000-940039 Fusion Installation - HyperPIB-PAM-Console Rev 0E

Installation/Operation
Wayne Fusion™ 1000/3000 Forecourt System

HyperPIB, PAM™ Emulation, and Console
P/N 000-940039-
Rev 0E
DANGER
READ THIS MANUAL BEFORE YOU BEGIN
Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Fail-
ure to follow the below precautions and the Warning and Caution instructions in this manual may
result in serious injury. Follow all rules, codes and laws that apply to your area and installation.
SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE
Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cabi-
net for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off
when servicing the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser
BEFORE beginning maintenance.
Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an
emergency. Have all leaks or defects repaired immediately.
HOW TO CONTACT WAYNE
Problems with the installation of this kit should be referred to Wayne Technical Support (1-800-
926-3737).
INDICATORS AND NOTATIONS
Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe
DANGER injury or possibly death.
Warning indicates a hazard or unsafe practice which, if not avoided, may result in
WARNING severe injury or possibly death.
Caution indicates a hazard or unsafe practice which, if not avoided, may result in minor
CAUTION injury.
Important information to consider, otherwise, improper installation and/or damage to

NOTE:
components may occur.
Wayne Fusion 1000/3000 Forecourt System
Installation/Operation
P/N 000-940039 Rev 0E May 2016 1

2 P/N 000-940039 Rev 0E May 2016
Table of Contents
Title Page
1 PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 HOW TO USE THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 RETURNING DAMAGED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 INSTALLATION LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11.1 Shutdown the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.1.1 Sites with Wayne Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.2 Fusion Forecourt Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11.2.1 Logging on to the Fusion Forecourt Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11.2.2 Clear Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11.2.3 Apply Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11.2.4 Language Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11.2.5 Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11.3 Payment Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
11.3.1 Payments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.3.2 Service Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.4 Pump Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11.4.1 Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11.4.2 Assign Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
11.5 Veeder-Root BIR Installations with EDIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11.6 Veeder-Root BIR Installations with CDIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11.6.1 Connect the CABs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.6.2 Connect the Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.6.3 Programming the Fusion Forecourt Controller for Sites with Veeder-Root BIR . 31
11.7 Programming the Fusion Forecourt Controller for 3rd Party POS . . . . . . . . . . . . . . . . . 34
11.7.1 HyperPIB Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.7.2 PAM Emulation™ Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11.7.3 Save the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11.8 Connecting to the POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
11.8.1 VeriFone Ruby, Topaz or Sapphire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
P/N 000-940039 Rev. 0E May 2016 iii

Table of Contents (continued)
Title Page
11.8.2 Gasboy POS or Fiscal POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

11.9 Installing a Site with Tokheim Dispensers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.10 Installing a Site with a Mix of Wayne and Gilbarco Pumps. . . . . . . . . . . . . . . . . . . . . . . 43
11.11 Installing a Site with 32 Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.12 Installing a Receipt Printer in the Console Configuration . . . . . . . . . . . . . . . . . . . . . . . . 44
11.12.1Create the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.12.2Configure Printer Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.12.3Adding the New Printer "TPG" to the POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.12.4Assigning Receipt Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.12.5Configuring Automatic Receipt Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.12.6Apply the Entire Configuration to the Fusion Forecourt Controller System . . . . 49
11.12.7Testing the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.13 Prices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
11.13.1Current Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
11.13.2Price Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11.13.3Price Change Delta Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.13.4Gallons/Liters Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.14 Emergency Button Access and Confirmation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11.15 Language Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.16 Date and Time Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.17 Station Name and Address Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.18 Fusion Forecourt Controller Health Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11.19 Database Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
11.20 Database Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.20.1 Database Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.20.2 Database Backup Using USB Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.20.3 Database Restore Using USB Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.21 IP Address Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.21.1 How to use the Putty Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.21.2 How to Change the IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.21.3 How to Use USB Maker to Change the IP Address. . . . . . . . . . . . . . . . . . . . . . 66
11.22 Fusion Forecourt Controller GSM/DSM Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.23.1 Powering the Fusion Forecourt Controller On and Off. . . . . . . . . . . . . . . . . . . . 68
11.23.2 Uncontrollable Sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.23.3 Fusion Forecourt Controller Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
12 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.1 Fusion Forecourt Controller Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
12.2 Fusion Forecourt Controller Rear Panel - Gilbarco CRIND. . . . . . . . . . . . . . . . . . . . . . . 72
12.3 Fusion Forecourt Controller Rear Panel - Console Configuration. . . . . . . . . . . . . . . . . . 73
12.4 Fusion Forecourt Controller Rear Panel - Tokheim Configuration . . . . . . . . . . . . . . . . . 73
12.5 Serial Port Pin-Outs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
iv P/N 000-940039 Rev. 0E May 2016

Table of Contents (continued)
Title Page
12.6 GRIB Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

12.7 Wayne TRAC/Speedpass Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
12.8 Current Loop GRIB Jumper Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
12.9 Current Loop GRIB Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.10 Serial-485 CAT GRIB Jumper Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.11 Serial-485 CAT GRIB Component Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.12 Serial to Current Loop GRIB Jumper Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.13 Serial to Current Loop GRIB Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
P/N 000-940039 Rev. 0E May 2016 v

1 PRODUCT
Product Wayne Fusion™ Forecourt Controller
Application 3rd Party POS and Console
Production Version Version 3.0.3.4
Hardware Platform Wayne Proprietary Hardware
2 INTRODUCTION
The Wayne Fusion™ Forecourt Controller is a device capable of supporting existing peripheral devices that are cur-
rently supported through the HyperPIB. This manual explains how to install the Fusion forecourt controller and config-
ure it for use as a Console or with a Ruby Verifone POS or any other supported brand of POS.
3 HOW TO USE THIS DOCUMENT

By following the installation instructions and performing the steps in the sequence presented, you will be assured of a
successful install.
NOTE: This kit may require installation of several wiring and hardware assemblies. Any installation or modification
must comply with the requirements of the National Electrical Code (NFPA 70), the Automotive and Marine
Service Station Code (NFPA 30A) and any other applicable codes
NOTE: You must wear a static wrist strap, part number 916962 or equivalent, securely attached to an earth ground,
when handling any circuit board, electronic component or assembly, or when reaching into the site
controller or dispenser computer enclosure. Do not use power tools.
4 UNPACKING AND INSPECTION

Complete the following steps:
1. Before opening any cartons, count the number of cartons and verify the carton count against the supplied
packing list.
2. Inspect the cartons for damage made during transit.
3. File claim information with the carrier on the bill of lading.
4. Retain cartons suspected of damage for future claim purposes.
NOTE: You must wear an anti-static wrist strap, part number 916962 when removing electronic components from
static packages. Attach the wrist strap securely to an earth grounding point to prevent possible damage
from static electricity.
5. Remove all equipment from the shipping cartons and carefully inspect for visible damage.
NOTE: Any damage should be brought to the attention of the carrier and claims made immediately. Return all
equipment to the respective cartons for protection until actual installation is made. Save all cartons until it is
certain that return shipments are not required.
P/N 000-940039 Rev. 0E May 2016 7

5 RETURNING DAMAGED COMPONENTS
Parts or components returned to the factory under warranty or for repair are subject to damage if not packaged
properly. Complete the following steps to return parts or components to the factory.
1. Place electronic components in an anti-static bag and in the original shipping cartons for return shipment
to the factory.
NOTE: If original shipping cartons are not available use a sturdy cardboard container and suitable packing
materials such as anti-static polyethylene foam or bubble pack, to ensure the component is firmly packed.
2. Include a Return Parts Tag with the defective component describing the particular problem with the part.
3. Make sure adequate insurance is provided when returning parts to the factory.
WARNING
If the parts or components arrive at our factory in a damaged condition and it is determined that the dam-
age is a direct result of inadequate or improper packaging, the damage will not be covered under the origi-
nal warranty and the customer or distributor will be held responsible for the cost of repairs necessary to
correct or replace the damaged parts.
6 SAFETY INFORMATION
Read NFPA 30A and NFPA 70 (U.S. Installations)
Before installing the equipment, the installer must read, understand and follow this manual, NFPA 30A, NFPA 70, and
applicable federal, state and local codes and regulations. Failure to do so may adversely affect the safe use and
operation of the equipment.
CSA C22.1 (Canadian Installations)
For installation in Canada the installer must read and understand this manual, CSA C22.1 (Canadian Electrical Code)
and applicable federal, provincial and local codes and regulations.
Emergency Power Cutoff
NFPA30A require that an emergency power cutoff be installed. An emergency power cutoff is a single control that
removes AC power from all site fueling equipment and submersible pumps. Make sure the control is accessible,
labeled clearly, and installed away from dispensers. Make sure all station employees know where the Emergency
Power Cutoff is located and how to operate it.
Electrical Circuits
Some of the procedures in this manual involve removal and connection of components during installation or service.
Remove power from the distribution box before executing these procedures.
Low Voltage
Do not be misled by the term "Low Voltage". Voltage potentials as low as 50 volts may cause death under adverse
conditions.
High Voltage
High voltage of 110 volts AC is used for operation of this equipment. Death on contact may result if safety proce-
dures are not followed.
8 P/N 000-940039 Rev. 0E May 2016

7 INSTALLATION LOCATION
The Fusion forecourt controller may be installed in a variety of locations, all the cabinets and required wireways must
be located in a non-hazardous area of an enclosed weather protected building.
Table 1: Mounting Location
Component Preferred Location Notes

Wayne Fusion Forecourt Back room; on wall near AC Power input required
Controller the wiring conduits for
pumps and CATs
Table 2: Space Requirements (in inches)
Component Width Height Depth

Wayne Fusion Forecourt 16 14 2
Controller
Dispenser conduit and Wiring requirements
Conduits used must be ¾ in. and the length of each conduit can be up to 330 feet from the Fusion forecourt controller
to the dispenser. Verify that approved wireways and threaded metallic conduit with tight connections are used, that
Data Link wiring is #18 AWG 600 Volt oil and gasoline resistant as a minimum.
Environmental Requirements
Ensure that all cabinets are located in an area that offers easy access for service, and free air space for cooling, 6"
away from other cabinets.
Care should be taken to ensure that the temperature of the cabinets does not exceed the operational ranges of 0°C to
40°C (32°F to 104°F)
Preliminary Wiring
The site wiring must be completed before installation of a Fusion Forecourt Controller.
Data Link and CAT Wiring
Two pairs of data link wires must be installed from each dispenser to the location of the Fusion forecourt controller
cabinet. One pair for pump communication and one pair for CAT communication.
8 CONFORMITY WITH STANDARDS

Ensure that all National, State, and local standards and codes are observed in site preparations, wiring, and installa-
tion.
Power Wiring
Confirm that all 120VAC to 240VAC wiring for outdoor equipment (line, neutral, relay select, etc.), is #14 AWG mini-
mum (unless local codes call for 12 gauge), stranded, oil and gasoline resistant.
One conduit from the breaker panel to a dedicated outlet located near the Fusion forecourt controller location is
required. The conduit must contain three 14 AWG wires; 110 to 240 VAC, Phase, Neutral and Ground. Do not use
electrical conduit to provide earth ground (earth ground does not exceed 5 ohms) The electrical wiring for the Fusion
forecourt controller dedicated outlet must be run through the Emergency Stop circuit at the site so that all electrical
P/N 000-940039 Rev. 0E May 2016 9

power is cut to the dedicated outlet for the Fusion forecourt controller whenever the Emergency Stop button is
pressed. Do not connect the Fusion forecourt controller power supply cord to any UPS.
The circuit powering the Fusion forecourt controller must not power other devices. This circuit must not share a con-
duit with wiring for devices drawing high amperage (compressor, freezer, etc.) or devices that are sources of RFI (TV,
microwave, intercom, etc.)
Data Wiring
Confirm that all data wiring for outdoor equipment (communication lines) is #18 AWG (minimum) stranded, oil and
gasoline resistant. Pump and CAT data wiring that attaches from the wiring trough to the Fusion forecourt controller
needs to be double insulated to satisfy NEC code for commercial use. Wayne recommends the use of the following
cable or equivalent for use as the pump and CAT communication wire for running between the wiring trough and the
Fusion forecourt controller.
Product SKU: C2404.41.10

Product Description: Communication & Control Cable, Multi-Conductor, Unshielded, UL 2464, NEC Type CM (UL) c(UL), CSA
CMG, No. of Conductors: 4, Gauge Size (AWG): 18, Conductor/Strands: 16/30, Jacket: Gray PVC,
Temperature Range: -20Â°C to +80Â°C - Gray - 1000 Ft. Reel
Product Category: Electronics - Communication & Control Cable, Multi-Conductor - Unshielded-18 AWG & 20 AWG - Gray
Product Construction:
Conductor: 20 or 18 AWG fully-annealed, stranded tinned copper per ASTM B-33
Insulation: Color Code: See charts below
Premium grade color coded PVC per UL 1007
Jacket: PVC, gray
Temperature Range: -20ÂºC to +80ÂºC
10 P/N 000-940039 Rev. 0E May 2016

Product Specification:
No. of Conductors: 4
Conductor Size (AWG): 18
Conductor/Strands: 16/30
Jacket Color: Gray
Nominal Insulation Thickness 0.016

(in):
Nominal Insulation Thickness 0.41

(mm):
Nominal Jacket Thickness (in): 0.032
Nominal Jacket Thickness (mm): 0.81
Nominal Outside Diameter (in): 0.258
Nominal Outside Diameter 6.55

(mm):
Color Code: 1
Nominal C-C Capacitance 28.0

(pF/ft):
Standard Packaging: 1000' Non-returnable Wood Reels
Standard Package Quantity: 1
UPC #: 079407700875
NOTE: Existing wiring that runs from the wiring trough out to the dispensers do not need to be modified since
those wires are protected within the wiring trough or conduit.
Codes
Confirm that all equipment is installed in accordance with the National Electrical Code (NFPA 70), the automotive and
Marine Service Station Code (NFPA 30A), and any other applicable State and local codes.
9 REQUIRED TOOLS
Refer to Table 3 for a list of tools required to install the Fusion forecourt controller.
Table 3: Required Tools
Quantity Description
1 Small Channel Lock pliers
1 Phillips Screwdriver Set (standard sizes)
1 Slotted Screwdriver Set (standard sizes)
P/N 000-940039 Rev. 0E May 2016 11

Table 3: Required Tools
1 Wire Cutters
1 Anti-static Wrist Strap
1 Needle Nose Pliers
1 Wire Strippers
16 to 32 Wire Nuts
1 Volt Meter
1 Diagonal Cutters
1 Standard Drill Bit Set
1 Drill
1 PC Feature Card Slot Blank
10 INSTALLATION OVERVIEW
1 4”
1
F u sio n B o x
Earth Ground at
Electrical Panel
"
A C O u tle t
wired to Serial C a b l e t o P O S (pumps)
Emergency
Stop button
Serial C a b l e t o P O S (CATs) optional
A C P o w e r w irin g fo r F u sio n
Double Shielded
AC Pow er B r i c k Communications Wires
C u sto m e r S u p p lie d M e ta llic W ire w a y
M e ta llic co n d u it to d isp e n se rs (o n e p e r d isp e n se r)

¾ ” re co m e n m e n d e d
Figure 10-1 Backroom Installation
11 INSTALLATION PROCEDURE
When possible, mount the Fusion Forecourt Controller at a location on the back wall near where there is access to
the wiring trough where the dispenser comm wires are located. If the Fusion forecourt controller is going to be a
HyperPIB replacement then the location will be where the HyperPIB EC was located. The previous diagram shows a
typical placement of the Fusion forecourt controller.
NOTE: If mounting the Fusion forecourt controller to a concrete wall, you will need concrete bits and appropriate
mounting hardware.
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NOTE: The Fusion forecourt controller mounting location may require different placement than shown. Whenever
handling boards and components that are susceptible to damage from static electrical discharge, BE SURE
to wear an anti-static wrist strap.
11.1 Shutdown the Site

____ 1. Stop all pumps one at a time, allowing current customers to complete their transactions.
____ 2. Shutdown the site and tape off the pumps and run EOD.
11.1.1 Sites with Wayne Dispensers

Perform the following steps if you are installing at a site with Wayne dispensers.
____ 1. Open the wiring trough and verify the labeling of the pump and CAT data wires.
____ 2. Disconnect pump and CAT wires from HyperPIB if present.
____ 3. Disconnect pump and CAT wire conduit from HyperPIB if present and remove the HyperPIB box.
____ 4. Extend discrete CAT and pump wire pairs from the wiring trough to the Fusion forecourt controller location
for each dispenser if needed.
NOTE: CAT data wires may have been bundled together in parallel within the wiring trough. Un-bundle the wire
pairs and splice extensions if needed so that each discrete CAT wire pair reaches the location of the Fusion
forecourt controller. Use double insulated wire specified in Section 8 for all exposed wiring from the wiring
trough to the Fusion forecourt controller.
11.2 Fusion Forecourt Controller Installation

____ 1. Select a Fusion Forecourt Controller mounting location on the wall near where the HyperPIB box was
located. The Fusion forecourt controller mounting bracket should be mounted on the wall first, then the
Fusion forecourt controller slides onto the mounting tabs or slots of the bracket. Orient the bracket/box so
that the data wire connectors are located on the right side and the vent holes are on the top and bottom.
The Fusion forecourt controller should not be mounted too far to the right otherwise visual access to the
XMIT and RCV LEDs, which are next to the GRIB connectors, will be limited. The opposite end of the box
has the Status display LEDs and should also be visible.
Mounting
pins
Mounting
slots
Mounting
stud
Fusion mounting
bracket
Figure 11-1 Mounting Bracket
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____ 2. After selecting a mounting location, attach the bracket to the wall using six screws through the six
mounting slots. Next, mount the Fusion forecourt controller to the bracket using the two mounting pins.
Secure with a screw using the hole in the Fusion forecourt controller case into the mounting stud.
____ 3. Route the pump data wires (2 pairs per connector) up to the pump GRIB plugs beginning with Dispenser
#1. Pump data wires can be connected as 2 loads per plug. Older pumps may limit you to 2 fueling points
per plug if they have 1 computer per side. See Figure 12-12 and Figure 12-13.
____ 4. Route the CAT data wires up to the CAT GRIB plug beginning with Dispenser #1. See Figure 12-9 and
Figure 12-11.
NOTE: The green GRIB connectors for the Pumps (Current Loop) are located on the right-hand row of connectors
while the black GRIB connector for the Wayne CATs (RS485/422) is located on the left-hand row of
connectors. See Figure 12-1.
____ 5. Insert the green current loop GRIB plugs into the appropriate GRIB sockets on the rear panel of the Fusion
forecourt controller beginning with the plug for Pump #1, #2, #3 and #4. See Figure 12-10.
____ 6. Insert the black CAT GRIB plug into the GRIB socket on the rear panel of the Fusion forecourt controller.
See Figure 12-9.
NOTE: Make a note of where all of the pumps and CATs are connected.
NOTE: The Fusion forecourt controller units ship pre-configured for BIR functionality. BIR communication is
through the 4th port of the Current Loop GRIB. If BIR functionality is not needed then remove the resistor
from the GRIB plug that is in the 4th port.
____ 7. Connect CAT serial communications cable from the existing POS into the DB9 connector on the Serial-485
CAT GRIB. See Figure 12-8.
NOTE: The cable length for serial communications @ 9600 baud is officially 50 feet. However, tests have shown
that lengths 150 or 200 feet have been known to work.
____ 8. Connect pump serial communications cable from the Ruby system into the bottom Serial port on the back
of the Fusion forecourt controller [the CUPS board]. See Figure 12-8.
____ 9. Complete the wiring, secure the conduit, etc.
____ 10. Plug the power brick into the dedicated120VAC power outlet which has been wired into the Emergency
Stop button, then plug the other end into the transformer input of the Fusion forecourt controller.
11.2.1 Logging on to the Fusion Forecourt Controller

To access the Fusion forecourt controller programming you can either log in using remote mode by connecting
a laptop to the Ethernet port, or you can also log in using local mode by directly connecting a display,
keyboard, and mouse.
Remote Mode
____ 1. Change the IP address of the laptop to match the IP scheme of the Fusion forecourt controller so that a
connection can be made.
____ 2. Change your Subnet Mask to 255.255.255.0
____ 3. Start an Internet Explorer session.
____ 4. In the Explorer Address bar, type in 192.168.1.20 and press <enter>. The following Screen will then be
displayed.
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Figure 11-2 Login Screen
____ 5. Enter the Admin in the Login field and enter Dresser3141 as the password. Press <enter> to continue.
Local Mode
____ 1. If logging on using local mode, Select the ADMIN user and enter the password of Dresser3141 then click
the Login button.
____ 2. Click the Config button then the Browser button. The following Login window will be displayed.

____ 3. Enter the Admin in the Login field and enter Dresser3141 as the password. Click the Login button to
continue.
11.2.2 Clear Configuration

____ 1. Navigate to Configuration > Maintenance > Clear Configuration to erase any configuration
programming done so far. You will be asked to confirm the command before processing the Clear
Configuration request.
Figure 11-4 Clear Configuration Menu
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11.2.3 Apply Configuration
____ Press the Apply Configuration, the system will not only validate the current programming, but try to apply the
configuration. If successful a message will be displayed with an OK button. Otherwise, an error message will
be displayed.
Figure 11-5 Apply Configuration
11.2.4 Language Setting

After logging into the Fusion forecourt controller, the language setting should be changed if the system is not
currently in the correct language.
Remote Mode
____ 1. From the Fusion forecourt controller, click Configuration then Generic. Select the Forecourt Manager
module then click the Search button.
____ 2. Scroll down to the Language option and click Language. Select the desired language from the pull-down
and click the Submit button.
____ 3. Click Send new Configuration to Fusion. The system should respond with an OK message. Click Close
Windows to exit.
____ 4. Reboot the Fusion forecourt controller by power cycling the system.
____ 5. From Internet Explorer, click the Tools tab then select Internet Options.
____ 6. Click the Languages button then select the desired language from the list.
____ 7. Click the Move Up button until the selected language is displayed at the top of the list.
____ 8. ClickOK then OK to exit back to Internet Explorer. Close Internet Explorer and re-open to start a new
session using the desired language.
Local Mode
____ 1. If logging on using local mode, Select the ADMIN user and enter the password of Dresser3141 then click
the Login button.
____ 2. Click Configuration then Generic. Select the Forecourt Manager module then click the Search button.
____ 3. Scroll down to the Language option and click Language. Select the desired language from the pull-down
and click the Submit button.
____ 4. Click Send new Configuration to Fusion. The Fusion forecourt controller should respond with an OK
message. Click Close Windows to exit.
____ 5. Reboot Fusion forecourt controller by power cycling the system.
11.2.5 Wizard
The Wizard is used to automatically set the most common pump programming settings when configuring a
Fusion forecourt controller. The Wizard will ask for equipment and site layout information and configure the
Fusion forecourt controller based on this input.
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____ 1. Log into the Web UI, Using Internet Explorer and navigate to Configuration > Others > Wizard to open the
first window of the Wizard.
Figure 11-6 Welcome to Configuration Wizard Window

Enter the following station configuration information in this window.
• Number of underground fuel storage tanks at the site
• Number of different products in the tanks
• Does the site sell blended grades - If so, how many?
• Number of pumps (fueling points)
• What brand of pumps do you have
• Are any of the underground tanks parallel or manifold suction type
• What type of Tank Monitor (if any)
____ 2. Click the Next button to continue, and the following window will be displayed.
Figure 11-7 List of Product Window

____ 3. This window is used to define the fuel product that resides in the underground tank. Enter the following fuel
product information.
• Name of the fuel product
• Number of the fuel product
• Fuel product type
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• Color to be used to define this grade
Figure 11-8 List of Tanks Window

____ 5. This window is used to define the configuration of the underground fuel tanks at the site. Enter the
following fuel product information.
• Assign the tank number
• Assign the product that is in the tank
• Define the tank capacity
Figure 11-9 List of Grade IDs

____ 7. This window is used to define the configuration of the fuel grades at the site. Enter the following fuel grade
information.
• Assign the Grade ID
• Assign the Grade Number
• Select the High Product source
• Assign the percentage of High Product used in the fuel grade (set at 100% for pure grades)
• Select the Low Product source (do not select a Low Product source for pure grades)
• Assign the percentage of Low Product used in the fuel grade (set at 0% for pure grades)
• Define the Measure Unit (Gallons or Liters)
• Select a color to represent the grade
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Figure 11-10 List of Communication Window
____ 9. This window is used to define the communication loops and assign them to physical ports on the GRIBs
which are installed in the Fusion forecourt controller. The GRIBs vary according to their function but
generally are used to communicate with the various devices on the forecourt. Enter the following
communication information.
• Device ID - Define a communication loop ID that will be used to identify the communication loop on the selected
GRIB.
• Type - Define the communications type to use for this communications loop.
• Port Name - This is the device name used by the Linux operating system to define the physical GRIB port on the
GRIB.
• Echo - This is normally set to ON.
____ 10. Click the Next button to continue, the following window will be displayed.
Figure 11-11 List of Assigned Pumps

____ 11. This window is used to define the pump type and to assign a communications loop to the pump. Enter the
following information.
• Brand - Use the pull-down to select the brand of the pump.
• Hoses Qty. - Enter the number of grades the pump dispenses.
• Loop Manager - Use the pull-down to select the communications loop that the pump (fueling point) uses.
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Figure 11-12 List of Hoses Window
____ 13. This window is used to assign fuel grades to the individual logical nozzles of the pump (fueling point). You
also assign the Suction high and Suction low to the hose which will determine the tank used and product
that is dispensed from the hose. For a pure grade, the Suction high programming is used to determine the
Grade for the hose. For a blended grade, the Suction high is programmed as the high grade and the
Suction low is programmed as the low grade.
• Physical ID - This value is the physical position number of the hose. The Physical ID is the same as the logical
nozzle assignment, however the Physical ID is counted starting with zero whereas the logical assignment is
counted starting with one (e.g. logical nozzle 1 has Physical ID 0).
• Grade ID - This value is the Grade Name for the product assigned to the hose.
• Suction high - This value is the fuel product used for a pure fuel grade. It is also the fuel product used as the high
product of a blended grade.
• Suction low - This value is not used for a pure fuel grade, however this is the fuel product used as the low prod-
uct of a blended grade.
NOTE: When entering the Physical ID above you can optionally leave the value at zero, then use Learning Mode to
physically lift each nozzle of the dispensers one at a time to “learn” the ID and automatically enter the
value.
____ 14. Once all the hoses have been programmed click the Next button to continue, and the following window
will be displayed.
Figure 11-13 End Process Window
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____ 15. This completes the Wizard pump programming. Click the End Process button to save the configuration in
memory. This configuration has not yet been sent to the Fusion forecourt controller so additional
programming can be done if required prior to sending the configuration to Fusion forecourt controller. The
following window will be displayed after the wizard saves the configuration programming.
Figure 11-14 Wizard Complete

____ 16. Click the Done button to exit the Wizard.
17. If additional configuration is required continue with Section 11.3. If configuration is complete, apply the
configuration as follows.
____ a. Navigate to Configuration > Maintenance > Apply Configuration, and then click OK when the
configuration is successfully applied.
____ b. Navigate to Configuration > Others > Reboot Fusion.
____ c. Select the Reboot Fusion button and the system will display:
The system will stop Fusion forecourt controller processes, shutdown the operating system and then reboot.
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11.3 Payment Types
Figure 11-15 Payment Types Menu

In the menu of payment types can vary according to the Fusion forecourt controller license and modules
installed. There are types of payments that belong to the system and can not be modified, and there are others
that come pre-loaded with the system. Other types of payments can be made by choosing a payment group,
as seen in the next few screens.
Figure 11-16 List of Payment Types

If you press the link Add New it displays the following screen, beneath the table of payment types, containing
the necessary fields to create a new type of payment:
Figure 11-17 Add Payment Types
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When creating a new payment type, you must choose the payment type from the Group pull-down, The
options can be configured:
Note: As with most screens modification of data, the ID field can not be changed. In this case, the Payment ID
field can be changed.
Once you've created or modified as necessary, should click on the link Send updated data to Fusion, which
will send the changes to the controller, to verify and update with the payment type. In this case a screen
messaging, confirming the change.
11.3.1 Payments
Log into the Web UI, Using Internet Explorer and navigate to Configuration > Generic > Payments.
Figure 11-18 Payments Parameters

This module groups the parameters relating to the payment of the sales generated at the pump.
* Auto Clear ID: Parameter indicates the type of payment that will be used when a pump sale is
automatically cleared. The sale can be set to Automatic or Unpaid and can be assigned per pump.
* Pending Sale: This value represents the number of stacked sales that will be allowed at the pump.
* Maximum Pending Sale Time: This value represents the maximum time that a sale will remain in a
pending state in seconds. A value of 0 means no maximum.
* Pending Sales Pay ID: When a pending sale is automatically paid then use this payment method.
Either Automatic , Unpaid, or leave at Select Value.
Click Send new Configuration to Fusion to send changes to the Fusion forecourt controller.
11.3.2 Service Modes

Log into the Web UI, Using Internet Explorer and navigate to Configuration > Generic > ServiceModes.
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Figure 11-19 Service Mode Parameters
This module defines the Service level of the defined pump. The choices are Full Service or Self Service and
can be defined on a per pump basis.
Click Send new Configuration to Fusion to send changes to the system.
11.4 Pump Groups
Figure 11-20 Pump Groups Menu

It is often useful to group certain reports by a specific group of pumps. To create a logical name for each
grouping of pumps, you must enter the menu Groups.
11.4.1 Groups
Existing entry
Figure 11-21 List of Pump Groups
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In the above example, you can create new groups by selecting Add New or you can modify existing groups by
selecting an existing entry under the Group Id column. The following screen will be displayed.
Figure 11-22 Add Pump Groups

On this screen you can enter the group name, and description then select the Add or Submit button to save.
Select the Add New link to create the pump group. Select Detail then Add New to assign pumps to the group.
To edit or delete a group, select the link in the "Group ID".
Note: A group can not be erased, if you have pumps associated with it.
At all times, if you want to display the group assignments, select the Detail link.
Figure 11-23 List of Pump Groups Complete
11.4.2 Assign Pump
Figure 11-24 Assign Pump Menu

Select Assign Pump and a table loaded with all the groups so far will be displayed. To access the detail of the
group select the link under the Group ID column. The following window will be displayed.
Figure 11-25 List of Assigned Pumps
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To add a new pump, select Add New. The following screen is displayed where you can assign a pump to the
group. Select the Add button to continue.
Figure 11-26 Add Pump

To remove a pump of the association to the group, select the pump you want, select the button Delete. See
the following figure.
Figure 11-27 Delete Pump
11.5 Veeder-Root BIR Installations with EDIM

If the site has a Veeder-Root Business Inventory Reconciliation (BIR) system installed then the installation of
the Fusion forecourt controller is different depending on the hardware at the site.
The Electronic Dispenser Interface Module (EDIM) solution sends commands from the Fusion forecourt
controller to the EDIM over a serial link by capturing pump control data and sending it to the EDIM module in
the Veeder-Root. A serial communication channel and a Tank Monitor must be defined in the Fusion forecourt
controller (via the Web UI) to enable this feature.
____ 1. Plug EDIM cable into DB9 EDIM connector on the Fusion forecourt controller. See Figure 12-1.
____ 2. Log into the Web UI, Using Internet Explorer and navigate to Configuration > Devices >
Communications.
Figure 11-28 EDIM Programming 1

____ 3. Select Add to bring up the next screen where you enter BIR1 then select Serial and click OK.
Figure 11-29 EDIM Programming 2
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____ 4. The following programming window is then displayed where the BIR1 programming values are set.
Figure 11-30 BIR1 Programming

Set the following values:
Baud Rate: 9600
Device ID: BIR1
Parity: ODD
Word Len: 7
Port ID: /dev/ttyS2 (COM3, the 3rd Serial Port - this is case sensitive and zero based!)
Stop Bits: 1
____ 5. Leave the other values unchanged and press Apply Changes.
____ 6. Next, Add a Tank Monitor by going to Configuration > Devices > TankMonitor and clicking Add. The
following window will then be displayed.
Figure 11-31 Tank Monitor Programming 1
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____ 7. Enter 1 and select Veeder from the pull-down and then press OK. The following window will be displayed.
Figure 11-32 Tank Monitor Programming 2

Set the following values:
Communications: BIR1
Send Transactions: YES
____ 8. Leave the other values unchanged and press Apply Changes then click Close Windows to exit.
____ 9. Reboot the Fusion forecourt controller for the changes to take effect.
11.6 Veeder-Root BIR Installations with CDIM

If you are installing the Fusion forecourt controller in a site which utilizes a Veeder-Root BIR (Business
Inventory Reconciliation) system, the following instructions will guide you through configuring the system to
work with the Fusion forecourt controller. The CDIM (Current Loop Dispenser Interface Module) has three
communications ports but the only ones that are used are Port 1 and Port 2.
Port 1
Port 2
Port 3
Figure 11-33 Veeder-Root CDIM Ports

Each CDIM port is attached to one (1) CAB (Cable Adapter Box) which can handle up to 16 Fueling Positions.
If a site has more than 16 Fueling Positions then a second CAB is required.
When a CAB is connected to a Current Loop GRIB, it will plug into Port 4 at pins 3(+) and 4(-). Pins 1 and 2 are
not used and should be connected with a 100 Ohm resistor as in Figure 11-34. This leaves Port 1, Port 2 and
Port 3 as connection points for the current loop wires coming from the dispensers.
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If a site has 16 Fueling Points they can be connected using one CAB and two Current Loop GRIBs. One GRIB
connects the 16 Fueling Points and the 2nd GRIB connects the CAB at port 9.
11.6.1 Connect the CABs

____ 1. Disconnect the CAB communications cable(s) which are connected to the Wayne Data Distribution box.
(Make a note of the polarity of the wires when disconnecting.)
____ 2. Attach the CAB communications wire(s) to a GRIB plug. See the example below.
- Pin 4
Pin 3
BIR
+
Figure 11-34 GRIB Plug

____ 3. Insert the GRIB plug into Port 4 of Current Loop GRIB #1.
____ 4. If there are two CABs then the CAB GRIB plugs get plugged into the Current Loop GRIB #2 at ports 8 and
9. See Figure 11-37.
See the following examples for configuration options when connecting up the CABs.
Figure 11-35 One CAB - 12 Fueling Points
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Figure 11-36 One CAB - 16 Fueling Points
Figure 11-37 Two CABs - 24 Fueling Points
11.6.2 Connect the Dispensers

____ 1. Connect the dispenser with the lowest Fueling Point number to the Current Loop GRIB #1 beginning with
Port #1. See Section 12.6. Continue plugging dispensers into the remaining available GRIB ports.
____ 2. If there are 2 CABs at the site then continue plugging any additional dispensers into the next set of GRIB
plugs on Current Loop GRIB #2.
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11.6.3 Programming the Fusion Forecourt Controller for Sites with Veeder-Root BIR
Click Configuration
then select Generic
Figure 11-38 Programming Screen 1

____ 1. Click Configuration, and then select Generic. The following window will be displayed.

____ 2. Select BIR Port from the module pull-down, then click Search. Scroll the display down to show the list of
BIR Port Parameters.The following window will be displayed where you verify that the BIR port is set to
Enabled.

____ 3. Click Port to open the following window. Use the drop-down to select the BIR CAB port address as
follows, and then click Submit. See the following window.
• Select /dev/gribport4 when the configuration has 1 Current Loop GRIB and 1 CAB
• Select /dev/gribport9 when the configuration has 2 Current Loop GRIBs and 1 CAB
• Select /dev/gribport8 when the configuration has 2 Current Loop GRIBs and 2 CABs
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____ 4. Click Second Port Pump to open the following window. Enter a number in the Param Value field as
follows, and then click Submit.
• If using a second BIR CAB, enter the lowest fueling point address of the pumps that are plugged into Current
Loop GRIB #2 - Port 6.
• If using only one BIR CAB, enter ‘0’ as the second port is not used.
IMPORTANT: If the "Second Port" is not used, then the "Second Port Pump" MUST be set to '0'

____ 5. If you are installing a site that has 2 CABs, then you will need to program the communication for the
second CAB. Click Second Port and the following window will be displayed.
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____ 6. Using the drop-down, select the second BIR CAB port address as /dev/gribport9 then click Submit.
____ 7. Click Send new Configuration to Fusion to download the new configuration to the Fusion forecourt
controller. The following windows will then be displayed.
then

____ 8. Click Close Windows to complete the process.
____ 9. Navigate to Configuration > Maintenance > Apply Configuration, and then click OK when the
____ 10. Navigate to Configuration > Others > Reboot Fusion.
____ 11. Select the Reboot Fusion button and the Fusion forecourt controller will display:
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The system processes shutdown the operating system and then reboot.
11.7 Programming the Fusion Forecourt Controller for 3rd Party POS
To access the Fusion forecourt controller programming screen, open an Internet Explorer session using a
laptop connected to the ethernet port.
____ 1. Change the IP address of the laptop to match the IP scheme on the Fusion forecourt controller so that a
connection can be made.
____ 2. Change your Subnet Mask to 255.255.255.0
____ 3. Start an Internet Explorer session.
____ 4. In the Explorer Address bar, type in 192.168.1.20 and press <enter>. The following Screen will then be
displayed.

____ 5. Enter Admin in the Login field and enter Dresser3141 in the Password field. Press <enter> to continue.
The following window will be displayed.
Click Configuration
then select Generic

____ 6. Click Configuration, and then select Generic. The following window will be displayed.
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Select HyperPIB or PAM Emulator
from the module pull-down
Click Search
Figure 11-47 Search Generic Parameters

____ 7. If configuring the Fusion forecourt controller to use the HyperPIB, continue with Section 11.7.1 below. If
configuring Fusion to use PAM Emulation, skip to Section 11.7.2 on page 37.
NOTE: When configuring the Fusion forecourt controller in Console mode without connecting a 3rd pary POS, be
sure to disable both the HyperPIB module (see step 2 on page 35) and the PAM Emulation module (see step
2 on page 37). Skip to Section 11.7.3 on page 38 and complete the Fusion forecourt controller configuration.
11.7.1 HyperPIB Configuration

____ 1. Select HyperPIB from the module pull-down, then click Search. Scroll the display down to show the List
of Generic Parameters.The following window will be displayed.
Enabled
Serial Port
Baud Rate
Authorization
Timeout
POS
Configuration
Figure 11-48 HyperPIB Generic Parameters

____ 2. Click Enabled to open the following window where you verify that 1-ENABLED is set from the Param pull-
down. Click the Submit button to save. See the following window.
NOTE: When setting up the HyperPIB Configuration then set the value for the PAM™ (Pump Access Module)
Emulator Communication Type to blank. See step 2 on page 37.
Submit button
Param Value
Figure 11-49 HyperPIB Programming Screen 1
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____ 3. Click Serial Port to open the following window where you verify that /dev/ttyS0 is set from the Param
pull-down. Click the Submit button to save. See the following window.
Submit button
Param Value

____ 4. Click Baud Rate to open the following window where you verify/set the Baud Rate to match your POS.
Click the Submit button to save. See the following window.
Submit button
Param Value

____ 5. Click Authorization Timeout to open the following window where you verify/set the Authorization Timeout
value to 300. Click the Submit button to save. See the following window.
Submit button
Param Value

____ 6. Click POS Configuration to open a window where you set the option to Yes or No. The first time you
configure the Fusion forecourt controller this value should be set to Yes to allow your system to download
configuration data to the Fusion forecourt controller. Once the download is complete, and the system has
been verified to be operational, return to this option and set it to No to prevent any changes to the Fusion
forecourt controller configuration. Click the Submit button to save.
Submit button
Param Value
____ 7. Skip to Section 11.7.3 to complete the configuration changes.
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11.7.2 PAM Emulation™ Configuration
____ 1. Select PAM from the module pull-down, then click Search. Scroll the display down to show the List of
Generic Parameters.The following window will be displayed.
Communication
Type
Baud Rate
POS
Configuration
Figure 11-54 PAM Generic Parameters

____ 2. Click Communication Type to open the following window where you set select Serial from the Param pull-
down. Click the Submit button to save. See the following window.
NOTE: When setting up the PAM Emulator be sure to set the HyperPIB Enabled option to 0-DISABLED. See step 2
on page 35
Submit button
Param Value
Figure 11-55 PAM Programming Screen 1
____ 3. Click Baud Rate to open the following window where you use the Param Value pull-down to set the baud
rate to match your POS. Click the Submit button to save. See the following window.
Submit button
Param Value

____ 4. Click POS Configuration to open a window where you set the option to Yes or No. The first time you
configure the Fusion forecourt controller this value should be set to Yes to allow your system to download
configuration data to the Fusion forecourt controller. Once the download is complete, and the system has
been verified to be operational, return to this option and set it to No to prevent any changes to the Fusion
forecourt controller configuration. Click the Submit button to save.
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Submit button
Param Value
11.7.3 Save the Configuration

____ 1. Click Send new Configuration to Fusion to download the new configuration to the Fusion forecourt
controller. See Figure 11-47.
____ 2. Click Close Windows. Next, click Configuration, and then select Generic. The following window will be
displayed.
Select ForecourtManager from the

module pull-down

____ 3. Select Forecourt Manager from the module pull-down, then click Search. Scroll the display down to
show the List of Generic Parameters.The following window will be displayed.
Retries for
auth/preset

____ 4. Click Retries for auth/preset to open the following window where 3 is set from the Param pull-down. This
controls the amount of retries that will be allowed during a prepay for a customer to select the grade to
pump. Click the Submit button to save. See the following window.
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Submit button
Param Value

5. Click Send New Configuration to Fusion.
then

____ 6. Click Close Windows to complete the process.
____ 7. Navigate to Configuration > Maintenance > Apply Configuration, and then click OK when the
____ 8. Close the Internet Explorer window by clicking the X in the upper right corner.
____ 9. Initialize Fuel Configuration on your POS. Once the download is complete, return to the Fusion forecourt
controller programming above to disable POS downloads.
____ 10. You will have to do a separate price change on the Ruby before the prices go out. The full initialize will not
send the prices.
11.8 Connecting to the POS

NOTE: The cable length for serial communications @ 9600 baud is officially 50 feet. However, tests have shown that
lengths 150 or 200 feet have been known to work.
11.8.1 VeriFone Ruby, Topaz or Sapphire

____ 1. Connect serial port adapter PN WU002401-0001 to the DB9 port on the serial GRIB for POS
communication to the card readers. See Figure 12-8.
____ 2. Connect serial port adapter PN WU002402-0001 to the HyperPIB POS connection for POS communication
to the pumps. See Figure 12-8.
____ 3. Connect the VeriFone serial cable (PN 13836-01) to from the serial port adapters on the Fusion forecourt
controller to the designated serial port on the VeriFone POS.
NOTE: If the Fusion forecourt controller Console is used as a backup when the Ruby system is down, you must
disconnect the Ruby to Fusion forecourt controller communications cable so that sales don’t get sent to the
Ruby system.
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11.8.2 Gasboy POS or Fiscal POS
NOTE: This also applies to any other POS that is using standard PC serial ports (DB9 male).
____ 1. Connect a Null Modem cable from the POS pump communication port to the Fusion forecourt controller
HyperPIB POS connection.
____ 2. Connect a straight-though serial cable from the POS card reader communication port to the Fusion
forecourt controller Serial IN port on the CAT GRIB.
11.9 Installing a Site with Tokheim Dispensers

____ 1. The Tokheim cable coming from J6 of the Tokheim 67A box in the following diagram (Cable A) will need to
be modified. Do not modify Cable B! The connector opposite the AMP 16 connector needs to be replaced
with a DB 9 pin female connector wired as follows:
Figure 11-62 Tokheim Wiring

____ 2. Pins 10 and 11 are soldered together to allow the E-Stop relay activation. A switch may be wired into this
for the E-Stop purpose if required.
____ 3. The DB 9 Pin Female connector will connect to the BIR Connection on the Fusion forecourt controller. See
Figure 12-7.
____ 4. To configure a communications device on the Fusion forecourt controller, go to Configuration > Devices
> Communication. Click the Add button to create a new device, the following window will be displayed
where you name the device Tokheim and define it as a Serial device then click OK.
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Define as Serial
Figure 11-63 Add Tokheim Communications Device
Figure 11-64 Communication Programming - Tokheim

5. Change the PortID to be /dev/ttyS2 then check that the remaining options are set as in the example above.
Click Apply Changes to save the current settings.
6. Go to Configuration > Devices > Loop Manager then click the Add button to create a Loop Manager
device. Define the device as Tok_Loop and then press the OK button to save.
Figure 11-65 Loop Manager - Tokheim

7. The following window will be displayed where you define the Communications Port as Tokheim then click
Apply Changes.
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Define as
Tokheim
Figure 11-66 Loop Manager - Tok_Loop

8. The following window will then be displayed showing the completed Loop Manager Setup.
Figure 11-67 Loop Manager Setup - Tokheim

9. Create the Tokheim pump devices and assign them to the newly created Loop Manager. On the Fusion
forecourt controller go to Configuration > Devices > Pump then click the Add button to create a new
pump.
Define as
Tokheim-US
Figure 11-68 Add Pump Device

10. Define the first Tokheim pump as 1 then use the pull-down to define the type as Tokheim-US. Click the
OK button to save and continue. The following programming window will be displayed where you assign
the newly created Communications Loop.
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Figure 11-69 Tokheim Pump Programming
11. Configure the pump settings according to the type of dispenser that you are setting up. Be sure to program
the following correctly:
• Pump Type of Computer - Simple or Double
• Hoses - Number of hoses
• Communications Loop - Tok_Loop
12. Click Apply Changes to save and continue. Repeat from Step 9 for addition dispensers.
11.10Installing a Site with a Mix of Wayne and Gilbarco Pumps

If you are Installing the Fusion forecourt controller at a site with a mix of pump brands like Wayne and Gilbarco,
then you will need to configure the site according to the following instructions.
____ 1. Make sure all the Gilbarco pumps are isolated on their own channel.
NOTE: If you are connecting a BIR, then you must use the EDIM solution since the CDIM solution will not work with
this configuration.
____ 2. Program the pumps at the POS as if they were all Wayne pumps.
____ 3. After you have created your configuration with the option of “POS Config = YES”, then turn the setting off
( set to “NO” ).
____ 4. Next, from the Web UI, delete the Wayne pumps that are going to be the replaced with Gilbarco pumps.
NOTE: Pumps cannot be removed from the middle of the list. The Gilbarco pumps will need to be added/replaced
at the end of the list.
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____ 5. From the Web UI, add the Gilbarco Pumps.
____ 6. Apply the Configuration.
____ 7. Go to Operations > Forecourt > Current Status and open the “Closed” pumps (Gilbarco).
11.11 Installing a Site with 32 Pumps

If you are Installing the Fusion forecourt controller at a site with 32 dispensers, then you will need to configure
the site according to the following instructions.
____ 1. Program the pumps from the Web UI as Gilbarco or Wayne pumps.
____ 2. Gilbarco physical fueling point addresses are limited to 16 unique addresses (typically ranging from 1-16).
Therefore, the first 16 Gilbarco fueling point addresses are connected to the first GRIB board. The
remainder of the Gilbarco fueling point addresses restart the numbering and are connected to the second
GRIB.
NOTE: When connecting up the dispensers to the GRIB boards, be sure that no two identical physical fueling point
addresses are connected to any one GRIB board.
____ 3. Wayne physical fueling point addresses range from 1-24. Therefore, the physical fueling point addresses
can go from 1-24 then repeat 1-8 for the 25th through the 32nd pump. This means that the Wayne
physical fueling points can cover 4 ports of the first GRIB board and 2 ports of the second GRIB board
before the addressing repeats.
____ 4. From the Web UI, the Gilbarco Pumps are addressed as 1-16 then start over again with 1-16.
____ 5. From the Web UI, the Wayne Pumps are addressed as 1-24 and then start over again with 1-8.
____ 6. Apply the Configuration.
NOTE: Refer to Figure 12-15 for the 32 pump wiring diagram.
11.12Installing a Receipt Printer in the Console Configuration

The following instructions detail the steps necessary to set up a printer on the Fusion forecourt controller
when setting up the Console. The standard printers that are used are TPG A794 or TPG A798. These instruc-
tions assume that the connection type used for the printer is serial and that the printer is connected to the
Fusion forecourt controller using the available serial port. Perform the following steps to set up the printer:
NOTE: A default printer called PRINTER should already be installed.
• Create printer
• Configure Printer parameters
• Assigning the new printer to default POS (which has pos ID 0)
• Configuring Receipt layout
• Assigning Receipt Layout
• Apply the entire configuration to the Fusion forecourt controller
• Test configured printer from Fusion forecourt controller console.
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11.12.1 Create the Printer
1. Go to POS > Configuration > Printers to add/see available printers.
Figure 11-70 Create the Printer 1

2. Click on Add New to add new printer with following information.
• Printer Id - Anything alphanumeric - Configure it to be TPG
• Computer - Fusion (typically this would remain same for Fusion forecourt controller)
• Type - Serial (this is standard since we use serial communication for Fusion forecourt controller
printers)
11.12.2 Configure Printer Parameters

Click on printer Id to configure printer parameters. You will see a screen similar to following example.
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Click on each individual parameter to enter corresponding values for each of them.
Add following values for the parameters.
• Bauds - 9600
• Parity - none
• Stop bits - 1
• Data bits - 8
• Flow - none
• Port Name - /dev/ttyS3 (Capital 'S' -Case sensitive configuration)
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11.12.3 Adding the New Printer "TPG" to the POS
Go to POS > Configuration > POS and click on Pos Id "0". If you have more than one POS configured then
select whatever POS ID you want to setup the printer. For now, use the default POS which is ID 0. After
selecting POS you will see a parameter configuration window. Click "add new" and select parameter
PRINTER_ID and add printer ID "TPG" or whatever ID you have given as part of printer creation.
Figure 11-74 Add New Printer TPG
11.12.4 Assigning Receipt Layout

1. Go to POS > Customers > Customers Types and the following window will be displayed.
Figure 11-75 Assign Receipt Layout

2. Click on customer type GEN.
3. Select the default receipt layout for sale ticket and click Submit. The example above has a receipt format
called SALE.
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11.12.5 Configuring Automatic Receipt Printing
1. Go to POS > Configuration > POS and click on Pos Id "0". If there is more than one POS configured then
select whichever POS ID that you want to setup the printer. For now use default POS which as id 0. After
selecting the POS ID you see the List of Results Parameter Configuration window. Click "add new" and
select parameter RECEIPT_PRINT_IMMEDIATELY. Click Add to add the parameter to the List of Results
Parameters Configuration.
Figure 11-76 Configure Automatic Receipt Printing 1

2. Click on the Print Receipts immediately parameter which is now listed in the List of Results
Parameters Configuration table. Click on the Print Receipts immediately pull-down to select the
behavior of the receipt printing function.
Figure 11-77 Configure Automatic Receipt Printing 2

3. Select from:
* No, Manually to only print the receipt manually
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* Yes, Automatic to print the receipt automatically (default)
* No, but Open Drawer to only open the drawer
4. Select the default receipt layout for sale ticket and click Submit. The example above has a receipt format
called SALE.
Note: This setting can be used to save receipt paper
11.12.6 Apply the Entire Configuration to the Fusion Forecourt Controller System
This is Final step in the process.
1. Go to POS > Configuration > Maintenance > Apply Configuration this will open a pop up window with
status.
Figure 11-78 Apply Configuration
11.12.7 Testing the Printer

1. Start Fusion forecourt controller console if it is not running. If it is already running, restart the Fusion
forecourt controller console for recent printer changes.
Figure 11-79 Test the Printer

2. Log in to the Fusion forecourt controller then Click Config > Printer.
3. You should see printer with the id 'tpg' or whatever the name you have given appear as a printer icon. If the
printer is not added then you won't see printer icon here. You can validate printer configuration too here.
4. Click on Test Page and if you see printer printing "print test" 4 times then you have successfully configured
the printer.
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11.13Prices
Figure 11-80 Price Change Menu

The prices of fuel products are administered by the Fusion forecourt controller, and must always be modified
using the Fusion forecourt controller and never directly at the dispenser. Should the Fusion forecourt controller
and the dispenser have a different price, the system will correct the price on the dispenser.
NOTE: Price changes can be done from the Console as well.
11.13.0.1 Entering a Price Change
Click Add New and
the following table

will be displayed
Figure 11-81 Enter Price Change

Use the link Add New, as shown in the image above to enter a new price change to be implemented by the
Fusion forecourt controller.
The first thing to do is indicate the date and time that the price change should be implemented. To implement
immediately, enter/indicate a date and time equal or prior to the time on the Fusion forecourt controller
console.
It is important to note that the date and time of the Fusion forecourt controller may vary from the date and time
of the machine that is running the web browser. This can be viewed on the top of the page header.
The date can be entered manually, in YYYYMMDD format (year, month and day) or by pressing on the
calendar image to the right of the date field, the same holds true when entering the time format hhmmss (hour,
minutes and seconds). Once these two fields are complete, press the Add button.
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Figure 11-82 Enter Price Change cont.
This enables the entry of new prices for products that need to change.You only need to enter the products that
need a price change while the other prices remain the same.
Select the product, the price level and then the unit price you want, including the decimal point. Then press the
Submit button, and continue with the next product.
Figure 11-83 Price Change Detail

Once the entry of all products with price changes has been made, we need to tell the Fusion forecourt
controller to update the data for processing. Click the link to the left of the page labelled Send price change
update to Fusion. See below.
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Figure 11-84 Send Price Change to the Fusion Forecourt Controller
11.13.0.2 Verifying the Price Change

Once the price change has been sent to the Fusion forecourt controller, you can track the status of it by
viewing the table List of Price Change. This tracks the status of price changes, you can refresh the content,
(usually by pressing the 'F5' on the browser).
Figure 11-85 Verify Price Change

You have to pay attention to three areas:
* Processed Date: This indicates the date on which the Fusion forecourt controller processed price
changes.
* Processed Time: This indicates the time that the Fusion forecourt controller processed price
changes.
* Result: The result of processing price changes. OK means that the change was implemented
correctly. ERROR indicates that something went wrong.
More information can be obtained through the reports of price changes, in the Reports section.
11.13.0.3 Editing a Price Change

Price changes that have not yet been processed by the Fusion forecourt controller, can be edited.
For editing, just click on the latest entry under the Price ID column in the List of Price Change table for the
change you want to edit.
Once edited, you have to press the Submit button under the List of Price Change Detail table for information
to be recorded. As before, Click the link to the left of the page labelled Send price change update to Fusion,
and the updated information will be sent to the Fusion forecourt controller.
Processed price changes can not be edited.
11.13.1 Current Prices
Figure 11-86 Current Prices Menu
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This functionality is used to display the current fuel prices of different grades.
Figure 11-87 Current Prices
11.13.2 Price Levels
Figure 11-88 Price Levels

This functionality is used to change to the current price levels for each dispenser. Once you click on Price
Levels the following window is displayed:
Figure 11-89 Price Levels Programming
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Using the pull-down for each Device Id, chose a price level for each dispenser, then press the Submit button.
11.13.3 Price Change Delta Amount

Price Change Delta amount is the allowable amount of a price change. Price changes cannot be in excess of
of this programmed limit. This is to prevent programming errors during price changes.
1. Go to Configuration > Generic and select the Forecourt Manager module.

2. Click Price Change Delta. Enter a parameter value and then click the Submit button.
Figure 11-90 Price Change Delta
11.13.4 Gallons/Liters Programming

Unit of measure programming is done from the Configuration > Devices > Grade section.
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Figure 11-91 Grade Programming
1. Select each of the grades that are available and then select Gallons or Liters from the Measure Unit pull-
down. Click on Apply Changes to save.
2. Next, navigate to POS > Inventory > Products, then click each Fuel ID.
3. Select the unit of measure from the Unit pull-down then click Submit.
4. Repeat for all the Fuel IDs listed.
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Figure 11-92 Unit of Measure Programming
11.14 Emergency Button Access and Confirmation

Emergency Button Access and Confirmation programming controls whether or not the Emergency button will
be available without a user being logged in and whether or not a confirmation is required.
1. Go to Configuration > Generic and select the Forecourt Manager module.
2. Click Emergency Button Access. Select Enabled or Disabled and then click the Submit button.
Figure 11-93 Emergency Button Access Programming

3. Click Emergency Stop Confirmation. Select Enabled or Disabled and then click the Submit button.
Figure 11-94 Emergency Stop Confirmation Programming
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11.15 Language Programming
The Fusion forecourt controller can be programmed for different languages to be used for the Web UI or for the
Console. Language programming is done from the Web UI which can be accessed remotely through a web
browser or locally using the Browser button from the Console.
1. Go to the Web UI and navigate to Configuration > Generic. Next, select Forecourt from the module pull-
down and click Search.
Figure 11-95 Forecourt Manager Search

2. Click on the Language option to open the following window.
Figure 11-96 Language Parameter

3. Select the desired language from the pull-down then click Submit. Next, click Send New Configuration to
Fusion.
11.16 Date and Time Programming

The current Date and Time can be programmed from the Browser by going to Configuration > Others > Set
Date and Time. The following window will be displayed.
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Calendar button
Figure 11-97 Set Date and Time

Set the date using the Calendar button, then set the time using the “hhmmss” format. Finally, set the Time
Zone using the Time Zone pull-down.
11.17Station Name and Address Programming

The station name and address can be programmed from the Browser by going to Configuration > Generic >
Forecourt Manager. Program the following values.
• Site Number
• Site Name
• Site Address
• Country
• Currency
• Currency (Abbrev)
• Date Format
11.18Fusion Forecourt Controller Health Programming

The Fusion forecourt controller can be programmed to take periodic measurements of internal temperatures
and also record the number of system Boots that have occured. Go to Configuration > Generic. Use the
module pull-down to locate FusionHealth. See the following example.
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Figure 11-98 Configuration > Generic > FusionHealth
1. Select FusionHealth and then click the Search button. The following options will be displayed.
Figure 11-99 Fusion Health

2. Click on the Enabled selection to enable or disable the Fusion Health options then click Submit.
Figure 11-100 Enable Fusion Health
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3. Click on the System Boot selection to enable or disable the System Boot logging, then click Submit.
Figure 11-101 Enable System Boot Logging

4. Click on the CPU Temp selection to define in minutes, how often to take the CPU temperature, then click
Submit.
Figure 11-102 Enable CPU Temp

5. Click on the System Temp selection to define in minutes, how often to take the System temperature, then
click Submit.
Figure 11-103 Enable System Temp

6. Click on the Keep Temperature Logs selection to define in days, how many days worth of logs to save,
then click Submit.
Figure 11-104 Keep Temperature Logs
11.19 Database Maintenance

Database maintenance involves a periodic cleanup of the database to purge unused and old data. The Fusion
forecourt controller can be programmed to perform this maintenance task at a specific time. Go to
Configuration > Generic. Use the module pull-down to locate Database Mant then click the Search button.
See the following example.
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Figure 11-105 Database Maintenance
1. Click on the Enable purification selection to enable or disable the database purification process then click
Submit.
Figure 11-106 Enable Database Purification Process

2. Click on the Purification day selection to define the day of the week to execute the purification process
then click Submit.
Figure 11-107 Define Database Purification Day

3. Click on the Purification time selection to define the time of day to execute the purification process then
click Submit.
Figure 11-108 Define Database Purification Time
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4. Click on the Purification Months selection to define how many months of data to keep in the database
then click Submit.
Figure 11-109 Define Database Purification Months
11.20 Database Backup and Restore

The Fusion forecourt controller database can be backed up and restored using two methods. The first will
backup the database locally on the Fusion forecourt controller. The second will allow you to backup the
database and copy it to a USB key.
Note that during Restore Database and Restore Configuration operations, any running sales will be lost
because the forecourt operations will be stopped.
11.20.1 Database Backup and Restore

Navigate to Operation > Database and the following window will be displayed where you can select from the
following options.
• Backup Database
• Restore Database
• Backup Configuration
• Restore Configuration
Figure 11-110 Database Functions

Select Backup Database to backup the current database. The following prompt will be displayed. Select OK
to continue.
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Figure 11-111 Backup Database
Select Restore Database to restore the current database. The following prompt will be displayed. Select OK
to continue.
Figure 11-112 Restore Database

Select Backup Configuration to backup the current configuration. The following prompt will be displayed.
Select OK to continue.
Figure 11-113 Backup Configuration

Select Restore Configuration to restore the current configuration. The following prompt will be displayed.
Select OK to continue.
Figure 11-114 Restore Configuration
11.20.2 Database Backup Using USB Maker

The USB Maker utility can be used to backup the Fusion forecourt controller database using a USB key.
1. First obtain the USB Maker utility from the ASONet and load it on your laptop.
2. Insert the USB key into your laptop and execute StartUSBMaker.bat, The following window will then be
displayed.
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Figure 11-115 USB Maker Window
3. Select the Backup DB tab; select Permission and USB Drive. Permission of "One Time" will direct the
USB to be used only once. If "Every Time" is selected, then every time this USB is used it will backup the
db - be careful when selecting this option!
4. Press the Submit button. You should get a "successful" notification. Now the USB key is ready to be
used.
5. Remove the USB key from your laptop and insert into the Fusion forecourt controller.
6. The system will beep once after a few seconds indicating the process has started.
7. After a few more seconds, the system will beep 4 times indicating success (3 low tones indicates failure).
The Fusion forecourt controller copies the database to \DresserWayne\Fusion\Backups\Database under a
unique filename. For example, the file DBbackup.fs00089bba86ab-20090903-100748 is created (MAC
address and date/time stamp).
As with all the USB operations, a log file is written to the USB key. Please review this logfile under
\DresserWayne\Fusion\usb.log for detailed information.
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11.20.3 Database Restore Using USB Maker
The USB Maker utility can be used to restore the Fusion forecourt controller database that was backed up
using a USB key.
displayed.

2. Select the Restore DB tab; Press the Upload button and select the location of Database to restore, set
Permission and USB Drive. Permission of "One Time" will direct the USB to be used only once. If "Every
Time" is selected, then every time this USB is used it will restore the db - be careful when selecting this
option!
used.
\DresserWayne\Fusion\usb.log for detailed information
11.21 IP Address Configuration

The Fusion forecourt controller is configured with the IP Address of 192.168.1.20. If you need to change the IP
address you must login the LINUX session with the user "ipchange" with the password "ipchange". There are
three ways to do this, one is connecting a screen and a keyboard to the Fusion forecourt controller, another is
by starting an SSH session through the PuTTy software. The third method involves using USB Maker to
program a USB key to perform the update when the key is inserted into the Fusion forecourt controller.
11.21.1 How to use the Putty Software

1. To access Linux through the putty software go to the Start menu, look up the Putty Shortcut and click on it.
If needed, the Putty software is available for download from the ASONet.
2. To start a session you have to complete the Host Name or IP address field and click Open.
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Figure 11-117 PuTTY Configuration Window
3. The profile of this user will start a session in the IP change script where you can add the new values and
restart the computer to apply the changes.
11.21.2 How to Change the IP Address

If you access through the Putty Software or using a Screen and a Keyboard you will follow the same steps,
first you must login and then you have to add the network values and restart the computer to apply the
changes.
Figure 11-119 Confirmation Screen
11.21.3 How to Use USB Maker to Change the IP Address

The USB Maker utility can be used to change the IP address of the Fusion forecourt controller using a USB
key.
1. First obtain the USB Maker utility from the ASONet and load it on your laptop.
displayed.
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3. Select the Network Configuration tab; enter IP Address, Permission and USB Drive. Permission of "One
Time" will direct the USB to be used only once. If "Every Time" is selected, then every time this USB is
used it will change the IP address - be careful when selecting this option!
used.
After the IP change, the Fusion forecourt controller automatically restarts the network with the new IP address.
There is no need to reboot.
\DresserWayne\Fusion\usb.log for detailed information.
11.22 Fusion Forecourt Controller GSM/DSM Configuration

The Fusion forecourt controller is available in two configurations:
• DSM configuration - includes the letter N in the Hardware Options section (i.e. T / AA1D1 / N / Z)
• GSM configuration - includes the letter O in the Hardware Optionis section (i.e. T / AA1D1 / O / Z)
GSM support is ony available with the SCC-Emulator. To connect a GSM to a 3rd party POS when using the
Fusion forecourt controller HyperPIB/PAM, refer to the POS documentation regarding the correct setup.
If the Fusion forecourt controller was ordered without the DSM option (GSM configuration), it can be modified
to add DSM support. A wiring change inside the Fusion forecourt controller and additional parts are required.
1. If present, remove cable WU001259-0001 from J14 on the CUPS board and COM2 of the SBC. This cable
will not be present on the Fusion forecourt controller UDB replacement. See Figure 12-3.
2. Connect cable WU001265-0001 to J6 on the CUPS board and J8 of the serial GRIB (the CAT GRIB). See
Figure 12-2.
3. Connect WU002344-0001 to the two-pin connector of WU002290-001. See Figure 12-4.
4. Connect the DB9 connector of WU002290-001, that is attached to WU002344-001, to the DSM and the
other to the top DB9 connector of the Fusion forecourt controller.
5. Plug WU002344-0001 into a power outlet.
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11.23 Troubleshooting
After the Fusion Forecourt Controller has been mounted and the system wiring has been completed, all of the
pumps and CATs should be online. If pumps or CATs remain offline then double-check for the correct polarity
of the pump current loop. The CAT communication wiring should also be double checked.
If a BIR system is not used then be sure to remove the resistor from the current loop GRIB of the 4th port.
Otherwise communication errors my occur if the resistor is left connected.
11.23.1 Powering the Fusion Forecourt Controller On and Off

Note that after pressing the power button in order to power down, the Fusion power down sequence can actu-
ally take up to a minute to complete. This is due to the internal battery backup of which is shutting down in a
controlled manner so that no file corruption occurs.
11.23.2 Uncontrollable Sales

If POS configuration changes are made while the pumps are fueling and Apply Configuration is then executed,
then uncontrollable sales may occur. To prevent this, always restart the Console whenever POS configuration
changes are made.
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11.23.3 Fusion Forecourt Controller Components
USB Ribbon USB Ribbon

Cable Cable
Pin 1 is
upper right
hand pin of
2x4 pin header
Pin 1 of ribbon
cable is the red
wire
CUPS Board Atom Board Power to

To GRIB 6-9 To GRIB 1-4
GRIB
(ribbon cable pin 1 - 4) (ribbon cable pin 5 - 8)
Figure 11-121 Fusion Forecourt Controller Components
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12 APPENDIX
12.1 Fusion Forecourt Controller Rear Panel

The following diagrams show the Fusion forecourt controller connections.
BIR/EDIM DSM/GSM
Connection
Power USB CAT GRIB Current Loop

button ports HyperPIB Serial IN
RS485 GRIB (Pumps)
POS Connection RS422/RS232
(CATs)
Transformer Requires Null Modem Requires Serial cable
Ethernet
input PN WU002402-0001 PN WU002401-0001
port
for POS Comm for CAT Comm
Figure 12-1 Rear Panel - Wayne Dispenser Configuration
CUPS
Board
DSM
Cable
Figure 12-2 DSM Cable Connection (WU0001265-0001) (J6 to GRIB J8)
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GSM
Cable
CUPS Board
Figure 12-3 GSM Cable Connection (WU0001259-0001) (J14 to COM2)
Connect to DSM
AC Transformer Connect to DSM

WU002344-0001 connector on
Fusion forecourt
controller
Figure 12-4 DSM Power Cable PN WU002290-001
12.2 Fusion Forecourt Controller Rear Panel - Gilbarco CRIND

The following diagrams show the Fusion forecourt controller rear panel connections for Gilbarco CRINDS
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BIR DSM/GSM
Connection
Power USB CL GRIB Current Loop

Current Loop GRIB (Pumps)
(CRINDS)
Ethernet
input PN WU002402-0001 PN WU002401-0001
port
Figure 12-5 Rear Panel - Gilbarco Dispenser Configuration
12.3 Fusion Forecourt Controller Rear Panel - Console Configuration

The following diagram shows the Fusion forecourt controller connections for the Console configuration.
BIR
Connection
Power Mouse Current Loop

button USB Ethernet GRIB (Pumps)
ports port Printer Console Keyboard
Speaker Transformer Port Display
input
Figure 12-6 Rear Panel - Console Configuration
12.4 Fusion Forecourt Controller Rear Panel - Tokheim Configuration

The following diagrams show the Fusion forecourt controller connections when configured for Tokheim pumps.
P/N 000-940039 Rev. 0E May 2016 73

Pump Communications
From J6 of Tokheim
67A box
Power USB
Ethernet
input PN WU002402-0001 PN WU002401-0001
port
Figure 12-7 Rear Panel - Tokheim Dispenser Configuration
12.5 Serial Port Pin-Outs

There are two serial ports in this Fusion forecourt controller configuration. The HyperPIB DB9 POS connector
on the CUPS board and RS422/232 connector on the GRIB board.
HyperPIB DB9
POS Connector Serial IN RS422/232
Figure 12-8 Serial Port Adapters and Pinouts
74 P/N 000-940039 Rev. 0E May 2016

12.6 GRIB Connectors
NOTE: Each GRIB Channel can connect with two dispensers (4 CATs)
PWR LED RCV LED CH 1
RCV LED CH 3
XMIT LED
Channel 1 Channel 2 Channel 3 Channel 4
RCV LED CH 2
RCV LED CH 4
Pin 1 CATs CATs CATs CATs

Pin 4
1&2 (+) 1&2 (-) 3&4 (+) 3&4 (-)
Figure 12-9 GRIB Connectors - CAT Configuration
P/N 000-940039 Rev. 0E May 2016 75

NOTE: Each GRIB Connector can connect with two dispensers (4 fueling points)
Channel 1 Channel 2 Channel 3 Channel 4
XMIT LED
RCV LED
Pin 1 Pump 1&2 Pump 1&2

Pin 4
(+) (-)
OR
XMIT LED
RCV LED
Pin 1 Pump Pump Pump Pump Pin 4

1&2(+) 1&2(-) 3&4(+) 3&4(-)
Figure 12-10 GRIB Connectors - Wayne Pump Configuration
(-) (+) (-) (+) (-) (+) (-) (+) (-)

(+) (-) (+) (-) (+) (-) (+)
CAT 1&2 CAT 3&4 CAT 5&6 CAT 7&8 CAT 9&10 CAT 11&12 CAT 13&14 CAT 15&16
Figure 12-11 GRIB Plug - Wayne CAT Configuration
76 P/N 000-940039 Rev. 0E May 2016

Pin 4
-
Pump #1
+ Pin 1
Figure 12-12 GRIB Plug - Single Pump (Dispenser) Per Plug Configuration
- Pin 4
Pump #2
+
Pin 1
-
Pump #1
+
Figure 12-13 GRIB Plug - Two Pumps (Dispensers) Per Plug Configuration
- Pin 4
BIR
+
Pin 1
Figure 12-14 GRIB Plug Used for BIR Communication in Channel 4
P/N 000-940039 Rev. 0E May 2016 77

Figure 12-15 HyperPIB 32 Fueling Point Configuration
12.7 Wayne TRAC/Speedpass Connections

Connect WayneTrac/Speedpass to the Fusion forecourt controller HyperPIB system by connecting J4 of the
WayneTrac controller to the GRIB as if it were an additional CAT. It does not matter which channel the Wayne-
Trac controller is connected to. See Figure 12-9.
NOTE: If cable PN 886752-001 is present and connected to J4 it should be removed first.
78 P/N 000-940039 Rev. 0E May 2016

2OR
0OWER
'.$

'.$
2OR

*
* 0OWER
*
0OWER
* '.$
*
'.$
*
*0
* *0 .ONE
*0
*
*0 ,EFT
*0
23 23

*0 *UMPER *

* 7HITE "LACK 'REEN
*0*0

0OWER3UPPLY

23 (OT .EUTRAL %ARTH
TO
$#"S
Figure 12-16 WayneTRAC Cabinet
12.8 Current Loop GRIB Jumper Configurations
Table 4: Current Loop GRIB Jumper Configurations
CH1 CH2 CH3 CH4

Dispenser JP1 JP2 JP3 JP4
Wayne 2&3 2&3 2&3 2&3
Gilbarco 1&2 1&2 1&2 1&2
P/N 000-940039 Rev. 0E May 2016 79

12.9 Current Loop GRIB Component Layout
12.10Serial-485 CAT GRIB Jumper Configurations

Table 5: Channel 1
GRIB JP1 JP2 JP3 JP4

485
Echo On 2&3 2&3 2&3 2&3
Echo Off 1&2 1&2 1&2 1&2
Serial JP5 JP6 JP7 JP8

Port
RS422 2&3 2&3 2&3 2&3
RS232 1&2 1&2 1&2 1&2
Off Off Off Off
80 P/N 000-940039 Rev. 0E May 2016

12.11Serial-485 CAT GRIB Component Layout
12.12Serial to Current Loop GRIB Jumper Configurations

Table 6: Serial to Current Loop GRIB Jumpers
CH1 CH2 CH3 CH4

Dispenser JP1 JP2 JP3 JP4
Wayne 2&3 2&3 2&3 2&3
Gilbarco 1&2 1&2 1&2 1&2
Serial JP5 JP6 JP7 JP8

Port
RS422 2&3 2&3 2&3 2&3
RS232 1&2 1&2 1&2 1&2
Off Off Off Off
P/N 000-940039 Rev. 0E May 2016 81

12.13Serial to Current Loop GRIB Component Layout
82 P/N 000-940039 Rev. 0E May 2016

83
5 4 3 2 1
KB1 6P J8 10P
WU001817 J7 10P LED2 LED1
8P USB5 & USB6 KYBD&Mouse Audio Activity Pwr
VGA
Bot Top
8P USB3 & USB4
(Heart
Beat)
8P
Figure 12-17 Fusion Forecourt Controller T/AA1Z0/0/Z Wiring Diagram

USB1 & USB2
D
SINGLE BOARD COMPUTER D
CN2 LINUX OS
RJ45 LAN2 2P 4P SATA2 EBX FORM FACTOR
NOVA ADAM
WU001261 WU001585
RJ45 LAN1
J2
WU002111 COOLER
10P COM1 CN1 2P 4P SATA1 PWR 4P
WU001421
WU001421
WU002708-0001
WU001274
WU001266 10P COM2
WU001258
10P COM3
WU001307
2P 3P 3P 3P 3P 10P COM4 8P 10P

J2 2P
7P
J3
J18 J19 J20 J22 J24 F_PANEL1 DIO1

+24V
+5V ,5AMP
+5V Out
J17
Pwr
PS Section +5V LED
10P
CUPS PCB ASSY
C C
Battery
+24V LED
WU000995
UPS Section BAT RDY LED

J12
2P
USB1
BAT EN LED
Charger
PF LED
J13
& Power Fail

2P
4P 3P
J5 J7
USB AUX PWR
WU001269
SBC
J11
PWR C/10 LED WU000813

4P
9P
J5
Reset
GRIB Current Loop
J16 LED1 Charge LED J21 Wayne/Gil 30/40 ma
WU001259
6P ACT DC IN 10P
COM1
J8
+24V LED
5P
J23
LED J14 GIL/TOK 4 CHNL

2P
WU001229
B
OUT 10P WU001259 2 DISPENSERS/CHNL B
J9 5P COM2
+24V 2-WIRE DSM/MSM/GSM
May 2016
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4
J6 2P
1-4 5-8 9-12 13-16
J10
DB9 J1 2P-Jack J4 2P USB USB RJ45 DB9 DB9

PINS SKT 4P 4P 4P 4P
To 2nd bot top Top bot
SERIAL
COM 3
Box
PWR TO +24V USB 6 USB 5 COM 2 COM 1
SW/LED GRN External OPTION OPTION
To POS
Not on PCB Supply
GSM
To Dispensers 1-16
Rev. 0E
TWO DISPENERS EACH
or
DSM/MSM
TO TOK 67 BOX
OR SECONDARY POS
LAN
OR Gil "G" BOX CAT 5 WIRE
P/N 000-940039
A A
Title
FUSION T/AA1Z0/x/x
Size Document Number R ev
B WU00***** X4
FUSION SYSTEM Date: Thursday, January 13, 2011 Sheet 1 of 1
5 4 3 2 1
84
5 4 3 2 1
KB1 6P J8 10P
WU001817 J7 10P LED2 LED1
8P USB5 & USB6 KYBD&Mouse Audio Activity Pwr
VGA
Top Bot
8P USB3 & USB4
(Heart
Beat)
8P
USB1 & USB2
D
CN2 LINUX OS
RJ45 LAN2 2P 4P SATA2 EBX FORM FACTOR
NOVA ADAM
WU001261 WU001585
RJ45 LAN1
J2
WU002111 COOLER
10P COM1 CN1 2P 4P SATA1 PWR 4P
WU002708-0001
WU001266 10P COM2
10P COM3
10P 8P 10P
WU001421
WU001421
2P 3P 3P 3P 3P COM4
WU001274
J2 2P
7P
J3
WU001258
+24V
WU001307
+5V ,5AMP
Pwr
J17
C PS Section +5V LED C
+5V Out
10P
+24V LED
Battery
WU002192-0001
2P
J12
BAT EN LED
WU000995
Charger
USB1
PF LED
CUPS PCB ASSY

& Power Fail
2P
J13
3P 2P 4P 3P
J7 J8 J5 J7
PWR DSM/MSM USB AUX PWR
WU001269
SBC
PWR C/10 LED Reset WU001850 WU000813
4P
9P
J11
J5
GRIB RS485, USB GRIB Current Loop
J16 LED1 Charge LED J21 (Serial GRIB) Wayne/Gil 30/40 ma
WU001259
6P ACT DC IN 10P
+24V LED COM1 4 CHNL
5P
J8
LED GIL/TOK 2 DISPENSERS/CHNL
OUT
2P
J23
B J14 10P WU001259 4 CHNL B
J9 5P COM2
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4
WU001265 J15 CH1 CH2 CH3 CH4 1-4 5-8 9-12 13-16
WU001229
J10
PINS SKT DB9
J6 2P
DSM or MSM J6 16P 4P 4P 4P 4P
To 2nd bot top Top bot SKT
OPTION
Box
PWR USB 6 USB 5 COM 2 COM 1
SW/LED GRN OPTION OPTION
TO +24V
COM 3
Not on PCB External TO POS
GSM
Supply or
DSM/MSM
P/N 000-940039
SECONDARY POS
LAN
RS232
Third Party POS
OR Gil "G" BOX CAT 5 WIRE

A A
To Dispensers 1-8
TWO DISPENERS EACH
Connections for TWO CATS/CH

SIX CATS LOAD MAX/CH
Title
Rev. 0E
FUSION T/AA1D1/x/x
Size Document Number R ev
Figure 12-18 Fusion Forecourt Controller T/AA1D1/0/Z Wiring Diagram

B 89XXXXX-XXX X4
FUSION SYSTEM Date: Wednesday, January 12, 2011 Sheet 1 of 1
5 4 3 2 1
May 2016
85
5 4 3 2 1
KB1 6P J8 10P LED1
WU001817 J7 10P LED2
8P USB5 & USB6 KYBD&Mouse Activity Pwr
Audio
Figure 12-19 Fusion Forecourt Controller T/AA2D1/0/Z Wiring Diagram

VGA Bot
USB3 & USB4 Top
8P
(Heart
Beat)
8P
USB1 & USB2
D
LINUX OS
RJ45 LAN2 CN2 EBX FORM FACTOR
2P 4P SATA2 NOVA ADAM
WU001261 WU001585
WU002111 RJ45 LAN1
J2
WU001266 COOLER
WU002192-0001
10P PWR 4P
WU001421
WU001421
CN1 2P 4P SATA1 WU002708-0001
WU001274
WU001258
10P COM2
10P COM3
WU001307
2P 3P 3P 3P 3P 10P COM4 8P 10P

J2 2P
7P
J3

+24V
+5V ,5AMP WU001266
+5V Out
J17
Pwr
PS Section +5V LED
10P
CUPS PCB ASSY
C C
Battery
+24V LED
WU000995

J12
2P
USB1
BAT EN LED
USB2
Charger
PF LED
J13
& Power Fail

2P
3P 2P 4P 3P 4P 3P
J7 J8 J5 J7 J5 J7
PWR DSM/MSM USB AUX PWR USB AUX PWR
WU001269
SBC
J11
PWR C/10 LED WU001850 WU000813 WU000813

4P
9P
J5
Reset
GRIB RS485, USB GRIB Current Loop GRIB Current Loop
J16 LED1 Charge LED J21 (Serial GRIB) Wayne/Gil 30/40 ma Wayne/Gil 30/40 ma
WU001259
6P ACT DC IN 10P
COM1
J8
+24V LED 4 CHNL 4 CHNL

5P
LED GIL/TOK J23 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL

2P
WU001229
OUT
May 2016
B J14 10P WU001259 4 CHNL B
J9 5P COM2
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4 J1 J2 J3 J4
J6 2P
J15 CH1 CH2 CH3 CH4 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16
J10

PINS SKT DB9 J6 16P 4P 4P 4P 4P 4P 4P 4P 4P
To 2nd bot top Top bot SKT
TWO DISPENERS EACH CH

COM 3
TWO DISPENERS EACH CH

Box
PWR USB 6 USB 5 COM 2 COM 1
SW/LED GRN
Third Party POS

TO +24V
To FP 1-16
Rev. 0E
Not on PCB
To FP 17-32
External To POS System
Supply
RS232
LAN
P/N 000-940039
CAT 5 WIRE
A A
TOK 67 BOX
OR SECONDARY POS Connections for TWO CATS/CH
SIX CATS LOAD MAX/CH Title
FUSION T/AA2D1/x/x
NOTE: FP Numbers are based on IGEM or DUPLEX Size Document Number R ev
B 89XXXXX-XXX X4
PUMP Computers in Dispensers (2 FP per IGEM or DUPLEX)
FUSION SYSTEM Date: Monday, January 17, 2011 Sheet 1 of 1
5 4 3 2 1
86 P/N 000-940039 Rev. 0E May 2016
INSTALLATION/OPERATION
Wayne Fusion 1000/3000 Forecourt System
© 2016 Wayne Fueling Systems.

Printed in the United States of America.
This manual and any software described herein are furnished under the terms of sale or other applicable contract in-
cluding any license, and may be used or copied only in accordance with those terms.
No part of this publication may be electronically or mechanically reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, except as permitted by such terms. Translation of this material to another language with-
out express written permission from Wayne Fueling Systems is prohibited.
This publication is intended for informational purposes only and this material is subject to change without notice. Wayne
Fueling Systems has not made, and does not make, any representations or warranties of any kind, expressed or im-
plied, with respect to any information in the publication, including any warranty as to the accuracy, correctness, or com-
pleteness of any of the information. Wayne Fueling Systems shall not be responsible or liable for any damages or losses
that occur as a result of the receipt and/or use of the information contained herein.
Wayne, the Wayne logo, iX Pay, Ovation, and combinations thereof are trademarks or registered trademarks of Wayne
Fueling Systems, in the United States and other countries. EMV is a registered trademark of EMVCo, LLC. NAMOS is
a trademark of Wincor Nixdorf. Other names are for informational purposes and may be trademarks of their respective
owners.
Wayne is located at 3814 Jarrett Way, Austin TX 78728.

Wayne’s general telephone number is (512)-388-8311.
This product complies with Part 15 of the FCC rules and regulations. Operation is subject to the fol-
lowing two conditions: (1) This product may not cause harmful interference, and (2) this product must
accept any interference received, including interference that may cause undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class A digital device
as set forth in Part 15 of the FCC Rules. Those limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy, and if it is not installed and used
in accordance with the instruction manual, it may cause harmful interference to radio communica-
tions. Operation of this equipment in a residential area is likely to cause harmful interference, in which
case you will be required to correct the interference at your own expense.
Modifications: Any modifications made to this product that are not approved by Wayne Fueling Sys-
tems could void your authority to operate this equipment.
Wayne Manufacturing Centers
Wayne U.S. Wayne Sweden Wayne China Wayne Brasil

Wayne Fueling Wayne Fueling Sys- Dresser Wayne Fuel Wayne Industria e
Systems LLC tems Sweden AB Equipment (Shang- Comercio Ltda
3814 Jarrett Way Hanögatan 10 hai) Co. Ltd Estrada do Timbó
Austin, TX 78728 Box 50559 1221 Dong Lu Road 126 - Higienópolis
USA SE-202 15 Malmö Pudong, Shanghai Rio de Janeiro, Brasil
Sweden China
© 2016 Wayne Fueling Systems P/N 000-940039 Rev 0E 05/2016

000-940039 Fusion Installation - HyperPIB-PAM-Console Rev 0E

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000-940039 Fusion Installation - HyperPIB-PAM-Console Rev 0E

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Installation/Operation

Wayne Fusion™ 1000/3000 Forecourt System

READ THIS MANUAL BEFORE YOU BEGIN

SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE

HOW TO CONTACT WAYNE

INDICATORS AND NOTATIONS

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

P/N 000-940039 Rev 0E May 2016 1

3 HOW TO USE THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 RETURNING DAMAGED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

P/N 000-940039 Rev. 0E May 2016 iii

11.8.2 Gasboy POS or Fiscal POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

iv P/N 000-940039 Rev. 0E May 2016

12.6 GRIB Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

P/N 000-940039 Rev. 0E May 2016 v

Product Wayne Fusion™ Forecourt Controller

Application 3rd Party POS and Console

Production Version Version 3.0.3.4

Hardware Platform Wayne Proprietary Hardware

3 HOW TO USE THIS DOCUMENT

4 UNPACKING AND INSPECTION

P/N 000-940039 Rev. 0E May 2016 7

CSA C22.1 (Canadian Installations)

Emergency Power Cutoff

8 P/N 000-940039 Rev. 0E May 2016

Table 1: Mounting Location

Component Preferred Location Notes

Table 2: Space Requirements (in inches)

Component Width Height Depth

Dispenser conduit and Wiring requirements

Data Link and CAT Wiring

8 CONFORMITY WITH STANDARDS

P/N 000-940039 Rev. 0E May 2016 9

Product SKU: C2404.41.10

Insulation: Color Code: See charts below

Premium grade color coded PVC per UL 1007

Jacket: PVC, gray

Temperature Range: -20ÂºC to +80ÂºC

10 P/N 000-940039 Rev. 0E May 2016

Conductor Size (AWG): 18

Jacket Color: Gray

Nominal Insulation Thickness 0.016

Nominal Insulation Thickness 0.41

Nominal Jacket Thickness (in): 0.032

Nominal Jacket Thickness (mm): 0.81

Nominal Outside Diameter (in): 0.258

Nominal Outside Diameter 6.55

Nominal C-C Capacitance 28.0

Standard Packaging: 1000' Non-returnable Wood Reels

Standard Package Quantity: 1

Table 3: Required Tools

1 Phillips Screwdriver Set (standard sizes)

1 Slotted Screwdriver Set (standard sizes)

P/N 000-940039 Rev. 0E May 2016 11

1 Anti-static Wrist Strap

1 Needle Nose Pliers

1 Standard Drill Bit Set

1 PC Feature Card Slot Blank

C u sto m e r S u p p lie d M e ta llic W ire w a y

M e ta llic co n d u it to d isp e n se rs (o n e p e r d isp e n se r)

Figure 10-1 Backroom Installation

12 P/N 000-940039 Rev. 0E May 2016