Helix Service Manual201404151630

Wayne Helix™
Fuel Dispensers
SERVICE
February 2013
DANGER
READ THIS MANUAL BEFORE YOU BEGIN
Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Failure
to follow the below precautions and the Warning and Caution instructions in this manual may result in
serious injury. Follow all rules, codes and laws that apply to your area and installation.
SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE
Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cabinet for
maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off when servicing
the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser BEFORE beginning
maintenance.
Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an emer-
gency. Have all leaks or defects repaired immediately.
EQUIPMENT PRECAUTIONS
Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before dis-
pensing product, otherwise, damage to the equipment may occur. Always use the approved method
for lifting the dispenser. Never lift by the nozzle boot, sheet metal, valance, etc., otherwise equipment
damage or personal injury may occur.
HOW TO CONTACT WAYNE
Trouble with the installation and operation of the dispenser should be referred to your authorized
Wayne service personnel or Wayne Technical Support (1-800-926-3737).
INDICATORS AND NOTATIONS
Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe injury or
DANGER possibly death.
Warning indicates a hazard or unsafe practice which, if not avoided, may result in severe injury or
WARNING possibly death.
CAUTION Caution indicates a hazard or unsafe practice which, if not avoided, may result in minor injury.
Important information to consider, otherwise, improper installation and/or damage to compo-

NOTE:
nents may occur.
Table of Contents
Title Page
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Unlocking the Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Payment Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Bezel Latches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Service View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Triple Bump Product Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Filter and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Proportional Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3.1 No Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.2 Slow Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3.3 Full Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 iMeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1 Check and Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Hose Outlet Casting and Tube Retainer Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 ELECTRONICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Power Distribution Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Dispenser Connection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Dispenser Power On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Heater/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Sales Volume and Unit Price Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6 Nozzle Switch Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 ISB Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.8 Nozzle Switch Converter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Temperature Module (Temp Comp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.10 TTL-CAN Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.11 WIP Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.12 Wayne Connect Module (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.13 Meter and WIP Assigments Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 ELECTRONIC BOARDS - LAYOUT AND CONNECTOR DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1 iGEM Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 iX R2 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Nozzle Switch Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Nozzle Switch Converter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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4.5 Temperature Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.6 TTL/CAN Converter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.7 ISB Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.8 Dispenser Connection Board - Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.9 Dispenser Connection Board - Suction Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.10 Sales Display and Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
4.11 Unit Price Display and Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4.12 Secure Payment Module (SPM) - Low Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.13 24V DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
4.14 Heater/Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
4.15 WIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.16 Wayne Connect Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5 PART NUMBERS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.1 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3 Nozzle Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
6 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

6.1 iGEM Computer Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.2 Nozzle Switch Converter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.3 Nozzle Switch Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.4 ISB Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
6.5 Nozzle Boot, Switch, or Flipper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
6.6 WIP Pulser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6.7 Proportional Valve Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.8 Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
6.8.1 iMeter Replacement (Removing Meter From Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
6.8.2 iMeter Replacement (Removing Meter With Base Casting and Coupling Attached) . . .57
6.8.3 Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
6.9 Product Tube Replacement - Using the Tube Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
6.10 Product Tube Replacement - Not Using the Tube Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
6.11 Outlet Casting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.12 Sales/Vol Display Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
6.13 Sales Display Glass and Panel Asssembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
6.14 Unit Price Display, Controller Board, and Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
6.14.1 UPD, Controller Board or Totalizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
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6.14.2 Unit Price Display Glass Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.15 QVGA Dispay, Softkey and Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.15.1 QVGA Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.15.2 Softkey and Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6.16 Dispenser Connection Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.17 24V Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.18 Heater/Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.19 Zebra Printer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.20 iX R2 Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.21 iX Pay Secure Payment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.21.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.21.2 SPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.22 Wayne Connect Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.23 Card Reader Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7 IGEM SOFTWARE AND SERVTERM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

7.1 Bootstrap Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8 TROUBLESHOOTING, ERROR CODES AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.1 Function Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.2 IR Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.3 ServTerm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.4 Error Codes and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.5 Problem Symptoms and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9 ZEBRA PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.1 Loading Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2 Indicator LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3 Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10 METER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
APPENDIX A iX Pay™ Secure Payment Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B Valance Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
APPENDIX D Model Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
APPENDIX E Torx Screwdriver kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
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Title Page
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1. INTRODUCTION
This manual contains detailed service information for Wayne Helix™ fuel dispensers. This manual
should be used only by Wayne certified technicians for troubleshooting and repair purposes.
The figures on the following pages show how to gain access to the inside of the dispenser for service.
1.1. FEATURES
Some of the features of Helix dispensers are listed below:
• Most current circuit design and functionality, with expansion capabilities for various types of
displays and future options
• New two-piece bezel
• Increased inner diameter of product tubes improves flow rate
• Many of the outside components and bezel parts snap in place and do not require hardware
• Improved serviceability of hydraulic components — valves, meters, and outlet castings. Using the
new tube removal tool, there is no longer a need to use ladders when replacing product tubes
• New filter/strainer casting and attached funnel to reduce fuel spills when changing filters
• Newly designed dual vapor barrier with a 1-1/2 inch space between the two barriers eliminates
need for lock nuts above and below the barrier — makes changing valve coil/conduit much
easier. WIP cables and nozzle switch wires no longer in a potted fitting and can be replaced indi-
vidually
• New power on/off switch located by the iGEM board shuts down power in the dispenser
• Easily replaceable nozzle boots
• Incorporates use of new USB printer
The following sections in this manual give details on the new hydraulic and electronic components
used in Helix dispensers.
1
1.2. UNLOCKING THE BEZEL
Follow the steps listed in Figure 1-1 to open the bezel and payment terminal for service.
1. Unlock bezel U-frame here

2. Raise frame to overhead service position
3. Unlock Payment Terminal Drawer (See Fig 1-2)
4. Locate tabs on latches underneath here
(See Figure 1-3)
5. Firmly push up on latches and then pull out to unsnap.
Figure 1-1 Helix Bezel Lock
The latches behind the bezel are shown in detail in Figure 1-3. Once the payment terminal drawer has
been unlocked and the latches have been released, the drawer can be pulled out as shown in Figure 1-2
and Figure 1-4.
2
1.3. PAYMENT TERMINAL
Lock
Payment
Terminal
Figure 1-2 Payment Terminal Drawer Lock
3
1.4. BEZEL LATCHES
Locate latch behind PTS panel and push upward. The right side of the bezel is shown here for clarity,
but there is a latch on both ends of the PTS panel. Push up on the tabs using one hand on each end.
Figure 1-3 Latches Behind the Payment Terminal Bezel.
4
1.5. SERVICE POSITION
Figure 1-4 Helix Dispenser Service View
5
6
2. HYDRAULICS
The hydraulic parts in the Helix dispenser are listed below. These basic parts are discussed in detail in this
section.
• Product Tubes
• Strainer and Filter
• Proportional Flow Control Valve
• iMeter and WIP
• Check & Pressure Relief Valve
• Hose Outlet Casting
2.1. TRIPLE BUMP PRODUCT TUBES

Helix dispensers use triple bump product tubing between the proportional valve and the new hose outlet
casting. As with the double bump tube, the triple bump connection eliminates the need to torque the
compression fittings that were used on flare tubing. The triple bump tube, along with a circular retaining
clip in the hose outlet casting, eliminates the need for a retaining pin at the outlet casting.
The triple bump tube is shown in Figure 2-1. When the tube is inserted into the outlet or valve casting, the
o-ring compresses and spreads across the space between the first and second bumps, making a tight seal
around the cylinder. The tube retaining pin at the valve and the retaining clip at the hose outlet are inserted
between the second and third bumps. The tube retaining pin and clip secure the tube, but they also
improve the seal by allowing some flexibility as to exactly where the seal is made. The pin and clip are
shown later in this section.
Product tubes are 24 mm, which is slightly larger than the 7/8" tubes used on previous dispenser models.
The new tubes have a slightly larger outer diameter, but they also have a larger inner diameter which
allows for increased flow rate.
The valve castings are new on Helix dispensers, but only because of the increased distance between the
two holes for the new tube retaining pin. The valve castings are made from the same material and have
the same inner diameter as the castings on Wayne™ Ovation series dispensers. The new castings will
support 24 mm triple bump or 7/8" double bump tubes because the outer diameter at the triple and double
bump locations on the tubes are the same. The castings on Ovation dispensers will not support 24mm
tubes because these tubes require the new tube retaining pin.
FIGURE 2-1 TRIPLE BUMP TUBE

2.2. FILTER AND STRAINER
The filter should be changed and the strainer cleaned on a regular basis. A dirty filter and strainer may
cause the dispenser to deliver fuel slowly. In some cases, this may appear to be a more serious service
related problem, when simply changing the filter and cleaning the strainer is all that is required.
Before removing the filter, trip the shear valve and turn OFF the circuit breaker for the associated
submersible pump.
The fuel filter is removed the same way an oil filter is removed from a car engine. As shown in Figure 2-
2, the new fuel funnel catches any fuel that is spilled and properly drains it into a container. Place a
container under the funnel spout when changing the filter.
To install the new filter, first apply a film of oil to the gasket and hand turn until the gasket contacts the
base. Then tighten one half turn. Open the emergency shear valve, turn the submersible circuit breaker
ON and check for leaks.
In new installations it may be necessary to change the filter frequently in the first few days of operation
in order to ensure proper operation.
Coupling
part of
iMeter base
Strainer located Spill funnel Filter

inside the casting
FIGURE 2-2 STRAINER CASTING, FILTER AND SPILL FUNNEL
The strainer is located inside the casting and held in place by the filter. Place a suitable container below
filter/strainer casting to catch product and sediment. Remove the filter and gently pull the strainer out
of the filter/strainer casting. Clean strainer screen of any debris. Reinstall strainer and a new filter.
If the underground installation is new, it may be necessary to clean the strainer screen two or three
times the first few days of operation to remove debris and pipe dope. After this, occasional cleaning of
the strainer is all that should be required. The fuel filter should be changed whenever the strainer is
cleaned.

2.3. PROPORTIONAL FLOW CONTROL VALVE
The proportional flow control valve and coil, and the new valve tube retaining pin are shown in Figure 2-3
and Figure 2-4 below. The valve is a pilot-operated, diaphragm solenoid valve. It has three main functions
in the dispenser:
• Positive shutoff
• Blend ratio control
• Flow rate regulation
Located between the meter and the hose outlet, the valve is controlled by a 24 VDC pulse width modulated
signal. Normally closed, the pilot opens by an amount proportional to the amount of current sent to the
valve coil. As the pilot raises off its seat, it reduces the pressure to the back side of the diaphragm causing
it to lift off of its seat as well. The same applies to the valve closing. In blending models, the diaphragm
follows the pilot back to the closed position as the current to the coil is reduced. During a sale, the iGEM
computer continually adjusts the current to the valves based on the desired blend ratio of the two feed-
stocks and the maximum allowable flow rate. In blenders, the high and low products remain separate until
they are mixed at the hose outlet.
Coil
Valve
Tube
Retaining
Pin
FIGURE 2-3 PROPORTIONAL FLOW CONTROL VALVE AND COIL
The valve tube retaining pin shown in Figure 2-4 is required for the valve and 24 mm tube used on Helix
dispensers.
FIGURE 2-4 VALVE TUBE RETAINING PIN
Also see related information on the valve and retaining pin in previous Section 2.1.
9

PROPORTIONAL FLOW CONTROL VALVE, continued
The proportional valve performs three basic functions in the dispenser. It provides positive shutoff, regu-
lates the ratio of blended feedstocks, and controls the flow rate through the hydraulic path by limiting the
maximum flow rate through a given hose.
The pilot operated proportional flow control valve consists of two main parts:
• The proportional valve

• The valve coil
The proportional valve is an electrically operated solenoid made up of a body and an operator. It controls
all flow through the dispenser.
The valve coil controls the operator of the valve. The coil is energized with a pulse width modulated (PWM)
signal that sends discrete bursts of current at a set frequency level. When the coil receives this signal, the
pilot inside the operator reacts to the changing magnetic field and moves up and down depending on the
amount of current through the coil. The position of the pilot relative to the pilot orifice in the diaphragm
controls the amount of flow.
In all Wayne dispensers using this valve, the general order of operation is the same. At the beginning of a
sale, the coil is energized with a minimum current level, allowing slow product flow to start. After a small
amount of product is delivered, the coil is energized with more current to initiate full regulated flow. For
preset sales, the dispenser will switch back to slow flow at a pre-determined point.
2.3.1. No Flow - Flow Control Valve Off

Flow control valve “Off” or no flow occurs when the inlet to the valve is charged. But there is no flow
required from the particular valve as in the instance where a submersible pump motor is running because
another fueling point is being used. The pilot stays closed allowing pump pressure to build on the back side
of the diaphragm, closing the outlet port.
2.3.2. Slow Flow - Flow Control Valve On

Flow control valve “On” slow flow occurs at the beginning of all sales, and again at the end of preset sales.
In this case the coil is energized with current bursts of shorter duration. This allows the pilot to slightly move
off its seat, allowing slow flow through the pilot orifice leading to the valve outlet, but not relieving enough
pressure to cause the diaphragm to open.
2.3.3. Full Regulated Flow - Flow Control Valve On

Flow control valve “On” full regulated flow occurs during the main portion of all sales. At this time, the coil
is energized with bursts of current of longer duration, pulling the pilot further off it’s seat, relieving the pres-
sure balance, and allowing the diaphragm to open by an amount relative to the distance between pilot and
the pilot orifice. The position of the pilot is constantly moving in very small increments based on the signals
sent from the computer relative to controlling a specific blend ratio and/or maintaining a maximum flow
rate of 10 GPM through a hose. As the computer senses the need to increase or decrease the amount of a
particular feedstock, it will send signals to the coil of longer (to open) or shorter (to close) duration. As a
result, the pilot moves up or down causing the diaphragm to follow its movement and achieve the proper
amount of flow.
When the delivery is complete, the coil is de-energized, allowing the pilot to return to its closed position. This
allows pressure to build on the back side of the diaphragm, forcing it to close and seal the outlet port
thereby stopping flow.
10

2.4. iMETER
The iMeter module, shown in Figure 2-5 below, contains two meters in one assembly and the Wayne™
Intelligent Pulser (WIP). Each of the two meters in the iMeter module is a positive displacement meter. In
remote dispensers, the bottom of the iMeter body is attached to the filter/strainer casting via a coupling as
shown in previous Figure 2-2. The iMeter body (the service part) is the same as used in previous dispenser
model series. The base of the meter is new since the coupling is part of the base.
The WIP pulser has two calibration doors - one for each meter. See Figure 2-6 and Figure 2-7. Only one
door may be opened at one time during meter calibration. If for any reason the pulser is replaced, be sure
the replacement pulser’s tabs snap into place in the meter slots before tightening the two screws securing
the pulser. More details on WIP operation are explained in the Electronics section of this manual. iMeter cali-
bration procedure is given in the Meter Calibration section.
Dispenser
Side 1 Dispenser
Side 2
FIGURE 2-5 iMETER AND WIP
2.4.1. Check and Pressure Relief Valve

There are two Check & Pressure Relief (C&PR) valves located in the meter dome underneath the valve cover
plates. See Figure 2-6 and Figure 2-7. The top mounted location allows for check valve replacement without
draining the meter body. Once a delivery is complete and the diaphragm valve is closed, the product pres-
sure between the check valve and the nozzle will be held at the pressure of the last delivery. If the pressure
should build up due to temperature rise in the hose or a car runs over the hose, the C&PR valve will relieve
the pressure buildup. The relief valve is set to relieve pressure between 30-50 psi.
11

Valve Cover
Dispenser
(Side 1) Seal Wires (2) iMeter Dome
Screws (2)
WIP securing
pulser
Calibration
Door
Dispenser
Side 2
Meter A
Meter B
FIGURE 2-6 IMETER SHOWING NEW WIP CALIBRATION SEAL WITHOUT USE OF BRACKET
FIGURE 2-7 IMETER SHOWING WIP CALIBRATION SEAL USING BRACKET AND PINS
12

2.5. Hose Outlet Casting and Tube Retainer Clip
The new outlet casting on Helix dispensers, shown in Figure 2-8 below, is smaller and lighter weight than
the outlet castings used on previous model series. In addition, as shown in Figure 2-10, this casting incor-
porates the use of a metal retainer clip that secures the triple bump tube. With this design, and with the use
of the new tube removal tool shown in Figure 2-9, service technicians will no longer need to use ladders to
access the top of the dispenser when removing product tubes. There are 1, 2, and 3 product outlet castings.
Hose outlet castings
2 Product 1 Product
Outlet Outlet
FIGURE 2-8 HOSE OUTLET CASTINGS
FIGURE 2-9 TOOL REMOVAL TOOL
13

Product tube
retainer clip
FIGURE 2-10 TUBE RETAINER CLIP
14

3. ELECTRONICS
Helix dispensers incorporate the use of the Wayne iGEM™ computer. The iGEM computer, located on side
1 of the dispenser, controls all functions of dispenser operation, except for Wayne ™CAT operations. CAT
operations are controlled by the iX™ R2 board located on side 2 of the dispenser.
The iGEM computer contains flash RAM memory and supports infrared IR remote control programming
and diagnostics. The IR remote is used to program computer functions such as filling mode, prices, blend
ratios, and fueling point number. The remote also is used to view the diagnostic statistics such as, error
codes, event counters, flow rates and calibration factors. The sensor for the IR remote is located on the
sales display controller board. See the iGEM Programming manual for a detailed discussion on IR remote
programming of the computer.
An important troubleshooting component on the computer board is the on-board LED indicators. In addi-
tion to voltage source indicators, the LEDs provide a visual indication of data link, pulser, and CAN bus
communications. See the Board Layout section for location and description of the LEDs and other compo-
nents on the iGEM board.
Another service tool is the Service Terminal (servTerm). servTerm is a software program that allows techni-
cians to interface the pump computer via a laptop to perform troubleshooting and other diagnostic proce-
dures. Pump software revision changes and model template configurations are performed by uploading
software from the laptop to the pump computer using the RS-232 link.
Servterm, the IR remote control, iGEM, and the new electronic boards shown in Figure 3-1 below are
required to service Helix dispensers.
Each of the boards shown below are discussed in detail in this section. A block diagram of the power distri-
bution to each of these boards is shown in Figure 3-2. Meter and WIP assignments are shown in Figure 3-3.
Heater/Fan Sales Display

Controller
Unit Price Controller
Serial/Parallel Converter TTL/CAN Converter

Connection Board -Suction
*ISB Temp Comp ISB
Connection Board - Remote
Nozzle Switch Interface Temp Comp Module
included in Temp Comp

* ISB Board is in a case models only
and ships as an assembly
3 channel board shown
Figure 3-1 NEW BOARDS USED IN HELIX DISPENSERS
15
3.1. POWER DISTRIBUTION BLOCK DIAGRAM
Part No. WU008123 Rev 01
16
QVGA QVGA Secure Contactless

Fan B/Light Scanner
Card Readers Card Reader
24V 24V 12V 5V 5V
Mag Stripe 5V SPM iX Board

Sales/Vol 24V Unit Price
Card Reader
Display 9V Display
Printer
24V Proportional
Valves
Relay Selects
iGEM 24V on Dispenser
Board Connection Bd
24 VDC Out
Fan Dispenser
Connection Board Nozzle Switch
Heater
Converter Board
AC Line 24VDC Out
Voltage
15V 15V
Power
Supply
Dispenser ISB Board
Power
AC In
Switch
15V
Wayne
Connect Nozzle Switch
(Optional) Interface Board
February 2013
15V 5V
AC Line
J-Box WIP’s Nozzles
Figure 3-2 Helix Power Distribution Block Diagram

See Section 4 Board Layouts for close up views of the boards and modules described in this section.
3.2. DISPENSER CONNECTION BOARD
The dispenser connection board combines the iGEM AC Relay board and the DC Distribution board and
centralizes all the power sources into one location. Current loop and data communications are also distrib-
uted from this board. AC power from the dispenser junction box comes into this board at J8. The board
provides AC power to the relay select lines an all other components. The connection board also provides AC
to the power supply, which returns 24 Vdc to the connection board where it is distributed to all other boards
and modules in the electronic head. The dispenser connection board also provides connections for future
optional components.
3.3. DISPENSER POWER ON/OFF SWITCH
New with Helix dispensers, the dispenser AC power switch is located on the chassis near the upper left corner
of the iGEM board. AC power from J56 on the dispenser connection board goes to the dispenser ON/Off
power switch. This switch will turn off power to the components on the connection board, therefore, all elec-
tronics in the head are shut down. See the Warning below related to the switch.
WARNING!
Turn the dispenser switch off when servicing the electronic boards and modules, however, keep in mind that
AC voltage will still be present at J8 on the Dispenser Connection board. Turn power off at the dispenser
circuit breaker inside the building when working on or near the dispenser connection board.
3.4. HEATER/FAN
The heater requires 120 VAC. The fan requires 24 Vdc, and it is always on regardless of the temperature. This
heater is designed to use less power than previous heaters. The heater setting is determined by the rotary
switch on the bottom of the assembly. The normal setting is the "E" position. The "0" position will turn the
heater off completely.
The setting on the switch determines the temperature at which the heater turns on. As the temperature
inside the electronics head gradually approaches this temperature, the heater gradually reduces output,
and, therefore power usage, until it approaches the set temperature.
3.5. SALES VOLUME AND UNIT PRICE DISPLAYS
Displays in Helix dispensers have white LCD digits or characters with a blue background that uses transflec-
tive backlighting technology. The micro-controller on the sales display controller board processes the data
from the iGEM computer. 24Vdc check points are at J10 and J11. To the right of these connectors is a green
LED that indicates 5V.
The Unit Price Display (UPD) controller board receives all communications, power and data from the sales
display controller board using RS-485 communications. An Ethernet cable is the only connection between
the two controller boards. A green LED in upper left corner of the UPD controller board indicates 5V.
17
3.6. NOZZLE SWITCH INTERFACE BOARD
All nozzle switch cables plug into the Nozzle Switch Interface board. This board is inside a blue case
mounted on the chassis in the hydraulics cabinet. The board is accessed by lifting the cover off the tabs
on the plastic case. There are thirteen connectors on this board, eight parallel inputs for nozzles and
four for door security switches. The other connector is the output to the ISB board on the serial commu-
nications channel.
The nozzle switch inputs and door switches are 5Vdc. The interface board changes these inputs to
15Vdc serial communications to the ISB.
3.7. ISB MODULE
The ISB Module consists of the board mounted inside a white or transparent case that is mounted on
top of the vapor barrier in the middle of the electronics head. The cable from the Nozzle Switch I/F board
and the pulser cables connect to the ISB board. The serial outputs for the WIP’s are sent to the iGEM
board. The serial output for the nozzles are sent to the Nozzle Switch Converter board.
3 Channel board is used for dispensers that have two WIP’s. If the dispenser has more that two WIP’s,
the 1-channel board is added and mounted on the opposite side of the ISB bracket. In this case, the
output of one of the WIP’s is sent to the 1-channel board, which then sends that signal along with the
third WIP’s signals to the iGEM board.
3.8. NOZZLE SWITCH CONVERTER BOARD
The Nozzle Switch Converter board is used to convert the nozzle serial communications back to parallel
for the nozzle signals going to the iGEM. The door security switches, if present, are handled in the same
manner.
3.9. TEMPERATURE MODULE (TEMP COMP)
Optional equipment.
Temperature probe cables plug into this board. The board is located inside a blue case mounted on the
chassis in the hydraulic cabinet. The board is accessed by lifting the cover off the tabs on the plastic
case. There are eleven connectors on this board, 10 of these are parallel inputs for the temperature
probes. The other connector is the signal output to the ISB board on a serial communications channel.
This connector also provides 15Vdc input power for the board.
3.10. TTL-CAN CONVERTER BOARD
The CAN-TTL Converter board receives temperature data from the temperature module board via TTL
level serial communication. The board provides the temperature module with 15Vdc power, and it
communicates the temperature data to the iGEM pump computer board via CAN bus. This board is
powered by the 24Vdc CAN bus power provided.
18
3.11. WIP
The Wayne™ Intelligent Pulser (WIP) contains two sets of magnetic sensors - one set for each meter. Inside
the meter dome, a rotating magnetic disk generates a changing magnetic field. The sensors detect changes
in the magnetic field which the pulser converts to digital pulses. The pulses are adjusted to meter output with
a calibration factor that is stored in the pulser memory.
The pulser has three Operational Modes: U.S. mode, Continental mode, and Euro mode.
In the U.S. mode, iMeter calibration is done with a 5 gallon test measure. In the Continental Mode, iMeter cali-
bration is done with a 20 liter test measure. Euro Mode is factory default - factory diagnostics.
The pulser’s Operational Mode is determined by the dispenser template (Read-only function - F16) loaded
into the pump computer’s memory. The operational mode tells the pulser which calibration factor will be
used for the iMeter calibration process. In other words, the mode identifies the size of the test measure you
are using when the amount of product dispensed in the test measure is within one of the predetermined
ranges defined for the 5 gallon and the 20 liter measurements. However, if the dispenser is set in one mode
(liters for example) and you try to calibrate using the 5 gallon test measure, the pulser will not accept the new
calibration factor during this process because the product dispensed in the test measure will not be within
the predetermined range. Because this calibration factor is essential for calibrating the iMeter to spec,
always ensure the correct mode is set after replacing a pulser or when performing meter calibrations.
To set the operational mode, communications between the pump computer and the pulser must be estab-
lished properly. Set the operational mode as follows:
1. Power up the dispenser.
2. Open both calibration doors on the pulser.
3. Cycle power to the dispenser.
4. Close the calibration doors.
Meters are tested and proven to be calibrateable at the factory before a dispenser is shipped. Local codes
and regulations may require verification of meter accuracy at Start-up and/or after replacing the pulser. If
verification or calibration is required, sufficient product must be run through each meter to thoroughly flush
out all air and completely fill the system prior to the calibration process. Meter verification accuracy and cali-
bration procedures are explained in a later section of this manual.
3.12. WAYNE CONNECT MODULE
The Wayne Connect™ IP-485® module allows the customer to use the existing underground pair of wires
for CAT communications instead of pulling new underground Ethernet cable.
The module converts the RS-485 signals (delivered by the existing underground pair of wires) to Ethernet
compatible signals which are then sent to the iX board. The iX board then drives the customer interface (the
card reader, keypad, and display screen) either directly, or through the SPM if the dispenser has SPM.
19
3.13. METER AND WIP ASSIGNMENTS BLOCK DIAGRAM
20
iGEM Nozzle Switch

Board Converter Board
ISB Board ISB Board
Nozzle Switch
Interface Board
Nozzles
M8 M7 M6 M5
METER WIP METER WIP METER WIP METER WIP

POS4 4 POS3 3 POS2 2 POS1 1
M4 M3 M2 M1
February 2013
S HIGH LOW EXAMPLE MODEL
Side A
Figure 3-3 Meter and WIP Assignments

4. ELECTRONIC BOARDS - LAYOUT AND CONNECTOR DESCRIPTIONS
This section shows the locations of the connectors on each of the electronic boards and modules. Pinout infor-
mation is also provided. While some of the connector pins are not accessible for troubleshooting, the description
given for these will help provide an understanding of the board and connector functions.
4.1. iGEM BOARD
For Helix dispensers, the iGEM board must have jumpers on each of the 2- pin connectors SW13A to D,
and SW14A to D. Eight jumpers (part number 4043601) are required. If these jumpers are not in place,
WIP communications through the Helix ISB board will be disrupted, resulting in error code 59.
Processor Activity Indicator
DS1: Red (Heartbeat) LED indicates processor activity. It will be blinking on and off at a steady rate as
long as the processor is running properly.
Power Indicators
These LEDs only indicate the presence of a voltage. They do not assure that the levels are correct.
DS6: Green LED indicates that the board is connected to power source on its 24VDC input line.
DS7: Green LED indicates that the board is generating 5VDC to power the logic.
DS8: Green LED indicates that the board is generating 8VDC for use on board and to power
associated assemblies.
DS13: Green LED indicates that the board is generating 15VDC which is used to power
the attached WIPs.
DS14: Green LED indicates that the board is generating 5VDC for use onboard.
Communication Indicators
POS Communications:
DS5: Red LED indicates activity on the Host Receive Line. The LED is on when the line is low.
DS12: Green LED indicates activity on the Transmit Line. The LED is on when the line is low.
Display Bit Bus Side 1 and 2 Communications:

DS3: Red LED indicates activity on Receive Line. The LED is on when the line is high.
DS9: Green LED indicates activity on the Transmit Line. The LED is on when the line is high.
WIP (Pulsers) Communications:

DS4: Red LED indicates activity on Receive Line. The LED is on when the line is low.
DS11: Green LED indicates activity on the Transmit Line. The LED is on when the line is low.
CAN Bus Communications:

DS2: Red LED indicates activity on Receive Line.
DS10: Green LED indicates activity on the Transmit Line.
These two LEDs flash very briefly; for example, at Authorize, PTS selection, or CAT activity.
21
Push Buttons Switch SW2
Red Green TOTs TOTs Reset S14
Current Loop Display Display Must Always
Laptop TX RECCAN Buzzer
1-4 5-8
Side 1 Side2 Bootstrap S13
Jumper S12D J6 J7 Be In The Program
J18 Bus Side 2 Side 1 J15 J16 Cold Start S15 Position
Data Link J13 J21 J22 (Not Used)
J25
Communication
Indicator LEDs
POS
Displays
Pulsers
CAN Bus
Heartbeat
Switch SW3
Must Always
Be In The OFF
Position For
POS Comm
Voltage LEDs
24 5 8 15V
24V In
J1
Laptop via
Null Modem
Cable
J26
February 2013
Relays Valves Nozzles Pulsers

J2 J3 J4 J5
Must have jumpers on all pins for Helix
22
iGEM COMPUTER BOARD

iGEM CONNECTORS, continued
Connector
Description Connects To Note
and Pin #
J1 24 VDC In 24V DC Distribution Bd J4 Typical Reading 23.9-24.1V
1 24V
2 24V
3 GND
4 GND
J2 Sub Pump Relays Relay Board J1 Typical Readings 23.9-24.1V

1 24 VDC
2 Pump Motor 2
3 24 VDC
4 Pump Motor 1
5 24 VDC
6 Pump Motor 4
7 24 VDC
8 Pump Motor 3
J3 Valve Outputs Proportional Valves Typical Voltage Readings for

1 24V Valve #9 checking the operation of the
proportional valves.
2 GND
MGDs:
3 24V Valve #4 slow flow 8Vdc
4 GND fast flow 19 Vdc
5 24V Valve #3 Blenders:
slow flow or fast
6 GND flow 8-19 Vdc
7 24V Valve #2
8 GND
9 24V Valve #1
10 GND
11 24V Valve #10
12 GND
13 24V Valve #8
14 GND
15 24V Valve #7
16 GND
17 24V Valve #6
18 GND
19 24V Valve #5
20 GND
J4 Nozzle Switch Inputs ISB J7 Typical Reading 5V
1 GND
2 NOZZ 4
3 GND
4 NOZZ 3
5 GND
6 NOZZ 2
7 GND
23
Connector
and Pin #
8 NOZZ 1
9 GND
10 NOZZ 8
11 GND
12 NOZZ 7
13 GND
14 NOZZ 6
15 GND
16 NOZZ 5
J5 WIP IN/OUT ISB J1 Typical Reading 14.8-15.2V

1 15 VDC
2 GND
3 WIP1 REC
4 WIP1 TX
5 GND
6 WIP2 REC
7 WIP2TX
8 GND
9 GND
10 WIP3 REC
11 WIP3 TX
12 GND
13 WIP4 REC
14 WIP4 TX
15 GND
16 15 VDC
J6 Totalizers from Side1 Outputs from Tots 1-4
1 24V
2 TOT 1
3 24V
4 TOT 2
5 24V
6 TOT 3
7 24V
8 TOT 4
9 N/C
10 N/C
J7 Totalizers from Side2 Outputs from Tots 5-8
1 24V
2 TOT5
3 24V
4 TOT6
5 24V
6 TOT7
7 24V
8 TOT8
9 N/C
24
Connector
and Pin #
10 N/C
J8 BackLight Output
1 SIDE A 24V
2 GND
3 SIDE B 24V
4 GND
J9 Red/Green Light Out-

puts
1 SIDE A 24V
2 GND
3 SIDE B 24V
4 GND
J10, J11, J12 SPARE IN/OUT

J13 CAN BUS I/O
1 TX/RC +
2 TX/RC -
3 24V
4 GND
J14 Euro Data Link Not used in U.S.
J15 Display Data Cable Bit Side 1 Display J1

Bus Side A (1)
1 DATA IN A
2 DATA OUT A
3 ADDRESS BIT A
4 CLOCK A
5 BUZZER A
6 STOP A
7 8 VDC Typ reading 7.8 - 8.2 VDC
8 GND
9 REMOTE
10 GND
J16 Display Data Cable Bit Side 2 Display J1

Bus Side B (2)
1 DAT IN B
2 DATA OUT B
3 ADDRESS BIT B
4 CLOCK B
5 BUZZER B
6 STOP B
25
Connector
and Pin #
7 8VDC Typ reading 7.8 - 8.2 Vdc
8 GND
9 REMOTE
10 GND
J21 BUZZER POWER

SIDE 2
1 8V
2 BUZZER 2
J22 BUZZER POWER
SIDE 1
1 8V
2 BUZZER 1
J23 CAT BUZZER

1 GND
2 BUZZ CAT
J24 Not used with Helix
J25 DATALINK DATALINK PAIR 1 S12D must have jumper for

1 DATA + communications with POS
2 DATD -
SW13A to D four 2-pin connectors Must have eight 2-pin jumpers installed on Helix dispensers for
SW14A to D four 2-pin connectors WIP communications through the ISB to iGEM
26
4.2. IX R2 BOARD
J36 J39 J30 J29 J28 J37

J27
USB Ethernet Port

USB USB USB USB
J10
Audio Out
J14
Printer
not used
J23 J7
QVGA - Side B
J41
Ovation LX
Lights
J32 Side A
J41
J42
Ovation LX
Lights
J24 Side B
QVGA - Side A
J11 J6
Power
J15
TX RX
LEDs
CR21 J13
February 2013
J1 J3 J2 Power J17
J46 CAN Bus LED J21 RS-485
J12
SW2 J5 Debug SW1
CAN Bus Termination Annunciator Port Reset Button
27
iX R2 Board Connectors, continued
Connector
and Pin #
J1
J2 CAN BUS
J3 CAN BUS
J5 Annunciator
J6
J7
J10 Audio Out
J11 Power
J12 Debug Port
J13
J14 Printer, not used
J15
J17 RS-485
J21
J23 QVGA Side B
J24 QVGA Side A
J27 USB Used for upgrades
J28 USB Printer 1
J29 USB Printer 2
J30 USB SPM 1
J32 Color QVGA
J36 Factory Use
J37 Ethernet Port
J39 USB SPM 2
J41 Ovation LX Lights -
Side B
J42 Ovation LX Lights -
Side A
J46
SW1 Reset Button
SW2 CAN Bus Termina-
tion
CR21 Power LED
28
4.3. NOZZLE SWITCH INTERFACE BOARD
Nozz 1 Nozz 4 Nozz 3 Nozz 2

Side 2
Wide Body Dispenser
Side 1
Nozz 2 Nozz 3 Nozz 4 Nozz 1
Connect the nozzle # above to the J# on the

J13 J1 J12 Interface board as shown in the table.
J13 J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11 J12

Side 1 Side 2 Side 1 Side 2
To ISB Nozz 1 Nozz 2 Nozz 3 Nozz 4 Nozz 1 Nozz 2 Nozz 3 Nozz 4 Door Sw Door Sw Door Sw Door Sw
Interface Board Connections: Nozz 1 Nozz 2

4.4. NOZZLE SWITCH CONVERTER BOARD Side 2
Nozzle #s are defined by their physical location
on the dispenser as shown in these diagrams.
Narrow Body Dispenser
For example, a wide body dispenser could have
J1
only two nozzles on side 1 and they could be in
J5 positions 3 and 4. Therefore, they would connect Side 1
Nozz 2 Nozz 1
to J3 and J4 on the Interface board.
Connect the nozzle # above to the J# on the
J4 Interface board as shown in the table above.
J2
Pin J1 J2 J4 J5 Pin J1 J2 J4 J5
1 Nozzle1 15V Bezel SW1 Security SW 1 6 Nozzle6 GND
February 2013
2 Nozzle2 TX Bezel SW2 Security SW 2 7 Nozzle7

3 Nozzle3 RX GND Security SW 3 8 Nozzle8
4 Nozzle4 GND GND Security SW 4 9 GND
29
5 Nozzle5 GND 10 GND

4.5. TEMPERATURE MODULE
30
J1 J11
Pin J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J11

1 RX FEED11 FEED21 FEED31 FEED41 FEED51 FEED61 FEED71 FEED81 FEED91 FEEDA1
2 TX RETU11 RETU21 RETU31 RETU41 RETU51 RETU61 RETU71 RETU81 RETU91 RETUA1
Common Common Common Common Common Common Common Common Common Common
3 15V Return Return Return Return Return Return Return Return Return Return
4 GND GND GND GND GND GND GND GND GND GND GND
4.6. TTL/CAN CONVERTER BOARD
J5
J1
J2
J3
Pin J1 J2 J3 J5
February 2013
1 CAN_HI CAN_HI 15V not used

2 CAN_LO CAN_LO TX
3 24V 24V RX
4 GND GND GND
5
4.7. ISB BOARD
The ISB board is enclosed in a white or transparent case located in the center of the electronic head.
The 3-channel ISB has the following interfaces:
iGEM-to-WIP Interface
Auxiliary ISB Interface
iGEM-to-Switch Interface
WIP-to-iGEM Interface
2nd WIP-to-iGEM Interface
Switch-to-iGEM Interface
The 1-channel ISB has the following interfaces:

iGEM-to-WIP Interface for 3rd WIP
WIP-to-iGEM Interface for 3rd WIP
Dispensers with more than two WIPs require a second ISB board - usually the 2-channel board.
J1 OUTPUT J2 J3
INPUT
J5 J8 J9
Channel 1 Channel 2 Channel 3
Three Channel ISB
Connector
and Pin #
J1 WIP’s 1and 2 iGEM Computer J5
1 POWER 1 15V Typ reading 14.2 - 15.8 VDC
2 GND
3 RC 1 Receives data from WIP1
4 TX 1 Transmits data to WIP1
5 GND
6 RC 2 Receives data from WIP2
7 TX 2 Transmits data to WIP2
8 GND
9 GND
10 RC 3 Receives data from WIP3 Via 2nd ISB
11 TX 3 Transmits data to WIP3 Via 2nd ISB
12 GND
31
14 TX 4 Receives data from WIP4 Via 2nd ISB
15 GND
16 POWER 2 15V Power for 2nd ISB
J2 2nd ISB J1
1 POWER 2 15V Typ reading 14.2 - 15.8 VDC
2 GND
5 GND
8 GND
9 GND
10
11
12 GND
13
14
15 GND
16 POWER 2 15V Power for 2nd ISB
J3 Nozzle Switch Convertor Bd J2

1 POWER 2 Power for Nozzle Converter board
2 TX DATA Transmits data to Conv Bd
3 RC DATA Receives data from Conv Bd
4 GND
J5 WIP1 Channel 1
1 TX DATA1 Transmits data to WIP1
2 RC DATA1 Receives data from WIP1
3 GND
4 POWER Power for WIP1
5 GND
J8 WIP2 Channel 2
1 TX DATA2 Transmits data to WIP2
2 RC DATA2 Receives data from WIP2
3 GND
4 POWER Power for WIP2
5 GND
J9 Nozzle Switch I/F Bd J13 Channel 3

1 RC DATA Receives data from I/F Bd
2 TX DATA Transmits data to I/F Bd
3 GND
4 POWER Power for Nozzle Sw Interface board
5 GND
32
4.8. DISPENSER CONNECTION BOARD - REMOTE MODELS
Dispenser J39 J41 J23 J26 J28

Switch AC In J37 J38 J40 J21 J24 J27 J29
J56 J8 J14
J44 J45
J12 J13 J43 J36 J24 J25

J11 J20
J10 J19
J9 J18
Connector
and Pin #
J8 120 VAC IN J-BOX

J9 120 VAC HEATER
J10 120 VAC TO POWER SUPPLY IGEM
J11 120 VAC TO POWER SUPPLY 2 If present for vacuum pump, future opt
J12 120 VAC OUT
J13 PUMP MC
J14 SUB PUMP RELAYS
February 2013
J19 DATA IN CURRENT LOOP

J20 DATA OUT CURRENT LOOP
J21 24 VDC E-NET
J22 24 VDC BATTERY
33
J23 24 VDC SALES DISPLAY

J24 24 VDC FAN
DISPENSER CONNECTION BOARD, continued
J25 24 VDC FROM POWER SUPPLY 2 If present for vacuum pump, future opt
J36 24 VDC FROM POWER SUPPLY
IGEM
J37 24 VDC SPM SIDE A
J38 24 VDC SPM SIDE B
J39 24 VDC IXR2 SIDE A
J40 24 VDC IXR2 SIDE B
J41 24 VDC iGEM
J42 24 VDC FOR 2 IXR2 BDS COLOR
QVGA
J43 DATA IN RS485 J-BOX
J44 DATA OUT RS485 IXR2
J45 DATA OUT RS485 FOR (2) IXR2 BOARDS
COLOR QVGA
J56 120 AC DISPENSER POWER
SWITCH
34
4.9. DISPENSER CONNECTION BOARD - SUCTION MODELS
This page for future use for sution models.
J39 J41 J23 J26 J28

J37 J40 J21 J24 J27 J29
J38
J56 J8 J9 J10 J11 J12 J18
J14
J15
J44 J45
J43 J36 J22 J25

J1 J2 J3 J4 J5 J6 J30 J31 J17 J18 J19 J20
Connector and Pin # Description Connects To Note
35
4.10. SALES DISPLAY AND CONTROL BOARD ASSEMBLY
J10 J11 J9 J3 J4 J8 J7
LED 5V
Batteries used in
some countries
Auth/Stand alone
jumper J6 J5
J2 J1 SW1
IR Sensor
Connector # Description Connects To Note
J1 Programming for factory use

J2 RS-485 Unit Price Display J1
J3 RS-485 for future use
J4 RS-485 for future use
J5 Display Interface Display Board
J6 Standalone/Local Auth
J7 Data Cable Bit Bus Computer J15 or J16 J15 Side A (1) J16 Side B (2)
J8 Preset Preset Keypad
J9 Ext Backlight On/Off
J10 24V In
J11 24V In
LED On Green Indicates 5V
SW1 Operation/Test switch Set to 0 for selftest
Set to 9 for normal operation
36
4.11. UNIT PRICE DISPLAY AND CONTROL BOARD
LED 5V J1 SW1 J2
J3 J4 J5 J6 J7
J1 RS-485 Sales Display Bd J2 Data and Power from sales dis-

play
J2 Programming company use
J3 UPD1
J4 UPD2
J5 UPD3
J6 UPD4
J7 UPD5
LED On Green Indicates 5V
SW1 Operation/Test Switch Set to 0 for selftest
Set to 1 for normal operation
37
4.12. SECURE PAYMENT MODULE (SPM) - LOW PROFILE
J12 J4 J8
USB iX Board DC PWR Secure Card Reader
J5
DC PWR
TTL Card
Reader
J15
Scanner
J6
Softkeys
J14
Factory J11
use Printer
DW-12
J1 J2 J3
DC Power Connectors
J1 DC PWR
J2 DC PWR
J3 DC PWR
J4 DC PWR
J5 DC PWR
J6 Softkeys
J8 Secure Card Reader If applicable
J10 TTL Card Reader
J11 Printer DW-12 If applicable
J12 USB iX Board
J14 For factory Use
J15 Scanner
38
4.13. 24V DC POWER SUPPLY
LED
J1
J2
Underneath
safety cover
Connector Connects To
Description Note
and Pin # Conn / Pin#
J1 AC Power Input Dispenser connector board AC In from Connector board

1 BK 1
2
3 W 2
4
5 G 3
J2 DC Power Output Dispenser Connector board DC Out to Connector board

1 BK 1 BK
2 BK 3 BK
3 W 2 W
4 W 4 W
LED ON Green = 24V
39
4.14. HEATER/FAN
SW1
J2
J1
LED
Bottom view Side view
Connector
and Pin #
J1 AC Power In Dispenser connector board AC In for heater
J2 DC Power In Dispenser connector board 24 VDC In for fan
LED RED when heater is

On
SW1 Thermostat Setting SW1 factory default setting is
position E for normal use.
40
4.15. WIP
WIP pinouts.
WIP
4.16. WAYNE CONNECT MODULE
Optional equipment.
Ethernet Ports
this side out of view BB Bus LED’s
P8
BB Bus
AC Power
Connection
P7
LF Bus
LF Bus LED’s
Connector Description Status
LED’s: Green Normal Operation

Yellow Unstable - Intermittent RS-485 Comm
Red Offline - Wiring/connections bad, P7 and P8 reversed
41
42
5. PART NUMBERS REFERENCE
This section contains a list of some common service parts. This list is for reference only and is not to be used
as an official stocking list. The list is given here to show the new parts and some of the existing parts used
in Helix dispensers.
5.1 ELECTRONICS
WM041368-0002 Sales Display Ass’y (includes controller board and display), white on blue
WM039007-0001 Unit Price Display Controller Board
WM040824-0007 Unit Price Display, UPD Single Price
WM040824-0009 Unit Price Display, UPD Dual Price
WU004677- QVGA Display, 5.7", with LED B/L (board is smaller than previous)
WU005093-0001 ISB Assembly, Three Channel, includes case
WU005093-0002 ISB Assembly, One Channel, includes case
WU004203-0001 Dispenser Connection Board, remote dispensers
WU006751-0001 Nozzle Switch Interface Board, Programmed, board only, not case
WU006752-0001 Nozzle Switch Converter Board, Programmed
WU007599-0001 PTS Button/Switch, includes button/magnet/dome
WM040524 Softkeys, 5.7"
WM042452-0001 Totalizer, EMT with connector
892638-006-359 SPM Keypad Ass’y, Low Profile
WU003096- iX R2 Board
WU006648-0001 Printer, Zebra
891687-R01 Printer, DW-12, Service kit, (existing part)
WM041211-0001 Heater/Fan, 300W, 24V
WM001908-R003 iGEM Board, (existing part, but needs jumpers installed in field)
004-921469-KIT WIP, for iMeter, black case, (existing part)
WU000371-0001 WIP, for Xflo meter, blue case, (existing part)
WM042603 Gasket, SPM Keypad
WM044173 Gasket, Card Reader
5.2 HYDRAULICS
existing p/n iMeter (same serv part as previous models, the base and strainer casting is new)
001-300954- Check Valve, iMeter, (existing part)
888613-001 O-ring, iMeter check valve, (existing part)
existing p/n Xflo same serv part as previous models (base/strainer casting is new)
WM011531-0001 Check Valve, Xflo meter, (existing part)
888613-001 O-ring, Xflo meter check valve, (existing part)
WM043174 Lock Pin, valve tube
WM040393 Retaining Clip, outlet casting tube
WM044244-0001 O-ring for triple bump tube
WM031449 Strainer
WM033193-0002 O-ring, strainer
WM038598-0001 O-ring, meter inlet coupling
WM037130 Funnel, spill, snaps onto inlet casting
43
5.3 NOZZLE BOOT PARTS
WM041075-0001 Boot
WM046400-0001 Flipper, with magnet
WM045692-0001 Switch
WM045692-0001 Nozzle Switch and Cable, N/C
5.4 TOOLS
Screw head size Where Used

#2 Phillips Head iX Red board, QVGA display board, card reader
T20 Torx head Boards - iGem, unit price display panel, small
converter bd, QVGA bracket, Wayne Connect module
T20 Torx head Sales display (T20 with flexible drive needed for rear screws)
T10 Torx head Printer carriage
3 mm Allen head Dispenser connection board
3 mm Allen head ISB case
3 mm Allen head Power Supply
3 mm Allen head Nozzle I/F board and cover
3 mm Allen head SPM
5 mm Allen head Side valance in front of outlet casting
5 mm Allen head Meter base, check valve covers and WIP
6 mm Allen head Nozzle boot
10 mm Hex head Meter to rail Side A
10 mm Hex head Meter to valve retaining plate
10 mm Hex head Junction box cover
10 mm Hex head ISB bracket
13 mm Hex head Rail ends side B
10 mm hex nuts Hose Outlet casting
7 mm hex nut Chassis ground wires in front of iGEM board
WU007681 Bezel Key U-frame and Payment Terminal, (DW2 Key)
WM008096 Printer Door Key, (DHW1 Key)
WM003119 Hydraulics Door Key, (3306 Key)
WM047463 Tube Removal Tool, (removing tubes from outlet casting)

Torx Screwdriver Kit Kit with flexible drive available at major tool stores and online
(See Appendix E for photo)
WM045329-0001 Self-tapping Screw, Torx, (for plastic)

WM045308-0002 Taptite Screw, Torx, (for sales/vol display ass’y)
WU008231-0001 Octane Stickers, Generic
44
6. REPLACEMENT PROCEDURES
This section provides the procedures required for replacing the major components in the dispenser. Before
power is removed from the dispenser, totals should be recorded in case of memory alteration.
WARNING
Electric Shock Hazard!
When corrective actions require the electrical power to the equipment be ON, use wiring diagrams,
connector drawings and other information in this manual to identify the electrical connections and
AVOID contact with the electrical power. Failure to do so may result in severe injury or death.
As a general rule, when removing and installing electronic boards, take care not to contact the boards with
one another. Do not lay spare boards on top one another, since contact between components might cause
damage to the circuit board coating, circuit board tracks, or circuit components.
Always keep replacement components in their anti-static shipping bags until they are installed. Put
replaced suspect components in the anti-static bags for return to the factory in original packaging and fill
out a return parts tag.
Before replacing any components, servicing personnel should wear a static guard wrist strap (part number
916962 or equivalent) securely attached to an earth grounding point in order to prevent damage to elec-
tronic components due to static electricity.
After replacing a component, make a thorough visual inspection of your work to ensure that all connec-
tions are secure, all mounting hardware is secure, and there are no loose washers, screws, tools, etc., lying
around that may cause a failure.
WARNING
The AC power switch (sometimes referred to as the dispenser power switch or the iGEM power switch)
inside the electronic head shuts off power to all components, except for the AC power going to J8 on
the dispenser connection board and leaving the board at J56 going to the switch. For this reason,
before working in proximity to the connection board, be sure to turn off power to the dispenser at the
circuit breaker inside the building. Failure to remove the power may result in severe injury or death.
WARNING
Before removing any components in the electronic section of the dispenser or when working in the
junction box, remove electrical power from the dispenser. More than one disconnect may be required
to remove power. Use a voltmeter to ensure AC power has been removed. Failure to remove the power
may result in serious injury or death.
WARNING
Before removing any components in the hydraulic system of the dispenser, trip the emergency shear
valve and remove electrical power from the dispenser and submersible pump(s) to prevent fuel spills.
Failure to do so could cause a fire hazard that may result in serious injury or death.
WARNING
Drain the fuel into an appropriate container and pour it into an underground tank to prevent spilling
fuel under and around the dispenser. Failure to do so could cause a fire hazard that may result in
serious injury or death.
45
6.1 IGEM COMPUTER BOARD REPLACEMENT
When replacing the computer, see the procedure used to re-flash the pump code and template as
explained in that section. While the new computer board may have pump code on-board, it may not
be the latest code and, in some cases, new pump code may not be compatible with the version of the
dispenser template on your laptop. Therefore, always use the latest version of pump code and the
latest version of the dispenser template to ensure compatibility. The latest versions can be downloaded
to your laptop from the Wayne ASONet.
1. Turn off power at the dispenser switch located to left of the iGEM board shown in the Fig 6-1 below.
2. Disconnect J1 24VDC power cable to computer board.
Note: Interchanging the Bit Bus and EM Totalizers cables will apply 24Vdc to the display board
and likely result in damage to the display board, therefore:
3. Tag and disconnect the cables to J15 and J16. (Bit Bus A and Bit Bus B). +8Vdc.
4. Tag and disconnect the cables to J6 and J7. (E-M Tots Side A and Side B). +24Vdc.
5. Disconnect all other wiring to the board.
6. Disconnect cables from retainers and move all cables aside.
7. Remove (4) screws from corners of the board and pull board down under the bracket and then
down and out to remove.
Note: For Helix dispensers, the iGEM board must have jumpers on each of the 2- pin connectors
SW13A to D, and SW14A to D. Eight jumpers (part number 4043601) are required. If these jumpers
are not in place, WIP communications through the Helix ISB board will be disrupted, resulting in
Error Code 59. See Fig 6-1 below and see the Board layout section earlier in this manual.
8. On the new iGEM replacement board, install jumpers as per the above Note. See iGEM board photo
in the Board Layout section for these jumper locations.
9. Install new board and reconnect cables. See note above.
10. Install new board using reverse procedure and reconnect all cables.
11. Re-flash the pump code and template as explained in the iGEM Code and servTerm section of this
manual.
Nozzle Switch
Dispenser Converter Board
Power Switch
(See AC power
switch Warning
on previous pg) Jumpers must be
in place. See Note.
FIG 6-1 IGEM AND NOZZLE SWITCH CONVERTER BOARDS

46
6.2 NOZZLE SWITCH CONVERTER BOARD
The Nozzle Switch Converter board is shown in Fig 6-1 on the previous page.
1. Turn off power at the dispenser switch located to left of the iGEM board.
2. Disconnect the cable to the ISB and the cable to iGEM.
3. Remove (2) T20 Torx screws and remove board.
4. Replace in reverse order.
6.3 NOZZLE SWITCH INTERFACE BOARD
The Nozzle Switch Converter board is shown in Fig 6-2.
1. Turn off power at the dispenser switch located to left of the iGEM board.
2. Lift cover on Switch I/F case.
3. Disconnect the nozzle switch cables and cable to the ISB.
4. Remove board from standoffs and remove from case.
Cable out
to ISB
Nozzle Switch
Cables Side A
Side B
FIG 6-2 NOZZLE SWITCH INTERFACE BOARD

Note: See the Nozzle Switch Interface Board in Section 4 for nozzle connector assignments.
47
6.4 ISB ASSEMBLY REPLACEMENT
The Intrinsic Safe Barrier circuit board is mounted inside a white or transparent plastic box in the center of
the electronic head on Side A. If a second ISB assembly is present, it is accessed and removed from side B.
The circuit board itself is not separately replaceable. The complete assembly (plastic box), as shown below
in Fig 6-3, must be replaced as follows:
1. Turn off power at the dispenser power switch.
2. Unplug the cables at the top of the ISB assembly. The cables go to iGEM and to the nozzle switch
converter board. If there are more than two WIP’s, a third cable will go to the second ISB.
3. At the lower part of the ISB box, push in on the tab on each side and raise and remove the lower cover.
4. Unplug the two WIP cables and the nozzle switch I/F cable from the bottom connectors.
5. Remove (2) 3mm Allen screws that secure the ISB case to the metal bracket and remove the assembly.
6. Replace assembly in reverse order.
3mm Allen screw, 2
lower cover removed
FIG 6-3 ISB ASSEMBLY
48
6.5 NOZZLE BOOT, SWITCH, OR FLIPPER REPLACEMENT
1. Remove the 6 mm hex socket head screw that secures the nozzle boot. See Fig 6-4.
2. Pull nozzle boot out from bottom and down to access the nozzle switch on back of the boot.
3. Remove switch by pushing on the tab and pulling out the switch.
4. To replace the switch, disconnect cable from Nozzle Switch Interface board, remove cable and replace.
5. To replace flipper, pull flipper out of the grooves in the boot, remove from boot and replace.
6. Replace boot as needed.
Tab/latch
securing
switch
6 mm hex
screw
Flipper
FIG 6-4 NOZZLE BOOT
49
6.6 WIP REPLACEMENT
iMeter pulsers are in a black case, while xFlo meter pulsers are in a blue case. They are not inter-
changeable.
Refer to Fig 6-5 below and Fig 6-7 in Meter Replacement section and replace the WIP as follows:
1. Cut and remove the seal wires on both calibration doors on the pulser.
2. Remove the calibration seal pins, iMeter only.
3. Loosen the (2) 5 mm Allen screws that secure the pulser to the meter dome and remove the pulser.
4. Remove the sealing bracket, iMeter only.
5. Press the two plastic tabs on end of pulser, lower the plastic cover, remove the rubber cap that
covers the small 8-pin connector, and disconnect the cable.
6. Connect the pulser cable to the new pulser. Align carefully - misaligned connector pins at the
pulser will prevent proper mode setting and calibration. Pin 1 on the connector inside the pulser
is located at the bottom of the pulser as shown in the figure below.
7. Re-install the rubber cap over top of connector and secure the plastic cover back in place over the
rubber cap and cable. Both ends of the cover must be snapped in place.
8. Install the new pulser, along with the sealing bracket if applicable, and secure with the (2) screws.
Do not install new seal wires at this time.
9. Follow the Pulser Operational Mode setting procedure and the Meter Verification Accuracy proce-
dure in this manual, and, if required, continue with the iMeter calibration procedure.
10. Install the seal pins, if applicable, and seal wires after completing the above steps.
FIG 6-5 WIP
50
The Warnings from the beginning of this section have been repeated below to reemphasize their importance.
WARNING
The AC power switch (sometimes referred to as the dispenser power switch or the iGEM power
switch) inside the electronic head shuts off power to all components, except for the AC power going
to J8 on the dispenser connection board and leaving the board at J56 going to the switch. For this
reason, before working in proximity to the connection board, be sure to turn off power to the
dispenser at the circuit breaker inside the building. Failure to remove the power may result in
severe injury or death.
WARNING
Before removing any components in the hydraulic system of the dispenser, trip the emergency
shear valve and remove electrical power from the dispenser and submersible pump(s) to prevent
fuel spills. Failure to do so could cause a fire hazard that may result in serious injury or death.
WARNING
Drain the fuel into an appropriate container and pour it into an underground tank to prevent
spilling fuel under and around the dispenser. Failure to do so could cause a fire hazard that may
result in serious injury or death.
WARNING
Before removing any components in the electronic section of the dispenser or when working in the
junction box, remove electrical power from the dispenser. More than one disconnect may be
required to remove power. Use a voltmeter to ensure AC power has been removed. Failure to
remove the power may result in severe injury or death.
51
6.7 PROPORTIONAL VALVE ASSEMBLY REPLACEMENT
The valve coil and conduit on Helix dispensers are an assembly and not separately replaceable. The
valve, coil, wiring and potted conduit can be replaced as an assembly or just the valve can be replaced.
The valve is the same as the valve used on previous model series, except for the distance between the
pin wholes in the valve body. This change is to accommodate the new valve tube retaining pin used to
secure the 24 mm tubes. See Fig 6-6.
To replace the valve without replacing coil/conduit assembly:
1. Trip emergency shear valve and run a sale to drain the line and relieve pressure.
2. Turn off power to the dispenser and submersible pump at the circuit breakers inside the building.
3. Push down on the name plate on top of the coil, then remove clip and name plate.
4. Raise coil/conduit assembly up and rotate away from the valve. Save spring washer under the coil.
Note: Conduit inside the head is not locked down on the vapor barrier, therefore, the conduit can
be moved up and down.
5. Place a container under the valve to catch the fuel.
6. Remove product tube lock pin from valve and remove tube from valve.
7. Loosen (2) 10 mm hex screws securing the valve retaining plate to the meter, and rotate retaining
plate upward.
8. Pull valve out from meter.
9. Install new o-ring on new valve and on product tube, Fig 6-7C. Replace in reverse order.
10. Power up dispenser and reset shear valve. Run sales to clear air from line, check for leaks and test
operation.
To replace the only coil/conduit assembly:
1. Power down the dispenser at the iGEM dispenser power switch inside the electronics head.
2. Disconnect valve coil wires at J3 on computer board.
3. Remove washer and rubber retainer from the top of valve conduit. Save parts.
4. Push down on the name plate on top of the coil, then remove clip and name plate.
5. Raise coil/conduit assembly up and rotate away from the valve. Save spring washer under the coil.
6. Pull conduit and wires down from vapor barrier.
7. Replace in reverse order and reconnect wires. Power up dispenser and test operation.
Conduit
rubber retainer Conduit
Coil
Retaining Plate
Valve
Retaining Pin
FIG 6-6 VALVE, COIL AND CONDUIT

52
6.8 METER REPLACEMENT
Two methods for removing the meter are discussed in this section.
6.8.1 iMeter Replacement - Removing meter from base

The procedure below is for removing the iMeter from the base casting then removing the meter
from the dispenser. Also see the procedure for removing the iMeter with the base casting and cou-
pling attached.
Refer to Fig 6-7 and Fig 6-8 the following page when performing these steps.
1. Trip the emergency shear valve.
2. Run a sale to drain line and relieve pressure.
4. Place a container under the filter funnel spout to catch fuel. See Section 2 Filter and Strainer.
5. Remove filter and strainer.
6. Cut and remove seal wires on the WIP, and remove the seal pins and bracket.
7. Loosen (2) 5 mm Allen screws that secure the pulser to the meter. Remove pulser and set aside
on top of adjacent meter. (In most cases it is not necessary to disconnect the pulser cable.)
8. Place container under the valve to catch fuel.
10. Loosen (2) 10 mm hex screws that secure the valve retaining plate to the meter and rotate
retaining plate upward.
11. Pull valve out from meter and rotate valve and conduit out and away from meter. See Fig 6-7C.
12. Repeat steps 8.-11. on opposite side.
13. Remove (6) 5 mm Allen screws that secure the meter to the base. (For the two middle screws use
5 mm on a drill bit socket with a 6” extension.)
14. Remove meter from side B of the dispenser.
15. Remove and discard the 3 o-rings in the base casting and install new o-rings. Apply white lithium
grease or Vaseline in the o-ring grooves. (The grease acts as a lubricant and as an adhesive to
help keep the o-rings seated in the grooves.
16. Install the new replacement meter onto the base and secure with the (6) 5 mm screws.
17. Replace o-ring on the valve.
53
iMeter Replacement, continued
18. Reinstall valve into meter and secure the valve retaining plate. (Be sure to seat the retaining plate
properly into the groove on the valve so that the o-ring is not pinched.)
19. Inspect product tube o-ring and replace as necessary.
20. Reinstall the product tube into the valve and secure the tube with the retaining pin. Be sure the pin
snaps in place.
22. Reinstall WIP.
23. Clean and reinstall the strainer and install new filter.
24. Turn power on to dispenser and submersible pump.
25. Reset the emergency shear valve.
26. Run test sales to clear air from lines and check for leaks.
27. Perform Meter Verification Accuracy and Calibration procedure as required.
54
conduit
and
coil
Retaining
Plate
Valve
Side B meter support rail Side A meter to rail screw. Meter

Side B Rail screw Lock
Loosen the screw on this side. screws
(one each end of rail) Pin
Side B screw must be removed.
Fig A Fig B
Valve rotated
away from meter
Product tube o-ring Fig C Valve o-ring
FIG 6-7 IMETER REPLACEMENT
55
Sealing pins and bracket
(2) 5 mm screws
on WIP
WIP
cable
5 mm on drill bit socket

For Meter middle screw each side use 5 mm on a drill bit socket
and a 6” extension.
FIG 6-8 WIP AND METER SCREWS
56
6.8.2 iMeter Replacement - Removing meter with the base casting and coupling attached
The procedure below is for removing the iMeter with the base casting and coupling attached. Also see
the procedure for removing the iMeter from the base casting then removing the meter from the dispenser.
Refer to Fig 6-7 and Fig 6-8 on the previous pages for items specific to the procedure below. Also see Fig
6-9 and Fig6-10 on the following pages.
4. Place a container under the filter funnel spout to catch fuel. See Section 2 Filter and Strainer.
5. Remove filter and strainer.
6. Cut and remove seal wires on the WIP and remove the seal pins and bracket.
7. Loosen (2) 5 mm Allen screws that secure the pulser to the meter. Remove pulser and set aside on top
of adjacent meter. (In most cases it is not necessary to disconnect the pulser cable.)
8. Place container under the valve to catch fuel.
10. Loosen (2) 10 mm hex screws that secure the valve retaining plate to the meter and rotate retaining
plate upward.
11. Pull valve out from meter and rotate valve and conduit out and away from meter. See Fig 6-7C.
13. On dispenser side A, loosen the 10 mm hex head screw securing the meter to the rail. On side B,
remove the 10 mm screw. See rail screws in Fig 6-7A.
14. On side B, remove the 14 mm hex head screw on each end of the meter support rail and then pull rail
outward and then down.
15. Disconnect the meter base coupling from the filter/strainer casting. (From side B, turn the coupling
right to left or clockwise to disconnect.) See Fig 6-9.
16. Remove meter (with base and coupling) from side B.
17. Remove (6) 5 mm Allen screws that secure the meter to the base.
18. Remove and discard the 3 o-rings in the meter base casting and install new o-rings. Apply white
lithium grease or Vaseline in the o-ring grooves. (The grease acts as a lubricant and as an adhesive
to help keep the o-rings seated in the grooves.
19. Apply lithium grease to the threads above the coupling. Install the new replacement meter onto the
base and secure with the (6) 5 mm screws.
57
iMeter Replacement, continued
20. Replace o-ring in the coupling at the top of the inlet/filter casting.
21. Install new meter (with base and coupling) from side B. Push the meter screw through the hole in the
side A rail then slide meter to the left in the slot to temporarily hold the meter, then align base coupling
with the inlet/filter casting and temporarily hand tighten the coupling.(From side B, turn the coupling
left to right or counter-clockwise to tighten.)
22. Raise side B support rail and resecure each end with the 14 mm hex head screw, then resecure meter
to rail using the10 mm hex head screw. On side A tighten the screw to secure the meter to the rail.
23. Replace o-ring on the valve.
24. Reinstall valve into meter and secure the valve retaining plate. (Be sure to seat the retaining plate prop-
erly into the groove on the valve so that the o-ring is not pinched.)
25. Inspect product tube o-ring and replace as necessary.
26. Reinstall the product tube into the valve and secure the tube with the lock pin. Be sure the pin snaps in
place.
28. Reinstall WIP.
29. Clean and reinstall the strainer and install new filter.
30. Turn power on to dispenser and submersible pump.
31. Reset the emergency shear valve.
32. Run test sales to clear air from lines and check for leaks.
33. Perform Meter Verification Accuracy and Calibration procedure as required.
58
Meter inlet
coupling
O-ring in top of
strainer casting
Apply lithium grease to

pipe threads
FIG 6-9 COUPLING UNDER THE METER
59
6.8.3 Check Valve Replacement
There are two check and pressure relief valves and o-rings in the meter - one for each meter. The valves are
located at the top of the meter, in the meter dome, under removable cover plates.
See Fig 6-10 for the iMeter and Fig 6-11 for the Xflo meter.
1. Remove the (2) 5 mm Allen screws that secure the valve cover to the meter dome and remove the valve
cover.
2. Remove the check valve and o-ring from the meter.
3. Install new valve and new o-ring.
Note: Seat valve fully by hand before re-installing the valve cover. Do not pinch the o-ring against the
meter.
4. Re-install the valve cover with the (2) screws.
(Black case)
FIG 6-10 IMETER SERVICEABLE PARTS.
60
Check Valve and O-ring
under Valve Covers
WIP
(Blue case)
FIG 6-11 XFLO METER SERVICEABLE PARTS
61
6.9 PRODUCT TUBE REPLACEMENT - USING THE TUBE REMOVAL TOOL
This procedure requires the tube removal service tool, p/n WM047463.
4. Place container under the proportional valve to catch fuel.
5. Remove tube retainer pin from valve and pull down on product tube to disconnect it from valve.
See Fig 6-12.
6. If necessary, remove hose from the outlet.
7. Remove the upper column cover as follows:

While pressing in the middle of the panel at the base to expand it around the edges, firmly pull
edge of panel straight out to unsnap it. See Fig 6-13 and Fig 6-14.
Note: Removing Upper Column covers. Screws are not used to secure the upper column cover.
It snaps into place. Avoid using tools to remove this cover. The proper way to remove the cover is
to press with one hand in the middle at the base and use other hand to unsnap the bottom edge..
8. Remove (6) 10 mm screws securing the lower side column cover and lift cover up and
remove. See Fig 6-15.
9. Attach tube removal tool to the product tube and slide the tool up firmly into the casting to
expand the fingers on the retainer. See Fig 6-16.
10. With the tool still firmly up into the casting, pull down on the tube and remove tube.
11. Install new o-rings on the ends of new tube.
12. Install new tube aligning upper end with the outlet and lower end with the valve and, then firmly
push upper end into the retainer in the outlet first and push the lower end up into the valve.
13. Be sure that the tube is firmly up into the valve and then insert tube retainer pin.
14. Reinstall hose as necessary.
15. Turn on power to dispenser.
16. Reset the shear valve.
17. Run a test sale to clear air from the line and check for leaks.
18. Reinstall lower column cover.
19. Reinstall upper column cover by firmly snapping it back into place.
62
Retaining
Pin at
Valve
FIG 6-12 VALVE AND PRODUCT TUBES
63
FIG 6-13 REMOVING UPPER SIDE COLUMN COVER, UNSNAP AT BOTTOM
FIG 6-14 REMOVING UPPER SIDE COLUMN COVER, PULL OUT AND DOWN
64
3 Screws
each side
FIG 6-15 REMOVING LOWER SIDE COLUMN COVER
65
FIG 6-16 USING TUBE REMOVAL TOOL
66
6.10 PRODUCT TUBE REPLACEMENT - NOT USING THE TUBE REMOVAL TOOL
This procedure must be used if the tube removal service tool cannot be used or is not available.
In addition to removing the side columns, this procedure requires removing the valance and the top plate
of the dispenser to gain access to the hose outlet casting and the tube retaining clip underneath the
casting.

4. Place container under the proportional valve to catch fuel.

5. Remove tube retainer pin from valve and pull down on product tube to disconnect it from valve. See
Fig 6-12.
6. Remove hose from the outlet.
7. Remove the upper column cover as follows:
While pressing in the middle of the panel at the base to expand it around the edges, firmly pull edge of
panel straight out to unsnap it. See Fig 6-13 and Fig 6-14.
Note: Removing Upper Column covers. Screws are not used to secure the upper column cover. It
snaps into place. Avoid using tools to remove this cover. The proper way to remove the cover is to press
with one hand in the middle at the base and use other hand to unsnap the bottom edge.
8. Remove (6) 10 mm screws securing the lower side column cover and lift cover up and
remove. See Fig 6-15.
9. Put tape around the four corners of the valance. This will help keep the valance together so it can be
removed in one piece.
10. Put flat blade screwdriver up under the end valance cover, locate tabs and spread tabs outward to
remove cover. SeeFig 6-17.
11. Remove 2 screws on end valance and let valance rest on the hooks.
12. Repeat steps for opposite end of valance and remove the valance.
13. Slide off and remove dispenser top cover plate. See Fig 6-18.
14. Remove 10 mm nuts on outlet casting. (1 nut on outer edge of casting and, depending on number of
products, remove 2, 4 or 6 nuts on casting).
15. Lift casting up and set aside.
16. Push product tube up, then use wire cutters to cut and remove the retainer.
17. Lower and remove product tube.
18. Install new retainer.
19. Reinstall outlet casting.
20. Install new o-rings on the ends of new tube.
21. Install new tube aligning upper end with the outlet and lower end with the valve and, then firmly push
upper end into the retainer in the outlet first and push the lower end up into the valve.
67
22. Be sure that the tube is firmly up into the valve and then insert tube retainer pin.
23. Reinstall hoses.
24. Turn on power to dispenser.
25. Reset the shear valve.
26. Run a test sale to clear air from the line and check for leaks.
27. Reinstall top cover plate.
28. Reinstall valance.
29. Reinstall lower column cover.
30. Reinstall upper column cover by firmly snapping it back into place.
68
Tabs under outer cover
End valance screws, 10 mm
FIG 6-17 Valance
69
.
Top Cover Plate
Nuts Outlet Casting

Top Cover Plate
Tube Retainer Clip
FIG 6-18 Outlet Casting and Tube Retainer Clip
70
6.11 OUTLET CASTING REPLACEMENT
Except for replacing the product tube, perform all the steps in Section 6.10 “PRODUCT TUBE REPLACEMENT
- Not Using the Tube removal Tool” on page 67. When using this procedure, replace the o-ring on the
existing tube before reinserting into the new outlet casting.
71
6.12 SALES/VOL DISPLAY REPLACEMENT
The sales display and the control board are not separately replaceable.
Note: Torx screwdriver with flexible shaft required for access to the inside corner screws on the boards.
Note: Be careful not to overtighten the screws as this will strip the threads on the plastic bezel.

2. Disconnect all cables from Sales display board. Fig 6-19.
3. Remove (4) T20 Torx screws from sales display and controller board and remove assembly.
4. Replace as an assembly.
Rear View
Front View
Service Part Assembly includes the Display and the Controller board
FIG 6-19 SALES DISPLAY ASSEMBLY

72
6.13 SALES DISPLAY GLASS AND PANEL ASSEMBLY REPLACEMENT
The display glass is not separately replaceable. If the glass needs to be replaced, the display glass
panel assembly must be replaced. Replacing the panel requires removing the U-frame of the bezel
on both sides of the dispenser as follows:
1. Raise bezel on both sides of the dispenser.
3. Disconnect all cables from sales display control board and remove control board/display
assembly as explained in previous Section 6.12.
4. Install the display assembly onto the new replacement panel and set aside.
5. Using a flat blade screwdriver, gently pull up on the latch under the bezel U-frame and then
slightly tap U-frame forward to keep the latch released on this side of frame. Fig 6-20.
Note: Some models also have a screw below the latch that will need removing.
6. Repeat step 5. on other side of the U-frame, then remove U-frame as shown in Fig 6-21.
7. Lower bezel.
8. Repeat the steps 5-8 on opposite side of dispenser. The U-frame on both sides must be
removed in order to perform the next step.
9. Remove the small top cover plate on both sides as shown in Fig 6-22.
10. Remove the turn screw and detach the bezel door stop as shown in Fig 6-23.
11. Release the latch under the pivot section of panel, as shown in Fig 6-24, and remove the sales
display panel.
12. Install new panel.
13. Reconnect cables to display control board.
14. Reinstall top cover plates.
15. Reinstall U-frames. After attaching the U-frame, lower it, and tap down on the top of bezel to
snap the latches back into place. Fig 6-25.
73
Release left latch then tap frame forward. Repeat for right latch.
Tap frame forward
FIG 6-20 RELEASE U-FRAME LATCHES
74
FIG 6-21 REMOVE U-FRAME
75
FIG 6-22 REMOVE TOP PLATE
FIG 6-23 DETACH DOOR STOP
76
FIG 6-24 REMOVE DISPLAY GLASS PANEL
77
FIG 6-25 PUSH DOWN ON TOP TO LATCH THE U-FRAME
78
6.14 UNIT PRICE DISPLAY, CONTROLLER BOARD, AND PANEL
The serviceable parts are shown in Fig 6-26 below. Replacement procedures for all of the components are
given in this section.
The PTS buttons/switches can be replaced at the front of the dispenser. The UPD’s, controller board, and
totalizers are separately replaceable. These can be replaced from underneath the payment terminal
drawer without removing it. As shown below, the display glass is part of the panel. To replace the panel,
the whole payment terminal drawer must be removed from the dispenser as explained in Section 6.14.2.
Display
Glass
Panel Ass’y Totalizer
PTS Button
Controller
Blank Cover
Board and
Totalizer
Bracket
UPD and
PTS Button
Controller
Board
separate
parts
FIG 6-26 UNIT PRICE AND PTS PANEL SERVICEABLE PARTS
6.14.1 UPD, Controller Board or Totalizer Replacement

2. Remove all PTS buttons. Place fingers up inside the button, push up and then pull out. See Fig 6-27.
3. From the underside of the payment terminal, disconnect cables at the top of the UPD controller board,
and move drain spout aside. See Fig 6-28.
4. Remove the (3) T20) Torx screws from the controller board panel.
5. Remove panel as shown in Fig 6-29.
6. Remove (2) T20 Torx screws from the board, then separate the board from the panel. Fig 6-30.
7. On the backside of the controller board, use needle nose pliers to straighten the metal tabs on the UPD’s,
and then remove the UPD’s.
8. Replace controller board, UPD’s or totalizers as needed. To replace totalizer, press the small tab on each
side of totalizer to remove from panel.
79
FIG 6-27 REMOVE PTS BUTTON
Drain
Spout Totalizers
not shown
Cables
(3) T20 Torx screws
FIG 6-28 UNDERNEATH PAYMENT TERMINAL DRAWER
80
FIG 6-29 REMOVE CONTROLLER BOARD PANEL
81
(4) Metal
tabs
securing
each UPD
FIG 6-30 REMOVE CONTROLLER BOARD FROM PANEL
82
6.14.2 Unit Price Display Glass Panel
To replace the display glass panel, the payment terminal will be removed. This is necessary to release the
latches as shown in Fig 6-32, and, more importantly, to properly install the new panel - it takes some force
to re-latch the panel. Be sure the new panel latches snap into place when installing.
1. Place the SPM into Maintenance mode. Refer to the iX Pay™ SPM manual.
2. Turn off power to the dispenser at the circuit breaker inside the building. This is necessary since some
connections are made to the dispenser connection board. See Warning at the beginning of this section.
3. Remove all PTS buttons. Place fingers up inside the button, push up, and then pull out. See previous Fig
6-27.
4. Disconnect and tag all of the payment terminal cables inside the dispenser.
5. Remove the drawer cable harness from the cable supports.
6. Slide the payment terminal out and detach the rails. Fig 6-31.
7. Place payment terminal on a protective flat surface, face down as shown in Fig 6-32.
8. Release (3) tabs, raise and remove panel.
9. Remove the Unit Price Controller board panel and install onto new display glass panel. Fig 6-33.
10. Install the new panel, making sure the (3) latch tabs are aligned, and pushing down until all three
latches snap in.
11. Reinstall payment terminal, PTS buttons, and reconnect cables.
12. Power up and place SPM into Operation mode.
13. Run a sale and check operation of payment terminal.
FIG 6-31 REMOVE PAYMENT TERMINAL
83
Latch Tabs
FIG 6-32 PAYMENT TERMINAL AND UNIT PRICE DISPLAY PANEL
84
Display glass panel assembly
Glass is not separately replaceable
FIG 6-33 DISPLAY GLASS PANEL
85
6.15 QVGA DISPLAY, SOFTKEY AND GLASS REPLACEMENT
See Section 6.15.2 to replace the softkeys or glass.

6.15.1 QVGA Display
2. Disconnect all cables from the QVGA display. Fig 6-34.
3. Remove (4) Torx screws from the fan bracket and remove fan/bracket.
4. Remove (4) standoff screws from display board and remove display.
5. Install new replacement display shown below.
6. Reinstall fan/bracket and reconnect cables.
fan bracket
screws
standoff
screws
Replacement
Display
Right
softkey
Left
softkey
FIG 6-34 QVGA DISPLAY
86
6.15.2 Softkey and Glass
The softkeys and glass are replaced separately. The softkeys are part of the rubber gasket shown
in Fig 6-35.
FIG 6-35 SOFTKEY AND GLASS ASSEMBLY
1. Follow the steps in previous Section 6.15.1 for removing the display.
2. After removing the display, remove (4) screws and remove display glass/softkey retaining bracket
shown in Fig 6-36.
bracket
screws
FIG 6-36 QVGA GLASS RETAINING BRACKET
3. Remove the softkey and glass assembly.
4. Remove the glass from the gasket.
5. Replace glass or gasket/softkeys and re-assemble.
6. Install the assembly onto the payment terminal window as shown in Fig 6-37.
87
FIG 6-37 REPLACEMENT PART INSTALLED
7. Remove the adhesive from the gasket material as shown in Fig 6-38.
FIG 6-38 REMOVE ADHESIVE FROM SOFTKEYS

8. Reinstall display glass retaining bracket. Feed the softkey cables through the holes in the bracket as
shown inFig 6-39.
88
Feed cables through holes in bracket
FIG 6-39 DISPLAY GLASS RETAINING BRACKET
9. Reinstall display using the standoff screws and reinstall fan/bracket assembly.
10. Reconnect cables.
11. Power up and check softkey operation.
89
6.16 DISPENSER CONNECTION BOARD REPLACEMENT
Turning off power at the dispenser switch in the electronics head does not turn off power to J8 on the con-
nection board. See Warning at the beginning of this section.
1. Turn off power to the dispenser at the circuit breaker inside the building.
2. Disconnect cables at the top of the ISB, then raise and remove cover. Fig 6-40.
3. On side B, remove the (2) 10 mm hex head screws that secure the ISB support bracket to the vapor
barrier.
4. Disconnect the bottom left cable and move ISB aside, away from the connection board. Fig 6-41
5 Disconnect all cables from the connection board. Fig 6-42. Tag cables as necessary for reconnecting.
6. Remove (6) 3 mm Allen screws. There are 3 screws on each end of the board. No screws in the middle.
7. Lift board off retainer clips and remove. Fig 6-43.
8. Install replacement board properly on the retaining clips and resecure with the screws.
9. Reconnect cables to connection board. See the Board Layout section in this manual for connector
assignments.
Note: There are several 4-pin connectors on the board. The RS-485 connectors are 4-pin, and the 24V
in from the power supply, and the 24V out to the SPM’s are also 4-pin. Reconnecting cables to the
wrong 4-pin connectors may damage the iX boards, and other components.
10. Reconnect bottom left cable to the ISB and resecure ISB to vapor barrier.
11. Reinstall cover on ISB and reconnect the top cables

12. Turn on power and test all dispenser operations.
10 mm screws
Side A Side B
FIG 6-40 ISB ASSEMBLY
90
FIG 6-41 MOVE ISB ASIDE
FIG 6-42 CONNECTION BOARD CABLES (ONE END SHOWN)
FIG 6-43 REMOVE CONNECTION BOARD
91
6.17 24V POWER SUPPLY REPLACEMENT
2. Disconnect DC cable on right side of power supply. Fig 6-44.
3. Remove protective cover from left side.
4. Loosen the (4) 3 mm Allen screws that secure the assembly to the mounting bracket.
5. Slide the power supply to the left, pull out, then disconnect AC cable and remove power supply.
6. Install new supply.
7. Reconnect cables.
8. Reinstall protective cover.
DC cable
(2) 3 mm screws
Cover
AC cable on each side Side B
FIG 6-44 POWER SUPPLY
92
6.18 HEATER/FAN REPLACEMENT
2. Disconnect AC and DC cables from the heater/fan module. Fig 6-45.
3. Press in on the retaining clip and slide heater/fan off of the bracket.
4. Install new heater/fan.
Retaining
Clip
AC Cable
DC Cable
FIG 6-45 HEATER AND FAN MODULE
93
6.19 ZEBRA PRINTER REPLACEMENT
1. Slide printer all the way out.

2. Disconnect the USB and power cables from the back of printer.
3. Push down on bracket latch behind printer while pushing printer inward. The three screws on
bottom of printer will slide out of the retaining slots on the bracket. Lift and remove printer.
Note: It may be necessary to firmly push and tap the printer inward to release it from the slots.
4. It should not be necessary, but if the printer does not slide inward, loosen Phillips head screw under-
neath the printer bracket, as shown in Fig 6-46, then push the printer inward.
FIG 6-46 ZEBRA PRINTER
94
6.20 iX R2 BOARD REPLACEMENT
1. Turn off power at the dispenser switch.

2. Disconnect all wiring from the board. Fig 6-47
3. Remove (6) Phillips screws and remove board.
4. Install new board.
Note: The replacement iXR2 board must have the USB ports in the vertical position to allow access to
the ports.
5. Reconnect cables and turn on power.
6. Install the latest recommended software on the board.
7. Follow the iX R2 Startup Configuration procedures in Appendix A of this manual.
8. If site is using a Gateway, follow procedures for setting the IP address.
(3) USB ports (6) Phillips

in vertical screws
position
FIG 6-47 IXR2 BOARD
95
6.21 iX PAY™ SECURE PAYMENT SPM KEYPAD REPLACEMENT
If replacing the battery only, be sure to keep the iX board powered up so that power remains ON to
the USB port on the SPM. If the battery is disconnected while power is Off or while the USB cable is dis-
connected, the SPM keys will be erased and the SPM will need to be replaced.
6.21.1 Battery Replacement

The battery can be replaced without removing the SMP, however there is limited access to the screw
that secures the battery clamp. If it becomes to difficult to remove or reinstall the screw, the SPM must
be removed while keeping power ON to the USB port during battery replacement. If this is the case,
first put the SPM into Maintenance Mode.
1. Print out a configuration report and verify battery voltage is low (below 3.2V).
2. With power On, disconnect battery from the SPM. Fig 6-48.
3. Loosen screw on the clamp securing the battery to the SPM and slide the battery out of the clamp.
4. Install and reconnect new battery to the SPM.
5. Print out a configuration report and verify battery voltage is 3.6V.
6. Run a sale to test operation of the SPM.
Note: Dispose of the old battery in accordance with local regulations governing battery disposal.
FIG 6-48 SPM AND BATTERY CLAMP
96
6.21.2 SPM Replacement
The USB drive provided with the replacement SPM MUST be returned with the failed SPM. This USB drive
must contain the iX RDM log files retrieved from the fueling point at fault - only these files should be on
the thumb drive.
1. Insert the USB drive provided into either of the USB ports on the iX board.
2. Reboot IX board.
3. Remove the USB drive when the screen displays “System initializing…”.
4. Use laptop to verify that log files were copied to the USB drive. The files should be in the fueling point
number subfolder in the “Log” folder. The files are Asset.xml, DMWatchdogTimer.log, and RDMLog.xml.
5. Place SPM into maintenance mode, if possible.
7. Disconnect all cables from the SPM. Fig 6-48.
8. Loosen the (2) Phillips screws at the top, then tilt the SPM forward and remove.
9. Install the new SPM.
10. Reconnect cables and ground.
11. Turn power on.
12. Follow the iX R2 Startup Configuration procedures in Appendix A of this manual to place the SPM into
Operation Mode.
13. Run a sale to test operation.
97
6.22 WAYNE CONNECT MODULE REPLACEMENT
Wayne Connect is optional equipment on Helix dispensers.

2. Disconnect all cables from the module and release cables from the cable tie on the bracket.
3. Press and release the latch tabs that secure the module bracket as shown below. There are two
tabs on both sides of the bracket.
4. Remove the bracket.
5. Remove the two screws that secure the module to the bracket.
Note: When reconnecting the cables to the two connectors at the bottom of the Wayne Connect mod-
ule, ensure that the cable coming from the Dispenser Connection board (J44-J45) connects to the
BB Bus (lower left) connector on the module and the cable coming from the iX board connects to
the LF Bus (lower right) connector on the module. If these cables are inadvertently swapped, the
payment terminal will be inoperative (offline).
Latch
tab
2 tabs on this
side out of view
See Note above Latch

for connections tab
FIG 6-49 WAYNE CONNECT MODULE
98
6.23 CARD READER REPLACEMENT
The card reader is located under the printer carriage. The carriage will be removed to access the card
reader.
1. Remove the (2) #10 Torx screws at the top of the metal printer carriage, slide the carriage back to disen-
gage the tabs on the bottom bracket, then remove the carriage. Fig 6-50.
FIG 6-50 PRINTER CARRIAGE

2. Remove and save the gasket.
3. Turn the carriage over (bottom side up) and let rest across the bezel slide rail. Fig 6-51.
4 Screws
Ground
wire
FIG 6-51 CARD READER UNDERNEATH CARRIAGE
4. Remove the (4) standard screws that secure the card reader and snout assembly to the metal carriage,
then remove reader/snout assembly.
5. Disconnect card reader cable.
99
CARD READER REPLACEMENT, continued
6. Remove the 4 Phillips screws on the reader, Fig 6-52, then separate the reader from the snout.
Snout
(4) Phillips
screws
Reader
FIG 6-52 CARD READER
7. Install new reader onto the snout.
8. Reconnect card reader cable.
9. Reinstall the assembly onto the metal carriage. Be sure to resecure the green ground wire in the same
location on the snout. The ground is needed to reduce static discharge when customers insert the card
and touch the snout panel.
10. Turn the carriage back over.
11. Reinstall the gasket onto the snout of card reader.
12. Reinstall the carriage onto the bottom bracket, slide in to engage the tabs, then resecure the carriage
to the bezel using the 2 #10 Torx screws.
100
7. IGEM SOFTWARE DOWNLOADS AND SERVTERM
Follow the procedure below to upload/download pump code and templates.
1 Power down the pump.

2 Connect laptop via a Null Modem Cable to J26 on computer board.
3 Power up pump first, and then open the Service Terminal Program (servTerm) on the laptop.
4 Click on iGEM Connect.
5 At the enter Pass 1 prompt, click on Password.
6 Select Default Password.
7 Go to appropriate function below by entering or selecting function.
95 To upload 96 To upload 97 To upload 98 To download 99 To download

custom template code to pc template to pc code to dispenser template to
to pc dispenser
select the filename select the _.bin filename select filename select the _.bin file select template from file or
select Dispenser Type
select save select save select Save waiting for flash to erase* select dispenser Options
uploading blocks begins uploading blocks begins uploading blocks begin downloading blocks begins click on Accept Settings
upload complete upload complete upload complete download complete waiting for flash to erase*
select iGEM Disconnect select iGEM Disconnect select iGEM Disconnect select iGEM Disconnect downloading blocks begins
power down pump power down pump power down pump power down pump download complete
disconnect laptop disconnect laptop disconnect laptop disconnect laptop select iGEM Disconnect
power up pump power up pump power up pump power up pump power down pump
disconnect laptop
power up pump
program prices, fueling point,

etc., with IR remote
1. If this process is now interrupted for any reason, the Bootstrap procedure must then be used to download to the dispenser,
therefore, do not run other programs or perform other actions on the desktop. See Bootstrap Procedure on the following
page.
101
7.1. Bootstrap Procedure
The Bootstrap procedure listed below must be performed if: 1) after selecting filename or template in
Function 98 or 99, the process of downloading to the pump computer is interrupted, or 2) a pump computer is
installed that does not have pump software code already onboard.
To Bootstrap the iGEM computer:
1 Power down iGEM at the dispenser power switch.
2 Connect laptop via RS-232 cable and adapter to J18 or use null modem cable to J26 on the computer board.
See iGEM connector locations in the Board Layout section of this manual.
3 Remove Current Loop jumper S12D.
4 Press and hold S13 push button.
5 Power up iGEM.
6 Release S13 push button.
7 Open the servTerm program.
8 Click on iGEM Bootstrap Connect.
9 Select the __.bin file (pump code or template file) to download to the dispenser. See Figure 7-1
10 Downloading blocks begin and then the message download complete is displayed.
11 Click on iGEM Disconnect.
12 Reinstall Current Loop jumper S12D.
13 Power down iGEM.
14 Disconnect laptop cable.
15 Power up iGEM.
Figure 7-1 Select Pump Code file

When downloading pump code, select the correct pump file name such as, iGEM_62.bin. Do not select flash LDR.bin file as this is
not a pump code file.
102
8. TROUBLESHOOTING, ERROR CODES, AND SOLUTIONS
This section provides a description of error codes, symptoms and corrective actions. The iGEM
computer’s on-board LED indicators, described in the Board Layout section of this manual, also aid
in troubleshooting.
WARNING
Electric Shock Hazard!
Some of the following corrective actions in this section may require the electrical power to
the equipment be ON. Use wiring diagrams, connector drawings and other information in this
manual to identify the electrical connections and AVOID contact with the electrical power. Failure
to do so may result in severe injury or death.
This section also describes the two means available to read the error codes: via the IR remote or the
laptop. However, in most repairs involving the pump computer, both will be used. For example, use the
remote to view the error code, and if the error is with the computer, use the laptop to re-flash the pump
code or template, and then use the remote again to reprogram unit prices, fueling point number, etc.
8.1 FUNCTION PROGRAMMING

The table below lists the iGEM programming functions. Refer to the iGEM Function Programming man-
ual for details on each function.
TABLE 8-1.FUNCTION PROGRAMMING
FUNCTION DESCRIPTION
F00 Exit Function
F01 Filling Modes
F02 Clock Configuration
F03 Set Side A Unit Prices
F04 Set Side B Unit Process
F05 Set Side A Fueling Point Address
F06 Set Side B Fueling Point Address
F07 Dispenser Configuration
F08 Side A Dispenser Type Configuration Part #1
F09 Side B Dispenser Type Configuration Part #1
F10 Side A Dispenser Type Configuration Part #2
F11 Side B Dispenser Type Configuration Part #2
F12 Side A Pump Assignments
F13 Side B Pump Assignments
F14 Dispenser Display Configuration
F15 Dispenser Annunciator Configuration
F16 Pulser Configuration
103
F17 Dispenser Limits Configuration
F18 Blend Ratio Configuration
F19 Volume Unit Specific Configuration
F20 Dispenser Serial Link Configuration
F21 Miscellaneous Configuration
F22 Sales Amount Calculation
F23 Miscellaneous Timers
F24 Local Preset Operating Configuration
F25 Local Preset Configuration Step Up (Various Keypad Configurations
F26 VAP Configuration
F27 Side A Dispenser Configuration
F28 Side B Dispenser Configuration
F29 Side A Liter Flow Rate Configuration
F30 Side B Liter Flow Rate Configuration
F31 Side A Gallon Flow Rate Configuration
F32 Side B Gallon Flow Rate Configuration
F33 Password Change
F34 Diagnostics
F35 Side A Vac A/L Calibration Data
F36 Side B Vac A/L Calibration Data
F37 Side A Satellite Configuration
F38 Side B Satellite Configuration
F39 Set Error Severity Level
F42 Miscellaneous Configuration, part 2
F43 Meter Channel Configuration
F50 ATC Configuration
F56 Door Security Configuration
F57 Product Select LED Variable Blink Rate
F67 DEF Control Configuration
F68 Additive Configuration
F95 Upload Dispenser Function Data (Save Custom Template)
F96 Upload Flash Memory - (Upload to PC)
104
F97 Upload Configuration - (Upload Template to PC)
F98 Download Flash Memory - (Download Code to Dispenser)
F99 Download Configuration - (Download Template to Dispenser)
8.2 USING THE IR REMOTE TO VIEW STATISTICS
Use the IR remote control to enter the Maintenance Mode and access statistics S21 and S22
to view error codes and event logs as follows:
press ENTER
enter Password _ _ _ _
press ENTER
enter Password again _ _ _ _
press ENTER
enter Statistic number
8.3 USING THE SERVICE TERMINAL PROGRAM (servTerm)
The Service Terminal Kit, part number 887722-001, includes the RS232 adapter board and cable, which in
addition to servTerm software and the IR remote, are required to perform some of the corrective actions
given in this section. Note: A null modem cable can be used instead of the above mentioned cable and
adapter board.
ServTerm allows a laptop computer to communicate with the pump computer through an RS232 link to
access dispenser functions and diagnostic data (statistics). Although you perform the programming
through the pump display, a description of the various functions and statistics appear on the laptop
display.
The procedure for using the servTerm to enter the Maintenance Mode is as follows:
1. Power down iGEM board at the dispenser power switch.
2. Connect laptop via RS-232 cable and adapter to J18 on the iGEM board or connect null modem cable
to J26 on the computer board.
3. With the servTerm on the laptop closed, power up the iGEM board.
4. Start the servTerm program. ServTerm will start communicating with the iGEM computer and the
dispenser will go into the maintenance mode.
105
8.4 ERROR CODES AND SOLUTIONS
TABLE 8-2. ERROR CODES AND SOLUTIONS
ERROR
DESCRIPTION PROBABLE CAUSE CORRECTIVE ACTION
CODES
1 Flash program CRC error Corrupt flash program area Replace iGEM computer base
2 Flash template CRC error Corrupt flash program area Replace iGEM computer base
3 RAM error RAM test failed. The RAM test runs in Replace iGEM
POST and before the start of a sale.
5* RAM Error Log CRC error Corrupt RAM Error Log data Replace iGEM computer base
6* RAM Function Programming CRC error Corrupt RAM Function data Replace iGEM computer base
7* RAM Unit Prices CRC error Corrupt RAM Unit Price data Replace iGEM computer base
8* RAM statistics CRC error Corrupt RAM Statistics data Replace iGEM computer base
9* RAM Event Log CRC error Corrupt RAM Event Log data Replace iGEM computer base
10* RAM Totals CRC Error Corrupt RAM Totals data Replace iGEM computer base
11* RAM Totalizers CRC Error Corrupt RAM Totalizers data Replace iGEM computer base
12* RAM Electro-magneticTotalizers CRC Error Corrupt RAM EMT data Replace iGEM computer base
13 Identi-PROM CRC error - Corrupt Identi-PROM data DISPLAY - Replace only if Dual Price Ovation or
Device #0 = Display Global Century/ Select Display
Device #1 = CPU CPU - Replace
14* RAM Timestamps CRC error Corrupted RAM Timestamp data Replace iGEM
detected in POST
15
16 Suppress overflow limit reached - Function Slow down limit to low defective flow Adjust slow down col (Disp or POS); Replace
19.12 and 19.22 control valve valve
17* RAM Meter Data CRC error Corrupt RAM Meter Non-Volatile data If re-occuring, replace iGEM
detected in POST
18* RAM Door Security data CRC error Corrupt Data Security data detected
in POST
19
20 n Consecutive Dispplay read back error - Defective display board or cable Replace display board or cable
Device #0 = Sales
Device #1 = Unit Price
Device #2 = Preset
21-24
25 Sale cannot start - Zero Unit Price Unit Price not set Set Unit Price
26
27 Sale cannot start - Unit Price changed. Func- Unit Price has changed prior to start Set Unit Price
tion 23.04 of sale
28 Sale cannot start - Need Preset Entry, Func- Sales require an entry from preset key Check Function 24.01
tion 24.01 pad
29
30 No communication with POS Timeout, Func- Communication lost with POS Verify connection to POS
tion 23.02
106
ERROR
CODES
31 POS buffer overflow (DART) Communication error with POS Verify DART connection to POS
32-33
34 Sale aborted because STOP button pushed STOP button pushed or defective Veriy STOP button functionality
35 Blend ratio out of tolerance. Function 7.02 Inlet pressures too low. Too high prod- Check inlet pressures. Check product flow paths
uct flow restriction (filters, strainers, valves)
36-38
39 Pulse output lags by more than one second Pulse output unable to keep up with Verify pulse output resolution settings. Function
fuel flowrate 19.15 / 19.25
40-41
42 Vapor recovery motor on when should be off Defective Vac board or cables. Defec- Replace Vac board or cables
tive iGEM computer. Replace iGEM
Defective Vac motor. Replace Vac motor
43 Vapor recovery motor off when should be on Defective Vac board or cables. Defec- Replace Vac board or cables
tive iGEM computer. Replace iGEM
Defective Vac motor. Replace Vac motor
44-45
46 Vapor recovery motor turning wrong direc- Defective Vac motor or cables. Defec- Replace Vac motor or cables
tion tive Vac board. Replace Vac board
47 Illegal sensor states from Vapor Recovery Defective Vac motor or cables. Defec- Replace Vac motor or cables
system tive Vac board. Replace Vac board
48 Vapor Recovery motor load HIGH Defective Vac motor or blocked vapor Replace Vac motor
path Check vapor return path (nozzle, hose)
49 Vapor Recovery motor load LOW Defective Vac motor Replace Vac motor
50 Jitter/Reverse limit reached on an In Transac- Defective WIP Replace WIP

tion WIP
51 Jitter limit reached on an idle WIP Defective WIP Replace WIP

Product crossflow Check for product crossflow
52-53
54 Reverse flow limit reached on idle WIP Defective check valve Replace valve
Unequal, too high or too low fuel pressures
55
56 Forward flow limit reached on an idle WIP Defective flow control valve Replace valve
Unequal, too high or too low fuel pressures
57
58 Communication lost to an in-Transaction Defective WIP. Replace WIP.

Defective ISB or cables. Replace ISB or cables.
59 Communication lost to an idle WIP Defective WIP. Replace WIP.

Defective ISB or cables. Replace ISB or cables.
60-61
62 WIP is outputting jitter during calibration Calibration volume exceeded limit. Too much fuel dispensed during calibration.
Defective WIP. Replace WIP.
63-66
67 WIP calibration OK bit status changed WIP has been calibrated
107
ERROR
CODES
68 WIP calibration door status changed WIP door was opened.closed
69 WIP last calibration status changed WIP last calibration successful
70 Timeout limit reached for No Flow. Function Defective flow control valve or cables. Replace valve or cables.
17.03 (flow never started) Defective pump/motor control relay.
Defective nozzle. Replace pump/motor control relay.
Replace nozzle.
71 n Consective No Flow timeouts. Function Defective flow control valve or cables. Replace valve or cables.
17.04 Defective pump/motor control relay.
Defective iGEM computer Replace nozzle.
Replace iGEM.
72 Timeout limit reached for Flow Lost. Function Defective flow control valve or cables. Replace valve or cables.
17.03 (flow lost during sale) Defective pump/motor control relay.
Replace iGEM.
73 n Consective Flow Lost timeouts. Function Defective flow control valve or cables. Replace valve or cables.
17.04 Defective pump/motor control relay.
Replace iGEM.
74 Sale terminated before preset limit reached - Defective flow control valve or cables. Replace valve or cables.
Unfinished filling Defective pump/motor control relay.
Replace iGEM.
75 n Consecutive unfinished fillings Defective flow control valve or cables. Replace valve or cables.
Defective pump/motor control relay.
Replace iGEM.
76 DEF low temperature Event #’s DEF temperature change signal

Event #1 = Low temp received
Event #2 = Low temp cleared
77 Additive Error 0- Additive configuration conflict Reload correct dispenser template

Device #'s: 1- No response from Additive Control- Check CAN connections and termination jump-
0 = Configuration Error ler board ers
1 = CAN Communication Error 2- Tank reported empty Add additive
2 = Tank Empty 3- Tank door reported open Close well door after filling the tank
3 = Tank Door Open 4- Additive motor not turning Check the LED codes on the Driver module
4 = Motor Failure 5- Additive Injector not able to keep Replace controller board
5 = Injection Fell Short up with flow rate Check for pump or additive line leaks. Repair/
6 = Flow Error 6- Additive flow not detected replace as necessary.
78-79
80 Software exception encountered: Internal iGEM board error indication Replace iGEM
0 = Mail buffer pool exhausted
1 = Mail send failed
2 = XMalloc failed
3 = Print buffer overflow
81-89
90 Fuel Temperature Board communication fail- Defective FTB. Replace FTB.

ure. iGEM lost comm with FTB Defectiv FTB cable. Replace FTB cable.
Defective iGEM board. Replace iGEM.
108
ERROR
CODES
91 Fuel Temperature Board - temperature probe Defective temperature probe. Replace temperature probe.
shorted Defective FTB. Relace FTB.
92 Fuel temperature Board - temperature probe Defective temperature probe. Replace temperature probe.
open Defective FTB. Relace FTB.
93 Fuel Temperature Board - Invalid type error Invalid fuel type selected in the FTB. Replace FTB
Internal FTB error.
94 ATC configuration error ATC function data programmed incor- Verify/correct ATC programming. Function 50
rectly
95 Fuel temperature board calibration error FTB detected calibration out of range.
Internal FTB error
96 Dispenser security breached: Door sensor switch activity detected See Function 56
Device #1 = Bezel door while armed
Device #2 = Hydraulic door
97 Dispenser Security Armed status change Indicates time/date that door/secu- See Function 56
Device #0 = Dispenser unarmed rity was armed/unarmed. Also indi-
Device #1 = Dispenser armed using One-Shot cates door security method being
Device #2 = Dispenser armed using Mainte- used.
nance mode
98
99 Hardware/Software mismatch Defective Vac board or cables. Replace Vac board or cable.
Device #0 = No proportional hardware Defective iGEM computer.
Device #1 = No vapor recovery hardware Hardware configuration detected. Replace iGEM.
Device #2 = Meter type does not match Hardware signal missing. 2 = Change meter or template
F16.04
Device #3 = Ovation II - not enough UPD’s 3 = Change UPD
installed
Device # 4 = Ovation II - too many UPD’s 4 = Change UPD
installed
* These errors can be a result of an iGEM code upgrade and should be ignored if occuring immediately after a code change.
8.5 PROBLEM SYMPTOMS AND SOLUTIONS

TABLE 8-3. SYMPTOMS AND SOLUTIONS
Symptom Probable Cause Corrective Action
Sale and UPD’s are 1 No AC power to dispenser or to Check control power circuit breaker is on.
out iGEM board Check dispenser power switch is on.
Check for AC input voltage at J8 on dispenser connection board.
If present, check connections on the board, replace board. If not
present check in J-box. If not present in J-box, problem is in site
wiring or inside the building. If present in J-box, problem is in
internal dispenser wiring/connections.
Check LED indicators on computer for DC power and Heartbeat.
If all are not On, see Probable Cause 2. If all are On, check 24V
power cable and data cable to sales display controller board.
109
TABLE 8-3. SYMPTOMS AND SOLUTIONS
Symptom Probable Cause Corrective Action
2 No DC power to computer All LEDs should be On. DS6 is 24V input LED. Check for 24 VDC
input at computer J1.
If present, replace computer.
If not present at J1, check DC output J41 on dispenser connec-
tion board. If present at J41, problem is wiring or connectors.
If not present at J41, check connection board J10 AC out to
power supply, if no voltage present, replace connection board.
Check J36 DC in from power supply. If present, replace connec-
tion board. Check power supply board J2 DC output, J1 AC input,
replace power supply as necessary.
Only Sales is out or No power to display controller For Sales display, check 5V LED is On on the controller board and
all UPD’s are out boards or defective display 24V at J10/J11. If present, replace sale display/controller board
assembly. If not present, check DC out from dispenser connec-
tion board J23 and check cable. Also, if side 2 of dispenser,
check 24V at side 1 sales display controller board J10/J11.
Replace display assembly.
For all UPD’s, check 5V LED is On on the controller board. If not,

check/replace cable from sales display controller board or
check sales display as described above. If LED is On, replace
UPD controller board.
Display Segments Defective display Perform display test F34.02.

Fail to Operate Dur- If sales display only, check/replace data cable to iGEM.
ing Reset Cycle Replace sales display and controller board assembly.
If an individual UPD, replace UPD.
If all UPD’s only, check/replace data cable to sales display con-
troller board.
Replace UPD controller board.
If both sales display and UPD’s, replace sales display.
If a replacement display controller board, check that switch SW1
is set correctly - see the board layout section in this manual.
If all displays,
Dispenser will not 1 No authorize to dispenser com- Set unit price in control system.
Reset puter. Control system unit price Set fueling point function F01.01.
set at 0.000, or no FP# at dis- Set unit price function F03 and F04 for stand-alone operation
penser. Set fueling point function F01.01 =2 for stand-alone operation
2 Defective PTS switch Select different grade. If works, replace defective PTS switch. If
does not work, see the following possible causes before replac-
ing the UPD controller board.
3 Defective Nozzle switch or Swap nozzle switch cable with a known working port on the
Nozzle Switch Interface board. Nozz Switch Interface board. If problem follows the cable,
replace nozzle switch. If problem does not follow the cable,
replace Nozzle Switch Interface board.
4 Defective Nozzle Switch Con- Replace

verter bd
5 Defective ISB Replace
6 Defective Computer Replace
110
9. ZEBRA PRINTER
Last receipt when out of paper Paper core
Paper
holders
Print head -
green lever
Feed
button
Indicators for
Power and Tab on paper holder, both sides
Status Fig 1. Zebra Printer
9.1 Loading Paper

1. Unlock and open printer door, shown on facing page. Slide printer assembly out. Fig 1.
2. Using both hands pull outward on the tabs on the two paper holders, release and remove core. Fig 2.
3. Insert new paper roll so that the paper feeds from the top of the roll into the printer. Fig 3.
4. With both hands below the paper roll, again pull outward on the tabs below the paper while also
using thumbs to pull outward at the top of the paper holder.
5. Push forward on the green lever and lift the print head to release the old paper, Fig 4. Remove the
paper. Fig 5.
6. Feed new paper into the slot in the printer until the paper is past the print head, Fig 6., then firmly
push down on the print head/green lever until the print head clicks (latches) into place.
7. The printer will automatically advance and cut the paper. Fig 7. Note: If the Status LED does not
change from red to green, cycle power by disconnecting and reconnecting the power cable.
8. Press the Feed button on the side of printer to print a test receipt. Fig 8. A test receipt is shown in
Fig 9. This sample receipt shows the software version number 2842E.
9. Slide the printer assembly back into the housing and lock printer door. Printer is ready for operation.
9.2 Indicator Lights

Power light: Green Power On. No light power Off.
Status light: Green Operating normally
One Red flash Paper jam
Two Red flashes Cutter jam
Three Red flashes Out of paper
Four Red flashes Print head (green lever) is lifted
Five red flashes Paper feed error
111

FIG 2. REMOVE PAPER CORE
FIG 3. INSERT NEW PAPER INTO THE HOLDER.

PAPER FEEDS FROM TOP OF THE ROLL
PULL OUTWARD ON TABS AT BOTTOM OF HOLDER
ALIGN AND ENGAGE PAPER CORE WITH HOLDER
112

FIG 4. PUSH GREEN LEVER FORWARD AND
RAISE PRINT HEAD
FIG 5. REMOVE PAPER FROM PRINT HEAD
113

FEED PAPER INTO THE SLOT PUSH DOWN ON THE PRINT HEAD UNTIL
IN THE PRINTER IT CLICKS (LATCHES)
FIG 6A FIG 6B
THE PRINTER WILL AUTOMATICALLY ADVANCE

AND CUT THE PAPER
FIG 7
114

THE GREEN STATUS LIGHT IS ON
PRESS THE FEED BUTTON TO PRINT A TEST RECEIPT
FIG 8
TEST PRINT SHOWS SOFTWARE VERSION

FIG 9
115

9.3 Clearing Paper Jams
Clear paper jams as follows:
Paper Jam - one flash error Pull paper out to clear the jam
Press the Feed button to advance the paper and

print a test receipt
FIG 10 Paper Jam - One Flash Error
116

Paper Feed - five flash error Push green lever forward. Lift print head
and pull paper out
Tear paper Push print head down firmly until it latches

Printer will advance and cut paper
FIG 11 Paper Feed Error - Five Flash Error
117

Paper Feed - five flash error Push green lever forward. Lift print head
Tear paper Push print head down firmly until it latches

Printer will advance and cut paper
FIG 12 Paper Feed Error - Also a Five Flash Error
118

10. METER CALIBRATION PROCEDURE
Helix dispensers may contain either iMeters or Xflo™ Meters. The calibration procedure in this section is used for
either of these meters.
Each meter assembly contains two meters. The WIP pulser (or XWIP for Xflo meter) contains two sets of sensors,
one set for each meter. On the front of the pulser, there are two calibration doors, one for each meter in the
assembly. The door closest to the front of the dispenser controls calibration of the front meter and the other
door controls calibration of the rear meter. Only one door may be opened at one time during meter calibration
(only one meter at a time can be calibrated). It is important to verify the product grade for each assembly to
assure the correct door is opened during the calibration process.
Dispensers have an operation mode setting that establishes the pulser’s calibration mode. This is set at the
factory in the dispenser template (Read Only function F16). The iMeter and the Xflo meter are calibrated using
the same procedure as shown below.
NOTE 1: In the Liter mode, in addition to 20 liters, a 10 liter of 5 liter test measure may be used if required by the
application. However, you should check with your jurisdiction on Weights & Measures tolerance requirements.
NOTE 2: For the U.S. and Canada, acceptance of +/- 3 cu. in. for a 5 gallon measurement and +/- 50 ml for a 20
liter measurement is only required for newly installed, newly placed in service devices for 30 days. After 30 days,
the tolerance is increased to +/- 6 cu. in. for 5 gallons and +/- 100 ml for 20 liters.
Variables in method and environment can account for significant measurement error during meter calibrations
therefore, the procedure below should be followed when calibrating or verifying any meter to ensure proper
calibration.
During Calibration Procedure
• Use NIST-traceable prover and ensure that it is on a level surface.

• Perform a can wet-down.
• Use consistent drain times (minimum 30 seconds recommended).
• Ensure splashing of fluid is minimized and nozzle has been drained of excess fluid.
Completing the Start-up Calibration Report
The Meter Calibration Startup Report is located in the back of this manual.
Completing the Start-up Calibration Report
Note:The attached Startup report can be used for any meter, however, for Xflo warranty it must be
sent to Wayne along with the dispenser startup forms.
1. UST Temperature: Enter the tank temperature reported from the tank monitor for each fuel type.
2. Dispenser Serial Number: Enter the dispenser serial number located on the serial plate.
3. Dispenser Model: Enter the complete dispenser model description located on the serial plate.
4. Station Fueling Point: Enter the station fueling point (FP) for the dispenser side under test.
5. Ambient Air Temperature: Enter the air temperature at the time of test.
119

6. Weather conditions at the dispenser: Circle or enter the conditions that apply when the test is being con-
ducted.
7. Meter Serial Number: Enter the serial number located on the serial label on the A side of the meter.
8. Dispenser Side A or B: Circle the dispenser side (A or B) under test.
9. Fuel Type: Enter the fuel type and grade under test.
10. Meter totals: Enter the meter total.
11. Initial Meter Purge Reading (cu in): Enter the can value (in line 6 of SU Report) after filling as close as possi-
ble to 5.000 gallons on the pump display.
12. Verification Value Fast Flow: (cu in): Enter the can value (in line 7 of SU Report) after filling as close as pos-
sible to 5.000 gallons on the pump display. If calibration is within +/- 0.1% (+/-1 cubic inch in 5-gallons),
skip steps 13 - 18.
13. Lift nozzle.
14. Open calibration door of meter to be calibrated. (Only one door can be opened at a time during the cali-
bration process.)
15. Display Volume Value at Calibration: Dispense 5 gallons (20 Liters) into the prover can exactly to the ‘0’
mark on the sight glass and then enter (in line 8 of SU Report) the amount shown on the volume display.
(Note: Write down the entire number).
16. Close the calibration door. (This now redefines the calibration factor in the pulser.)
17. Hang up nozzle.
18. Verification Value Fast Flow: (cu in): Ensure calibration took successfully within
+/- 0.1% (+/-1 cubic inch in 5-gallons). (Enter in line 9 of SU Report). (Repeat steps 13 - 18 if outside
expected limit.)
19. Verification Value Slow Flow: Ensure the meter remains in calibration at a slow flow rate (enter in line 10 of
SU Report).
20. Seal calibration door.
How to Determine a Successful Calibration
1. Meter verification value must be within +/- 1 cubic inch of zero at fast flow.
2. Throttled flow: Slow flow value must be within 2.5 cubic inches of the verification value above.
Factors That May Influence Calibration Values
• TEMPERATURE: The properties of fuel cause it to expand and or contract as temperature changes. Condi-
tions where there is a difference between the metered fuel and the reference initial calibration tempera-
ture could cause a measurement error of approximately 0.06% for each 1°F degree of temperature
change.
• AIR: Hydraulic lines and piping that are not properly purged can require 2 to 4 cubic inches to pressurize
which result in negative prover readings.
• CHECK VALVES: Malfunction of this component can cause small amount of fuel flow to be diverted back
through the idle hydraulic tree. This could cause a negative prover reading.
120

APPENDIX A
iX Pay™ Secure Payment Configuration

(SPM) EPP U.S. version 2.2.20.0.
Details on the iX R2 board and the SPM keypad are given in the Electronic Boards Layout and Connector
Descriptions section of this manual.
The R2 board is installed on side A of the dispenser. A single iX R2 board controls both SPM’s on a dual-
sided dispenser with QVGA displays and softkeys.
iX R2 production dispensers are pre-configured at the factory. The configuration at startup is to answer
the screen prompts on side A. Once the CAT addresses (Terminal IDs) are set from side A, and the correct
side is confirmed, the information is copied to side B. At the end of the configuration, the technician per-
forms the diagnostic test on side A and then puts side A into Operation. Once completed on side A, the
technician needs to perform only the Diagnostic test on side B and put side B into Operation.
At power-up, the configuration steps are performed by pressing the #2 softkey on the left side when the
“One Moment Please” message is displayed. The screen sequence on initial Power Up is given on the fol-
lowing pages.
iX R2 production dispensers are configured for a single iX board, dual-sided, and QVGA displays with soft-
keys enabled. For any other configuration, new software must be obtained from the ASONet.
A-1
January 2013 Part No. WU008123 Rev 01
Initial Configuration Procedure
Follow the procedure below to startup iX R2 SPM dispensers, starting on SIDE A:
1. At power up the following screens will be displayed.
2. Hold down the #2 softkey when the One moment please screen is displayed. It is displayed for only 5
seconds. The ‘2’ softkey is the second key to the left of the display.
1 5
#2 6
softkey
3 7
4 8
NOTE: If you miss the screen, reboot and try again.
3. Select Yes if the dispenser is a Helix model or has a Compact Payment Terminal.
A-2
Part No. WU008123 Rev 01 January 2013
4. Adjust the contrast if needed
5. Single or Dual Sided.
6. Enter the fueling point (terminal) number
A-3
7. Select the appropriate Side (A or B). .
8. Verify the date and time. Correct if needed.
NOTE: SINCE THE IX AUTOMATICALLY RESETS ONCE EVERY 24 HOURS AT 2:00 A.M., CORRECT TIME ENTRY IS ESSENTIAL TO AVOID
RESETTING DURING NORMAL BUSINESS HOURS.
9. Enable Softkeys as necessary.
10. Enable Softkey Extension as necessary. .
A-4
11. Enable Function and Softkeys as necessary. This will make the softkeys on the keypad
mirror the softkeys on the display panel. Always select “Yes” for Helix dispensers.
12. Enable pump iSense as necessary.
13. Select Fixed length as necessary.
A-5
14. Select Yes if the dispenser is using a Contactless Card Reader.Note that a Bill Acceptor and a
Contactless Reader cannot be attached and configured at the same time. These two devices
share the same COM Port. Answering Yes to this will Enable the Contactless Reader and the
Transparent Mode screen will be displayed.
Answer No at the Transparent Mode screen unless instructed to do otherwise for a specific
customer or vendor.
15. Select Yes if the dispenser is using a Zebra printer, otherwise, select No.
16. If Yes was selected at the above prompt for the Zebra printer, an A or B test receipt will be
printed. Select the value shown on the receipt.
A-6
17. Select Yes to Remove Receipt Header. The most typical selection is No.
18. Select Yes if dispenser is using a secure card reader.
19. Select Yes if dispenser is using a secure magnetic card reader only.
20. On the keypad, enter the terminal number for the opposite side then press the enter key.
A-7
Note: At this point the configuration data is copied to side B.
21. Test the operation of each softkey then press Cancel.
22. Test operation of each key on the keypad.
Non-numeric keys will be displayed as HEX values as shown below.
0x03 0x43
0x02 0x42
0x01 0x41
0x00 0x40
0x10 0x30
A-8
23. Select Pump Test as necessary.
24. The following screen is displayed if Yes was selected for the pump test.
25. Scan a Bar Code if dispenser is equipped with a barcode scanner.
A-9
26. Test the operation of the card reader. The following screens will be displayed:.
For dispensers that have a secure mag card reader, a description of the LED indicator light on the card
reader is listed below:
Green flashing: The system is going through reboot/power cycle, card reader reports good.
Green solid: Card reader is ready for use.
Orange flashing: Waiting for Maintenance mode challenge code.
Orange solid: System is in Maintenance mode.
Red flashing Beached card reader.
No light: Breached SPM or cable to card reader disconnected.
A-10
27. On dispenser side A, when the configuration is complete, select Reset as shown below. The
Diagnostics Complete screen will be displayed, a configuration report* will print, and the
system will automatically reboot. After side A is placed into Operation, the technician
needs to perform only the Diagnostic test on side B and put side B into Operation. A
sample configuration report is shown in Figure 2.
*The configuration printout will not show the iX software version number under the Prod-
uct Name heading. Proceed with placing the system into the Operation mode and then
obtain the version number in the Diagnostic mode, see Note in step 33.
28. Select Reset.
The screen below will be displayed.
System automatically reboots here. New EPP keypads will come up

in the Wait for Install mode as indicated by the screen below.
A-11
29. At this time the system can be placed into Operation.
Select
Operation
30. Enter access code.
31. Select Ready.
32. Press Cancel.
A-12
33. The system is now in the Operation mode. Press Cancel to finish and wait for the online POS prompt,
see step 34.
NOTE: To view the iX Pay software version number, select Sys Info and the screen below will be
displayed. To print a configuration report showing the software version number, go into the Diagnostic
mode and go to the printer test. The software ID will be shown under the Product Name on the
printout.
.
System is in
Operation mode
34. The offline prompt will be displayed until communications are established with the POS. The default
prompt is shown below. Run test sales to verify operation.
Offline prompt
screen
Sys Info
screen
A-13
A-14
Figure 2 Configuration Report
Dispenser Side
CAT Address
(Terminal ID)
Battery Mode: logs
each time dispenser
Software ID power is off
Note: Software
version does not
show on config
report. Run the Mode
diagnostic test
to print version.
Erase Reason
Serial No.
Battery
Status
Authentication
Card Reader
Type:
TTL or Secure. Key Type
If a Contactless
Reader is enabled
“Contactless’ and Time
its firmware and
s/n will be shown.
A-15
A-16
APPENDIX B
VALANCE INSTALLATION INSTRUCTIONS

1. Remove two 10 mm hex head screws on the end of top cover. Repeat for opposite end.
2. Attach one end valance, pushing it back completely and secure with the two screws.
3. Attach the other end valance, but let rest on the outer hooks, do not secure.
4. Attach side valance to fixed end valance, then loosely attach to the other end valance.
5. Attach other side valance to fixed end valance, then loosely attach to the other end valance.
6. Secure the two side valances to the loose end valance, then secure the end valance with the two
screws.
7. Attach (snap in) the end cover on both ends of the valance.
Screws
STEP 1 STEP 2
STEP 3 AND STEP 4

B-1
STEP 5
STEP 6 AND STEP 7
B-2
APPENDIX C
WIRING DIAGRAMS
Wiring diagram drawing PN WU044012

Description Drawing Page Number for NA
Dispenser 6
Suction Pump 7
iXR2 and SPM 10
Wayne Connect 12
C-1
5 4 3 2 1
PCB75 PCB76
J10 W 92L +24 SW J10
J9 VCC+24 J7 W M043007 J7 VCC+24 J9
J1 EX.BL ON/OFF BIT BUS PCB108 BIT BUS EX.BL ON/OFF J1
J8 ICSP W 92D BIT BUS A J15 J16 W 92E BIT BUS B ICSP J8
KEYBOARD BIT-BUS A BIT-BUS B PCB65 KEYBOARD
J11 W M043007 CPU BOARD W M043007 J11
J5 LCD S/W VCC+24_ IEC FULL w CAN J13 W 93 VCC+24_ LCD S/W J5
DISPLAY J2 CAN I/O W M042321-0001 J1 J2 J2 DISPLAY
UPD PCB72 W U005354-0001 UPD
J6 J3 TTL-CAN J3 J6
LED COM RS485 J4 CPU BOARD IEC W M001908-0003 J4 W 88 J4 RS485 LED COM
CONVERTER
J3
RS485_ NOZZLE W M040747-0001 J1 J4 RS485_
Display S/W W M041368-0001 J5 W U004491-0001 W M041368-0001
WIP NOZZLE SWITCH
SW 155
J2
CONVERTER
J21 J5
D BUZZER1 D
J22 BZR2 DOOR SWITCHES
BUZZER2
J3 J9
PCB68 VALVES RED/GREEN LIGHT ALARM W M??????-???? PCB67
J10 886495-002
KEY SPARE OUT 1-2 KEY
PAD PAD
J1 J8 J12 J1
BACK LIGHT SPARE IN 1-2
WM040870-0003
W92B UPD A
J6 J17
TOTALIZER 1-4 BÜRKET VAP
WM040866-0001
W92H NOZZLE
WM043007
WM040870-0003
W92F WIP
KEY PAD KEY PAD
SPARE OUT 3-4
W92C UPD B
J7
WM043007
POWER +24V
TOTALIZER 5-8
W92G VALVE
WM043007
RS485/422
W M045769-0001
PUMP MC
US/UK CL
ON/OFF W 40
W82
SWITCH TO iX BOARD J2, J5
J1
J2
J1
J11
J14
J20 W92J RS485/422 J25

PCB33
J41 W92K +24V iGEM

J13 W92I PUMP MC
UNIT
J23 W92A +24 SW

PRICE PCB34
WM043007
WM043007
WM043007
DISPLAY J1
WM043007
MODULE UNIT
PRICE
J1 DISPLAY
UNIT PRICE DISPLAY MODULE
WM040216-0002
C EMT17 C
W M042452-0002 J1
J56
J46
J47
UNIT PRICE DISPLAY
EMT18
W M042452-0002 J1 W 162 J48 J36
POWER 24V DISPLAY

SWITCH ON/OFF
MC
EMT 1-4
EMT 5-8
POWER 24V iGEM
DATA CL
J49 EMT 1 24V PS2
W85
EMT20 W M045337-0001
W M042452-0002 J1 J50 EMT 2 J11
EMT19 J51 EMT 3 120V PS2
W M042452-0002 J1 J52 EMT 4
EMT21 J53 EMT 5 PCB73 PCB74
W M042452-0002 J1 J54 EMT 6
J1
J2
J3
J1
J2
J3
EMT22 J55 EMT 7
W M042452-0002 J1 W 163 EMT 8 W U004200-0001 W U004200-0001
PS5 INTRINSICALLY INTRINSICALLY
EMT24 W M045337-0001 J10 W 86 1 SAFE BARRIER SAFE BARRIER
W M042452-0002 J1 PCB78A 120V PS1 W M040286-0001 6 C0N1 24V POWER
CON6 SUPPLY
J5
J8
J9
J5
J8
J9
EMT23 BOARD
W M042452-0002 J1 CONNECTOR, DISPENSER, NA J25 W 87 W M027313-0001
24V PUMP W M040297-0001
W U004203-0001
HTR8 W 100
J9 J1
DATA IN 485
W 84 HEATER W M042343-0001
PUMP CTRL
DATA IN CL
120V CTRL
HEATER W M044536-0001 230V FAN
120V OUT
J1 J2
SIDE A CALL BUTTON J24 W 83 24V
+24V_HTR W M023796-0001 W M044405
SPEAKER/MIC
J8
J19
J43
J14
J12
PCB124
WM040834-0001
WM040834-0001
TEMPERATURE
J1
WM040992-0001
MODULE PHASE 2
WM040834-0001
WM040834-0001
B J1 B
W M038162-0001
J10
J11
SIDE B CALL BUTTON
J2
J3
J4
J5
J6
J7
J8
J9
W97
W98
W99
W95
W96
SPEAKER/MIC
WM001682-0002
WM001682-0002
PCB70
WM001682-0002
WM001682-0002
J1
J1
J13
NOZZLE SWITCH
J1
J1
WIP15
WIP16
WU007655-0001
SIDE A NOZZLE SWITCHES INTERFACE

RIGHT MOST NOZZLE SWITCH W U004201
WIP13
WIP14
J10
J11
J12
SHALL BE CONNECTED TO J1.
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
J2
J3
J4
J5
J6
J7
J8
J9
J2, J3, AND THEN J4 WILL BE W IP W IP
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
USED CONSECUTIVELY RIGHT TO
VALVE
VALVE
VALVE
VALVE
VALVE
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
SOLENOID VALVE
LEFT NO MATER THE PLACEMENT W IP W IP

W94
WM045692-0001
WM045692-0001
WM040341 TEMPERATURE
VALVE_5
VALVE_6
VALVE_7
VALVE_8
VALVE_10
WM045692-0001
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
VALVE_1
VALVE_2
VALVE_3
VALVE_4
VALVE_9
WM045692-0001
WM045692-0001
WM045692-0001
SW70 SENSOR
SW71 SENSOR
SW72 SENSOR
SW73 SENSOR
SW74 SENSOR
SW75 SENSOR
SW76 SENSOR
SW77 SENSOR
SW78 SENSOR
SW99 SENSOR
SIDE A
SIDE B
SIDE B NOZZLE SWITCHES
WM045692-0001
WM045692-0001
LEFT MOST NOZZLE SWITCH
WM045692-0001
1
WM045692-0001
J1
J1
J1
J1
JB9B W U000847-0001 J6, J7, AND THEN J8 WILL BE
J1
J1
J1
SIDE A RIGHT TO LEFT SIDE B LEFT TO RIGHT 4 USED CONSECUTIVELY LEFT TO NOZZLE NOZZLE NOZZLE NOZZLE
J1
ALWAYS START WITH 1 ALWAYS START WITH 5 2 RIGHT NO MATER THE PLACEMENT SWITCH SWITCH NOZZLE SWITCH SWITCH NOZZLE
3
NO MATER THE PLACEMENT NO MATER THE PLACEMENT SWITCH SWITCH NOZZLE DOOR DOOR
SW 01 SW 02 SW 04 SW 05 NOZZLE SWITCH SWITCH SWITCH
SW 03 SW 06 SWITCH
SW 08 SW 159 SW 160
SW 07
35235,(7$5<,1)250$7,217+,6'2&80(17&217$,1635235,(7$5<$1'&21),'(17,$/,1)250$7,21
3$*(,1)250$7,21 $33529$/&/$66
January 2013
A ,7,6/2$1(')25/,0,7('385326(621/<$1'5(0$,167+(3523(57<2)7+(:$<1(',9,6,212) A
'5(66(5,1&,70$<127%(5(352'8&(',1:+2/(25,13$57:,7+2877+(:5,77(1&216(172) 6&$/(
5HODWHG'UDZLQJ
UL/CUL DISPENSER
7+(:$<1(',9,6,21$1'0867127%(',6&/26('723(56216127+$9,1*1(('2)68&+',6&/2685(
&216,67(17:,7+7+(385326(2)7+(/2$1,70867127%(86(')25$1<385326(27+(57+$1
1$
)257+(%(1(),72)7+(:$<1(',9,6,217+,6'2&80(17,672%(5(7851('727+(:$<1(',9,6,21
7,7/( '5$:,1*12
:0
83215(48(67$1'258321&203/(7,212)7+(86()25:+,&+,7:$6/2$1('
$33529(' :,5,1*',$*5$0

+HOL[6\VWHP&DEOLQJ 6+((7 2)
'5$:1 '(6&5,37,212)&+$1*(
5(9 '$7( (&112
'HVFULEWLRQ2I&KDQJH FORM REF WMXXXXXX Rev 01.
5 4 3 2 1
5 4 3 2 1
PCB59 PCB60
J10 W 64L +24 SW J10
J9 VCC+24 J7 W M043007 J7 VCC+24 J9
J1 EX.BL ON/OFF BIT BUS PCB109 BIT BUS EX.BL ON/OFF J1
J8 ICSP W 64D BIT BUS A J15 J16 W 64E BIT BUS B ICSP J8
KEYBOARD J11 W M043007 BIT-BUS A CPU BOARD BIT-BUS B W M043007 PCB51 J11 KEYBOARD
J5 LCD S/W VCC+24_ IEC FULL w CAN J13 W 75 VCC+24_ LCD S/W J5
DISPLAY J2 CAN I/O W M042321-0001 J1 J2 J2 DISPLAY
UPD PCB18 W U005354-0001 UPD
J6 J3 TTL-CAN J3 J6
LED COM RS485 J4 CPU BOARD IEC W M001908-0003 J4 W 60 J4 RS485 LED COM
CONVERTER
J3
RS485_ NOZZLE W M040747-0001 J1 J4 RS485_
Display S/W W M041368-0001 J5 W U004491-0001 Display S/W W M041368-0001
WIP NOZZLE SWITCH
J2
CONVERTER SW 156
January 2013
J21 J5
D BUZZER1 D
J22 BZR1
BUZZER2 DOOR SWITCHES
J3 J9
PCB54 VALVES RED/GREEN LIGHT ALARM PCB53
886495-002 W M??????-????
KEY J10 KEY
SPARE OUT 1-2
PAD PAD
J1 J8 J12 J1
BACK LIGHT SPARE IN 1-2
WM040870-0003
W64B UPD A
J6 J17
WM040866-0001
WM040870-0003
TOTALIZER 1-4 BÜRKET VAP
W64C UPD B
W64H NOZZLE
WM043007
W64F WIP
KEY PAD KEY PAD
SPARE OUT 3-4

J7
WM043007
POWER +24V
TOTALIZER 5-8
RS485/422
W M045769-0001
PUMP MC
US/UK CL
W71
ON/OFF W 40
SWITCH TO iX BOARD J2, J5
J1
J2
J1
J11
J14
J20 W64J RS485/422 J25

PCB35
J41 W64K +24V iGEM

UNIT
J13 W64I PUMP MC

J23 W64A +24 SW
PRICE
W64G VALVE
J1 PCB52
WM043007
WM043007
WM043007
WM043007
WM043007
DISPLAY
MODULE UNIT
PRICE
J1 DISPLAY
UNIT PRICE DISPLAY MODULE
WM040216-0002
C EMT25
J1 C
J56
J46
J47
W M042452-0002 UNIT PRICE DISPLAY
EMT26 PCB61A
W M042452-0002 J1 W 164 J48 J36
POWER 24V DISPLAY

SWITCH ON/OFF
MC
EMT 1-4
EMT 5-8
POWER 24V iGEM
DATA CL
J49 EMT 1 24V PS2
W36
EMT28 W M045337-0001
W M042452-0002 J1 J50 EMT 2 J11
EMT27 J51 EMT 3 120V PS2
W M042452-0002 J1 J52 EMT 4
EMT30 J53 EMT 5 PCB19 PCB58
W M042452-0002 J1 J54 EMT 6
J1
J2
J3
J1
J2
J3
EMT29 J55 EMT 7
W M042452-0002 J1 W 165 EMT 8 W U004200-0001 W U004200-0001
PS4 INTRINSICALLY INTRINSICALLY
EMT32 W M045337-0001 BOARD J10 W 37 1 SAFE BARRIER SAFE BARRIER
W M042452-0002 J1 CONNECTOR, SUCTION PUMPS, NA 120V PS1 W M040286-0001 6 C0N1 24V POWER
CON6 SUPPLY
J5
J8
J9
J5
J8
J9
EMT31
W M042452-0002 J1 J25 W 38 W M027313-0001
24V PUMP W M040297-0001
W U006410
HTR7 W 70
120V OUTPUT J9 W 35 J1 HEATER W M042343-0001
PUMP1 CTRL
PUMP2 CTRL
PUMP3 CTRL
PUMP4 CTRL
HEATER 230V FAN
DATA IN 485
W M044536-0001
DATA IN CL
120V CTRL J2
J24 W 32 24V
+24V_HTR W M023796-0001 W M044405
PCB125
J12
J8
J19
J43
J14
J15
J16
J17
WM040834-0001
WM040834-0001
TEMPERATURE
J1
SIDE A NOZZLE SWITCHES
WM040992-0001
MODULE PHASE 2
WM040834-0001
WM040834-0001
B RIGHT MOST NOZZLE SWITCH
B
W M038162-0001
J10
J11
J2, J3, AND THEN J4 WILL BE
J2
J3
J4
J5
J6
J7
J8
J9
USED CONSECUTIVELY RIGHT TO
W143
W144
LEFT NO MATER THE PLACEMENT
W145
W141
W142
WM001682-0002
WM001682-0002
PCB97
WM001682-0002
WM001682-0002
SIDE B NOZZLE SWITCHES
J1
J1
W 76 LEFT MOST NOZZLE SWITCH
J13
W M045755-0001 SHALL BE CONNECTED TO J5. NOZZLE SWITCH
J1
J1
WIP23
WIP24
W 156 J6, J7, AND THEN J8 WILL BE INTERFACE
W M045746-0001 USED CONSECUTIVELY LEFT TO W U004201
WIP21
WIP22
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
J10
J11
J12
J1
J2
J3
J4
J5
J6
J7
J8
J9
W 157 RIGHT NO MATER THE PLACEMENT
W IP W IP
W M045746-0001
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
J1
J1
J1
J1
J1
J1
J1
J1
J1
J1
W 158 W IP W IP
W M045746-0001
W 159
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
SOLENOID
WM045692-0001
WM045692-0001
W M045746-0001
WM045692-0001
WM045692-0001
WM045692-0001
WM045692-0001
VAL25
VAL26
VAL27
VAL28
VAL29
VAL30
VAL31
VAL32
VAL34
VAL33
SW100 SENSOR
SW101 SENSOR
SW102 SENSOR
SW103 SENSOR
SW104 SENSOR
SW105 SENSOR
SW106 SENSOR
SW107 SENSOR
SW108 SENSOR
SW109 SENSOR
MOTOR MOTOR
WM045692-0001
WM045692-0001
WM045692-0001
WM045692-0001
1
J1
MTR7 MTR9
J1
J1
J1
JB4B W U000847-0002
J1
MOTOR NOZZLE
J1
J1
J1
4 NOZZLE NOZZLE SWITCH NOZZLE DOOR DOOR
MOTOR NOZZLE
2
3
SWITCH SWITCH NOZZLE SW 110 SWITCH NOZZLE NOZZLE SWITCH SWITCH SWITCH
MTR6 SWITCH SWITCH SWITCH
SW 67 SW 68 SW 111 SW 161 SW 162
MTR8 SW 114
SW 69 SW 112 SW 113
A 35235,(7$5<,1)250$7,217+,6'2&80(17&217$,1635235,(7$5<$1'&21),'(17,$/,1)250$7,21
,7,6/2$1(')25/,0,7('385326(621/<$1'5(0$,167+(3523(57<2)7+(:$<1(',9,6,212) 3$*(,1)250$7,21 $33529$/&/$66 A
'5(66(5,1&,70$<127%(5(352'8&(',1:+2/(25,13$57:,7+2877+(:5,77(1&216(172) 6&$/(
5HODWHG'UDZLQJ
UL/CUL SUCTION PUMP
7+(:$<1(',9,6,21$1'0867127%(',6&/26('723(56216127+$9,1*1(('2)68&+',6&/2685(
&216,67(17:,7+7+(385326(2)7+(/2$1,70867127%(86(')25$1<385326(27+(57+$1
1$
)257+(%(1(),72)7+(:$<1(',9,6,217+,6'2&80(17,672%(5(7851('727+(:$<1(',9,6,21
7,7/( '5$:,1*12
:0
83215(48(67$1'258321&203/(7,212)7+(86()25:+,&+,7:$6/2$1('
$33529(' :,5,1*',$*5$0

'5$:1 '(6&5,37,212)&+$1*(
5(9 '$7( (&112
5 4 3 2 1
5 4 3 2 1
J37 J14
W ?? E-NET PRINTER-232
J17 J39
J6 RS-485 USB J8
SOFT-KEYS
J11 RS422 RS485 J10
iX3_R2
TFT-LCD
J5 PWR AUDIO J7
MONO
MONO
RS232
RS232
W 40 J2 ANUNCIATOR KYPD-232
BKLT
USB
USB
USB
USB
TO iGEM J13, J21 W 40 CAN
OR TTL/CAN W M040568-0001 J3
CAN2
CONVERTER J2
J27
J23
J28
J15
J21
J32
J46
J13
J24
J29
J30
D CONTACTLESS READER W 48 W 47 CONTACTLESS READER D
RS-232 W M040238-0001 W M040238-0001 RS-232
W 62 W 61
W M0?????-???? W M0?????-????
W 45 W 44
W M042821-0001 W M042821-0001
WM040490-0001
W 46 W 42
WM040913-0001
BK_LIGHT DATA W M024585-0001 W M024585-0001 BK_LIGHT DATA
MONOCHROME QVGA MONOCHROME QVGA
PCB48B
W137
J21
W138
W U004203-0001 24V E-NET FAN
FAN BOARD
+24V KYPD-A
+24V KYPD-B
PRINTER CONNECTOR, DISPENSER, NA PRINTER
DATA PT A
DATA PT B
+24V iX-A
+24V iX-B
PWR
PWR
USB
USB
SOFT KEYS
SOFT KEYS
SCANNER
J37
J39
J44
J40
J45
J38
SCANNER
WM045724-0001
WM040572-0001
WM040572-0001
WM045724-0001
WM045452-0001
C C
WM045452-0001
W53
W41
W50
W52
W51
W43
J15 J6 J3 J2 J11
PCB41 J11 J2 J3 J6 J15
U16
SCANNER SOFTKEY PWR3 PWR2 PRINTER
PRINTER PWR2 PWR3 SOFTKEY SCANNER
SPM-KYPD J12
USB J12 SPM-KYPD
SPM KEYPAD USB SPM KEYPAD
J1
PWR1 J1
PWR1
RS232 C/RPWR4 MAG C/R PWR5
PWR5 MAG C/R PWR4 RS232 C/R
J8 J4 J10 J5
J5 J10 J4 J8
WM040280-0001
WM040280-0001
W39
W49
B B
J1
J1
MSR DATA
MSR DATA
W U003908-0001
MAG STRIPE ONLY W U003908-0001
CARD READER MAG STRIPE ONLY
CARD READER
35235,(7$5<,1)250$7,217+,6'2&80(17&217$,1635235,(7$5<$1'&21),'(17,$/,1)250$7,21
3$*(,1)250$7,21 $33529$/&/$66
January 2013
A ,7,6/2$1(')25/,0,7('385326(621/<$1'5(0$,167+(3523(57<2)7+(:$<1(',9,6,212) A
'5(66(5,1&,70$<127%(5(352'8&(',1:+2/(25,13$57:,7+2877+(:5,77(1&216(172) 6&$/(
5HODWHG'UDZLQJ
PAYMENT TERMINAL WITH MONCHROME QVGA DISPLAY
7+(:$<1(',9,6,21$1'0867127%(',6&/26('723(56216127+$9,1*1(('2)68&+',6&/2685(
&216,67(17:,7+7+(385326(2)7+(/2$1,70867127%(86(')25$1<385326(27+(57+$1
1$
)257+(%(1(),72)7+(:$<1(',9,6,217+,6'2&80(17,672%(5(7851('727+(:$<1(',9,6,21
7,7/( '5$:,1*12
:0
83215(48(67$1'258321&203/(7,212)7+(86()25:+,&+,7:$6/2$1('
$33529(' :,5,1*',$*5$0

'5$:1 '(6&5,37,212)&+$1*(
5(9 '$7( (&112
5 4 3 2 1
5 4 3 2 1
January 2013
D D
C C
W 188 W ??? iX BOARD(S) J17

W U005309-0001
PCB107
WAYNE CONNECT
TO CONNECTOR BOARD J18 W ??? AC IN E-NET
W 187 W ??? TO iX J37(STANDARD OR SIDE A)
GND PORT1 W M040870-0001
W 192 LF BUS PORT2 W 186 TO iX J37 (SIDE B)
FROM CONNECTOR BOARD J44 W ??? BB BUS PORT3 W ???
W M046118-0001 W M040870-0001
W AYNE CONNECT
B B
A 35235,(7$5<,1)250$7,217+,6'2&80(17&217$,1635235,(7$5<$1'&21),'(17,$/,1)250$7,21
,7,6/2$1(')25/,0,7('385326(621/<$1'5(0$,167+(3523(57<2)7+(:$<1(',9,6,212) 3$*(,1)250$7,21 $33529$/&/$66 A
'5(66(5,1&,70$<127%(5(352'8&(',1:+2/(25,13$57:,7+2877+(:5,77(1&216(172)
PAYMENT TERMINAL OPTIONS 6&$/(
7+(:$<1(',9,6,21$1'0867127%(',6&/26('723(56216127+$9,1*1(('2)68&+',6&/2685(
&216,67(17:,7+7+(385326(2)7+(/2$1,70867127%(86(')25$1<385326(27+(57+$1
1$ 5HODWHG'UDZLQJ
)257+(%(1(),72)7+(:$<1(',9,6,217+,6'2&80(17,672%(5(7851('727+(:$<1(',9,6,21
7,7/( '5$:,1*12
:0
83215(48(67$1'258321&203/(7,212)7+(86()25:+,&+,7:$6/2$1('
$33529(' :,5,1*',$*5$0

'5$:1 '(6&5,37,212)&+$1*(
5(9 '$7( (&112
5 4 3 2 1
C-6
APPENDIX D
HYDRAULIC CONFIGURATIONS
WAYNE HELIX™ 4000 & 5000 MODEL DISPENSERS
Below are graphical layouts of the available hydraulic configurations for the Helix H-Style dis-
penser models. The graphics can be interpreted as follows, using the H(W/L)44-44 model as
an example.
D-1
February 2013 P/N WU008123 Rev 01
11-11: SINGLE PRODUCT
Single-Sided: H(W/L)22-220
Single-Sided: H(N/L)11-110 Vista Equivalent: 399
Vista Equivalent: 387
22-22: 2-PRODUCT NON-BLENDER 33-3X: 3-PRODUCT NON-BLENDER

(MULTI & UNI-HOSE)
Single-Sided: H(N/L)22-220
D-2
P/N WU008123 Rev 01 January 2013
44-4X: 4-PRODUCT NON-BLENDER
(MULTI & UNI-HOSE)
Vista Equivalent: 390/U
Vista Equivalent: 390/U Narrow
D-3
January 2013 P/N WU008123 Rev 01
2X-21: 2-PRODUCT NARROW BLEND-
ER (3-5 Grades)
2X-21: 2-PRODUCT WIEDE BLENDER
(3-5 Grades)
Single-Sided: H(N/L)24-210 Single-Sided: H(N/L)23-210

Vista Equivalent: 585 Vista Equivalent: 590/U
D-4
34-32: 3+1 PRODUCT BLENDER (Nar-
row & Wide)
Vista Equivalent: 595 Narrow
Single-Sided: H(N/L)25-210 Single-Sided: H(W/L)34-320

Vista Equivalent: 595/U Vista Equivalent: 595
D-5
January 2013 P/N WU008123 Rev 01
45-43 4-PRODUCT 3+1+1 Multi-

Blender
Vista Equivalent: N/A
D-6
APPENDIX E
TORX SCREWDRIVER KIT
An example of a Torx™ screwdriver kit is shown in the photo below. Similar kits are available
online and at many of the major tool stores.
E-1
E-2
HELIX FUEL DISPENSERS
SERVICE
This manual was produced on a personal computer using Adobe® FrameMaker® and Photoshop®
Page design uses GE Inspira Fonts
© 2013 Wayne, A GE Energy Business

All rights reserved.
Printed in the United States of America.
Adobe® FrameMaker® and Photoshop® are trademarks of Adobe Systems, Inc.
All other brand names and trademarks mentioned are the properties of their respective holders.
This manual and the software described herein are furnished under license and may be used or copied
only in accordance with the terms of such license.
No part of this publication may be electronically or mechanically reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, except as permitted by such license. Translation of this ma-
terial to another language without express written permission from Wayne is prohibited.
This publication is intended for informational purposes only and this material is subject to change without
notice. Wayne has not made, and does not make, any representations or warranties of any kind, express
or implied, with respect to any information in the publication, including any warranty as to the accuracy,
correctness, or completeness of any of the information, and Wayne shall not be responsible or liable for
any damages or losses that occur as a result of the receipt and/or use of the information contained here-
in.
Wayne is located at 3814 Jarrett Way, Austin TX 78728

Wayne’s general telephone number is (512) 388-8311
Wayne 3814 Jarrett Way, Austin, TX 78728 (512) 388-8311
Part No. WU008123 Rev 01 © 2013 Wayne, A GE Energy Business 1/13

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Wayne Helix™

READ THIS MANUAL BEFORE YOU BEGIN

SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE

HOW TO CONTACT WAYNE

INDICATORS AND NOTATIONS

Important information to consider, otherwise, improper installation and/or damage to compo-

4 ELECTRONIC BOARDS - LAYOUT AND CONNECTOR DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 PART NUMBERS REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

7 IGEM SOFTWARE AND SERVTERM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8 TROUBLESHOOTING, ERROR CODES AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9 ZEBRA PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

10 METER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

APPENDIX A iX Pay™ Secure Payment Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B Valance Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

APPENDIX C Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

APPENDIX D Model Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

APPENDIX E Torx Screwdriver kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

Some of the features of Helix dispensers are listed below:

• New two-piece bezel

• Increased inner diameter of product tubes improves flow rate

• Easily replaceable nozzle boots

• Incorporates use of new USB printer

1. Unlock bezel U-frame here

Figure 1-1 Helix Bezel Lock

Figure 1-2 Payment Terminal Drawer Lock

Figure 1-3 Latches Behind the Payment Terminal Bezel.

Figure 1-4 Helix Dispenser Service View

• Strainer and Filter

• Proportional Flow Control Valve

• iMeter and WIP

• Check & Pressure Relief Valve

• Hose Outlet Casting

2.1. TRIPLE BUMP PRODUCT TUBES

FIGURE 2-1 TRIPLE BUMP TUBE

February 2013 Part No. WU008123 Rev 01

Strainer located Spill funnel Filter

FIGURE 2-2 STRAINER CASTING, FILTER AND SPILL FUNNEL

Part No. WU008123 Rev 01 February 2013

FIGURE 2-3 PROPORTIONAL FLOW CONTROL VALVE AND COIL

FIGURE 2-4 VALVE TUBE RETAINING PIN

February 2013 Part No. WU008123 Rev 01

• The proportional valve

2.3.1. No Flow - Flow Control Valve Off

2.3.2. Slow Flow - Flow Control Valve On

2.3.3. Full Regulated Flow - Flow Control Valve On

Part No. WU008123 Rev 01 February 2013

FIGURE 2-5 iMETER AND WIP

2.4.1. Check and Pressure Relief Valve

February 2013 Part No. WU008123 Rev 01

Part No. WU008123 Rev 01 February 2013

Hose outlet castings

FIGURE 2-9 TOOL REMOVAL TOOL

February 2013 Part No. WU008123 Rev 01

FIGURE 2-10 TUBE RETAINER CLIP

Part No. WU008123 Rev 01 February 2013

Heater/Fan Sales Display

Serial/Parallel Converter TTL/CAN Converter

*ISB Temp Comp ISB

Connection Board - Remote

Nozzle Switch Interface Temp Comp Module

included in Temp Comp

Figure 3-1 NEW BOARDS USED IN HELIX DISPENSERS

QVGA QVGA Secure Contactless