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User ManualHelix™WM048521

Rev 07 - PRELIMINARY

AE

Read this manual before starting any installation, service, or maintenance workFuel dispensers contain both electrical components and a hazardous, flammable and poten-tially explosive liquid. Failure to follow the below precautions and the Warning and Cautioninstructions in this manual may result in serious injury. In addition, it is your responsibility tofollow all rules, codes, regulations, and laws that apply to your location and type of work beingperformed.

Safety precautionsMake sure that ALL power to the dispenser is turned OFF before opening the cabinet orstarting work. Physically lock, restrict access to, and/or tag the circuit breakers you turn off.In addition, be sure to trip (close) all emergency valves under the dispenser (if installed)BEFORE you begin.Make sure that you locate the facility’s emergency shut-off button, and know how to turn OFFpower to the dispenser and submersible pumps (if any) in an emergency.Never allow a leaking pump to run! Use appropriate measures to clean up any fuel on theforecourt, and ensure that any leaks or issues that could cause a leak are attended to andrepaired immediately.

Indicators and notations

Note!Indicates extra information or tip.

NOTICE!

Highlights an essential element of a procedure tohelp ensure accuracy, completeness, and appro-priate performance.

CAUTION!

Indicates a potentially hazardous situation, whichif not avoided, could result in personal (non-lethal)injury or equipment damage.

WM048521 Rev 07 - PRELIMINARY 11/2014

WARNING!

INDICATES A POTENTIALLY HAZARDOUS SIT-UATION, WHICH, IF NOT AVOIDED COULDRESULT IN DEATH OR SERIOUS INJURY.

DANGER!

INDICATESAHAZARDOUSSITUATION,WHICH,IF NOT AVOIDED, WILL RESULT IN DEATH ORSERIOUS INJURY.


Table of Contents

31 Introduction .........................................................................................................31.1 Dispensers Covered ...............................................................................51.1.1 Wayne iGEM™ Computer Software .................................................................51.1.2 Determining Dispenser Sides A & B .................................................................61.1.3 Parts of the Pump .............................................................................................71.1.4 Product Liability .................................................................................................71.1.5 Intended Use .....................................................................................................81.1.6 What is DEF? ....................................................................................................92 Important Safety Items ........................................................................................92.1 Safety Items You Should Know ...............................................................92.2 Classification Schemes ...........................................................................122.3 Portable Tanks and Containers ...............................................................122.4 Health Note .............................................................................................122.5 Safety Precautions - Operation and Maintenance ..................................122.6.1 Health and Safety Regulations ..........................................................................132.6.2 Health and Safety Regulations - DEF ...............................................................142.7 Dispenser Safety Features .....................................................................153 Operation ............................................................................................................153.1 Introduction .............................................................................................153.2 How to Get Service On Your Dispenser ..................................................153.3 Infrared Remote Control .........................................................................163.4 Basic Dispenser Requirements ...............................................................163.5 Programming Functions ..........................................................................173.6 Access to Functions ................................................................................183.7 Annunciator Operation Check .................................................................183.8 Set Clock Function (F 02) .......................................................................193.9 Exit Function (F00) ..................................................................................203.10 Password Change (F33) .........................................................................213.11 Filling Modes (F01) .................................................................................223.12 Setting Unit Prices ..................................................................................223.12.1 F03 - Set Side A Unit Prices .............................................................................233.12.2 F04 - Set Side B Unit Prices .............................................................................233.12.3 Changing the Unit Price (F03) ...........................................................................253.13 Authorizing the Dispenser .......................................................................253.14 Disable Stand-alone Operation ...............................................................263.15 Operating the Dispenser .........................................................................263.16 Initial Delivery ..........................................................................................273.17 Restarting After Power Failure or Shutdown ..........................................273.18 Cycling Power to Clear Faults .................................................................273.19 Error Codes .............................................................................................283.20 Resetting After All Stop ...........................................................................

WM048521 Rev 07 - PRELIMINARY 11/2014 1

Table of Contents

293.21 Electronic Totalizer Readings ..................................................................293.21.1 Totalizer Volume Readings by Meter Position ...................................................293.21.2 Electro-Mechanical Totalizer Operation ............................................................314 Operator Maintenance ........................................................................................314.1 Hose and Hose Retractor .......................................................................314.2 Filter / Strainer - Remote .........................................................................334.3 Dispenser cleaning .................................................................................334.4 Meter Maintenance .................................................................................

Appendices

35A Dissasembly - Recycling .....................................................................................35A.1 Empty the fuel out of the pump ...............................................................35A.2 Dispenser recycling .................................................................................36B Declaration of Conformance ...............................................................................37C Glossary of Terms and Acronyms .......................................................................

2 WM048521 Rev 07 - PRELIMINARY 11/2014

Table of Contents

1 Introduction

This manual covers general user information on the operation andmaintenance of theWayne®

Helix™ fuel dispenser models outlined in Section 1.1 Dispensers Covered, on page 3.Computer function settings that are necessary for Helix dispenser operation, such as unitprices and fueling point ID’s, are also included in this manual. If additional information onfunction settings and statistics is required, refer to the Helix Dispenser Service manual(WM048523).The following items are required for the operation and maintenance of Helix dispensers:

• Infrared remote control (IR remote or IRC) - Wayne part number (p/n) WM002290

• Printer door key - DHW1 key

• Lower bezel door and sliding bezel tray keys - DW2 key

• Hydraulic door key - Wayne p/n WU007681Any questions concerning operation of the dispenser that are not covered in this manualshould be referred to your local service provider.

1.1 Dispensers CoveredThis manual applies to the following style of Helix dispenser that has been approved by IEC:

• C-Style, Wayne Helix™ 6000 fuel dispenser

• Your dispenser activation is Auto ON

• Your dispenser has a DEF (Diesel Exhaust Fluid) pumpRefer to Figure1.1 to determinemodel attributes defined in themodel number of the dispenser.The dispenser model number can be located on the dispenser name plate, receipts, orshipping documentation and the scope of this manual applies only to the dispenser modelas specified therein.


1 Introduction

STYLEC = C-styleH = H-styleS = Small Style

NO. GRADES OUT 1 - 8If blender, count up +1 per each blendingpossibility between 2 grades

DESIGNW = WideN = NarrowH = High HoseL = Low Hose

ORIENTATIONID = Island Dual Sided UIIS = Island Single Sided UILM = Lane MirroredLU = Lane UnMirrored*

NO. GRADES IN1 - 5

*NOTE: The position prior to andfollowing the slash '/' can contain two(2) digits as shown in this example.The 'L' & 'U' specify 'Lane' &'UnMirrored'.

NO. HYDRAULICPOSITIONS0 - 5

NO. HOSES / NOZZLE POSITIONS PER SIDE1 digit = Symmetric. Same number, solution, andflows on both sides A & B.2 digits = Asymmetric. Different number,solutions, or flows on Sides A & B.1st Digit = Side A2nd Digit = Side B

NOTE: The last two positions shown herecan contain multiple digits

Example:H(W/LU)23-21PR

BASIC TECHNICAL FEATURESA = AdditiveB = BiodieselC = CNG (Compressed Natural Gas)D = DEF (Diesel Exhaust Fluid)E = EthanolF = FleetG = Enhanced CapacityH = Super-High CapacityJ = Ultra-High CapacityL = LPG (Liquified Petroleum Gas)M = MediaP = PaymentR = RemoteS = SuctionT = TerminalU = 4 UsersV = Vapor RecoveryW = Main (Back-to-Back)X = BackY = SAT Master (Satellite)Z = SAT Slave (Satellite)

b

a

c

d

e

f

g

h

X X X X X X X X( / ) -a b c d e f g h

Figure 1.1: Helix Model Designation


1 Introduction

1.1.1 Wayne iGEM™ Computer SoftwareHelix model dispensers are delivered pre-installed with iGEM computer software, version 62or later which can also be downloaded via laptop computer by a Wayne certified ServiceTechnician. ServTerm version 6.1.5 or later is required for servicing (loading the computersoftware or dispenser configuration template), however, this is not required for installationor startup of the dispenser.

1.1.2 Determining Dispenser Sides A & BLocate the Wayne name plate on the outside of the dispenser. If, while facing the dispenser,the name plate is on your right side, you are facing side A of the dispenser. If the name plateis on the left side, you are facing side B of the dispenser.


1 Introduction

1.1.3 Parts of the Pump

nozzle boot

nozzle

hose

hydraulic module cabinet

base frame

hydraulic door lock

electronic head

Example shown is an Helix 6000 DEF fuel dispenserFigure 1.2: Dispenser


1 Introduction

sales / volume / price display

softkeys

VGA display

printer door lock

card readerkeypad

Example shown is an Helix 6000 - DEF fuel dispenserFigure 1.3: Dispenser Bezel

1.1.4 Product LiabilityWayne declines all responsibility for product liability if any modifications, additions, etc., havebeen made to the equipment without the written consent of Wayne.

1.1.5 Intended UseThe pump is designed and approved for measuring and movement of a Diesel Exhaust Fluid(DEF) in correct quantities, from tank to vehicle.


1 Introduction

1.1.6 What is DEF?Diesel Exhaust Fluid (DEF), also referred to as AdBlue® in Europe, is a very aggressivechemical fluid made of an aqueous urea solution of 32.5%, however, it is not flammable. Itis used for injection to the exhaust system of a vehicle to improve the catalytic process. Be-cause of this, it is extremely sensitive to contamination from other fluids, metals, dust, dirt,etc. The only approved testing liquid during production is distilled water that does not contam-inate the urea product. There is always distilled water remaining in valves and other fragileparts and as distilled water has a freezing point of around 0 degrees Celcius it means thatDEF equipment has to be kept above freezing point during all phases of transportation, de-livery, installation, and operation.AdBlue® is a registered trademark of Verband der Automobilindustrie e.V.


1 Introduction

2 Important Safety Items

2.1 Safety Items You Should Know• Know how to turn OFF power to the dispenser in an emergency.

• Know how to turn OFF power to submersible pumps in an emergency.

• Regularly inspect all external fuel carrying components such as hoses, nozzles, break-aways, etc. for damage or leaks.

• Regularly inspect dispenser housing parts for damage or leaks.

• Have all leaks or defects repaired immediately.

• Test the Emergency (Shear) Valve by opening and closing several times at least onceper year.

• Use of automatic safety nozzles prevents overfilling fuel tanks and avoids spilling fuel.

• Avoid tipping the nozzle downward and spilling excess fuel.

• Sufficient lighting must be provided to allow safe use of the dispensers.

• A clearly visible and identifiable station Emergency Stop Switch must be provided at thestation to shut OFF power to all station dispensers and submersible pumps in case of anemergency.

• Portable tanks (containers) of 12 gallons (45 liters) or less shall not be filled while theyare in or on a motor vehicle. See Warning information about this subject in the followingsection.

• Hose retractor mechanisms are spring loaded and can pose a possible injury.

• Stow hoses to prevent tripping and falling.

• Care should be taken to prevent fuel spillage. If spillage occurs, clean up immediately.

• Know the Hazardous Zone area around the dispenser.

2.2 Classification Schemes

ExampleProtection ClassRisk TypesZones

In a tankExiaA risk area where explosive gas mix-ture exists all of the time or during along period.

0

Within the meter(within the hy-draulic areas andcolumn of thepump)

Exd, Exe, Exib,Exp, Exia, Exs

A risk area where explosive gas mix-ture may occasionally exist during nor-mal operation.

1



ExampleProtection ClassRisk TypesZones

Exd, Exe, Exib,Exp, Exia, Exs,Exo, Exq

A risk area where explosive gas mix-ture is not expected to exist duringnormal operation and, if it does existanyway, it will be infrequent and for ashort period of time.

2



INSERT CLASSIFICATION SCHEME HERE

2.3 Portable Tanks and ContainersPortable containers of 12 gallons (45 liters) or less shall not be filled while they are in or ona motor vehicle. Filling portable containers, especially when they are sitting on a non-conduc-tive surface such as a floor mat or a plastic bedliner in the back of a pick-up truck, can presenta possible safety hazard and should be avoided as so stated in the following WARNING:

WARNING!FIRE HAZARD!

The flow of gasoline through the dispenser nozzlecan produce static electricity which can cause afire if gasoline is pumped into an ungroundedgasoline container. To avoid static buildup and thepossible resulting serious injury:

• Place approved container on the ground. Donot fill the container in the vehicle or truck bed.

• Keep the nozzle in contact with the can or con-tainer while filling. Do not use an automaticpump handle (latch-open) device.

2.4 Health Note

WARNING!Toxic Substances!

Be advised that contact with petroleum fuel andinhalation of fuel vapors can cause serious damageto your health.

2.5 Safety Precautions - Operation and Maintenance• Only persons knowledgeable in performing the required maintenance shall perform the

work.

• All electrical power to the dispensing device and pump servicing the dispenser shall beshut off at the main electrical disconnect panel.

• All vehicle traffic and unauthorized persons shall be prevented from coming within 20 feet(6 meters) of the dispensing device.

2.6.1 Health and Safety RegulationsIt is important that the following rules and regulations are followed when flammable liquidsare used:



• It is prohibited to smoke and light fire or bring open flame close to the pump.

• Stop the engine while refuelling.

• The distribution box must be easily accessible and access must not be blocked by goodsetc.

• Always ask a specialist to make electrical installations of any kind. Special regulations areapplicable!

• Please watch for any leakage from pumps. If there is a leakage, cut all power to the pumpand call Wayne After Sales Service.

• Always comply with the regulations regarding handling of petrol and oil, published by eachoil company.

• Always comply with public authority requirements related to the vapor recovery system.

• Make sure that a suitable fire extinguisher is in place and is easily accessible.

• To avoid malfunction or damage to the pump, make sure that there is enough fuel in eachtank.

• Adequate personal safety equipment should be used during maintenance of the equipment(gloves, breathing mask, glasses etc.).

2.6.2 Health and Safety Regulations - DEFIt is important that the following rules and regulations are followed:

• The dispenser must be placed outside hazardous areas.

• The distribution box must be easily-accessible and may not be blocked by goods or otheritems.

• Always let specialists make electrical installations of all kinds. Special regulations apply!

• Please pay attention to any leakage from the dispenser. If there is a leak, cut the powerto the pump and call Wayne After Sales Service at ( PHONE NUMBER HERE).

• Always follow all regulations regarding handling of Urea published by each distributor orsupplier.

• The customer must ensure that DEF does not come in contact with the skin or eyes whilere-filling. It is the responsiblity of the station owner to post applicable warning and cautionstatements and/or stickers in a place on the dispenser that is visible to the customer.

• To avoid incorrect function or damage to the pump, ensure that there is enough Urea liquidin the front.

• Adequate personal safety equipment should be used during maintenance of the equipment(gloves, safety glasses, etc.)

Note!To prevent damage in the hydraulic cabinet dispenser doors should be in place during rainyand/or icy weather conditions. Also, check the nozzle boot flipper (if present) for freedom ofmovement. If ice or snow has formed on the flipper, it should be cleared to prevent unecessarydamage.



2.7 Dispenser Safety FeaturesHelix dispensers come equipped with certain features that increase the safety of those personswho come in contact with the dispenser, including customers, store employees and mainte-nance technicians. Inclusion of these features depend upon the installation location and ap-plicable laws and regulations.

• Emergency Shut-off (Shear) Valves - (optional)An emergency valve is designed to close the product line in case of shock or fire. Theshear valve functions if the dispenser is knocked out of position.

• Hose RetractorHelix dispensers are equipped with a hose retractor that will break away from the dispenserin the event that a customer drives off while the hose is still attached to the vehicle.

Note!On dispensers equipped with the Hose Retractor option, the hose clampmust bemountedupstream of the breakaway device to avoid damage to the dispenser in the event of adrive-off.

The combined hose, breakaway, and whip maximum lengths are listed in the table below.

Loopback Type2 Hoses per Side

Loopback Type1 Hose per Side

Crossover Type1 Hose per Side

14' 0" (4.27m)

10’ 0’’ (3.05 m)10’ 0’’ (3.05 m)Non-Vapor 3/4” (19.050mm)

14’ 0’’ (4.27 m)14’ 0’’ (4.27 m)Non-Vapor 5/8” (15.875mm)

• Break-away Hose (optional)Some Helix dispensers are equipped with a hose that will break away from the dispenserin the event that a customer drives off while the hose is still attached to the vehicle. AL-WAYS contact an authorized service provider after a breakaway accident. The followingparts must always be changed: Breakaway Valve (WM002174).



3 Operation

3.1 IntroductionYou will need to access the maintenance mode in order to program functions and/or viewstatistics. The function and statistics data appear in the money, volume, and unit price displaywindows. The infrared interface is similar to a television remote control. It has 16 buttons andis used to access dispenser functions. This interface uses only the pump display for userfeedback. There is no additional display. Refer to Section 3.3 Infrared Remote Control, onpage 15.

3.2 How to Get Service On Your DispenserTrouble with the operation of the dispenser should be referred to your local Wayne authorizedservice personnel or call the your local service provider.

Note!Any modification, repair, or service to the dispenser not in accordance with the original designmay invalidate compliance with the equipment certifications such as CE Marking, UL-listing,etc. Consult manufacturer as necessary.

3.3 Infrared Remote ControlThe Infrared Remote Control (IRC or IR remote) is used to access dispenser functions andsub-functions, and diagnostics (statistics). When held close to the infrared eye on the displayboard, the remote can be used to set unit prices, fueling point IDs, and read electronic total-izers.

Figure 3.1: Infrared Remote Control (IRC or IR Remote)A description of each key on the IR remote is given in the following table.

When xx.xx sub-functionis shown on theunit price display

When F 'xx'is shown on theunit price display

When F - -is shown on theunit price display

IRCkeys

Next higher sub-function level

Next higher func-tion #

F00NEXT


3 Operation

When xx.xx sub-functionis shown on theunit price display

When F 'xx'is shown on theunit price display

When F - -is shown on theunit price display

IRCkeys



S - - (statisticsmode)

UP



S - - (statisticsmode)

DOWN

Back to functionlevel (except whileentering new val-ue, it displays thechange)

sub-function level(xx.xx)

Pressing 3 timeswill exit configura-tion mode withoutsaving

ENTER

Back to functionlevel (except whileentering new val-ue; can be used toerase last digittyped)

F - -n/aCLEAR

Must use this keyto enter new data

n/an/a#

If you clear thedisplay with the"#" key first, it willchange the valueof the sub-functionto the digits en-tered after press-ing ENTER

After pressing EN-TER, will take youto the Functionlevel of the digitsentered

After pressing EN-TER, will take youto the Functionlevel of the digitsentered

DIGITS

Note!When in Statistics mode (S - - ) or (S "xx") are shown on the Unit Price Display, the abovecommands work the same way.

3.4 Basic Dispenser RequirementsUnit prices must be set and the dispenser must be authorized for the dispenser to operate.If the dispenser is connected to a POS control system and you want to operate the dispenserin the stand-alone mode independently from the control system, perform the following steps:

• Use IR remote control and set the Filling Mode to Stand-alone.

3.5 Programming Functions• Change Unit Price (F03)


3 Operation

• Exit Function (F00)

• Filling Modes (F01)

• Password Change (F33)

• Access to Functions

3.6 Access to FunctionsPress the CRC button on the iGEM board.Access the programming mode by pressing one of the following keys on the remote control:

Station manager entry using the station manager password"1"

Operator entry using the operator password"2"

The programmingmode asks you for a password twice before allowing access to the functions.A 10-second time-out is built into the password entry code.After 3 seconds the display shows:

When the word PASS 1 appears on the sales display, you have 20 seconds to start enteringthe password entry code. The timer restarts after you press a key. When you finish enteringthe password, press <ENTER> (=E).PASS 2 appears in the sales display window, prompting you to enter the password again.The display shows:

Note!If you press nothing more, press <ENTER> (=E) or press the wrong password, or there isno confirmation after pressing the password and the <ENTER> key, the computer will leavethis function automatically after 10 seconds.

Note!If you press the wrong keys, press <CLEAR> (=C) key to erase the last digit you typed.

Press again the pasword to confurm and press <ENTER>.Press <ENTER>.The display shows the Function screen:


3 Operation

When you enter the programming mode, the unit price display windows show "F - -", themoney display window shows the software version number, and the volume display windowshows the software version number, and the volume display window shows the date of thesoftware version. To edit or view specific functions, enter any function number using thenumber keys and press <ENTER>. The corresponding number appears in the money displaywindow.

3.7 Annunciator Operation CheckCheck that the annunciator (beeper or buzzer) is operating properly on each side of the dis-penser. When pressing the keys on the CAT keypad or the Push-to-Start / Grade Selectbuttons on the bezel, you should hear the annunciator beep.

3.8 Set Clock Function (F 02)Function F02.00 displays the time (HH.MM), F02.01 is the date (MM.DD) and F02.02 is theyear (YY.YY)

Unit Price Dis-play

Status DisplayVolume DisplayIRC Command

PASS 1Press either EN-TER, 1, or 2, de-pending on accesslevel

PASS 2Type the corre-sponding pass-wordPress ENTER

F - -DateiGEM softwaresetting

Type the pass-word againPress ENTER

F 02- - - - - -Type 2Press ENTER

2.00Time in HH.MMformat

- - - - - -Press ENTER

2.00Time in HH.MMformat

Press #


3 Operation

Unit Price Dis-play

Status DisplayVolume DisplayIRC Command

2.00Entered time inHH.MM format

- - - - - -Type the currenttime in 24-hourformat of HH.MM- Press ENTER

2.01Date in MM.DDformat

- - - - - -Press NEXT

2.01date in MM.DDformat

Press #

2.01entered date inMMDD format

- - - - - -Type the currentdate in the formatof MMDD- Press ENTER

F 02year in YYYY for-mat

- - - - - -Press NEXT

F 02year in YYYY for-mat

Press #

F 02current year inYYYY format

- - - - - -Type the currentyear in the formatof YYYY- Press ENTER

F 02- - - - - -Press ENTER

3.9 Exit Function (F00)Use this function to select one of three maintenance mode exits.

Press 00

the display shows:Press <ENTER>



3 Operation

the display shows:Press <#>

Select one of three mainte-nance mode exits:

= Do not exit and do not save changes01

= Exit, but do not save changes02

= Exit and save changes03

If you have entered 03, the displayshows:

Press <ENTER>


3.10 Password Change (F33)For access to functions, see Section 3.6 Access to Functions, on page 17

Select this function to change the password.

Press 33



Select the sub-function with<NEXT>:

Station Manager Password33.01(max. 6 characters)

Station Operator Password33.02(max. 6 characters)


3 Operation

Dashes appear instead of regular en-tries, as shown:

Press <#>, the money displaygoes blank.Enter the new password.


Dashes appear instead of the regularentries:

Enter the new password twice(2 times)

If the password is correct, the dashesand PASS flashes

Press <ENTER>

If the password was changed, thedashes flash

Press <ENTER>

Note!Use F00 Exit Function - Option 3 to exit and save changes.

3.11 Filling Modes (F01)For access to functions see Section 3.6 Access to Functions, on page 17

Select this function to change the Filling Mode.

Press 01


the display shows:(the actual status is shown on volume display)

Press <ENTER>

the amount shows blanks:Press <#>


3 Operation

(the new Operating mode is shown on amountdisplay)

Enter the new Fill-ing Mode

= Serial Mode - dispenser controlled by site con-troller via serial link.

1

= Stand Alone Mode - dispenser not supervisedby a site controller

2

= Serial W&M mode - same as #1 but 3 volumedecimals

3

= Stand Alone W&M - same as #2 but 3 volumedecimals

4

= Serial W&MMode - ATC, inspection of tempera-ture compensation

5

= Stand Alone W&M Mode - ATC, inspection oftemperature compensation

6

the display shows:the new Operating mode is shown on volume dis-play

Press <ENTER>

If the Filling Mode was changed, the dashes flashPress <ENTER>

Note!To exit and save changes uses F00 Exit Function, option 3.

3.12 Setting Unit Prices

3.12.1 F03 - Set Side A Unit PricesSub-function numbers are in the format below..0N Set prices.1N Not used (Set cash prices)N Logical nozzle number 1-4 (5-8 (optional)

Note!The Unit Prices are initialised after Coldstart to 99.01, 99.02, 99.03, 99.04 and so on.


3 Operation

3.12.2 F04 - Set Side B Unit Prices

Note!The Unit Prices are initialised after Coldstart to 9911, 9912, 9913, 9914.

3.12.3 Changing the Unit Price (F03)If a control system is connected, its prices override the prices in the pump and the pricesprogrammed in this sub-function are not used.

3.12.3.1 Changing Prices on Side AFor access to functions go to Section 3.6 Access to Functions, on page 17.

The display shows the function screen.

The display shows:Press 03Press <ENTER>

The display shows:Press <ENTER>

Note!To access the other unit price, press <NEXT>

Sub-function 3.01 is responsible for changing unit price of fuel at nozzle 1 on side A and soon, according to the table below.

SideNozzle(Position)

Sub-FunctionCredit Prices

A13.01

A23.02


Sub-FunctionCash Prices

A13.11

A23.12

Example: I have two pumps programmed to a unitprice of €1.300 and want to change to €1.420.Perform the following steps:


3 Operation

The dotted part onpaying total of dis-play will be erased.

Press the <#> key.

Enter the desired valueExample: 1420


To change from one sub-functon to another usethe <NEXT> key.(Example: from 3.01 to 3.02)The same procedure applies to change the cashproces(Sub-functions 3.11 to 3.12)

To SAVE all changes, follow EXIT procedure of"F00" exiting, value 3. (Refer to table)

3.12.3.2 Changing Prices on Side BSub-function 4.01 is responsible for changing unit price of fuel at nozzle 1 on side A and soon, according to the table below.


Sub-FunctionCredit Prices

B14.01

B24.02


Sub-FunctionCash Prices

B14.11

B24.12

Example: I have two pumps programmed to a unitprice of €1.300 and want to change to €1.420.Perform the following steps:


3 Operation

The dotted part onpaying total of dis-play will be erased.

Press the <#> key.

Enter the desired valueExample: 1420


To change from one sub-functon to another usethe <NEXT> key.(Example: from 4.01 to 4.02)The same procedure applies to change the cashprices.(Sub-functions 4.11 to 4.12)

To save all changes, follow exit procedure of "F00"exiting, value 3.

3.13 Authorizing the DispenserThe dispenser must be authorized before it will dispense product.The dispenser filling mode is set in programming function F01. In stand-alone mode (notconnected to a control system), the dispenser is always authorized.When connected to a control system, the system programming determines authorization.

3.14 Disable Stand-alone OperationOnce the dispenser is switched over to the POS control system, standalone operation maynot be required. As an extra security measure, the jumper that enables stand-alone operationmay be removed. The jumper (J6) is located on the unit price display board as shown inFigure 3.2.

1 Access dispenser Filling Mode function F 01 and set sub-function to 1.01 for serial mode.

2 Open the service door.

3 Remove the J6 jumper from the Unit Price Display board (Figure Figure 3.2).

4 Close and lock the service door.


3 Operation

J6 jumper

Figure 3.2: Sales Display with J6 Jumper

3.15 Operating the Dispenser1 Remove the nozzle from the nozzle boot for either the blended hose or the single product

hose. The nozzle boot switch will turn on. The unit price displays of the product(s) notselected will show dashes.

2 Push a grade selection button for the desired product to select one of the products fromthe blending hose, or the one product from the single product hose. The dispenser willreset and prepare for delivery. The sale display will show all eights, then blanks, then themoney and volume portion of the display will reset to zero. The unit prices not selectedwill be blank or show dashes. The grade selection button that was pressed will be contin-uously lit; the others will be dark. The correct pump(s) will start at the beginning of thereset cycle and the solenoid valve(s) will open approximately three seconds later. Productselection can be changed any time before product flow is sensed by the computer.

3 Dispense product. (Pressing the optional Stop button will stop product flow only. Thenozzle boot switch must be cycled and the dispenser must then be reset before that sideof the dispenser can continue operation.)

4 Return the nozzle to the nozzle boot. The nozzle boot switch will turn off; the sale will becomplete and ready to pay.

3.16 Initial DeliveryTo dispense product from a newly-installed dispenser, make sure unit prices are set (aspreviously described) and proceed as follows:

1 Authorize the dispenser.

2 Remove the nozzle, start the reset sequence and observe the reset cycle; make sure allsales display and unit price display elements operate.

3 Check that when reset is started, the correct submersible pump motor is activated, andat the end of the display reset (approximately three seconds) the solenoid valve(s) opens(listen for the audible click of the valve(s).


3 Operation

4 After verifying air is bled properly from each trunk line, slowly dispense product througheach dispenser until free of air. Dispense enough product through each hose of eachdispenser to ensure the dispenser and the lines are free of air, before checking the meters.

Note!Make sure the product lines are properly bled before dispensing any product through aremote dispenser.

3.17 Restarting After Power Failure or ShutdownAfter loss of power, the display accurately displays the amount of the sale, in money andvolume, for approximately 15 minutes. When power is restored, all sales information returnsto the displays. Any sales in progress will be ended; old sales should be paid and the dispenserreauthorized if more product is to be dispensed.If the dispenser does not operate properly when power is restored (does not deliver product,or does not reset), record both the money and volume shown on the display (so sales canbe paid for) and perform the following:

1 Ensure all nozzles on the side are in their nozzle boots.


3 Remove the nozzle from the nozzle boot. The dispenser should operate normally. If thedispenser does not resume normal operation, try cycling power as described in the nextsection.

3.18 Cycling Power to Clear FaultsIf a fault in the dispenser is detected by the computer, an error message will be displayed inthe sale display as described in Section 3.19 Error Codes, on page 27. Record the displayederror message. It may be possible to restart the dispenser by following the sequence below:

1 Ensure all nozzles are properly seated in the nozzle boot.

2 Turn the control power circuit breaker OFF for approximately five seconds. The dispenserannunciator will sound. Turn the control power circuit breaker ON; the dispenser annunci-ator will again sound.


4 Remove the nozzle from the nozzle boot. The dispenser should operate normally.If it is not possible to restart the dispenser using this procedure, or if an error message con-tinues to be displayed, consult appropriate service personnel. Be certain to give the servicepersonnel the amount at which the dispenser stopped and the exact error message.

3.19 Error CodesComputer error codes can be displayed on the side of the dispenser where the error occurredby accessing the sub-functions S21.XX for Side 1 and S22.XX for Side 2, where XX is between01 and 50 and represents the error/events records maintained by the computer program -with 01 being the most recent. The computer can store up to 50 errors per side, continuingto store errors beyond the 50th by cycling the error buffer with new errors inserted at the topof the buffer. When this happens, an error is deleted at the bottom of the buffer for every newerror that is inserted in the top of the buffer.


3 Operation

Errors are displayed in an alternating 2-page format. Information in the error pages is givenbelow.

Page 2 error informationPage 1 error information

MM.DD.YYHH.MM

CCC.DD.NN

Where:Where:

MM = monthHH = hour

DD = dayMM = minute

YY = yearCC = error code

C = filing countDD = device number

NN = logical nozzle number

The complete description of the error codes is given in the Helix Programming Manual (p/nWM048525).Computer errors are read by entering the Maintenance Mode and accessing the correctstatistical function and its sub-functions. Perform the following steps using the remote control.Bold type denote remote control function; italicized type represents dispenser response.Accessing the error code Sub-function.

1 Press ENTER. PASS 1 (enter password).

2 Press ENTER. PASS 2 (enter password).

3 Press ENTER. The unit price display will show F.

4 Press either UP or DOWN to enter the statistics viewing mode. The unit price display willshow S— indicating that a number needs to be selected.

5 Press 21 to access S21 (error data for Side 1 or A which is the junction box side).

6 Press ENTER. The unit price display will show 21.01, the first and most recent error datafor Side 1. The data will be displayed in the 2-page format described earlier, in an alternat-ing sequence, at a 1 second per page rate.

7 Pressing NEXT accesses 21.02 and the display shows information for the second errorlogged. By pressing NEXT, the error buffer can be viewed completely.

8 To exit, press CLEAR, then UP or DOWN. The unit price display will show S—.

9 Press ENTER three (3) times to exit to the normal display.

3.20 Resetting After All StopThis section applies to Helix dispenser models connected to a Point of Sale (POS) system.Pressing the All Stop key on the POS system sends a signal to the dispenser computer tointerrupt product flow.To resume product flow, refer to the applicable manual for the Point of Sale system used atyour location.


3 Operation

3.21 Electronic Totalizer Readings

3.21.1 Totalizer Volume Readings by Meter PositionMeter volume totals are stored in statistical functions that are accessed using the remotecontrol. The totals for Side 1 are stored in function S05 and those for Side 2 are stored infunction S06. The value of the meter totals are stored in the sub-functions that take the format.M0, where M is the meter number. For example, M=5 for the high feedstock iMeter locatedon Side 1 of a remote series blender. For Side 2 of the same meter, M=1.Meter electronic totalizers are read by entering the Maintenance Mode and accessing thecorrect function and associated sub-functions. Perform the following steps using the remotecontrol. Bold type denote remote control function; italicized type represents dispenser re-sponse.Accessing the Meter Volume Totalizer Sub-function for Side 1:

• Press ENTERPASS 1 (enter password).

• Press ENTERPASS 2 (enter password).

• Press ENTER. The unit price display will show F.

• Press eitherUP orDOWN arrow to enter the statistics viewing mode. The unit price displaywill show S— (indicating that a number needs to be selected).

• Press 05 to access S05.

• Press ENTER. The unit price display will show S05 (indicating that the statistical functionhas been accessed).

• Press ENTER to access the sub-functions of S05. The unit price display will show 5.10(note here that M=1).

Consecutive pressing of NEXT will allow access to the next sub-function, incrementing thevalue of M by (.1). For example, to access S05.20, press NEXT. The unit price display willshow 5.20. The value of the meter volume totals is shown in a format such that the leastsignificant six (6) digits of the data value appear on the volume display, while higher ordernon-zero digits of the data value, if present, appear on the money display. Leading zerosappear as blanks.Quick Exit

1 Press the CLEAR key until the unit price display window shows S - - .

2 Press ENTER three times. This causes the maintenance mode task to immediately termi-nate.

3.21.2 Electro-Mechanical Totalizer OperationTotalizers are optional on Helix dispensers. Electro-Mechanical totalizers are located on thejunction box side of the dispenser. There is one totalizer for each meter. The totalizer positionson the bezel relate to the meter position numbers. The physical position of the totalizers, leftto right, on the bezel represent meter positions.


3 Operation

The totalizer shows seven digits and reads in whole units (gallons or liters). Fractional amountsthat are left over from a previous sale are stored in the dispenser computer. When the nextsale of the same product ends, if the fractional amounts from the new sale and previoussale(s) combined are one (1) whole unit or greater, the Electro-Mechanical totalizer is adjustedone whole increment; i.e., if five consecutive sales end with a fractional amount of .2, theElectro-Mechanical totalizer will not account for the fractions until after the fifth sale.


3 Operation

4 Operator Maintenance

CAUTION!Fire Hazard!

Do not re-install a broken break-away valve. In-stalling a damaged valvemay result in a hazardouscondition that could result in serious injury by fireor explosion.

Note!To prevent damage to components located in the hydraulic cabinet, dispenser doors shouldbe in place during rainy and/or icy weather conditions.

4.1 Hose and Hose Retractor

Note!On dispensers equipped with the Hose Retractor option, the hose clamp must be mountedupstream of the breakaway device to avoid damage to the dispenser in the event of a drive-off.

The combined hose, breakaway, and whip maximum lengths are listed below.

Loopback type2 hoses per side

Loopback type1 hose per side

Crossover type1 hose per side

14 ft(4.27 m)

10 ft10 ftNon-vapor 3/4 in.(3.05 m)(3.05 m)(.019 m)

14' 0"14' 0"Non-vapor 5/8 in.(4.27 m)(4.27 m)(.016 m)

4.2 Filter / Strainer - RemoteThe filter should be changed and the strainer cleaned on a regular basis. A dirty filter andstrainer may cause the dispenser to deliver fuel slowly. In some cases, this may appear tobe a more serious service related problem, when simply changing the filter and cleaning thestrainer is all that is required.Before removing the filter, trip the impact valve and turn OFF the circuit breaker for the asso-ciated submersible pump.



The fuel filter is removed the same way an oil filter is removed from a car engine. As shownbelow, the new fuel funnel catches any fuel that is spilled and will properly drain it into acontainer. Place a container under the funnel spout when changing the filter.To install the new filter, first apply a film of oil to the gasket and hand turn until the gasketcontacts the base. Then tighten one half turn. Open the emergency shear valve, turn thesubmersible circuit breaker ON and check for leaks.In new installations it may be necessary to change the filter frequently in the first few daysof operation in order to ensure proper operation.The strainer is located inside the casting and held in place by the filter. Place a suitablecontainer below filter/strainer casting to catch product and sediment. Remove the filter andgently pull the strainer out of the filter/strainer casting. Clean strainer screen of any debris.Reinstall strainer and a new filter.If the underground installation is new, it may be necessary to clean the strainer screen twoor three times the first few days of operation to remove debris and pipe dope. After this, oc-casional cleaning of the strainer is all that should be required. The fuel filter should be changedwhenever the strainer is cleaned.

WARNING!Electric Shock Hazard!

Before removing the filter and strainer turn thepower to the dispenser and submersible pump(s)off and close the emergency shut-off valves on thedispenser being serviced. Failure to do so mayresult in a hazardous condition that can result inserious injury due to electric shock.

Figure 4.1: Remote filter



4.3 Dispenser cleaningDispenser cleaning should be done frequently and in the manner outlined below. We can notstress enough that regular care of the dispenser is the most important element of the cleaningprocedure. It prevents dirt and liquids from permeating the surface materials and formingstains that can only be removed with more abrasive and aggressive cleaning methods.

Note!Do not use pressurized water (even from a garden hose) to wash or rinse off a dispenser.Under no circumstance should power washers be used to clean a dispenser. This can forcewater into the electronic head and cause damage to the electronic components in the dis-penser rendering it inoperative.Do not use all-purpose cleaners.Do not use gasoline or other petroleum-based products to clean the dispenser.Use only mild cleaners such as regular manual dish washing detergents or soap! Waynetakes no responsibility for damage on the product caused by aggressive cleaning detergentsnot approved for cleaning use by Wayne.

Note!It is important to wipe down the dispenser with a clean cloth and clear water after everycleaning.

Note!Periodic waxing of the dispenser surfaces is essential to maintain the original finish and in-hibit corrosion. Stainless steel surfaces should be polished with a non-abrasive silicone wax.

Note!No chlorine based cleaners can be used on the stainless steel.

4.4 Meter MaintenanceAll dispenser meters are calibrated and sealed at the factory prior to shipment and delivery.



Appendix A Dissasembly - Recycling

WARNING!

Disconnect mains power prior to any work, to pre-vent damage which may result in electric shock orfire.

WARNING!Danger of tipping!

Please note that the centre of gravity is not in thecentre, and varies from one pump model to anoth-er.

A.1 Empty the fuel out of the pumpIt is important that there is no fuel in the pump before disassembly.Blank the inlet pipes with a flange and gasket.Between one and four pump units must be emptied and blanked, depending on the pumpmodel.If necessary, ask a transport company for special regulations.

NamePart no.

Flange for blinding of the inlet pipe

Washer, BRB 8, 4X16 FZ (3p)WB000232-0004

Nut, M6M M8 FZB (3p)WB000228-0004

Transport gasket for new inletWM004482

Flange blind for new inletWM004481

A.2 Dispenser recyclingThe dispenser must be recycled according to the applicable regulations in the country whereit is installed.


A Dissasembly - Recycling

Appendix B Declaration of Conformance

The 'X' suffix after the certificate number relates to the following special condition for safeuse:

1 When intended for use with ethanol blended fuels the user shall:

• ensure that the fuel shall not excess 90% ethanol with minimum water content;

• access the suitability of parts used in the construction of the fuel system for long termsuitability with such fuels with due regard to the use corrosion inhibitors;

• give due consideration to the correct selection of supplementary fittings (safe breaks,etc.).

2 Where petrol fuel dispensers are shipped without nozzles, the equipment shall be fittedwith nozzles complying with EN13012 prior to being put into use.

3 Where petrol fuel dispensers are shipped without hoses, the equipment shall be fitted withhoses complying with EN1360 or EN13483 prior to being put into use.


B Declaration of Conformance

Appendix C Glossary of Terms and Acronyms

Table C.1:

DEFINITIONTERM

a product added to the gasoline to enhance perfor-mance

additive

aluminumALU

the surrounding area or environment (as in ambi-ent temperature)

ambient

beeper, buzzerAnnunciator

automatic temperature compensationATC

the outer rim at the upper part of the dispenserbezel

clearing the fuel lines of air (also, purging)bleeding

mixes two fuels together to obtain a third; ablending dispenser

blender

the amount or quantity of each of the two fuelsadded together to obtain the third fuel

blend ratios

a printed circuit board; one of the electronic boardsin the dispenser

board

(as in computers, loading software)bootstrap

device between the hose and dispenser thatbreaks if the hose is accidentally pulled by the car

breakaway

see emergency valvebreakaway valve

Check and Pressure Relief ValveC&PR valve

customer-activated terminalCAT

a type electrical devicecircuit breaker

enclosure used for routing electrical wiresconduit

small section of pipe used to connect two pipestogether

coupling

the frame of a dispenser in the shape of the En-glish letter C

C-syle

a communication circuit used by the dispenserand POS system

current loop

a tube having two raised areas on the endsdouble bump tube


C Glossary of Terms and Acronyms

DEFINITIONTERM

a catchement container (to catch liquids)drip pan

a pan used to drain or catch the fuel to keep it fromspilling onto the ground

drip pan

electronic headEH

electronic head and payment terminalEHPM

mechanical device controlled by electricity (as inelectro-mechanical totalizer)

electro-mechanical

this valve is designed to close the fuel suupply lineif a vehicle crashes into the dispenser or if thereis fire in the dispenser; also known as shear valve,crash valve and breakaway valve

emergency valve

electro-mechanical totalizersEMT

electro-static dischargeESD

device that captures small unwanted particles inthe gasoline or diesel fuel

filter

used to drain fuel into a pan or container in orderto prevent spilling

fuel funnel

a number assigned to a dispenser so that it canbe identified on a communications network

fueling point identificationaddress (FPID)

the amount or volume of fuel before temperaturecompensation

gross volume

name of a vapor recovery systemHealy

dispenser is designed for a higher fuel flow rateand therefore delivers a higher volume of fuel ascompared to a standard capacity dispenser

high capacity

flexible tubing that connects the nozzle to the dis-penser and where gasoline, petrol, or other productflows through

hose

the frame of a dispenser in the shape of the En-glish letter H

H-style

more than one source: (Wayne - Hybrid cardreader that reads both magnetic strip cards andcards that contain a micro-chip that has the cardnumber

hybrid

location at a meter, valve, or casting where thefuel enters

inlet



DEFINITIONTERM

barrier inside the dispenser - the area below thebarrier is free from hazardous electrical sparks

Intrinsic Safe Barrier (ISB)

when the nozzle is located on the left or right sidesof the dispenser, as opposed to front or back sides

island-oriented

unwanted electrical pulses or interference (as injitter pulses)

jitter

small wire or connector used to join together topins in a connector or on a circuit board

jumper

a metal box located near the bottom of the dis-penser

junction box

when the nozzle is located on the front or backsides of the dispenser as opposed to th left or rightsides

lane oriented

lower electronic enclosureLEE

the fuel hose is connected near the middle of thedispenesr, as opposed to high at the top

low hose

low temperatureLT

lift-to-start (to activate dispenser)LTS

dispenser component that measures the amountof fuel dispensed.

meter

the amount or volume of fuel after temperaturecompensation

net volume

device at the end of the hose that is inserted intothe vehicle (or container) when dispenseing prod-uct

nozzle

the holder (on the dispenser) of the nozzle whenit is not in use

nozzle boot

location at a meter, valve, or casting where thefuel exits

outlet

a metal or aluminum type mold where the hose isconnected to the dispenser

outlet casting

part numberP/N

as in payment terminal on the dispenser where apayment is made by credit card

payment terminal (PT)

platform or base that the dispenser sits on (alsoreferred to as 'island' in some areas)

pedestal



DEFINITIONTERM

sealant used on the threads of a pipe; pipe sealantpipe dope

Point of SalePOS

to pour fuel into the pump to clear out the air inorder to start the pump properly

prime

fuel tube; the tube that contains the fuel or thatfuel moves through

product tube

push-to-start (to activate dispenser)PTS

device that generates signalspulser

clearing the fuel lines of airpurge

an electrical component used in the dispenserrelay

the pump for the dispenser is located in the under-ground tank; not inside the dispenser

remote (pump)

something left over or remaining (as in residue)residual

used to secure or hold a tube in placeretainer clip (pin)

pulls hose back into place after useretractor

shows the total sale amount and the volume dis-pensed

sales/volume display

a small dispenser connected to and controlled byanother dispenser that is referred to the master

satellite (dispenser)

a software application also known as the ServiceTerminal program

servTerm

see emergency valveshear valve

a glass cylinder used for visually measuring vol-ume of fuel

sight glass

a short (small) type of dispenserSmall-style

as in buttons or keys on a keypadsoftkey

electro-mechanically operated valvesolenoid valve

secure payment moduleSPM

dispenser is not connected to or communicatingwith the POS

stand-alone mode

standardStd

device that captures small unwanted particles inthe gasoline or diesel fuel

strainer



DEFINITIONTERM

pump that is located in the underground tanksubmersible

the pump for the dispenser is located inside thedispenser

suction (pump)

rotating force applied to tighten; amount of forceused to tighten a screw or pipe

torque

a brand name of a type of screwTorx™

totalizer -TOT

device on the dispenser that counts and displaysthe total volume units

totalizer (TOT)

Transponder-activated CATTRAC

a tube having three raised areas on the endtriple bump tube

shows the fuel price per gallon or per litreunit price display (UPD)

a type of couplinguniversal joint

Unit Price DisplayUPD

Un-interruptible Power SupplyUPS

air has been removed (as in a vacuum line)vacuum

cosmetic panels around the top of the dispenservalance

system that claims fuel vapors, minimizing expo-sure to the customer and environment

vapor recovery

Wayne Intelligent Pulser; a type of meter manufac-tured by Wayne

WIP

a type of meter manufactured by WayneXflo



WarrantyAny alternations or, additions to, or unauthorized work performed on the equipment withoutmanufacturer’s express written consent shall void any existing product warranty. Please seeproduct warranty information for additional details.Use only genuine parts.

Copyright notice© 2014 Wayne Fueling SystemsThe contents of this manual may not be copied in whole or in part without the express writtenconsent of Wayne Fueling Systems.Wayne Fueling Systems reserves the right to make revisions to this manual without priornotice.


Wayne BrazilWayne ChinaWayne SwedenHeadquartersDresser Industria eDresser Wayne FuelWayneWayneComercio Ltda.EquipmentHanögatan 10Dresser, Inc.Estrada do Timbo(Shanghai) Co., Ltd.Box 505593814 Jarrett Way

Austin, TX 78728 126-Bonsucesso1221 Dong Lu RoadSE-202 15 MalmöUSA Rio de Janeiro, BrasilPudong, ShanghaiSweden

China

© 2014 Wayne Fueling Systems WM048521 Rev 07 - PRELIMINARY 11/2014

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