payment Errors

# Veeder-Root ATG Alarm Code Reference

**Category:** Equipment / ATG / Veeder-Root
**Equipment:** TLS-350, TLS-450PLUS, TLS-4/TLS-4B
**Last Updated:** 12/25/2024
**Difficulty:** Intermediate
**Cross-Reference:** [CSLD Failures](./veeder-root-csld-failures.md), [Error Codes Reference](./error-codes-diagnostic-reference.md)

---

## Quick Reference

**Veeder-Root Technical Support:** 800-323-1799
**Hours:** Monday-Friday, 8:00 AM - 6:00 PM ET
**Email:** technicalsupport@veeder.com

---

## 1. Console Identification

| Console | Display | Normal Status |
|---------|---------|---------------|
| TLS-350 (Legacy) | Text LCD | "ALL FUNCTIONS NORMAL" |
| TLS-450PLUS | Color touchscreen | "SYSTEM STATUS" (green) |
| TLS-4/TLS-4B | Web-enabled touchscreen | Green status bar |

---

## 2. Device Identifier Codes

All alarm messages begin with a device identifier:

| Code | Device | Code | Device |
|------|--------|------|--------|
| T | Tank | L | Liquid Sensor |
| MS | Mag Sensor | V | Vapor Sensor |
| Q | PLLD Line | G | Groundwater Sensor |
| Ln | Product Line | C/H | 2-Wire/3-Wire CL Sensor |
| Pm | Pump | Pc | Pump Controller |
| P | Printer | R | Relay/Receiver |
| Co | Communication | I | External Input |

---

## 3. CRITICAL Alarms - Immediate Action Required

**Stop all operations and notify supervisor immediately.**

| Alarm | Device | Meaning | Immediate Action |
|-------|--------|---------|------------------|
| **Overfill Alarm** | T | Fuel exceeded 90% limit | STOP delivery; check for spillage |
| **Sudden Loss Alarm** | T | Unexplained fuel loss during idle | Check for gross leak; notify supervisor |
| **Gross Test Fail (3.0 gph)** | T, Q | Failed catastrophic leak test | Dispensing halts; investigate immediately |
| **Sensor Fuel Alarm** | L, G, V, MS | Hydrocarbon in containment | Product in secondary containment; potential release |
| **Low Liquid Alarm (brine)** | L | Brine level dropped in interstice | Inner tank wall breach; fuel leak into interstitial |
| **PLLD Shutdown** | Q | Line shut down - failed leak test | Line disabled until resolved |

---

## 4. Tank Alarms (Device ID: T)

### Product Level Alarms

| Alarm | Priority | Trigger | Action |
|-------|----------|---------|--------|
| Overfill Alarm | **CRITICAL** | >90% capacity | Stop delivery immediately |
| Maximum Product Alarm | ALARM | Above programmed max | Stop delivery; allow dispensing |
| High Product Alarm | ALARM | >95% of limit | Warning to slow/stop delivery |
| Fuel Out Alarm | ALARM | <10 inches | Cannot pump; immediate delivery |
| Low Product Alarm | ALARM | Below programmed min | Call for delivery |
| Delivery Needed Warning | Warning | Below warning level | Schedule routine delivery |

### Water Detection Alarms

| Alarm | Priority | Threshold | Action |
|-------|----------|-----------|--------|
| High Water Alarm | ALARM | 2-4 inches (programmable) | Remove water immediately |
| High Water Warning | Warning | Below alarm limit | Schedule water removal |
| Water/Phase Separation | ALARM | Density anomaly | Test fuel quality; remove contaminated product |

### Temperature Alarms

| Alarm | Trigger | Notes |
|-------|---------|-------|
| Low Temperature Alarm | Below -4°F (-20°C) | May affect probe readings |
| Cold Product Warning | At -4°F | Monitor conditions |

---

## 5. Leak Detection Alarms

### In-Tank Leak Detection (CSLD/SLD)

| Alarm | Test Type | Threshold | Response |
|-------|-----------|-----------|----------|
| Periodic Test Fail | 0.2 gph monthly | >0.2 gal/hour | Rerun; 2nd failure = report |
| Annual Test Fail | 0.1 gph precision | >0.1 gal/hour | Rerun with proper conditions |
| Gross Test Fail | 3.0 gph | >3.0 gal/hour | **CRITICAL** - immediate investigation |
| CSLD Rate Increase Warning | Continuous | Unexplained increase | Check siphon, vapor recovery |
| No CSLD Idle Time Warning | Continuous | Insufficient quiet time | Site too active; manual test needed |

### Common False Alarm Causes

- Recent deliveries (wait 8+ hours after delivery)
- Incorrect thermal coefficient settings
- Worn siphon components or clogged return lines
- Torn diaphragm on mechanical LLD
- Pressure vent cap malfunction
- Tank less than 1/3 full

### Line Leak Detection (PLLD) Alarms (Device ID: Q)

| Alarm | Test Rate | Meaning | Response |
|-------|-----------|---------|----------|
| Gross Test Fail Alarm | 3.0 gph | Catastrophic line leak at 10 PSI | Pump shuts down automatically |
| Periodic Test Fail | 0.2 gph | Monthly precision failure | May halt dispensing; retest |
| 0.1 gph Line Test Fail | 0.1 gph | Annual precision failure | Line investigation required |
| Line Equipment Alarm | — | Pressure hardware problem | Service required |
| Sensor Open Alarm | <-8 PSI | Sensor malfunction | Dispensing halts |
| Continuous Handle Alarm | 16 hrs default | Dispenser handle stuck | Check dispenser operation |

---

## 6. Probe & Sensor Alarms

### MAG Probe Alarms

| Alarm | Device ID | Cause | Action |
|-------|-----------|-------|--------|
| Probe Out Alarm | T | Hardware failure - disconnected | Power off; check connections; inspect cable |
| Mag Sensor Comm Alarm | MS | Lost communication | Check wiring; verify barrier board |
| Cold Temp Warning | T | Below -4°F | Wait for temperature increase |
| Leak Test Invalid—Recent Delivery | T | Delivery within 8 hours | Retest after 8+ hours |
| Leak Test Invalid—Tank Level Low | T | Insufficient product | Fill to at least 1/3 capacity |
| Ghost Deliveries | T | Electrical noise | Check grounding; use shielded cables |

### MAG Probe Troubleshooting

| Issue | Solution |
|-------|----------|
| Fuel float stuck in riser | Remove float; install split-ring collar (P/N 576008-617) |
| Intermittent readings | Check for open/shorted wires; use epoxy seal kits |
| Communication errors | Verify conduit grounding; VFD STPs cause interference |

### Interstitial Sensor Alarms (Device ID: L, MS)

| Alarm | Sensor Type | Meaning | Priority |
|-------|-------------|---------|----------|
| Fuel Alarm | Discriminating | Hydrocarbon in interstitial | **CRITICAL** |
| High Liquid Alarm | All types | 8" (pan) or 10" (sump) | Remove liquid; investigate |
| Liquid Warning | All types | 1" liquid detected | Monitor; prepare for removal |
| Low Liquid Alarm | Brine/hydrostatic | Brine level decreased | **CRITICAL** - tank wall breach |
| Sensor Out Alarm | All types | Lost communication | Check wiring; replace sensor |
| Position Alarm | Position-sensitive | Sensor displaced | Reposition properly |

**Sensor Types:**
- Discriminating (P/N 794380-341, 794380-343): Differentiate fuel from water
- Non-discriminating: Trigger for any liquid

### Vapor & Groundwater Sensors (Device ID: V, G)

| Alarm | Device ID | Meaning | Action |
|-------|-----------|---------|--------|
| Fuel Alarm | V, G | Hydrocarbon exceeds threshold | Investigate leak |
| Water Out Alarm | G | Water below float switch | Check groundwater table |
| Sensor Out | V, G | Communication failure | Check wiring; replace if needed |

---

## 7. System & Equipment Alarms

### Power & Communication

| Alarm | Cause | Action |
|-------|-------|--------|
| Battery Off/Backup Failure | Backup battery failed | Do NOT power off; contact service (TLS-350 only) |
| Comm Out Alarm | Device not communicating (16+ timeouts) | Check wiring |
| Autodial Failed | Failed remote connection | Verify address book; check modem |
| No Dial Tone Alarm | Phone line lost | Check phone line and modem |
| Email Failed | Failed to send notification | Verify email settings and network |

### Printer & Memory

| Alarm | Cause | Resolution |
|-------|-------|------------|
| Printer Out of Paper | Paper roll empty | TLS-4xx: P/N 514100-456; TLS-3xx: P/N 514100-210 |
| Printer Error | Feed roller release open | Push release lever UP |
| iButton Fault Warning | iButton damaged (<20 days) | Replace iButton |
| iButton Fault Alarm | iButton failure 20+ days | Replace immediately |
| **Unrecoverable Data Error (H8)** | **CRITICAL** | Contact Technical Support; DO NOT power cycle |

---

## 8. Console Operation Procedures

### Viewing & Acknowledging Alarms

**TLS-350:**
1. Press **ALARM/TEST** (red key) to silence beeper
2. Press **FUNCTION** until "ALARM HISTORY" displays
3. Press **STEP** to scroll through history
4. Press **PRINT** for printed report

**TLS-450PLUS / TLS-4:**
1. Touch **status bar** (upper left) to view active alarms
2. Touch **status bar** again to acknowledge and silence
3. Navigate: **Menu → Reports → Alarms** for history
4. No display: Press red **ALARM RESET** button on front panel

### Acknowledging vs. Resolving

- **Acknowledging** = Silences beeper only; condition remains active
- **Resolving** = Fix underlying cause; alarm clears automatically

### Generating Compliance Reports

**TLS-350 Diagnostic Mode:**
- Press **MODE** until "DIAGNOSTIC MODE"
- Press **FUNCTION** to cycle: System → In-Tank → Sensor → Line Leak → CSLD

**TLS-450PLUS/TLS-4:**
- **Menu → Reports → Environmental**
- Available: Tank Test Results, CSLD Reports, Sensor Status, Line Leak Results

### Serial Interface Function Codes

| Code | Function | Command |
|------|----------|---------|
| 001 | System Reset | S00100 |
| 003 | Remote Alarm Reset | S00300 |
| 111 | Priority Alarm History | I11100 |
| 113 | Active Alarm Report | I11300 |
| 203 | Leak Detect Report | I203TT (TT=tank#) |

---

## 9. Troubleshooting Decision Guide

### When to Clear vs. Investigate

**Clear the alarm if:**
- Root cause identified and corrected
- Single test failure followed by passing retest
- Known event caused condition (delivery during test)

**Investigate further if:**
- Alarm recurs after clearing
- Multiple related alarms simultaneously
- Two consecutive test failures
- Any product loss or fuel in containment
- Unexplained volume variances

### Escalation Criteria

**Notify supervisor immediately:**
- Any CRITICAL alarm
- Visible fuel spill or odor
- Second consecutive leak test failure
- Fuel in any containment sump or interstitial

**Contact Veeder-Root (800-323-1799):**
- Unrecoverable Data Error (H8)
- System Self-Test Errors
- iButton Fault Alarm
- Recurring alarms after troubleshooting

---

## 10. Regulatory Compliance

### EPA Release Detection (40 CFR 280)

| Requirement | Threshold | Frequency |
|-------------|-----------|-----------|
| Tank leak monitoring | 0.2 gph detection | Monthly (30 days) |
| Tank tightness test | 0.1 gph detection | 5-year interval |
| Line leak detection | 3.0 gph at 10 PSI | Each transaction |
| Annual operability testing | All components | Every 12 months |
| Walkthrough inspections | Equipment checks | Monthly |

### Reporting Triggers (40 CFR 280.50)

**Report within 24 hours if:**
- ATG alarm cannot be explained as false alarm
- Leak test failure confirmed by second test
- Fuel detected by interstitial/sump/groundwater sensor
- Unexplained inventory loss
- Fuel odor or visible contamination

### Documentation Retention

| Record Type | Period |
|-------------|--------|
| Monitoring results and test records | 5 years |
| Walkthrough inspection records | 1 year minimum on-site |
| Equipment performance claims | 5 years |
| Repair documentation | Life of tank system |
| Alarm logs with response actions | 5 years (recommended) |

---

## 11. Alarm Priority Matrix

| Priority | Alarm Types | Response | Report Required |
|----------|-------------|----------|-----------------|
| **CRITICAL** | Overfill, Sudden Loss, Gross Test Fail, Sensor Fuel, Low Liquid (brine) | Immediate | Yes, within 24 hrs |
| **HIGH** | Periodic Test Fail (2nd), High Liquid, Probe Out | Within 2 hours | Yes, if confirmed |
| **MEDIUM** | High Water, Annual Test Fail, Sensor Out | Same day | Document internally |
| **LOW** | Delivery Needed, Paper Out, Warnings | Within 48 hours | No |

---

## 12. Support Contacts & Documentation

### Veeder-Root Technical Support

- **Phone:** 800-323-1799
- **Email:** technicalsupport@veeder.com
- **Hours:** Monday-Friday, 8:00 AM - 6:00 PM ET
- **Documents:** veeder.com/us/technical-document-library

### Gilbarco Veeder-Root Customer Service

- **General:** (336) 547-5000
- **Toll-Free:** 800-873-3313
- **Insite360/ATG Support:** 800-997-7725

### Key Manual Numbers

| Manual | Part Number |
|--------|-------------|
| TLS System Warnings & Alarms | 577014-243 |
| TLS-350 Troubleshooting | 576013-818 |
| TLS-450PLUS Troubleshooting | 577014-075 |
| Operability Testing Guide | 577013-814 |
| PLLD Alarm Quick Help | 577013-727 |

---

## Related Documentation

- [Veeder-Root CSLD Failures](./veeder-root-csld-failures.md)
- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md)
- [STP Troubleshooting Guide](./stp-troubleshooting-guide.md)

---

*This reference covers TLS-350, TLS-450PLUS, and TLS-4 systems. Field technicians should treat red alarms as immediate priorities. Two consecutive test failures require agency notification within 24 hours in most jurisdictions.*


Veeder-Root ATG Alarm Code Reference

# Veeder-Root CSLD Failures: The Thermal Coefficient Secret

**Last Updated:** 12/09/2025  
**Category:** Tank Monitoring / ATG  
**Difficulty:** Advanced  
**Impact:** HIGH - Saves countless return trips

---

## 🎯 The Problem 99% of Techs Don't Know

> *"There is a different thermal coefficient for E10 fuel than there is for non-ethanol fuel. This setting alone, in extreme temp changes, will cause tanks to fail automated testing."*

**Result:** Endless return trips for CSLD failures that "can't be fixed."

---

## 📊 The Thermal Coefficients

| Fuel Type | Thermal Coefficient | Notes |
|-----------|---------------------|-------|
| **E10 (Ethanol blend)** | 0.00069 | Most common fuel today |
| **100% Gasoline** | 0.00070 | No ethanol |

**The Difference:** 0.00001 - seems tiny, but in extreme temperature swings, it causes the Veeder-Root to calculate volume changes incorrectly, triggering false CSLD failures.

---

## 🔧 How to Fix It

### Step 1: Identify Fuel Type in Tank

- E10 = 10% ethanol blend (most unleaded today)
- E0 = No ethanol (premium at some stations)
- E15/E85 = Higher ethanol (different coefficients)

### Step 2: Access Veeder-Root Console

1. Navigate to Tank Setup
2. Find Thermal Coefficient setting
3. Verify correct value for fuel type

### Step 3: Set Correct Coefficient

```
E10 Fuel: 0.00069
Pure Gasoline: 0.00070
```

### Step 4: Re-run CSLD Test

After correcting the coefficient, the CSLD test should pass.

---

## 🧪 Understanding CSLD Rate Increases

### What the Numbers Mean

| Rate Direction | Indicates | Common Causes |
|----------------|-----------|---------------|
| **Negative increase** | Air entering tank | Loose tank cap, bad pressure/vac vent cap |
| **Positive increase** | Fuel leaking back into tank | STP check valve, siphon check valve |

### Diagnostic Approach

**For Negative Rates:**
1. Check tank cap - is it tight?
2. Inspect pressure/vacuum vent cap
3. Look for any openings in tank system

**For Positive Rates:**
1. Test STP check valve
2. Test siphon check valve
3. Check for any backflow paths

---

## 💡 Pro Tips

### Why This Matters
- E10 became standard years ago
- Many Veeder-Root systems were configured for straight gas
- Settings were never updated
- Techs keep returning, running tests, finding "nothing wrong"
- Tank passes sometimes, fails others (temperature dependent)

### The Pattern
If CSLD failures happen:
- More often in spring/fall (temperature swings)
- After cold fronts
- Randomly with no apparent leak

**CHECK THE THERMAL COEFFICIENT FIRST.**

---

## 📋 Checklist for CSLD Failures

- [ ] Verify thermal coefficient matches fuel type
- [ ] Check tank cap condition and seal
- [ ] Inspect P/V vent cap
- [ ] Test STP check valve
- [ ] Test siphon check valve
- [ ] Review CSLD history for patterns
- [ ] Note temperature conditions during failures

---

## 📞 When to Escalate

If coefficient is correct and failures continue:
1. Request tank tightness test
2. Check for physical damage
3. Inspect all penetrations
4. Consider line leak detection system

---

*"This setting alone is costing businesses countless return trips for CSLD failures, and no one can fix it... but me, I guess."*



Veeder-Root CSLD Failures: The Thermal Coefficient Secret

Verifone Commander POS Networking Guide

# Wayne Ovation/Helix iGEM Dispenser Troubleshooting Guide

**Category:** Troubleshooting / Wayne
**Equipment:** Wayne Ovation, Wayne Helix, iGEM Controller
**Last Updated:** 12/25/2024
**Cross-Reference:** [Error Codes Reference](./error-codes-diagnostic-reference.md), [Tools Page](/tools)

---

## Quick Reference

**Wayne/Dover Technical Support:** Contact your authorized service center
**Required Tools:**
- iGEM ServTerm Software v7.0.37+
- Null modem cable (DB9)
- USB-to-serial adapter with FTDI chipset
- Laptop with serial port or reliable USB adapter

---

## Understanding the iGEM Controller

The **iGEM (Intelligent Global Electronics Module)** is the brain of Wayne Ovation and Helix dispensers. It monitors all dispenser components and logs faults accessible via Statistics functions:
- **S21.XX** - Side 1 fault history
- **S22.XX** - Side 2 fault history

### Error Classification System

| Class | Meaning | Action Required |
|-------|---------|-----------------|
| **A** | Logged only | Review during maintenance |
| **B** | Sale termination | Diagnose after customer complaint |
| **C** | Side disabled until power cycle | Requires immediate attention |
| **E** | Catastrophic/possible fraud | **Security investigation required** |
| **H** | Critical | Immediate attention needed |

---

## Common Troubleshooting Scenarios

### 1. No Communication with POS (Error 30)

**Symptoms:** Dispenser shows offline on POS, "No Comm" errors

**Diagnostic Steps:**

1. **Verify Physical Connection**
   - Check RS-485 wiring: A to A, B to B terminals
   - Ensure termination resistors are correct on last dispenser in chain
   - Check for damaged cables, especially at junction boxes

2. **Verify iGEM Settings (via ServTerm)**
   - F20.00 - Protocol setting (match POS type)
   - F20.01 - Baud rate (default 9600)
   - F05/F06 - FPID address (must be unique per dispenser)

3. **Check F23.02** - Communication timeout setting
   - If timeout is too short, intermittent connection issues occur

**Common Fixes:**
- Replace damaged RS-485 cables
- Correct address conflicts (two dispensers with same FPID)
- Verify proper termination

---

### 2. Display Read Back Errors (Error 20)

**Symptoms:** Display shows garbage characters or doesn't update

**Diagnostic Steps:**

1. **Check Display Ribbon Cables**
   - Reseat cables at display board and controller
   - Look for corrosion or damage on connectors
   - Inspect for pinched cables

2. **Verify F17.02 Setting**
   - Controls display timeout
   - Incorrect setting causes display sync issues

3. **Device Identification:**
   - Device 0 = Sales display
   - Device 1 = Unit price display
   - Device 2 = Preset display

**Common Fixes:**
- Reseat ribbon cables
- Replace corroded display board
- Replace display if persistent

---

### 3. WIP (Whaley Industrial Products) Meter Errors

#### Error 49: Illegal WIP Incrementation (Class E)

**THIS IS A CRITICAL SECURITY ERROR**

**Possible Causes:**
- **Tampering attempt** - Most serious, requires investigation
- WIP pulser malfunction
- Calibration door not properly secured

**Diagnostic Steps:**

1. **Inspect WIP Pulser**
   - Look for signs of tampering
   - Verify factory seals are intact
   - Check serial numbers match records

2. **Verify Calibration Door**
   - Door must be fully closed
   - W&M seal must be intact

3. **Document Everything**
   - Take photos before touching anything
   - Note time of error
   - Check if during a transaction

**Action Required:**
- If tampering suspected: **Contact security/law enforcement**
- If legitimate malfunction: Replace WIP pulser, document replacement

---

#### Error 50: Jitter/Reverse Limit on In-Transaction WIP (Class B)

**Symptoms:** Transaction terminates unexpectedly

**Common Causes:**
- WIP vibration from calibration door movement
- Loose WIP mounting
- Air in hydraulic lines
- Product crossflow between grades

**Diagnostic Steps:**

1. **Secure WIP to Meter**
   - Ensure snap clips are fully engaged
   - Tighten mounting hardware

2. **Check Calibration Door**
   - Secure port cover if vibrating during transactions

3. **Bleed Air from System**
   - Check for air pockets in hydraulic lines
   - May require cycling pumps

4. **Check for Crossflow**
   - Verify blend valves are sealing properly
   - Look for internal leaks

**Common Fixes:**
- Secure WIP mounting
- Close calibration port cover
- Bleed hydraulic system
- Replace blend valve if crossflow detected

---

#### Error 52: No Response from WIP in Use (Class H)

**Symptoms:** Dispenser goes offline during transaction

**Diagnostic Steps:**

1. **Check WIP Cable Connection**
   - At meter end
   - At iGEM controller
   - Look for cable damage

2. **Verify WIP LED Activity**
   - Should blink during transaction
   - No blink = communication failure

**Common Fixes:**
- Repair/replace WIP cable
- Replace WIP pulser if cable tests good

---

### 4. Flow Errors

#### Error 70: Timeout - No Flow Start

**Symptoms:** Customer presses start, fuel won't flow

**Diagnostic Steps:**

1. **Check Fuel Supply Chain**
   - Is tank empty? Check ATG levels
   - Is STP running? Listen/feel for operation
   - Check shear valve open
   - Check filters for restriction

2. **Verify Valve Operation**
   - Proportional valve should open on start
   - Listen for valve click
   - Check valve driver on iGEM board

3. **Check for Error 74**
   - Indicates pump (STP) not running
   - May be thermal overload, check STP panel

**Common Fixes:**
- Schedule fuel delivery
- Reset STP thermal overload
- Clean/replace filters
- Replace proportional valve

---

#### Error 72: Timeout - Flow Lost During Sale

**Symptoms:** Fuel stops mid-transaction

**Common Causes:**
- Tank ran empty during transaction
- Air in lines
- STP thermal overload (pump overheated)

**Diagnostic Steps:**

1. **Check Tank Level**
   - ATG reading should show product
   - If low, schedule delivery

2. **Check STP Status**
   - Visit STP panel
   - Look for fault lights
   - Check for thermal overload trip

3. **Purge Air if Present**
   - Cycle dispenser multiple times
   - May need extended operation to clear

**Common Fixes:**
- Refuel tank
- Reset STP thermal protection (let cool first!)
- Bleed air from lines
- Investigate repeated thermal trips (may indicate STP failure)

---

### 5. Blend Ratio Errors (Error 35)

**Symptoms:** Mid-grade (e.g., 89 octane) doesn't dispense correctly

**Common Causes:**
- Unequal inlet pressures between grades
- Clogged filter on one grade
- Blend valve not responding properly

**Diagnostic Steps:**

1. **Check Inlet Pressures**
   - Both grades should have equal pressure
   - Use pressure gauge at manifold
   - Low pressure on one side = filter or STP issue

2. **Observe Blend Valve Operation**
   - Watch during dispensing
   - Should alternate between grades
   - Stuck valve = mechanical failure

3. **Check Filter Condition**
   - Differential pressure across filter
   - Visual inspection if accessible

**Common Fixes:**
- Replace clogged filter
- Equalize line pressures
- Replace blend valve assembly

---

### 6. Vapor Recovery Errors

#### Error 42: Vapor Motor On When Should Be Off

**Symptoms:** VR motor runs continuously

**Diagnostic Steps:**

1. **Check Motor Relay**
   - On dispenser connection board
   - May be stuck in energized position

2. **Verify Sensor Feedback**
   - Check feedback signals to iGEM
   - May indicate stuck sensor

**Common Fixes:**
- Replace motor relay
- Replace vapor sensor

---

#### Error 48: Vapor Motor Load High

**Symptoms:** Motor draws excessive current, may trip breaker

**Diagnostic Steps:**

1. **Inspect Vapor Path**
   - Check for blockages
   - Debris in nozzle vapor ports
   - Kinked vapor hose

2. **Listen for Motor Issues**
   - Unusual sounds indicate bearing failure
   - High-pitched whine = excessive load

**Common Fixes:**
- Clear vapor path blockages
- Replace damaged vapor hose
- Replace motor if bearings failed

---

## Accessing iGEM Statistics and Settings

### Required Equipment
1. Laptop with ServTerm software installed
2. Null modem cable (DB9 female to DB9 female)
3. USB-to-serial adapter (FTDI chipset recommended)

### Connection Procedure

1. **Power down dispenser** (recommended for first connection)
2. Connect null modem cable to iGEM service port
3. Open ServTerm, select correct COM port
4. Power up dispenser
5. ServTerm should establish communication automatically

### Key Settings Locations

| Function | Setting | Purpose |
|----------|---------|---------|
| F05/F06 | FPID Address | Dispenser identification on RS-485 network |
| F16 | Hydraulic Configuration | Must match actual piping |
| F17 | Display Settings | Timeout and behavior |
| F20 | Communication Protocol | POS communication settings |
| F23 | Timeout Settings | Communication and flow timeouts |
| S21.XX | Side 1 Fault History | Error log for troubleshooting |
| S22.XX | Side 2 Fault History | Error log for troubleshooting |

---

## Preventive Maintenance Checklist

### Daily (Operator)
- [ ] Visual inspection for leaks
- [ ] Check display brightness/readability
- [ ] Verify prices displayed correctly

### Weekly (Technician)
- [ ] Check door gaskets
- [ ] Inspect hanging hardware
- [ ] Review ATG alarm history

### Monthly
- [ ] Download and review fault logs
- [ ] Clean dispenser exterior and filters
- [ ] Check electrical connections for corrosion

### Annually
- [ ] Calibration verification
- [ ] Full electrical inspection
- [ ] Filter replacement
- [ ] O-ring inspection and replacement

---

## When to Escalate to Wayne/Dover Support

Contact technical support when:
- Error 49 (possible tampering) detected
- Repeated firmware/Flash CRC errors (Error 1, 2)
- Multiple dispensers with same communication issue
- iGEM board replacement needed
- Warranty repair situations

**Before Calling, Document:**
1. Dispenser serial number
2. iGEM firmware version
3. Exact error code and timestamp
4. Steps already attempted
5. Photo of fault log if possible

---

## Related Documentation

- [Error Codes Diagnostic Reference](./error-codes-diagnostic-reference.md) - Complete error code listing for all equipment
- [STP Troubleshooting Guide](./stp-troubleshooting-guide.md) - Submersible pump issues
- [Veeder-Root CSLD Failures](./veeder-root-csld-failures.md) - Tank monitor troubleshooting

---

*This guide is based on Wayne Helix Service Manual (WM048523), iGEM Programming Manual (WM048524), and field technician experience. Always consult current manufacturer documentation for your specific equipment revision.*


Wayne Ovation/Helix iGEM Dispenser Troubleshooting Guide

# Western Oklahoma Petroleum Service Market Analysis

**Category:** Territory / Market Research
**Region:** Oklahoma City Metro, I-35 Corridor, Western Oklahoma
**Last Updated:** 12/25/2024
**Cross-Reference:** [I-44 Corridor Research](./i44-corridor-analysis.md), [Eastern Oklahoma Coverage](./eastern-oklahoma-coverage.md)

---

## Quick Reference

**OCC Testing License Hotline:** Oklahoma Corporation Commission
**OPMCA (Trade Association):** 405-842-6625 | candace@opmca4you.com

---

## Market Overview

The Oklahoma City metro contains an estimated **400-600 gas stations and convenience stores**, representing significant service revenue potential. Oklahoma statewide has approximately 2,614 convenience stores, with OKC capturing a substantial share as the state's largest metro.

### Major Chain Presence

| Operator | OKC Metro Sites | Notes |
|----------|----------------|-------|
| **7-Eleven** | 100-150 | Acquired from Brown family in 2020; refreshing stores |
| **OnCue** | 50-55 | OKC-based; aggressive expansion |
| **Murphy USA** | ~20 | Walmart-adjacent locations |
| **Casey's** | 4-15 | Expanding via acquisitions |
| **Love's Travel Stops** | 5-8 major | HQ in OKC; highway locations |
| **QuikTrip** | 2 | NEW entrant Feb/Oct 2024 |
| **Phillips 66/Conoco branded** | 75-100 | Dominant fuel brand statewide |

### Key Market Developments (2024)

**QuikTrip's February 2024 market entry** is the most significant recent disruption. After decades of avoiding OKC due to a historical "gentleman's agreement" with former 7-Eleven ownership, QT opened travel centers in:
- Moore (I-35 & 27th Street)
- Oklahoma City (I-35 & Hefner Road)

Their high-volume, large-format stores (20 car fueling positions plus diesel bays) will drive competitive responses requiring equipment investments.

**Love's Travel Stops** (HQ: 10601 N Pennsylvania Ave, OKC) operates 644+ locations nationwide with ~40 new stores annually. Subsidiaries include Trillium CNG and Speedco (430+ truck service centers).

**OnCue** recently opened their largest travel center at I-35 and Grand with 31 fueling positions. Additional expansion approved at Broadway Extension and Wilshire in northeast OKC.

---

## Competitor Landscape

### National Players (Gilbarco-Focused)

| Company | Description | OKC Contact |
|---------|-------------|-------------|
| **D&H United Fueling Solutions** | Acquired Petroleum Marketers Equipment (est. 1966) in July 2021. 350+ employees, 12 branches. Authorized Gilbarco/Veeder-Root. | 2010 Exchange Ave, OKC (405) 235-4471 |
| **Guardian Fueling Technologies** | Entered OK Feb 2024 with Gilbarco PMA designation. 650+ pros, 350+ techs. | OKC Branch - guardianfueltech.com |
| **JF Petroleum Group** | 1,700+ employees, 46 branches nationally. Aug 2025 acquired Maverick Petroleum. | OKC office |

### Wayne/Dover Dealers (Less Saturated)

| Company | Coverage | Contact |
|---------|----------|---------|
| **Domino Equipment Company** | Primary Wayne/Dover distributor for OK. Founded 1989, 51-200 employees. | OKC: 8130 W. Reno Ave; Tulsa: 8175 E. 46th Place |
| **Texoma Pump Repair** | Southern OK and North Texas. Wayne dealer + VeriFone certified. | Duncan, OK: 512 Industrial Drive, (580) 475-0046 |

### Parts Sourcing Contacts

| Company | Brands | Location | Contact |
|---------|--------|----------|---------|
| D&H United | Gilbarco, Veeder-Root | 2010 Exchange Ave, OKC | (405) 235-4471 |
| Guardian Fueling | Gilbarco, OPW, Franklin | OKC Branch | guardianfueltech.com |
| Domino Equipment | Wayne | 8130 W. Reno Ave, OKC | dominoequipment.com |
| Texoma Pump | Wayne, VeriFone, Franklin/Incon | Duncan, OK | (580) 475-0046 |
| P.B. Hoidale | Multi-brand | 6617 W. Reno Ave, OKC | (405) 495-7010 |

---

## Territory Logistics (From Hulbert)

The **158-mile, 2.5-hour drive** from Hulbert to downtown OKC creates a fundamental service model challenge.

### Drive Times by Destination

| Destination | Distance | Time | Same-Day Feasibility |
|-------------|----------|------|---------------------|
| Midwest City | 148 mi | 2h 20m | Feasible with early start |
| Downtown OKC | 158 mi | 2h 26m | Borderline - long day |
| Edmond | 158 mi | 2h 30m | Borderline |
| Moore | 164 mi | 2h 35m | Difficult |
| Norman | 174 mi | 2h 44m | Requires overnight |
| Yukon/El Reno | 172-186 mi | 2h 40-55m | Requires overnight |

### Route & Toll Costs

- **Primary Route:** OK-51 to Tulsa (55 mi, ~1 hr) then I-44 Turner Turnpike to OKC (86 mi, ~90 min)
- **PikePass toll:** ~$5.40 each way ($10.80 round-trip)
- **Cash toll:** $8.75-10.50 per direction
- **January 2025:** 15% toll increase took effect
- **Future:** 6% increases planned every 2 years starting 2027

### Satellite Office Recommendation

A **Midwest City** or **I-35/I-240 interchange** satellite office offers the most strategic positioning:
- Closest major metro area from Hulbert
- Proximity to Tinker AFB (25,000+ employees, defense contractors)
- Tinker Business & Industrial Park - service-oriented commercial space
- Lower lease rates than downtown
- Industrial/flex space: ~$4-8/sq ft annually

Without a satellite, schedule **2-3 day OKC service trips** with overnight stays rather than attempting daily round-trips (316 miles, 5+ hours driving).

---

## Regulatory & Growth Opportunities

### New October 2024 Testing License Requirement

The Oklahoma Corporation Commission now mandates that **all individuals testing UST and/or AST systems must be OCC Licensed Testers**. This creates:
- Immediate demand for certified testing services
- Potential shortage of qualified providers
- Market entry wedge for licensed operators

### Growth Corridors

| Area | Key Stats |
|------|-----------|
| **Yukon/Canadian County** | Fastest-growing county in OK; 55,200 vehicles/day at I-40/Garth Brooks Blvd |
| **Edmond** | Population 97,452 in 2024 (+3.9% growth), approaching 100,000 threshold |
| **Northeast OKC** | "The Half" entertainment development approved with new OnCue location |
| **Norman** | +1.6% growth with projected 5.8% rent growth |

### EV Charging Opportunity

- Oklahoma received **$66 million** in federal NEVI funding over 5 years
- Love's secured 8 of 13 initial grants ($5.1M) for EV chargers on I-35, I-40, I-44
- Francis Energy (Tulsa-based) maintains 263 stations across 109 OK locations
- EV charger installation/maintenance = adjacent service opportunity

### EMV Terminal Upgrades

Many stations still require payment terminal modernization following October 2021 liability shift. Non-compliant stations face potential fraud losses of tens of thousands monthly.

---

## Strategic Recommendations

### Market Entry Strategy

1. **Establish PikePass accounts** for all service vehicles (~40% toll cost reduction)
2. **Target Midwest City/Tinker AFB area** as initial territory - closest access from Hulbert
3. **Pursue OCC Licensed Tester certification** to capture compliance-driven demand
4. **Differentiate through Wayne/VeriFone specialization** rather than competing head-to-head with Gilbarco-focused majors
5. **Network through OPMCA** (405-842-6625) to access 250+ member companies representing 2,700 outlets
6. **Evaluate satellite office** in Midwest City or I-35/I-240 area within 12-18 months if volume justifies

### Competitive Positioning

**Gilbarco territory is saturated** - Guardian secured PMA in Feb 2024, joining D&H United and JF Petroleum.

**Wayne/Dover has fewer authorized dealers** - A Wayne-focused service provider in OKC metro core could differentiate, particularly for customers seeking alternatives to Gilbarco-centric majors.

---

## Trade Association

**Oklahoma Petroleum Marketers & Convenience Store Association (OPMCA)**
- Address: 6420 North Santa Fe, Suite B, OKC
- Phone: 405-842-6625
- Contact: candace@opmca4you.com
- Members: 250+ companies with 2,700+ retail outlets

---

*Research conducted December 2024. Market conditions subject to change.*


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