Helix Installation Manual Rev 002

Installation Manual
Helix
WM048526
Rev 02
AE
Read this manual before starting any installation, service, or maintenance work
Fuel dispensers contain both electrical components 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. In addition, it is your responsibility to follow all rules,
codes, regulations, and laws that apply to your location and type of work being performed.
Safety precautions
Make sure that ALL power to the dispenser is turned OFF before opening the cabinet or starting
work. Physically lock, restrict access to, and/or tag the circuit breakers you turn off. In addition,
be sure to trip (close) all emergency valves under the dispenser (if installed) BEFORE you begin.
Make sure that you locate the facility’s emergency shut-off button, and know how to turn OFF
power to the dispenser and submersible pumps (if any) in an emergency.
Never allow a leaking pump to run! Use appropriate measures to clean up any fuel on the forecourt,
and ensure that any leaks or issues that could cause a leak are attended to and repaired immedi-
ately.
Indicators and notations
Note !
Indicates extra information or tip.
NOTICE!
Highlights an essential element of a procedure to

help ensure accuracy, completeness, and appropriate
performance.
CAUTION!
Indicates a potentially hazardous situation, which if

not avoided, could result in personal (non-lethal) injury
or equipment damage.
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WARNING!
INDICATES A POTENTIALLY HAZARDOUS SITUATION,

WHICH, IF NOT AVOIDED COULD RESULT IN DEATH
OR SERIOUS INJURY.
DANGER!
INDICATES A HAZARDOUS SITUATION, WHICH, IF NOT

AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
WM048526 Rev 02 05/2013

Table of Contents
Table of Contents
1 Introduction .................................................................................................................................................... 3
1.1 Dispensers Covered ................................................................................................................... 3
1.2 Wayne iGEM™ Computer Software .................................................................................... 4
1.3 Safety precautions ..................................................................................................................... 4
1.4 Bezel .................................................................................................................................................. 7
2 Installation ...................................................................................................................................................... 8
2.1 Helpful Tips .................................................................................................................................... 8
2.1.1 Determining Dispenser Sides A & B ................................................................................................... 8
2.1.2 Determining HI & LO - Product Piping .............................................................................................. 8
2.1.3 Pump Control Wiring at Junction Box .............................................................................................. 8
2.1.4 Dispenser ON/OFF Switch ...................................................................................................................... 8
2.1.5 iX R2 Board Reset Button ....................................................................................................................... 9
2.2 Inspect Equipment ..................................................................................................................... 10
2.3 Island Construction, Dispenser Anchoring, and Piping ............................................. 10
2.4 Emergency Shear Valves ......................................................................................................... 10
2.5 Vapor return piping .................................................................................................................... 12
2.6 Lifting and installing dispenser ............................................................................................. 12
2.7 Electrical wiring ............................................................................................................................ 13
2.7.1 General ........................................................................................................................................................... 13
2.7.2 Dispenser to Wayne Control System interconnection ............................................................... 13
2.7.3 Full service (stand-alone) dispensers ................................................................................................ 14
2.7.4 Multiple dispenser wiring ....................................................................................................................... 15
2.8 Bleeding product lines (remote dispensers) ................................................................... 15
2.9 Calibration of Wayne iMeter™ Piston Fuel Flow Meters ........................................... 15
2.9.1 Bleeding product lines (remote dispensers) ................................................................................... 16
2.9.2 Dispenser purging at startup: new dispensers and/or meters only .................................... 16
2.9.3 During calibration procedure ............................................................................................................... 16
2.9.4 Completing the startup calibration report ...................................................................................... 17
2.9.5 How to determine a successful calibration .................................................................................... 18
2.9.6 Factors that may influence calibration values .............................................................................. 18
3 Startup .............................................................................................................................................................. 19
3.1 Initial checkout ............................................................................................................................. 19
3.2 IR remote control ........................................................................................................................ 20
3.3 iX Pay™ Secure Payment Platform Configuration ....................................................... 21
3.3.1 Initial Configuration Procedure ............................................................................................................ 21
3.4 Set clock function (F 02) ........................................................................................................... 37
3.5 Logical nozzle / hose positions ............................................................................................. 38
3.6 Setting Unit Prices ...................................................................................................................... 40
3.7 Setting Blend Ratios ................................................................................................................... 43
3.8 Setting the Fueling Point ID (FPID) ....................................................................................... 47
3.9 Authorizing the Dispenser ....................................................................................................... 49
3.10 Initial Delivery ............................................................................................................................... 49
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Table of Contents
3.11 Disable Stand-Alone Operation ............................................................................................ 49

3.12 Electronic Totalizer Readings ................................................................................................ 51
3.12.1 Totalizer readings by hose (product) position ................................................................................ 51
3.12.2 Totalizer volume readings by meter position ................................................................................ 52
3.12.3 Electro-mechanical totalizer operation ............................................................................................ 52
3.13 Nozzle Boot Switch Check ....................................................................................................... 53
3.14 Annunciator Operation Check .............................................................................................. 53
3.15 iX PAY Secure Payment ............................................................................................................. 53
3.16 Audit Reporting Display Mode (Weights & Measures) ................................................ 53
4 Operation ......................................................................................................................................................... 55
4.1 How to get service on your dispenser .............................................................................. 55
4.2 Basic dispenser requirements .............................................................................................. 55
4.3 Operating the dispenser .......................................................................................................... 55
4.4 Restarting after power failure or shutdown ................................................................... 56
4.5 Cycling power to clear faults ................................................................................................. 56
4.6 Error codes ..................................................................................................................................... 56
4.7 Resetting after all stop ............................................................................................................. 57
4.8 Stand-alone operation ............................................................................................................. 58
5 Maintenance .................................................................................................................................................. 60
5.1 Hose and Hose Retractor ........................................................................................................ 60
5.2 Filter / Strainer - Remote ......................................................................................................... 60
5.3 Dispenser Cleaning .................................................................................................................... 62
5.3.1 Painted Surfaces ........................................................................................................................................ 62
5.3.2 Dispenser Cleaning Process .................................................................................................................. 62
5.3.3 Glass and Clear Plastic Surfaces ......................................................................................................... 63
5.3.4 Stainless Steel Surfaces .......................................................................................................................... 63
5.4 Meter Maintenance .................................................................................................................... 63
5.5 Printer Maintenance - Zebra Printers ................................................................................ 63
5.5.1 Printer Specification ................................................................................................................................. 63
5.5.2 Thermal Characteristics .......................................................................................................................... 64
5.5.3 Thermal Response Range ...................................................................................................................... 64
5.5.4 Residual Particles ....................................................................................................................................... 64
5.5.5 Loading Printer Paper .............................................................................................................................. 65
Appendices
A Installation Drawings ................................................................................................................................. 71
B Site Interconnection Diagrams .............................................................................................................. 78
C Hydraulic Configurations - Helix 4000 & 5000 Model Dispensers ........................................ 83
D Calibration Setup Report .......................................................................................................................... 88
E U.S. METROLOGICAL AUDIT TRAILS IN US iGEM ............................................................................. 90
F Glossary of Terms and Acronyms ........................................................................................................ 101
2 WM048526 Rev 02 05/2013

1 Introduction
1 Introduction
This manual covers general user information on the operation and maintenance of the Helix™
dispenser models outlined in Dispensers Covered3. This manual also includes installation and
footprint drawings that show locations of the product inlets and conduits. Computer function
settings that are necessary for Helix dispenser start-up and operation such as setting prices, blend
ratios, and fueling point ID's are also included. If additional information on function settings and
statistics is required refer to the Helix Dispenser Service Manual (p/n WM048523).
The following items are required for the operation and maintenance of Helix dispensers:
• Infrared remote control (IR remote or IRC) - Wayne part number 886446-001
• Printer door - DHW1 key
• Lower bezel door and sliding bezel tray locks - DW2 key
• Hydraulic door key - 3306 key - Wayne part number WM003119
• Any questions concerning installation and operation of the dispenser that are not covered in
this manual should be referred to Wayne Technical Support at +1 800 926 3737.
1.1 Dispensers Covered

This manual covers Helix 4000 (narrow) and 5000 (wide) model dispensers whose attributes can
be determined by referring to the Model String Designation below. The dispenser model number
can be located on the dispenser name plate, receipts, or shipping documentation.
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1 Introduction
Figure 1.1: Helix Model String Designation
1.2 Wayne iGEM™ Computer Software

Helix model dispensers are delivered pre-installed with Wayne iGEM™ computer software version
62 or later which can also be downloaded via laptop computer. ServTerm version 6.1.5 or later is
required for servicing (loading the computer software or dispenser configuration template), how-
ever this is not required for installation or startup of the dispenser. If it becomes necessary to re-
install pump software, always use the latest version.
1.3 Safety precautions

NFPA 30A 1 states that:
“When maintenance to dispensing devices is necessary and such maintenance is capable of
causing accidental release or ignition of liquid, the following precautionsh shall be taken before
such maintenance is begun:
1 Only persons knowledgeable in performing the required maintenance shall perform the work.
2 All electrical power to the dispensing devices, and to all associated control circuits shall be cut
off at the main electrical disconnect panel.
3 The emergency shut-off valve at the dispenser, if installed, shall be closed.
1 Reprinted with permission from NFPA 30A-2012, Automotive and Marine Service Station Codes, Copyright
©2012, National Fire Protection Association, Quincy MA 02169. This reprinted material is not the complete
and official position of the National Fire Protection Association on the referenced subject, which is represented
only by the standard in its entirety..
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1 Introduction
4 All vehicle traffic and unauthorized persons shall be prevented from coming within 6 m (20 ft)
of the dispensing device.”
WARNING!
ELECTRIC SHOCK HAZARD!
More than one disconnect switch may be required to

de-energize the dispenser for maintenance and ser-
vicing. Use a voltmeter to make sure ALL circuits in
the dispenser are de-energized. Failure to do so may
result in serious injury.
Lockout/Tagout requirements of the U. S. Dept. of Labor, Occupational Safety and Health Admin-
istration (OSHA) may also apply. Refer to Title 29, Part 1910 of the Code of Federal Regulations
(29CFR1910), Control of Hazardous Energy Source (Lockout/Tagout).
Note !
To prevent damage to components located in the hydraulic cabinet, dispenser doors should be
in place during rainy and/or icy weather conditions. Also, check the nozzle boot flipper for freedom
of movement. If ice has formed on the flipper, it should be cleared to prevent unnecessary damage.
Pertinent information and codes are available from the following sources:
Table 1.1: Code Sources
Fiberglass Petroleum Tank and Pipe Institute American Petroleum Institute (API)
1150 South Wilcrest Dr. Suite 101 1220 L Street, N.W.
Houston, TX 77099-4343 Washington, DC 20005-4070
+1(281)568-4100 +1(202) 682-8000
www.fiberglasstankandpipe.com www.api.org
National Fire Protection Association (NFPA) National Assoc. Corrosion Engineers
One Batterymarch Park (NACE)
Quincy, MA 02169-7471 1440 South Creek Dr.
+1(617) 770-3000 Houston, TX 77084-4906
www.nfpa.org +1(281) 2286223 or +1(800)797-6223
www.nace.org
Petroleum Equipment Institute (PEI) National Leak Prevention Association
6514 E. 69th St. (NLPA)
Tulsa, OK 74133-1729 685 Fields Ertel Road
+1(918) 494-9696 Cincinnati, OH 45241
www.pei.org +1(815) 301-2785
www.nlpa-online.org
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1 Introduction
Underwriters Laboratories, Inc. (UL) Steel Tank Institute (STI/SPFA)

Customer Service Location 944 Donata Ct.
2600 North West Lake Rd. Lake Zurich, IL, 60047
Camas, WA 98607-5842 +1(847)438-8265
+1(312) 272-8800 www.steeltank.com
www.ul.com
United States Environmental Protection Agency Underwriters Laboratories of Canada
Office of Underground Storage Tanks 7 Underwriters Road
401 M St., SW (05-400WF) Scarsborough, Ontario, Canada M1R3A9
Washington, DC 20640 +1(866)937-3852
+1(703) 308-8850 (Underground Storage Tanks) www.ul.com/canada/eng/pages/
www.epa.gov/swerust1/index.htm
Western Fire Chiefs Association
727 Center Street NE, Suite 300
Salem, OR 97301
+1(800)758-3473
www.wfca.com
U. S. Department of Labor
Occupational Safety and Health Administration (OSHA)
Washington, DC 20402
• Call OSHA at (202) 523-8148 to determine specific needs; OSHA rules are covered by Title
29 of the Code of Federal Regulations (29 CFR.)
www.osha.gov
• Order OSHA publications from:
Government Printing Office (GPO)
Washington, DC 22304
(202) 783-3238
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1 Introduction
1.4 Bezel
sales display
VGA display
softkeys
printer door
lock
keypad
printer
unit price
displays
PTS/Grade select
buttons
Figure 1.2: Dispenser Bezel (Example shown is an Helix 4000 fuel dispenser)
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2 Installation
2 Installation
2.1 Helpful Tips
Note !
It is recommended to shut down power to all dispenser installation locations at the site prior to
installation instead of shutting down power to each dispenser location individiually as each instal-
lation occurs.
2.1.1 Determining Dispenser Sides A & B

• Locate the Wayne name plate on the outside of the dispenser. If, while facing the dispenser
name plate is on your right side, you are facing Side A of the dispenser.
• Remove the hydraulic cabinet door from both sides of the dispenser. The side containing the
Junction box (J-box) is Side A.
• Open the electronics cabinet and locate the CAT board, which is located on Side A. The iX R2
(red) board is located on Side B.
2.1.2 Determining HI & LO - Product Piping

While facing Side A, HI product is on the far right side of dispenser and LO is to the left of HI.
2.1.3 Pump Control Wiring at Junction Box

Pump control wiring at the Junction Box Terminal Strip is outlined in the following table. Appendix
X contains a complete list of Junction Box Terminal Strip wiring designations.
Termi- Color Connection Product Description

nal
3 Black Pump Control 1 LO

4 Black Pump Control 2 HI
5 Black Pump Control 3 Open
6 Black Pump Control 4 Single (for diesel or other single
fuel type)
2.1.4 Dispenser ON/OFF Switch

A power switch to each dispenser is located in the electronics cabinet to the left of the CAT board.
Refer to the following figure.
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2 Installation
CAT board
ON / OFF
Figure 2.1: Dispenser ON / OFF Switch
2.1.5 iX R2 Board Reset Button

A reset button is located on the iX R2 board. Refer to the following figure for button location. This
may be useul while performing the initial startup of the dispenser.
reset button
Figure 2.2: iX R2 Board Reset Button
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2 Installation
2.2 Inspect Equipment

Examine the shipment immediately upon arrival to ensure no damage or loss has occurred in
transit. Make sure that all the component parts, including keys and optional equipment (if any),
are included in the shipment. Verify and save the Packing Slip, Bill of Lading, Invoice, and all other
documents included in the shipment. Damaged or lost equipment must be reported to the carrier.
Any damage or loss that occurs in transit is not covered under the Wayne Warranty.
2.3 Island Construction, Dispenser Anchoring, and Piping

Product lines must avoid the creation of vapor in the lines and deliver a minimum pressure of 25
psi at the dispenser inlet when all dispensers at the station dispensing the same product are op-
erating.
A concrete foundation must be provided for the dispenser. Do not pour concrete around product
lines or electrical conduit risers.
Anchor bolts must be installed in the island to allow the dispenser to be bolted down in accordance
with NFPA requirements. The base of the dispenser contains four bolt hole slots (5/8 inch by 2
inch) for anchoring the dispenser to the island. Use of all anchoring locations is re-commended.
Position the anchor bolts in accordance with the dimensions shown on the Installation Instruction
drawings for the applicable dispenser model located in the back of this manual.
Vertical supply risers and electrical conduits must be located per the Installation Instruction for
the appropriate model. Proper height must be maintained to avoid undue stress on the dispenser.
External parts such as pipes, nipples, and fittings that come into contact with ethanol fuel must
be ethanol-compatible and made only with Schedule 40 pipe using UL-classified Saf-T-Lok Teflon
pipe sealant.
2.4 Emergency Shear Valves
WARNING!
For remote dispensers, a UL-Listed 2 , rigidly-anchored

emergency shut-off valve must be installed, in accor-
dance with the manufacturer's instructions in each
supply line at the base of each dispenser. For a typical
emergency valve installation refer to the figure below.
Failure to install the proper emergency shut-off valve
will present a hazardous condition that could result
in serious injury.
2 "Listed" means published on a list by a nationally-recognized testing laboratory (NRTL) which is responsible
for product evaluation and is acceptable to the authority having jurisdiction. Underwriter Laboratories, Inc.
(UL) is one example of an NRTL. For more information on NRTL's, see Title 29, Parts 1907 and 1910 of the Code
of Federal Regulations, Safety Testing, or Certification of Certain Worklplace Equipment and Materials.
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2 Installation
dispenser inlet dispenser base frame

(1-1/2") anchor bolt
valve
shear point actuator
lever
top of
concrete
island
trip lever pipe plug
(pull down to for
close valve) bleeding
product
lines
product inlet
under pump cavity
Figure 2.3: Typical Emergency Valve Installation

The Emergency valve is designed to close the product line due to shock or fire. The shear section,
shown above, functions if the dispenser is knocked out of position.
Note !
The shear valve must always be at ground plane. The pedestal is considered an extension of the
dispenser, not the island.
Note !
Wayne does not supply the meter inlet pipe nipple or the union shown above.
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2 Installation
WARNING!
Installation of a rotating shear valve instead of a

rigidly-mounted shear valve will result in malfunction
and possible injury. The shear valve can not rotate in
any direction.
2.5 Vapor return piping

NFPA 30A Section 4-3-7 states that a vapor return pipe inside the dispenser housing shall have a
shear section or flexible connector so that the liquid emergency shut-off valve will function prop-
erly. Wayne’s vapor connections are secured to the chassis allowing for the use of a shear section.
Wayne dispensers provide 1" NPT pipe connections at the base of the dispenser for vapor return
connections. (See the installation foot print for location in Appendix B.) A minimum 1" riser at each
dispenser is connected to a minimum 2" return piping to the underground tank. If more than six
(6) fueling points are connected, then underground piping must be a minimum of 3". All lines should
be sloped at a minimum of 1/8” per foot (1/4” per foot preferred) from the dispenser to the tank
to avoid liquid traps. Note: There is no vapor recovery for the Ethanol product on E85 Helix dis-
pensers.
2.6 Lifting and installing dispenser

Remove the shipping carton from the dispenser and, if the dispenser is equipped with an optional
valance, survey the site to determine if it should be installed before or after the dispenser is set
on the island. Wayne recommends installing the valance after the dispenser is installed, if practical,
to protect it from installation damage. See the Valance Module drawing in the back of this manual.
Use door key to unlock and then remove the lower doors.
Install (2) eye-bolts in the dispenser top castings and lift the dispenser onto the island as per Lifting
Instructions in the back of this manual. When handling Helix dispensers, LIFT ONLY PER LIFTING
INSTRUCTIONS DRAWING contained in the appendix of this manual. Do not lift by the electronic
enclosure, nozzle boot, or any external panels.
Bolt the dispenser into place, remove the shipping discs from the meter inlets, and connect the
product piping per the appropriate Installation Instruction drawing. When installing a blending
dispenser, make sure the Lo and Hi product inlets (and, if applicable, the single product inlet) are
correctly located.
To ensure tight, leak-proof connections when making piping connections, wash all cutting oils off
the threads and use a UL-classified pipe joint sealing compound, rated for use with petroleum-
based products.
12 WM048526 Rev 02 05/2013

2 Installation
WARNING!
Explosive or flammable vapors!
Explosive or flammable vapors may accumulate

within the dispenser housing. All piping connections
in the final installation must be accurately fitted and
all threaded joints tightly made up with a Listed
gasoline-resistant pipe joint compound. Put the
compound on male threads only, being careful not
to get excess inside the pipe or fittings. Failure to
perform the above will present a hazardous condition
that could result in serious injury.
2.7 Electrical wiring
2.7.1 General
Wayne recommends employing a qualified electrician for all wiring. A hazardous liquid is being
handled, so it is important to ensure that all wiring is in accordance with the National Electrical
Code (NFPA 70) as well as all federal, state and local regulations. Note: UL requires that all electrical
connections to the dispenser be made with threaded, rigid conduit and properly sealed conductors.
Note: All dispensers and electrical connection boxes must be grounded per NFPA 70.UL
2.7.2 Dispenser to Wayne Control System interconnection

Dispenser installation wiring diagrams are provided in this manual. The system interconnection
wiring diagrams supplied are for reference purposes. Use these diagrams along with the wiring
diagrams supplied with the control system for laying out the system wiring requirements for a
new site or when making changes to an existing one.
1 Two data wires to the Data Distribution Cabinet are required for the Wayne control system
console operation.
2 Two data wires to the Site Controller Cabinet are required for dispenser card processing CAT
operation.
3 Two data wires to the Site Controller Cabinet are required for Wayne TRAC operation.
4 One ethernet cable (gas and oil resistant) is required for dispensers equipped with the IDPOS
or iX CAT option from the switch in the dispenser to the switch in the building, see Section ,
Figure 2-5 and Figure 2-6. A UL AWM Ethernet cable, Category 5 or higher, rated at least 300
V, 60 degrees C with a gasoline and oil resistant jacket may be used. The conduit in the dispenser
must be potted at the end of the installation.
Note !
When data wires are installed, only the two data wires from the Data Distribution Cabinet used
for pump control are to be terminated at the dispenser’s terminal strip. The additional data wires
should not be physically connected to the data terminals on the dispenser’s terminal strip. Instead
they should be properly terminated individually using wire nuts.
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2 Installation
Dispenser Conduit and Wiring Recommendations

Verify that 3/4 inch conduit is used and that the length of each conduit does not exceed 150 feet
from the Data Distribution Cabinet to the Dispenser. Verify the approved wireways and threaded
metallic conduit with tight connections are used, that #14 AWG 500 Volt oil and gasoline resistant
AC power wires are used as a minimum (unless local codes require #12).
Pump Relay Section (Remote)
Verify that for each product, one #14 AWG conductor is connected from the relay Select Terminal
in the dispenser to the appropriate Relay Select Terminal in the Pump Relay Cabinet. Also verify
that the Control Power neutral is wired to the Pump Relay Cabinet as shown on the Interconnection
Wiring Diagrams.
Pump Motors (Suction)
Verify that Pump Motor wiring is connected to the circuit breaker panel or in a wireway as shown
on the Interconnection Wiring Diagrams.
Power Wiring
Confirm that all 120VAC wiring for outdoor equipment (line, neutral, relay select, etc.) is 14 gauge
minimum (unless local codes call for 12 gauge), stranded, and oil and gasoline resistant.
Data Wiring
Confirm that all data wiring for outdoor equipment (communication lines) is 18 gauge minimum,
stranded, and oil and gas resistant.
WARNING!
Electric Shock Hazard!
No connections (including neutral) may be shared

between groups of dispensers. A separate Control
Power Circuit Breaker must be provided for each
group. Failure to do so may result in serious injury.
2.7.3 Full service (stand-alone) dispensers

For full service operation, make electrical connections as shown on the Installation Wiring Diagrams.
The electrical connections illustrated are typical when additional like model dispensers are used.
Data wires shown on the wiring diagram are for connecting the dispenser to the Data Distribution
Cabinet and the Site Controller Cabinet in a Wayne Control System. These data wires are not re-
quired for the full service (stand-alone) dispenser. However, the six optional data wires and cable,
whichever are applicable, should be run at initial installation if a control system or optional
equipment is being installed or may be installed in the future.
Remote dispensers require a relay to control the submersible pump motor. These relays are
available as an option with the Wayne control system. If the dispenser is not connected to a Wayne
control system, a UL Listed magnetic motor controller assembly, constructed with Potter and
Brumfield Relay No. PRD7AYO (120) or equivalent, shall be used.
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2 Installation
A maximum of 12 dispensers (24 fueling points) may be connected to a single PRD7AYO (120) relay;
other relays may have different limitations. All dispensers operating the same pump control relay
must be connected to the same circuit breaker; this may require multiple control relays for a
submersible pump.
Ensure that the submersible pump receives its power from its own separate circuit breaker as il-
lustrated in the Typical Site Wiring Diagram.
2.7.4 Multiple dispenser wiring

A primary requirement in dispenser installation wiring is to provide a means for disconnecting all
power connections, including the neutral, to the dispensers for safe shutdown and servicing of
the units. Each dispenser could be provided with a separate control Power Circuit Breaker. If this
is not desirable or practical, several dispensers can be grouped together and tied to the same
Control Power Circuit Breaker as illustrated in the Typical Site Wiring Diagram. A group of dispensers
would then consist of all the dispensers and associated Submersible Pump Control Relay coils
supplied by the same Control Power Circuit Breaker.
When more than one dispenser within the group activates the same submersible pump, the Relay
Select lines may be commoned at the Submersible Pump Control Relay Coil terminal up to a
maximum of 12 connections (24 fueling points). Where more than 12 connections activate the
same submersible pump, additional relays should be used and the contacts paralleled as illustrated
in the Typical Site Wiring Diagram.
In larger installations, dispensers can be separated into multiple groups.
2.8 Bleeding product lines (remote dispensers)
Note !
To avoid severe damage to the dispenser, all air and air pockets must be bled from the product
trunk lines before attempting to dispense product
Perform the following steps:

1 Make sure the power to the appropriate submersible pump is OFF.
2 To bleed air from a trunk line, remove the pipe plug from the safety impact valve on the dispenser
farthest from the storage tank. For pipe plug location see Figure 2-2 earlier in this section.
3 Attach a flexible hose to the pipe plug opening in the safety impact valve. Energize the appro-
priate submersible pump and allow the air to bleed out of the trunk line into a test can until
product flows into the test can. De-energize the submersible pump and replace the pipe plug.
Repeat the procedure for each product and each trunk line.
2.9 Calibration of Wayne iMeter™ Piston Fuel Flow Meters

Each meter assembly contains two meters. The WIP pulser 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 foor 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.
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2 Installation
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 !
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 tol-
erance requirements.
Note !
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.
2.9.1 Bleeding product lines (remote dispensers)
Note !
Applies to new dispensers only!
Note !
To avoid severe damage to the dispenser, all air and air pockets must be bled from the product
trunk lines before attempting to dispense product.
• Make sure the power to the appropriate submersible pump is OFF.

• To bleed air from a trunk line, remove the pipe plug from the safety impact valve on the dispenser
farthest from the storage tank.
• Attach a flexible hose to the pipe plug opening in the safety impact valve. Energize the appro-
priate submersible pump and allow the air to bleed out of the trunk line into a test can until
product flows into the test can. Turn off power to the submersible pump and replace the pipe
plug. Repeat the procedure for each product and each trunk line.
2.9.2 Dispenser purging at startup: new dispensers and/or meters only

Purge 50 continuous gallons through each meter starting at the furthest dispenser away from
the tank. Note that this will require at least a 55-gallon container. This ensures air is properly
eliminated for all piping and dispenser hydraulics prior to initial calibration. Any air in the system
will result in measurement error.
2.9.3 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.
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2.9.4 Completing the startup calibration report

The Meter Startup Report is located in the back of this manual.
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.
6 Weather conditions at the dispenser: Circle or enter the conditions that apply when the test is
being conducted.
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 possible 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 possible 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 calibration 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 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.
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2 Installation
2.9.5 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.
2.9.6 Factors that may influence calibration values

• Temperature: The properties of fuel cause it to expand and or contract as temperature changes.
Conditions where there is a difference between the metered fuel and the reference initial cali-
bration temperature 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.
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3 Startup
3.1 Initial checkout

Before applying power to the dispenser, double-check the wiring to ensure it is correctly routed
and terminated. Turn on the dispenser control power at the circuit breaker and the submersible
pump or suction pump motor circuit breakers. Verify the dispenser powers on and all lights work.
The dispenser displays will show some numbers, usually the last sale run during factory test.
The dispenser template, which configures the dispenser, has been loaded in the dispenser and
tested at the factory. The dispenser will have the necessary data such as unit prices and blend
ratios to allow the dispenser to operate in stand-alone at installation to purge product lines and
test operation. At start-up, the procedures in this section should be performed in sequential order
to ensure proper operation before the dispenser is switched over to control system operation.
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3.2 IR remote control

The Infrared Remote Control (IRC) is used to access dispenser functions and sub-functions, and
diagnostics (statistics). When held close to the infrared eye on the display board, the IRC can be
used to set unit prices, fueling point ID's, blend ratios, and read electronic totalizers. Remote control
button descriptions are given in the following table.
IRC When F - - is shown on When F 'xx' is shown When xx.xx sub-function is shown
Keys the unit price display on the unit price dis- on the unit price display
play
NEXT F00 Next higher function # Next higher sub-function level.

UP S - - (statistics mode) Next higher function # Next higher sub-function level.
DOWN S - - (statistics mode) Next higher function # Next higher sub-function level.
EN- Pressing 3 times will Sub-function level Back to function level (except after
TER exit configuration mode (xx.xx) entering new value, it displays the
without saving change)
CLEAR N/A F-- Back to function level (except while
entering new value can be used to
erase last digit typed)
# N/A N/A Must use this key to enter new data
DIG- After pressing ENTER, After pressing ENTER When clearing the display with the
ITS will take you to the will take you to the “#” key first, it will change the value
Function level of the Function level of the of the sub-function to the digits
digits entered digits entered entered after pressing ENTER
When in Statistics Mode (S - - or S “xx” on Unit Price Display, the above commands work the same
way.
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3.3 iX Pay™ Secure Payment Platform Configuration

(SPM) EPP U.S. version 2.2.20.0.
Connection details of the iX Pay Secure Payment (R2) board and the SPM keypad are given in Fig-
ure 3.1.
The board is installed on side A of the dispenser. A single iX R2 board controls both SPMs on a
dual-sided dispenser with QVGA displays and softkeys.
iX Pay Secure Payment (R2) production dispensers are pre-configured at the factory. The configu-
ration 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 performs 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 Diag-
nostic 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 following pages.
iX Pay Secure Payment (R2) production dispensers are configured for a single iX board, dual-sided,
and QVGA displays with softkeys enabled. For any other configuration, new software must be
obtained from ASONet.
J37
J29 J28 J27
J36 J39 J30 Ethernet
USB USB USB
Port
J10 J14 Printer

Audio Out (if app)
J7
J23
QVGA Side J41
B Ovation LX Lights
Side A
J32
J42
Ovation LX Lights
J24 Side B
QVGA Side A J6
TX RX
J11 LEDs
J15
SW2 J3 J2 CR21 J13 J12 J21

J46 J1 SW1
CAN CAN Bus J17
Power Debug Reset
Bus RS-485
LED Port Button
Termination
Figure 3.1: iX Pay (R2) Board Layout
3.3.1 Initial Configuration Procedure

Follow the procedure below to startup iX Pay Secure Payment (R2) dispensers, starting on SIDE A.
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1 At power up the following screens will be displayed.
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2 Hold down the #2 softkey when the Temporarily Out of Service screen is displayed. It is displayed
for only 5 seconds. The ‘2’ softkey is the second key to the left of the display. NOTE: If you miss
the screen, reboot and try again.
1 5
# 2 Softkey 6
3 7
4 8
3 Select YES if the dispenser is a Helix dispenser model or has a Compact Payment Terminal
(CPT).
4 Adjust the contrast if needed.
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5 Choose SINGLE or DUAL-SIDED.
6 Enter the fueling point (terminal) number.
7 Select the appropriate Side (A or B).
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8 Verify the date and time. Correct if needed.
Note !
Since the iX Pay (R2) board 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.
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11 Enable Function and Softkeys as necessary.
12 Enable pump iSense as necessary.
13 Select Fixed length as necessary.
14 Select YES if the dispenser is using a Contactles Card Reader. Note that a Bill Acceptor and a
Contactless Reader cannot be attached and configured at the same times. These two devices
share the same COM Port. Answering YES to this prompt 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.
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15 Select YES if the dispenser is using a Zebra printer, otherwise, select NO.
16 The printer will print a receipt. Select the value shown on the receipt.
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17 Select YES to Remove Receipt Header? prompt. (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.
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20 On the keypad, enter the terminal number for the opposite side and then press the ENTER key.
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 show HEX values. See below
for displayed numbers.
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3 Startup
Non-numeric keys will show HEX values. See below for displayed numbers.
0x03 0x43
0x02 0x42
0x01 0x41
0x00 0x40
23 Select Pump Test as necessary.
24 The following screen is displayed if YES was selected for the pump test.
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25 Scan a Bar Code if dispenser is equipped with a barcode scanner.
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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 Secure 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: Breached card reader.
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No light: Breached SPM or cable to card reader discon-

nected.
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 X at the end of this section.
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.
29 At this time the system can be placed into OPERATION.
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30 Enter access code.
31 Select READY.
32 Press CANCEL.
33 The system is now in Operation mode. Press CANCEL to finish and wait for the online POS
prompt. See Step 34.
Note !
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.
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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
System Info Screen
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Dispenser Side
CAT address
(terminal ID) Battery Mode: logs
Software ID each time
4
NOTE : Software ID
dispenser power is
does not show up on off
config report. Run the SPM mode
diagnostic test to print
version. Erase Reason
Serial No. Battery
Authentication
Card Reader Type:

(TTL or Secure)
Time
Figure 3.2: iX Pay Configuration Report
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3.4 Set clock function (F 02)

Function F02.00 displays the time (HH.MM), F02.01 is the date (MM.DD) and F02.02 is the year
(YY.YY)
IRC Command Volume Dis- Status Display Unit Price

play Display
Press either ENTER, 1, or 2, de- PASS 1

pending on access level
Type the corresponding pass- PASS 2
word
Press ENTER
Type the password again iGem software Date F--
Press ENTER setting
Type 2 ------ F 02
Press ENTER
Press ENTER ------ Time in HH.MMforma] 2.00
(if time is correct skip to step
8)
Press # Time in HH.MMformat 2.00
Type the current time in 24-hour ------ Entered time in HH.MM for- 2.00
format of HH.MM mat
- Press ENTER
Press NEXT ------ Date in MM.DD format 2.01
(if date is correct skip to step
11)
Press # date in MM.DD format 2.01
Type the current date in the for- ------ entered date in MMDD for- 2.01
mat of MMDD mat
- Press ENTER
Press NEXT ------ year in YYYY format F 02
(if year is correct, skip to
step 14)
Press # year in YYYY format F 02
Type the current year in the for- ------ current year in YYYY format F 02
mat of YYYY
- Press ENTER
Press ENTER ------ F 02
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3.5 Logical nozzle / hose positions

The physical number of hoses on one side of the dispenser is not the same as the number of
electronic hose positions on that side. Unit prices and blend ratios are set in electronic hose position
or logical nozzle order. The H(N/L)34-32 model blender has 2 hoses per side and 3 inlets, but 4
grade selects/logical nozzles. Logical nozzles are assigned positions 1 through 7, depending on
the dispenser model as shown in the following table.
Three product MGD models have one hose per side and three logical nozzles, which are positions:
1, 2, and 3. For non-blending models, these products are shown as the X, Y, Z products in the table
below.
Logical nozzle positions for the Helix models are listed below.
Helix model # be- Dispenser descrip- N=7 N=6 N=5 N=4 N=3 N=2 N=1
gins with tions
H(N/L)11-11 1 Hose X
Non-blender
H(N/L)22-22 2 Hose Y X
Non-Blender
H(N/L)23-21 1 Hose LO BL HI
Blender
H(N/L)23-22 2 Hose LO BL HI
Blender
H(N/L)24-21 1 Hose LO LO-BL MID- HI- HI
Blender BL BL
H(N/L)25-21 1 Hose LO LO-BL MID- HI- HI

Blender BL BL
H(N/L)33-31 3 Hose Z Y X
Non-Blender
H(N/L)34-32 2 Hose LO LO-BL HI-BL HI
Blender
H(W/L)22-22 2 Hose Y X
Non-Blender
H(W/L)23-21 1 Hose LO LO-BL BL HI S
Blender
H(W/L)24-21 1 Hose LO LO-BL MID- HI- HI
Blender BL BL
H(W/L)25-21 1 Hose LO LO-BL HI- HI

Blender BL
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Helix model # be- Dispenser descrip- N=7 N=6 N=5 N=4 N=3 N=2 N=1
gins with tions
H(W/L)33-31 1 Hose Z Y X
Non-Blender
H(W/L)33-33 3 Hose Y X
Non-Blender
H(W/L)34-32 2 Hose LO LO-BL HI-BL HI
Blender
H(W/L)34-34 4 Hose LO LO-BL BL HI S
Blender
H(W/L)44-42 2 Hose W Z Y X
Non-Blender
H(W/L)44-44 4 Hose W Z Y X
Non-Blender
H(W/L)45-43 3 Hose LO BL HI S2 S1
Blender
1
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3.6 Setting Unit Prices

The procedure below is used to set the dispenser unit prices when operating in stand-alone mode
or when communications with the POS system is disabled. When communications with the POS
system is enabled, the POS prices will override prices that were manually input at the dispenser.
To set unit prices on side 1 and side 2, functions F 03 and F 04 are accessed using the remote
control (IRC). Credit prices on side 1 are set using sub-functions F03.0N while cash prices are set
using sub-functions F 03.1N. N is the nozzle number as shown in Logical nozzle / hose positions.
For side 2, the corresponding sub-functions are F 04.0N and F 04.1N, respectively.
Perform the steps listed in the following table to set prices at the dispenser.
IRC COMMAND SALES DISPLAY VOLUME DISPLAY UNIT NOZZLE

PRICE DIS- #
PLAY
LOAD CREDIT PRICES - SIDE 1

Press ENTER PASS 1
Type the corresponding PASS 2
PASSWORD
Press ENTER
Type the PASSWORD again iGem software Date F --
Press ENTER version
Type 3 ------ F 03
Press ENTER, ENTER
Press # ------ Existing Credit Price 3.01 Noz 1
Type numbers ________________
ENTER New Credit Price
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
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3 Startup

PRICE DIS- #
PLAY

Type numbers ________________
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
LOAD CASH PRICES - SIDE 1
Type numbers ________________
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
Type numbers ________________
NEXT
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3 Startup

PRICE DIS- #
PLAY

Type numbers ________________
NEXT
Type numbers ________________
NEXT
ENTER ------ F 03
Press UP ------ F 04
Proceed with Credit and Cash Prices for Side 2 in F04 then SAVE CHANGES as follows:
Type 0 ------ F 00
ENTER
ENTER ------ 1 0.00
Press # ------ 3 0.00
Type 3
ENTER
ENTER CHANGE STORED
ENTER Last Sale Last Volume amount New Price
Amount
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3.7 Setting Blend Ratios

The procedure below is used to set the dispenser blend ratios. When enabled, the POS system
verifies and confirms that its blend ratio data corresponds to the manually set blend ratios. The
POS system will not allow fuel to be dispensed if this set of numbers do not match.
The dispenser template defines a dispenser model and assigns logical nozzle numbers to the hose
positions as shown in Logical nozzle / hose positions. Once this is done, the function F18 is accessed
to set the blend ratios, using the remote control interface. The sub-function F18.1N, where N is
the logical nozzle number, is used to set the blend ratios for side 1 and the sub-function F18.2N
is used to set the blend ratios for side 2. Active values of N are given on page 38.
Using the remote control, perform the steps in the following table to change and save the blend
ratios.
Note !
See table in the Setting Unit Prices section for models and nozzle positions.
IRC COMMAND SALES DIS- VOLUME DISPLAY UNIT NOZ-

PLAY PRICE DIS- ZLE
PLAY
SIDE 1
Press ENTER PASS 1
PASSWORD
Press ENTER
Type the PASSWORD again iGem soft- Date F --
Press ENTER ware version
- Type 18 ------ F 18
- Press ENTER, ENTER
Press # ------ - Existing blend ratio 18.11 Noz 1
Type blend ratio -New blend ratio
Press ENTER
Press NEXT
Press # ------ -Current 2 blend ratio 18.12 Noz 2
Press ENTER
Press NEXT
Press ENTER
Press NEXT
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3 Startup

PLAY PRICE DIS- ZLE
PLAY

Press ENTER
Press NEXT
Press ENTER
Press NEXT
Press ENTER
Press NEXT
Press ENTER
Press NEXT
SIDE 2
Press ENTER
Press NEXT
Press ENTER
Press NEXT
Press ENTER
Press NEXT
Press ENTER
Press NEXT
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PLAY PRICE DIS- ZLE
PLAY

Press ENTER
Press NEXT
Press ENTER
Press NEXT
Press ENTER
Press NEXT
ENTER ------ F 18
Type 0 F 00
ENTER
ENTER ------ 1 0.00
Press # ------ 3 0.00
Type 3
ENTER
ENTER change
stored
Last Sale Last Volume Amount Current
Amount Unit Proce
Example: Changing the Blend Ratio

1 When the desired logical nozzle is shown on the unit price display, enter the desired value of
the blend ratio by using UP and DOWN keys on the remote control interface or by typing the
# sign followed by the value of the blend ratio, followed by ENTER. For example, to change the
value of the blend ratio from 101 to 89, press the DOWN button until 89 appears on the price
display, then press ENTER, or type in #89, ENTER.
2 Continue until all the blend ratios are entered for Side 1 and Side 2.
Note !
The volume display will indicate the value of the blend ratio corresponding to logical nozzle
#1(N=1). If there is no data for this logical nozzle, the number “101” will be displayed.
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3 Startup
For reference, the following is a 50% blend ratio setting for a single hose blender, Helix model
B12/3 xxxx. Any unused position has to be set to 101 not 0.
Side 1 Side 2
18.11 = 101 18.21 = 101

18.12 = 101 18.22 = 101
18.13 = 100 Super (Hi Feedstock) 18.23 = 100
18.14 = 101 18.24 = 101
18.15 = 50 Plus (Blend BL) 18.25 = 50
18.16 = 101 18.26 = 101
18.17 = 0 Regular(Lo Feedstock) 18.27 = 0
Typically, stations sell the low and high grades at zero and 100 percent ratios and may sell the
middle grade at 35 percent or some other intermediate value between 0 and 100. On the above
model, the technician would need to change only sub-functions 18.15 and 18.25 to the inter-
mediate value.
As a reminder, always get the blend ratios from the station owner to avoid any confusion over
which values to use.
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3.8 Setting the Fueling Point ID (FPID)

The procedure in the following table is used to set the dispenser fueling point address. The dispenser
FPID should be entered and saved before control is transferred to the POS system.
Functions F05 and F06 are accessed to set the FPID on Side 1 and Side 2, respectively. To set the
FPID, the desired FPID must be entered and saved.
IRC Command Sales Display Volume Display Unit Price Dis-

play
Set Fueling Point Address Side 1 (Serial Filling Mode Only)

ENTER PASS 1
PASSWORD
Press ENTER
Type the PASSWORD again (iGem software [date] F--
Press ENTER version)
Type 5 ------ F 05
Press ENTER
Press ENTER ------ Fuel point address 5.00
for Side 1 in X for-
mat
Type desired FPID ------ New fuel point ad- 5.00
Press ENTER dress for Side 1

Set Fueling Point Address Side 2 (Serial Filling Mode Only)
Type 6 ------ F 06
Press ENTER
Press ENTER ------ Fuel Point Address 6.00
for Side 2
Type desired FPID # ------ New Fuel Point Ad- 6.00
Press ENTER dress for Side 2

Exiting and Saving the Configuration
Type 0 ------ F 00
Press ENTER
Press ENTER ------ 1 0.00
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3 Startup
IRC Command Sales Display Volume Display Unit Price Dis-

play
Press UP key to exit (example ------ 3 0.00

shown is 3, exit and save)
* 1 = Do not exit and do not save
changes
* 2 = Exit and do not save
changes
* 3 = Exit and save changes
Press ENTER
Press ENTER CHAnGE StorEd Current Price
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3.9 Authorizing the Dispenser

The dispenser must be authorized before it will dispense product.
The dispenser filling mode is set in programming function F01. In stand-alone mode (not connected
to a control system), the dispenser is always authorized unless the dispenser is equipped with the
(optional) Authorize keyswitch on the bezel. This momentary contact keyswitch can be used for
one-time authorizations.
When connected to a control system, the system programming determines authorization.
Note !
At Startup, the local Authorize switch jumper should be removed as explained in the Disable Stand-
alone Operation section.
3.10 Initial Delivery

To dispense product from a newly installed dispenser, make sure unit prices and blend ratios are
set (as previously described) and proceed as follows:
1 Authorize the dispenser.
2 Remove the nozzle, start the reset sequence and observe the reset cycle; make sure all sales
display and unit price display elements operate.
3 Check that when reset is started, the correct submersible pump motor is activated, and at the
end of the display reset (approximately three seconds) the solenoid valve(s) opens (listen for
the audible click of the valve(s).
4 Note !
Make sure the product lines are properly bled before dispensing any product through a remote
dispenser. Make sure suction pumps are primed before dispensing any product through a
suction pump.
After verifying air is bled properly from each trunk line, slowly dispense product through each
dispenser until free of air. Dispense enough product through each hose of each dispenser to
ensure the dispenser and the lines are free of air, before checking the meters.
5 For dispensers equipped with Wayne Vac, verify that the correct vacuum pump motor is running
when dispensing product. Verify by checking that air is being drawn through the vapor return
hole(s) in each nozzle spout. Also, see Testing Procedures manual, p/n 917947.
3.11 Disable Stand-Alone Operation

Once the dispenser is switched over to the POS control system, standalone operation should not
be required. As an extra security measure, the jumper that enables stand-alone operation should
be removed. The jumper is located on the sales display display board as shown in Figure 3.3.
1 Access dispenser Filling Mode function F01 and set sub-function to 1.01 for serial mode.
2 Open the service door.
3 See Figure 3.3 for location of the Local Authorize jumper (J6) on the Unit Price Display board.
4 Remove the J6 jumper.
5 Close and lock service door.
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J6 jumper
Figure 3.3: Sales Display with J6 Jumper
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3.12 Electronic Totalizer Readings
3.12.1 Totalizer readings by hose (product) position

Each fueling point of the dispenser maintains electronic totalizers for both money and volume.
Dispensers equipped for Cash/Credit operation also keep separate cash and credit totalizers by
grade. Rather than mechanical totalizers, each position has an electro-mechanical totalizer for
each feedstock. See Figure for EMT locations.
Electronic totals are stored in statistical functions that are accessed using the IR remote control.
The totals for Side 1 are stored in statistical function S01 and those for Side 2 are stored in statis-
tical function S02. The associated sub-functions take the format TN, where T is the type of totals
defined below and nozzle postion N depends on the dispenser model as defined in Table 3-3.
T = totals type
1 = Volume
2 = Total Money
3 = Credit
4 = Cash
5 = Serial Filing Mode Count
6 = Stand Alone Mode Filling Count
For example, volume totals by hose position for Side 1 are accessed by examining the contents
of statistical function S01.1N while money totals are obtained by accessing S01.2N, where N is
the hose position number. For Side 2, the corresponding functions for these variables are S02.1N
and S02.2N, respectively.
To read the electronic totalizers, perform the following steps using the IR remote. Bold type denote
remote control function; italicized type represents dispenser response:
Accessing the Totalizer Sub-function
1 Press ENTER
2 Enter PASS 1 (enter password)
3 Enter PASS 2 (enter password)
4 Press ENTER. The unit price display will show F
5 Press either UP or DOWN to enter the statistics viewing mode. The unit price display will show
S— (indicating a number needs to be selected)
6 Press 01 to access S01
7 Press ENTER. The unit price display will show S01 indicating the function has been accessed.
8 Press ENTER to access the sub-functions of S01. The unit price display will show 1.11 and the
sales display shows the side 1, volume for nozzle position 1.
Consecutive presses of NEXT will advance to the next sub-function, incrementing the value of N
by (01). For example, pressing NEXT advances the statistical function to S01.12 and the unit price
display will show 1.12. The least significant six (6) digits of the data value appear on the volume
display, while higher order non-zero digits of the data value, if present, appear on the money display.
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3 Startup
3.12.2 Totalizer volume readings by meter position

Meter volume totals are stored in statistical functions that are accessed using the remote control.
The totals for Side 1 are stored in function S05 and those for Side 2 are stored in function S06. The
value of the meter totals are stored in the sub-functions that take the format .M0, where M is the
meter number. For example, M=5 for the high feedstock iMeter located on Side 1 of a remote series
blender. For Side 2 of the same meter, M=1.
Note !
There is no relationship between meter position and hose position. For example, in Table 3-3, po-
sitions N=1 and N=5 are not the high feedstock of a remote series blender used in the example
above.
Meter electronic totalizers are read by entering the Maintenance Mode and accessing the correct
function and associated sub-functions. Perform the following steps using the remote control. Bold
type denote remote control function; italicized type represents dispenser response.
Accessing the Meter Volume Totalizer Sub-function for Side 1:
• Press ENTER
PASS 1 (enter password)
• Press ENTER
PASS 2 (enter password)
• Press ENTER. The unit price display will show F
• Press either UP or DOWN arrow to enter the statistics viewing mode. The unit price display will
show S— (indicating that a number needs to be selected)
• Press 05 to access S05
• Press ENTER. The unit price display will show S05 (indicating that the statistical function has
been accessed)
• Press ENTER to access the sub-functions of S05. The unit price display will show 5.10 (note here
that M=1)
Consecutive pressing of NEXT will allow access to the next sub-function, incrementing the value
of M by (.1). For example, to access S05.20, press NEXT. The unit price display will show 5.20. The
value of the meter volume totals is shown in a format such that the least significant six (6) digits
of the data value appear on the volume display, while higher order non-zero digits of the data
value, if present, appear on the money display. Leading zeros appear as blanks.
Quick Exit
1 Press the CLEAR key until the unit price display window shows S - - .
2 Press ENTER three times. This causes the maintenance mode task to immediately terminate.
3.12.3 Electro-mechanical totalizer operation

Totalizers are optional on Helix dispensers. Electro-Mechanical totalizers are located on the junction
box side of the dispenser. There is one totalizer for each meter. The totalizer positions on the bezel
relate to the meter position numbers. The physical position of the totalizers, left to right, on the
bezel represent meter positions.
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3 Startup
The totalizer shows seven digits and reads in whole units (gallons or liters). Fractional amounts
that are left over from a previous sale are stored in the dispenser computer. When the next sale
of the same product ends, if the fractional amounts from the new sale and previous sale(s) com-
bined are one (1) whole unit or greater, the Electro-Mechanical totalizer is adjusted one whole in-
crement; i.e., if five consecutive sales end with a fractional amount of .2, the Electro-Mechanical
totalizer will not account for the fractions until after the fifth sale.
3.13 Nozzle Boot Switch Check

In the Helix style nozzle boot, a proximity switch and a magnetic actuator are used for nozzle
on/off operation. The proximity switch is attached to the back of the nozzle boot casting. The
magnetic actuator is located inside the spring-loaded flipper, which is installed from the top front
of the boot casting. When the nozzle is removed, the flipper rotates the magnetic actuator and
aligns the actuator with the proximity switch, turning the switch on. There is no adjustment for
the switch.
Check the operation of the nozzle switch as follows:
1 Authorize the dispenser and remove the nozzle from the nozzle boot to make sure the switch
turns on. An on switch will be indicated by the lighted Push-to-Start buttons and the unit price
displays blinking.
2 Insert nozzle slowly into the nozzle boot and check that the switch turns off. An off switch is
indicated by the lighted Push-to-Start buttons turning off and the unit price displays stop
blinking.
3.14 Annunciator Operation Check

Check that the annunciator is operating properly on each side of the dispenser. When pressing
the keys on the CAT keypad or the Push-to-Start/Grade Select buttons on the bezel, you should
hear the annunciator beep.
3.15 iX PAY Secure Payment

Follow the procedures in the Secure Payment Module (SPM) Startup and Service manual (p/n
W2940014) for diagnostic test, configuration, and putting the SPM into operation. The iX Pay Secure
Payment Start-up procedure is located in a previous section in this manual.
3.16 Audit Reporting Display Mode (Weights & Measures)

(For Weights and Measures Officials & Service Purposes Only)
On the computer the Weights and Measures audit trail is accessed by the use of a hand held remote.
By entering the Weights and Measure mode, one can view both the blend ratio audit trail and
volume metering unit change counter required by Weights and Measures.
The Weights and Measures mode is side specific, therefore, it shows the blend ratio logs and volume
metering unit logs for the side that your are facing.
Entering into this mode occurs via the remote control. Remotes are available at the station. Both
the audit trail data and gallons to liters conversion data is obtained by the use of the hand held
remote. To use the remote, point at the sales display near the center of the area where the Totals
and Volume valves are displayed. Keep the remote within 12 inches of the main sales display for
proper operation.
To enter the Weights and Measures mode perform the following:
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3 Startup
1 Press ENTER and then press CLEAR twice.

If you do not press another button in 20 seconds or there is no interaction from the remote,
the computer will step through the values.
2 The sales display will show bLEnd rAtioS with the current blend ratios for all blended products.
3 Press NEXT to view the Blend Ratio Change Counter mode.
4 Pressing NEXT will allow you to toggle through each blend ratio change counter and pressing
NEXT button again will enter into the View Volume Metering Unit Change Counters mode.
5 The sale display will show n, where n equals the Unit Change Event Number.
6 The volume display contains the metering unit that it was changed to with the following de-
scription:
LitErs Liters volume unit
US GAL U.S. Gallons volume unit
IP GAL Imperial Gallons volume unit
7 Press CLEAR and then ENTER three times to go out of the Weights and Measures mode.
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4 Operation
4.1 How to get service on your dispenser

Trouble with operation of the dispenser should be referred to your local Wayne authorized service
personnel or call the Wayne Help Desk at 1-800-289-2963.
Note !
Any modification, repair, or service to the dispenser not in accordance with the original design
may invalidate compliance with the equipment certifications such as CE Marking, UL, etc. Consult
manufacturer as necessary.
4.2 Basic dispenser requirements

Unit prices must be set and the dispenser must be authorized for the dispenser to operate. If the
dispenser is connected to a control system, each dispenser must have a unique fueling point
number set for communication with the system as discussed in Section 3.
If the dispenser is connected to a 2400 MCS, Wayne Plus or Nucleus POS system and you want to
operate the dispenser in the stand-alone mode, independently from the control system, perform
the following steps:
• Move the Authorize switch on the dispenser to the full service position.
• If the dispenser is not equipped with the Authorize switch, jumper J7 on the Unit Price Display
board must be installed.
• Access function programming and set the Filling Mode to Stand-alone, as explained in the
Stand Alone Operation section below.
4.3 Operating the dispenser

1 Authorize the dispenser via the Authorize switch on the dispenser or via the control system.
2 Remove the nozzle from the nozzle boot for either the blended hose or the single product hose.
The nozzle boot switch will turn on. The unit price displays of the product(s) not selected will
show dashes. If the blending hose is selected, the lighted grade selection buttons for the
blending products will blink until a grade selection button is pressed; if the single product hose
is selected, the lighted grade selection button for the single product will blink until it is pressed.
3 Push a grade selection button for the desired product to select one of the products from the
blending hose, or the one product from the single product hose. The dispenser will reset and
prepare for delivery. The sale display will show all eights, then blanks, then the money and
volume portion of the display will reset to zero. The unit prices not selected will be blank or
show dashes. The grade selection button that was pressed will be steadily lit; the others will
be dark. The correct submersible pump(s) will start at the beginning of the reset cycle and the
solenoid valve(s) will open approximately three seconds later. Product selection can be changed
any time before product flow is sensed by the computer.
4 Dispense product. (Pressing the optional Stop button will stop product flow only. The nozzle
boot switch must be cycled and the dispenser must then be reset before that side of the dis-
penser can continue operation.)
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4 Operation
5 Return the nozzle to the nozzle boot. The nozzle boot switch will turn off; the sale will be complete
and ready to pay.
Note !
NFPA 30A requires the dispenser to be “manually activated.” This requires a separate intentional
operation (Push to Start, Cash/Credit selection, or grade selection) after the nozzle is removed
from its hang up position.
4.4 Restarting after power failure or shutdown

After loss of power, the display accurately displays the amount of the sale, in money and volume,
for approximately 15 minutes. When power is restored, all sales information returns to the displays.
Any sales in progress will be ended; old sales should be paid and the dispenser reauthorized if
more product is to be dispensed.
If the dispenser does not operate properly when power is restored (does not deliver product or
does not reset), record both the money and volume shown on the display (so sale can be paid)
and perform the following:
1 Ensure all nozzles are properly seated in the nozzle boot.
3 Remove the nozzle from the nozzle boot. The dispenser should operate normally. If the dispenser
does not resume normal operation, try cycling power as described in the next section.
4.5 Cycling power to clear faults

If a fault in the dispenser is detected by the computer, an error message will be displayed in the
sale display as described in Section 4.7. Record the displayed error message. It may be possible
to restart the dispenser by the following sequence:
1 Ensure all nozzles are properly seated in the nozzle boot(s).
2 Turn the control power circuit breaker off for approximately five seconds; the dispenser annun-
ciator will sound. Turn the control power circuit breaker on; the dispenser annunciator will
sound again.
4 Remove the nozzle from the nozzle boot. The dispenser should operate normally.
If it is not possible to restart the dispenser using this procedure, or if an error message continues
to be displayed, consult appropriate service personnel. Be certain to give the service personnel
the amount at which the dispenser stopped and the exact error message given on the sales display.
4.6 Error codes

Computer error codes can be displayed on the side of the dispenser where the error occurred by
accessing sub-functions S21.XX for Side 1 and S22.XX for Side 2, where XX is between 01 and 50
and represents the error/events records maintained by the computer program - with 01 being
the most recent. The computer can store up to 50 errors per side, continuing to store errors beyond
the 50th by cycling the error buffer with new errors inserted at the top of the buffer. When this
happens, an error is deleted at the bottom of the buffer for every new error that is inserted in the
top of the buffer. Only the last 50 errors are stored.
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4 Operation
Errors are displayed in an alternating 2-page format. Information in the error pages is given below.
Page 1 error information page 2 error information
HH.MM MM.DD.YY
CC.DD.NN C
Where: Where:
HH = hour MM = month
MM = minute DD = day
CC = error code YY = year
DD = device number C = filling count
NN = logical nozzle number
The complete description of the error codes is given in the Helix Service manual.
Computer errors are read by entering the Maintenance Mode and accessing the correct statistical
function and its sub-functions. Perform the following steps using the remote control. Bold type
denote remote control function; italicized type represents dispenser response.
Accessing the error code Sub-function
1 Press ENTER
2 PASS 1 (enter password)
3 Press ENTER
5 Press ENTER. The unit price display will show F
6 Press either UP or DOWN to enter the statistics viewing mode. The unit price display will show
S— indicating that a number needs to be selected.
7 Press 21 to access S21 (error data for Side 1 or A which is the junction box side)
8 Press ENTER. The unit price display will show 21.01, the first and most recent error data for
Side 1. The data will be displayed in the 2-page format described earlier, in an alternating se-
quence, at a 1 second per page rate.
9 Pressing NEXT accesses 21.02 and the display shows information for the second error logged.
By pressing NEXT, the error buffer can be viewed completely.
10 To exit, press CLEAR, then UP or DOWN. The unit price display will show S—.
11 Press ENTER three times to exit to the normal display.
4.7 Resetting after all stop

This section applies to models connected to a Wayne Control system. Pressing the All Stop key on
the 2400 MCS or Wayne Plus or Nucleus sends a signal to the dispenser computer to interrupt
product flow. To resume product flow:
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4 Operation
• 2400 MCS - All of the unpaid/stopped indicators will be illuminated on the 2400 MCS console.
Press Clear until the console display is totally blank. Press Pump Start. At this point all un-
paid/stopped indicators will go out and fuel flow may resume.
• Wayne Plus - All fueling point numbers will be shown in reverse index (light fueling point numbers
on a dark background) on the Wayne Plus. Press 0, Pump #, and Pump Start. At this point all
operational fueling points will be shown in normal format (dark fueling point numbers on a
light background) and fuel flow may resume.
• Nucleus - All fueling point numbers will be shown with the STOP sign. Press the ALL START key.
At this point all the fueling points will show the gas pump icon and all or each can be authorized.
4.8 Stand-alone operation
Note !
All nozzles must be hung up before performing the following procedure.
The dispenser may be placed in stand-alone operation - not operated by a control system. To set
the dispenser in stand-alone, the correct function and its corresponding sub-function must be
accessed. Next, the filling mode is changed to its new setting and the data is saved. To access the
desired sub-function, the following steps must be performed using the remote control. Bold type
denote remote control function and italicized type represents dispenser response. NOTE: See ad-
ditional requirements for standalone operation in Appendix C.
Accessing the filling mode Sub-function
1 Press ENTER
3 Press ENTER
5 Press ENTER. The unit price display will show F— , indicating that it needs a function number
to proceed)
6 Press 01 to access F01
7 Press ENTER. The unit price display will show F01, indicating that the function has been accessed)
8 Press ENTER to access the sub-functions of F01. The unit price display will show 1.01 and the
volume display will show a 1 indicating that the dispenser is in serial filling or that the dispenser
is being controlled by the site controller via serial link.
9 Press UP to increment the value of function 1.02 by unity, followed by ENTER, or press # and
type 2 followed by ENTER (here 2 means that the filling mode is Stand-alone Mode, dispenser
not supervised by site controller).
Saving the new setting
1 Press ENTER. The price display will show “– – – – – –“, the volume display will be blank and the
unit price display will show the last sub-function accessed.
2 Press 00 (to access F00)
3 Press ENTER. The unit price should now display F00, the price display will show “– – – – – –“ and
the volume and the volume display will be blank.
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4 Operation
4 Press ENTER and the volume display will show a 1.

5 Press UP twice to change the value in the volume display from 1 to 3.
6 Press ENTER. The volume display should show a 3.
7 Press ENTER
8 CHANGE STORED should appear on the display momentarily. The display returns to normal in
a few seconds.
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5 Maintenance
5 Maintenance
Note !
To prevent damage to components located in the hydraulic cabinet, dispenser doors should be
in place during rainy and/or icy conditions.
5.1 Hose and Hose Retractor
Note !
Never re-install a broken break-away valve.
NFPA code requires that a Listed emergency breakaway device designed to retain liquid on both
sides of the break-away point, must be installed on each hose dispensing Class liquids; these devices
must be installed and maintained per the manufacturer's instructions. Refer to your state and local
coderequirements that apply to your installation.
Note !
On dispensers equipped with the hose retractor option, the hose clamp must be mounted upstream
of the break-away device to avoid damage to the dispenser in the event of a drive-off.
The combined hose, break-away, and whip maximum lengths are listed in the following table:
Crossover type Loopback type Loopback type

1 hose per side 1 hose per side 2 hoses per side
14 ft
(4.27 m)
Non-vapor 3/4 in 10 ft 10 ft
(.016m) (3.05 m) (3.05 m)
Non-vapor 5/8 in 14 ft 14 ft
(.019 m) (4.27 m) (4.27 m)
5.2 Filter / Strainer - Remote

The filter should be changed and the strainer should be 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 that is required.
Before removing the filter, trip the impact 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 below,
the new funnel catches fuel that is spilled and will properly drain it into a container. Place a con-
tainer under the funnel spout when changing the filter.
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5 Maintenance
The strainer is located inside the casting and held in place by the filter. Place a suitable container
below the 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. Re-install strainer
and a new filter.
To install the new filter, first apply a thin coat 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 sub-
mersible 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 op-
eration in order to ensure proper operation.
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.
Note !
Replacement fuel filter should be UL-recongnized. The recommended gasoline and ethanol fuel
filters are rated at 10 micron.
NOTICE!
Turn power off!
Before removing the filter and strainer, turn the

power to the dispenser and submersible pump(s) OFF
and close the emergency shut-off valves on the dis-
penser being serviced. Failure to do so may result in
a hazardous condition that can result in serious injury.
Figure 5.1: Remote filter
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5 Maintenance
5.3 Dispenser Cleaning

Dispenser cleaning should be done frequently and in the manner outlined below. We cannot stress
enough that regular care of the dispenser is the most important element of the cleaning procedure.
It prevents dirt and liquids from permeating the surface materials and forming stains that can
only be removed with more abrasive and aggressive cleaning methods.
Note !
Do not use pressurized water (even from a garden hose) to wash or rinse off a dispenser. Under
no circumstance should power washers be used to clean a dispenser. This can force water into
the electronic head and cause damage to the electronic components in the dispenser rendering
it inoperative.
Do not use all-purpose cleaners.
Do not use gasoline or other petroleum based products to clean the dispenser.
5.3.1 Painted Surfaces

Wayne uses automotive grade paint on all painted surfaces of our dispenser. As such, they can
be maintained in the same manner as one would maintain a personal vehicle. The cleaningn
process level for all Wayne dispensers is based on the amount of dirt or stains on the dispensers.
We recommend starting with level one and moving to the secornd and third levels only as neces-
sary.
5.3.2 Dispenser Cleaning Process

Wayne recommends using one of the cleaning levels listed below for maintaining dispensers. As
with maintaining any painted surface, the climate and surrounding environment will be a factor
in how often the dispensers will require cleaning.
There are three levels in the cleaning process. The first level describes the standard cleaning process
for dispensers. Levels two and three describe the process for cleaning dispensers that have per-
sistent and stubborn stains. Wayne strongly recommends to begin cleaning dispensers using the
level one process. If stains are still present, it may be necessary to move to level two or three, de-
pending on the severity of the stains.
• Level One
The first step should be to wash the dispenser using a clean, non-abrasive cloth, warm water,
and a mild household cleaner. Dishwashing liquids with degreasing agents work well to remove
most of the dirt that accumulates on the dispenser.
After the above cleaning process, be sure to wipe down the entire dispenser with a clean cloth
and clean water. Cleaning residue left on the dispenser will actually attract dirt and lead to a
graying effect.
• Level Two
The second step, aimed at removing persistent stains, is to use a more aggressive, non-abrasive
household cleaner or non-abrasive industrial cleaners.
After cleaning, be sure to wipe down the entire dispenser with a clean cloth and clean water.
• Level Three
The third step, only for the most stubborn stains, is to use mildly abrasive cleaners. After
cleaning, be sure to wipe down the entire dispenser with a clean cloth and clean water.
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5 Maintenance
Periodic waxing of the dispenser surfaces is essential to maintain the original finish and inhibit
corrosion. Painted surfaces should be waxed with an automotive wax or polish.
5.3.3 Glass and Clear Plastic Surfaces

Glass and clear plastic surfaces can be cleaned as in the first step. A household glass cleaner can
also be used. It is important that nothing abrasive is used on these surfaces. Please use extra
caution during levels two and three cleaning to avoid contact with display windows. Should the
more aggressive cleaners come in contact with the displays, please wash with water immediately.
5.3.4 Stainless Steel Surfaces

Exposure to contaminants can cause a discoloration of the stainless steel panels. If the discoloration
persists after washing as instructed above, the use of an abrasive powder cleaner is very effective
in restoring the original shine. Always rub in the same direction of the brush finish on the metal
to prevent scratching the stainless steel.
Note !
It is important to wipe down the dispenser with a clean cloth and clean water after every cleaning.
Periodic waxing of the dispenser surfaces is essential to maintain the original finish and inhibit
corrosion. Stainless steel surfaces should be polished with a non-abrasive silicone wax.
Note !
No chlorine-based cleaners can be used on the stainless stell, especially if the dispenser is located
in a marine environment.
5.4 Meter Maintenance

All meters in the dispensers are determined to be calibrateable when shipped from the factory.
It is recommended that Wayne fuel meters be periodically checked for acceptable accuracy based
on NCWM 3 Handbook 44 under the General Code, G-UR.4, Maintenance Requirements and Liquid
Measuring Device Code, Section 3.30. If adjustments need to be made, one would follow the pro-
cedure in the service manuals for the respective equipment. All adjustments shall be made in ac-
cordance with G-UR.4 Maintenance Requirements of Handbook 44.
5.5 Printer Maintenance - Zebra Printers
5.5.1 Printer Specification

The printer in Helix model dispensers uses thermal printer paper with the following specifications:
Basic weight 58.0 ± 5.0 (g/sq meter)

Caliper .0023 - .0028 in.
(.0058 - .0071 cm)
Elmendorf Tear Main direction - 20 mg (min.)
Cross direction - 20 mg (min)
Smoothness Berk seconds
250 - 550
3 National Conference on Weights and Measures
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5 Maintenance
Base paper Kansaki P-300

Koehler KT55F18
5.5.2 Thermal Characteristics

Paper shall not display a visual change in the background color during use and/or storage under
cyclic conditions of temperature ranging between 5°C to 52°C with variable humidity ranging
between 0% and 90%.
5.5.3 Thermal Response Range

Initiation 75°C (167°F)
Functional 85°C (185°F)
Developed Image Black
Paper roll configuration
Inside core diameter .68 - .79 in.
(1.727 - 2.006 cm)
Core annular thickness .10 - .28 in.
(.254 - .711 cm)
Paper and core width 2.32 - 2.36 in.
(5.89 - 5.994 cm)
Finished roll diameter 3.80 - 4.00 in.
(9.652 - 10.16 cm)
5.5.4 Residual Particles

The annular are represented by the sheared edges of the paper, both sides shall not have more
than one particle per square inch nor more than five particles in total per annular surface area.
The test for particles shall consist of impressing the adhesive side of a one inch square, or equiv-
alent, strip of black adhesive tape against the surface; removing the strip of tape and examining
the adhesive surface for adhering particles.
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5 Maintenance
5.5.5 Loading Printer Paper
last receipt when out of

paper paper core
paper holders
print head -
green lever
feed button
tab on paper
Indicators for
holder both
Power and
sides
Status
Figure 5.2: Zebra printer components

Load paper as follows:
1 Unlock and open printer door. Slide printer assembly out. (Figure 5.2)
2 Using both hands pull outward on the tabs on the two paper holders to release and remove
core.
Figure 5.3: Remove paper core
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5 Maintenance
3 Insert new paper roll so that the paper feeds from the top of the roll into the printer. Paper
feeds from the top of the roll. Pull outward on tabs at bottom of hoder. Align and engage paper
core with holder.
Figure 5.4: Insert new paper

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. Remove the
paper.
Figure 5.5: Push green lever forward and raise print head
66 WM048526 Rev 02 05/2013

5 Maintenance
Figure 5.6: Remove paper from print head

6 Feed new paper into the slot in the printer until the paper is past the print head, then firmly
push down on the print head / green lever until the print head clicks (latches) into place.
Figure 5.7: Feed paper into slot
Figure 5.8: Push down on print head until it clicks (latches)
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5 Maintenance
7 The printer will automatically advance and cut the paper. The green status light will be on.
Figure 5.9: Paper will advance and cut paper

8 Press the feed button on the side of printer to print a test receipt. A test receipt is shown below.
This sample receipt shows the software version number 2842E.
Figure 5.10: Press feed button to print test receipt

9 Slide the printer assembly back into the housing and lock printer door. Printer is ready for op-
eration.
Figure 5.11: Test receipt - shows software version
Power light Green - Power ON

No light - Power OFF
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5 Maintenance
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
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A Installation Drawings
Appendix A Installation Drawings
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Helix Lifting Instructions - Sh. 1
72 WM048526 Rev 02 05/2013

Helix Lifting Instructions - Sh. 2
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Installation Instruction - Helix 4000 Remote
74 WM048526 Rev 02 05/2013

Installation Instruction - Helix 5000 Remote
WM048526 Rev 02 05/2013 75

Installation Wiring Diagram
76 WM048526 Rev 02 05/2013

Junction Box Terminal Strip Wiring
Terminal Color Connection Product Designa-

tion
1 Black AC Hot
2
3 Black Pump Control 1 LO
4 Black Pump Control 2 HI
5 Black Pump Control 3 Open
6 Black Pump Control4 Single
7 Black Neutral
8 Black AC Neutral
9 Orange CAT TX / RX +
10 Orange CAT TX / RX -
11 White Current Loop 1 +
12 White Current Loop 2 -
NC Orange Wayne Trac TX / RX +
NC Orange Wayne TracTX / RX -
option NC Blue Side A Intercom Speaker +
option NC White Side A Intercom Speaker -
option NC Blue Side A Call Button +
option NC Blue Side A Call Button -
option NC Brown Side B Intercom Speaker +
option NC White Side B Intercom Speaker -
option NC Brown Side B Call Button +
option NC Brown Side B Call Button -
WM048526 Rev 02 05/2013 77

B Site Interconnection Diagrams
Appendix B Site Interconnection Diagrams
78 WM048526 Rev 02 05/2013

Backroom Installation
WM048526 Rev 02 05/2013 79

Data Distribution Cabinet to Dispensers
80 WM048526 Rev 02 05/2013

Pump Relay Installation Wiring Diagram
WM048526 Rev 02 05/2013 81

Dispenser Card Processing (CATs)
82 WM048526 Rev 02 05/2013

C Hydraulic Configurations - Helix 4000 & 5000 Model Dispensers
Appendix C Hydraulic Configurations - Helix 4000 & 5000 Model Dispensers
Below are graphical layouts of the available hydraulic configurations for the different Helix H-Style
dispenser models. The graphics can be interpreted as follows, using the H(W/L)44-44 model as
an example.
WM048526 Rev 02 05/2013 83

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
84 WM048526 Rev 02 05/2013

44-4X: 4-PRODUCT NON-BLENDER

(MULTI & UNI-HOSE)
Vista Equivalent: 390/U
Vista Equivalent: 390/U Narrow
WM048526 Rev 02 05/2013 85

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
86 WM048526 Rev 02 05/2013

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
WM048526 Rev 02 05/2013 87

88
START-UP CALIBRATION REPORT
Station Name __________________________ Task# ____________
Certified Technician___________________ Tech ID_____________________Installing Contractor ____________________________
Authorized Service Organization____________________________________________Oil Co. ID#_________________ Task# ___________
______________________________________________________________________Station Name__________________________________
______________________________________________________________________Address______________________________________
Telephone _________________________________Start-up Date_______________ City_________________State_______ZIP___________
Calibration Date_____________ Telephone (______)_____________________________
Calibration record must be completely and accurately filled out to insure an accurate calibration test.
Verify 50 gallon minimum has been dispensed from each grade at each fueling point to insure all air has been purged from the system.
UST temperature- (Fuel Type 1):________ UST temperature- (Fuel Type 2):_______ UST temperature- (Fuel Type 3):_______
Dispenser Serial Number:___________________ Dispenser Model Number:___________________ Station Fueling Point________

Ambient Air temperature:_____________________
Weather Conditon at Dispenser (Circle) - Sun, Shade, Rain, Snow, Wind, Other___________________________________________
1 Meter Type
Appendix D Calibration Setup Report
2 Meter Serial Number:

3 Fuel Type and Grade
4 Dispenser Side A or B A B A B A B A B
5 Meter Totals
6 Initial Meter Purge Reading (cu. in.)
7 Verification Value Fast Flow: (cu. in.)

8 Display Volume Value at Calibration: (gals)
9 Verification Value Fast Flow: (cu. in.)
10 Verification Value Slow Flow: (cu. in.)
Line 5- From electromechanical or electronic totals
Line 6- Initial meter purge draft into 5-gallon test prover
Line 7- Verify calibration: Meter under test must calibrate within +/- 0.1% (+/- 1 cubic inch in 5 gallons)
WM048526
Line 8- Record volume displayed while filling to zero mark on the prover can in Calibration mode
Line 9- Verify calibration: Meter under test must calibrate within +/- 0.1% (+/- 1 cubic inch in 5 gallons)
Line 10- Verification Value Slow - Conduct test on nozzle first latch or approx. 1 GPM
Rev 02
05/2013
D Calibration Setup Report
WM048526 Rev 02 05/2013 89

E U.S. METROLOGICAL AUDIT TRAILS IN US iGEM
Appendix E U.S. METROLOGICAL AUDIT TRAILS IN US iGEM
The following diagrams illustrate the Audit Trails contained in the US iGEM. Arrows between the
pictures show which key is used on the remote control to navigate between the screens. The first
diagram shows the upper level screens and subsequent diagrams illustrate the details contained
in each log and how to navigate down into those logs.
Note !
Dislays shown in these instructions are from previous model displays, however, the iGEM process
and data shown on displays in the audit trails process shown here have not changed.
90 WM048526 Rev 02 05/2013

UPPER LEVEL
The upper level of the metrological audit trail is shown below. Pressing CLEAR advances to the next event log.
iGEM currently contains the following event logs: Blend Ratio changes, Unit of Measure/Meter Type changes, Pulse
Output Resolution changes, ATC changes, Product Pressurization changes, and Program changes. As indicated
below, the information will be shown on the sales/volume and unit price displays.
Blend Ratio Change Log

(Not displayed on non-blender)
Last Sale Unit of Measure Change Log
Sale/Vol
display
CLEAR CLEAR
Unit Price displays
CLEAR
ATC Configuration Change Log Product Pressurization Change

Pulse Output Resolution
Change Log (Rev 41 & up) (Rev 38 & up) Log (Rev 50 & up)
CLEAR CLEAR
CLEAR
Metrological Function Data

Program Change Log Settings (Read Only!)
(Rev 53 & up) (Rev 38 & up)
CLEAR CLEAR
CLEAR
Last Sales Display
WM048526 Rev 02 05/2013 91

BLEND RATIOS
The audit trail event log for blend ratios is shown below. Pressing ENTER when at the upper level takes you into the
specific blend ratio changes for each product. The blend ratio event log is not displayed on non-blending dispens-
ers. The event counter has a capacity of 1000 ) 1-1000. Details of the last 10 changes to each product are logged.
Current Blend Ratios
CLEAR
ENTER
NEXT NEXT
“ch 4” = total number of changes ENTER ENTER

“br 100” = current blend ratio
NEXT
“Pr 4” = product 4 Last 10 blend ratio changes for PR 5 Last 10 blend ratio changes for PR 6
“9.30.09” = Date of change

“09.04” = Time of Change
toggle
“bC 1” blend ratio change record 1
“LOCAL” = change made at fueling point

“100” = new blend ratio 100
NEXT
“bC 1” = blend ration change record 1
toggle
“bC 3-9” = Change Records 3-9

NEXT
“nonE” = No changes
“bC 10 blend ration change record 10
92 WM048526 Rev 02 05/2013

MEASURE/METER TYPE
This log tracks the unit of measure as well as the type of meter for which the iGEM is configured. The event coun-
ter has a capacity of 1000 (1-1000). Details of the last 10 changes are logged.
CLEAR CLEAR
“7.01” = 7 total changes,

meter type = 1 (iMeter)
ENTER
“US GAL” = Currently set to US Gallons
“Unit” = Unit of measure change record 1
toggle
“1” Meter Type = 1 (iMeter) “9.30.09” = Date of change

“US Gal” = US Gallons “09.04” = Time of Change
“UC 1” = Unit of measure change record 1 “bC 1” blend ratio change record 1
NEXT
toggle
NEXT
“UC 3-9” = Unit of measure change records #3-#9

NEXT
“nonE” = No Changes
“UC 10” = Unit of measure change record 10
WM048526 Rev 02 05/2013 93

PULSE OUTPUT CONFIGURATION CHANGE
The pulse output configuration change event log is shown below. The log tracks changes to pulse output configu-
ration programming. The event counter has a capacity of 1000 (1-1000). Details of the last 10 changes are logged.
CLEAR CLEAR
“2” = Event Counter, 2 total changes

“L 0”: L = Dispenser was in liters mode at last PO change
0 = pulse output is disabled
ENTER
“P0ut” Pulse output change log
toggle
“9.30.09” = Date of change

“L 0”: L = Dispenser was in liters mode at this PO change
“09.04” = Time of change
0 = pulse output is disabled “PO 1” = Pulse output change record 1
“P 01” Pulse output change record #1
NEXT
toggle
“G 100”: G = Dispenser was in Gallons mode

at this PO change
NEXT
100 = 100 pulses/gallon

“P 02” Pulse output change record #2
PO 3-9” Pulse Output Resolution change records #3-#9

NEXT
“nonE” = No Changes
“UC 10” = Unit of measure change record 10
94 WM048526 Rev 02 05/2013

AUTOMATIC TEMPERATURE COMPENSATION - AUDIT TRAIL
The audit trail to track Automatic Temperature Compensation configuration changes is shown below. The event
counter has a capacity of 1000 (1-1000). Details of the last 20 changes are logged. Refer to the next page for
details of the individual meter configurations.
CLEAR CLEAR
“2” = Event Counter, 2 total changes

“tC OFF” = Automatic temperature compensation
ENTER is currently disabled
“Atc” = ATC change log
toggle
“tCOFF = ATC was disabled ENTER

“tC 1” ATC change record #1 “9.30.09” = Date of change
“09.04” = Time of change
“PO 1” = Pulse output change record 1
NEXT
probe and fuel type

log for change record #1
toggle
ENTER
“tCON = ATC was enabled
NEXT
“tC 2” ATC change record #2

probe and fuel type
log for change record #2
“tC 3-9” ATC change records #3-#9
NEXT
“nonE” = no change record

“tC 10” = ATC change record #10
WM048526 Rev 02 05/2013 95

AUTOMATIC TEMPERATURE COMPENSATION - CONFIGURATION CHANGE DETAILS
The details of each ATC configuration change are shown below. This log shows the ATC probes and fuel tupe
assigned to each possible meter in the dispenser.
toggle
NEXT
ENTER
NEXT
“1 P1” = Meter 1 assigned probe #1

“0-GAS” = Fuel Type- Gas
“tC 2” ATC change record #2 NEXT
NEXT
“4 P0” = Meter 4, No probe assigned

NEXT “0-GAS” Fuel Type - Gas
“tC 2” ATC change record #2
NEXT
NEXT
NEXT
“7 P3” = Meter 7 assigned probe #3

“1-.SL” = Fuel Type - Diesel
“tC 2” = ATC change record #2
96 WM048526 Rev 02 05/2013

PRODUCT PRESSURIZATION - CHANGE LOG
The Product Pressurization change log tracks the changes made to the product pressurization change function,
f21.07. The details of the last ten changes are kept, as well as a counter for the total number of changes are kept
as well as a counter for the total number of changes to this function setting (1-1000).
CLEAR CLEAR
“3” = Event Counter - 3 total changes

“1-0n” = Setting of function 21.07
1=product pressurization enabled
“PPL” = Product pressurization log
ENTER
toggle
“1-0n” = Setting of function 21.07 “10.01.09” = Date of Change

1 = product pressurization enabled “13.37” = Time of Change
“PP1” = Product Pressurization change record 1 “PP 1” = Product Pressurization change record 1
NEXT
toggle
NEXT
“PP 3-9” Product Pressurization change records #3-#9

NEXT
WM048526 Rev 02 05/2013 97

PROGRAM CHANGE LOG
The Program Change log tracks details of the last ten programs that were loaded onto the iGem board. A counter
also tracks the total number of program loads (1-1000).
CLEAR
CLEAR
ENTER “4” = Event Counter, 4 total changes

“54.02” Spftware Rev currently loaded
“PC” Program Change Log
toggle
“54.02” = Software Rev loaded “10.01.09” = Date of Change

“PC 1” = Program Change change record 1 “13.12” = Time of Change
“PC 1” Program Change change record 1
NEXT
toggle
NEXT
“PP 3-9” Program Change change records #3-#9

NEXT
98 WM048526 Rev 02 05/2013

METER TOTALS DISPLAY
The meter totals display is shown below. Volume totals for each meter associated with this fueling point are dis-
played. Meters not assigned to this fueling point will display 0.000.
CLEAR CLEAR
“0.000” = Volume total for meter 1

“tot 1” = volume totals record for meter #1
NEXT
NEXT
“tot3-tot7” = Meter totals for meters 3-7

NEXT
“0.000” = Volume total for meter 8

“tot8” = volume totals record for meter #8
WM048526 Rev 02 05/2013 99

METROLOGICAL FUNCTION DATA DISPLAY
The display of metrological function data setttings are shown below. This is shown at the end of the audit trail dis-
play and allows a “read only” view of the actual data values currently assigned to the functions/sub-functions in
iGem (see iGem programming manual for values).
CLEAR CLEAR
ENTER
NEXT
ENTER
Sub-function
- data for F17
NEXT
NEXT
ENTER
Sub-function data for F19
NEXT
NEXT
ENTER
Sub-function data for F22
NEXT
100 WM048526 Rev 02 05/2013

F Glossary of Terms and Acronyms
Appendix F Glossary of Terms and Acronyms
Table F.1:
TERM DEFINITION
additive a product added to the gasoline to enhance perfor-

mance
ALU aluminum
ambient the surrounding area or environment (as in ambient
temperature)
Annunciator beeper, buzzer
ATC automatic temperature compensation
bezel the outer rim at the upper part of the dispenser
bleeding clearing the fuel lines of air (also, purging)
blender mixes two fuels together to obtain a third; a blending
dispenser
blend ratios the amount or quantity of each of the two fuels
added together to obtain the third fuel
board a printed circuit board; one of the electronic boards
in the dispenser
bootstrap (as in computers, loading software)
breakaway device between the hose and dispenser that breaks
if the hose is accidentally pulled by the car
breakaway valve see emergency valve
C&PR valve Check and Pressure Relief Valve
CAT customer-activated terminal
circuit breaker a type electrical device
conduit enclosure used for routing electrical wires
coupling small section of pipe used to connect two pipes to-
gether
C-syle the frame of a dispenser in the shape of the English
letter C
current loop a communication circuit used by the dispenser and
POS system
double bump tube a tube having two raised areas on the ends
WM048526 Rev 02 05/2013 101

TERM DEFINITION
drip pan a catchement container (to catch liquids)

drip pan a pan used to drain or catch the fuel to keep it from
spilling onto the ground
EH electronic head
EHPM electronic head and payment terminal
electro-mechanical mechanical device controlled by electricity (as in
electro-mechanical totalizer)
emergency valve this valve is designed to close the fuel suupply line if
a vehicle crashes into the dispenser or if there is fire
in the dispenser; also known as shear valve, crash
valve and breakaway valve
EMT electro-mechanical totalizers
ESD electro-static discharge
filter device that captures small unwanted particles in the
gasoline or diesel fuel
fuel funnel used to drain fuel into a pan or container in order to
prevent spilling
fueling point identification ad- a number assigned to a dispenser so that it can be
dress (FPID) identified on a communications network
gross volume the amount or volume of fuel before temperature
compensation
Healy name of a vapor recovery system
high capacity dispenser is designed for a higher fuel flow rate and
therefore delivers a higher volume of fuel as com-
pared to a standard capacity dispenser
hose flexible tubing that connects the nozzle to the dis-
penser and where gasoline, petrol, or other product
flows through
H-style the frame of a dispenser in the shape of the English
letter H
hybrid more than one source: (Wayne - Hybrid card reader
that reads both magnetic strip cards and cards that
contain a micro-chip that has the card number
inlet location at a meter, valve, or casting where the fuel
enters
102 WM048526 Rev 02 05/2013

TERM DEFINITION
Intrinsic Safe Barrier (ISB) barrier inside the dispenser - the area below the
barrier is free from hazardous electrical sparks
island-oriented when the nozzle is located on the left or right sides
of the dispenser, as opposed to front or back sides
jitter unwanted electrical pulses or interference (as in jitter
pulses)
jumper small wire or connector used to join together to pins
in a connector or on a circuit board
junction box a metal box located near the bottom of the dispenser
lane oriented when the nozzle is located on the front or back sides
of the dispenser as opposed to th left or right sides
LEE lower electronic enclosure
low hose the fuel hose is connected near the middle of the
dispenesr, as opposed to high at the top
LT low temperature
LTS lift-to-start (to activate dispenser)
meter dispenser component that measures the
net volume the amount or volume of fuel after temperature
compensation
nozzle device at the end of the hose that is inserted into the
vehicle (or container) when dispenseing product
nozzle boot the holder (on the dispenser) of the nozzle when it is
not in use
outlet location at a meter, valve, or casting where the fuel
exits
outlet casting a metal or aluminum type mold where the hose is
connected to the dispenser
P/N part number
payment terminal (PT) as in payment terminal on the dispenser where a
payment is made by credit card
pedestal platform or base that the dispenser sits on (also re-
ferred to as 'island' in some areas)
pipe dope sealant used on the threads of a pipe; pipe sealant
POS Point of Sale
WM048526 Rev 02 05/2013 103

TERM DEFINITION
prime to pour fuel into the pump to clear out the air in order
to start the pump properly
product tube fuel tube; the tube that contains the fuel or that fuel
moves through
PTS push-to-start (to activate dispenser)
pulser device that generates signals
purge clearing the fuel lines of air
relay an electrical component used in the dispenser
remote (pump) the pump for the dispenser is located in the under-
ground tank; not inside the dispenser
residual something left over or remaining (as in residue)
retainer clip (pin) used to secure or hold a tube in place
retractor pulls hose back into place after use
sales/volume display shows the total sale amount and the volume dis-
pensed
satellite (dispenser) a small dispenser connected to and controlled by
another dispenser that is referred to the master
servTerm a software application also known as the Service
Terminal program
shear valve see emergency valve
sight glass a glass cylinder used for visually measuring volume
of fuel
Small-style a short (small) type of dispenser
softkey as in buttons or keys on a keypad
solenoid valve electro-mechanically operated valve
SPM secure payment module
stand-alone mode dispenser is not connected to or communicating with
the POS
Std standard
strainer device that captures small unwanted particles in the
gasoline or diesel fuel
submersible pump that is located in the underground tank
104 WM048526 Rev 02 05/2013

TERM DEFINITION
suction (pump) the pump for the dispenser is located inside the dis-
penser
torque rotating force applied to tighten; amount of force
used to tighten a screw or pipe
Torx™ a brand name of a type of screw
TOT totalizer -
totalizer (TOT) device on the dispenser that counts and displays the
total volume units
TRAC Transponder-activated CAT
triple bump tube a tube having three raised areas on the end
unit price display (UPD) shows the fuel price per gallon or per litre
universal joint a type of coupling
UPD Unit Price Display
UPS Un-interruptible Power Supply
vacuum air has been removed (as in a vacuum line)
valance cosmetic panels around the top of the dispenser
vapor recovery system that claims fuel vapors, minimizing exposure
to the customer and environment
WIP Wayne Integrated Pulser; a type of meter manufac-
tured by Wayne
Xflo a type of meter manufactured by Wayne
WM048526 Rev 02 05/2013 105

Warranty
Any alternations or, additions to, or unauthorized work performed on the equipment without
manufacturer’s express written consent shall void any existing product warranty. Please see
product warranty information for additional details.
Use only genuine parts.
Copyright notice
© 2012 Wayne, A GE Energy Business. The contents of this manual may not be copied in whole
or in part without the express written consent of Wayne.
Wayne reserves the right to make revisions to this manual without prior notice.
WM048526 Rev 02 05/2013

Headquarters Wayne Sweden Wayne China Wayne Brazil
Wayne Dresser Wayne AB Dresser Wayne Fuel Dresser Industria e
Dresser, Inc. Hanögatan 10 Equipment Comercio Ltda.
3814 Jarrett Way Box 50559 (Shanghai) Co., Ltd. Estrada do Timbo
Austin, TX 78728 SE-202 15 Malmö 1221 Dong Lu Road 126-Bonsucesso
USA Sweden Pudong, Shanghai Rio de Janeiro,
China Brasil
© 2013 Wayne, A GE Energy Business WM048526 Rev 02 05/2013

Helix Installation Manual Rev 002

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Installation Manual

Indicators and notations

Highlights an essential element of a procedure to

Indicates a potentially hazardous situation, which if

WM048526 Rev 02 05/2013

INDICATES A POTENTIALLY HAZARDOUS SITUATION,

INDICATES A HAZARDOUS SITUATION, WHICH, IF NOT

WM048526 Rev 02 05/2013

WM048526 Rev 02 05/2013 1

3.11 Disable Stand-Alone Operation ............................................................................................ 49

2 WM048526 Rev 02 05/2013

1.1 Dispensers Covered

WM048526 Rev 02 05/2013 3

Figure 1.1: Helix Model String Designation

1.2 Wayne iGEM™ Computer Software

1.3 Safety precautions

4 WM048526 Rev 02 05/2013

More than one disconnect switch may be required to

WM048526 Rev 02 05/2013 5

Underwriters Laboratories, Inc. (UL) Steel Tank Institute (STI/SPFA)

6 WM048526 Rev 02 05/2013

WM048526 Rev 02 05/2013 7

2.1 Helpful Tips

2.1.1 Determining Dispenser Sides A & B

2.1.2 Determining HI & LO - Product Piping

2.1.3 Pump Control Wiring at Junction Box

Termi- Color Connection Product Description

3 Black Pump Control 1 LO

2.1.4 Dispenser ON/OFF Switch

8 WM048526 Rev 02 05/2013

Figure 2.1: Dispenser ON / OFF Switch

2.1.5 iX R2 Board Reset Button

Figure 2.2: iX R2 Board Reset Button

WM048526 Rev 02 05/2013 9

2.2 Inspect Equipment

2.3 Island Construction, Dispenser Anchoring, and Piping

2.4 Emergency Shear Valves

For remote dispensers, a UL-Listed 2 , rigidly-anchored

10 WM048526 Rev 02 05/2013

dispenser inlet dispenser base frame

under pump cavity

Figure 2.3: Typical Emergency Valve Installation

WM048526 Rev 02 05/2013 11

Installation of a rotating shear valve instead of a

2.5 Vapor return piping

2.6 Lifting and installing dispenser

12 WM048526 Rev 02 05/2013

Explosive or flammable vapors may accumulate

2.7 Electrical wiring

2.7.2 Dispenser to Wayne Control System interconnection

WM048526 Rev 02 05/2013 13

Dispenser Conduit and Wiring Recommendations

No connections (including neutral) may be shared

2.7.3 Full service (stand-alone) dispensers

14 WM048526 Rev 02 05/2013

2.7.4 Multiple dispenser wiring

2.8 Bleeding product lines (remote dispensers)

Perform the following steps:

2.9 Calibration of Wayne iMeter™ Piston Fuel Flow Meters

WM048526 Rev 02 05/2013 15

2.9.1 Bleeding product lines (remote dispensers)

• Make sure the power to the appropriate submersible pump is OFF.

2.9.2 Dispenser purging at startup: new dispensers and/or meters only

2.9.3 During calibration procedure