Wayne B23/5 Installation & Operation Manual

Ovation Dispensers

INSTALLATION

OPERATION

DANGER

READ THIS MANUAL BEFORE YOU BEGIN

Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid.
Failure to follow the below precautions and the Warning and Caution instructions in this manual
may result in serious injury. Follow all rules, codes and laws that apply to your area and installa­tion.

SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE

Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cab­inet for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off
when servicing the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser
BEFORE beginning maintenance.

Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an
emergency. Have all leaks or defects repaired immediately.

EQUIPMENT PRECAUTIONS

Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before
dispensing product, otherwise, damage to the equipment may occur. Always use the approved
method for lifting the dispenser. Never lift by the nozzle boot, sheet metal, valance, etc., other­wise equipment damage or personal injury may occur.

HOW TO CONTACT WAYNE

Technical questions related to the installation of the dispenser should be referred to Wayne
Technical Support (1-800-926-3737). Customers needing help with the operation of the dis­penser should call the Wayne Help Desk (1-800-289-2963).

INDICATORS AND NOTATIONS

DANGER

WARNING

CAUTION

NOTE:

Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe injury
or possibly death.

Warning indicates a hazard or unsafe practice which, if not avoided, may
injury or possibly death.

Caution indicates a hazard or unsafe practice which, if not avoided, may

Important information to consider, otherwise, improper installation and/or damage to compo­nents may occur.

result in severe

result in minor injury.

November 2008 Part No. 920559 Rev H

Ovation Series

Dispensers

Installation & Operation

November 2008 Part No. 920559 Rev H

November 2008 Part No. 920559 Rev H

Table of Contents

Title Page

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Dispensers Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Local, State, and Federal Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Inspect the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Island Construction, Dispenser Anchoring, and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Emergency Shut-off Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Vapor Return Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Lifting and Installing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6.2 Dispenser to Control System Wiring Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.6.3 Field Wiring for Dispensers Without a Junction Box. . . . . . . . . . . . . . . . . . . . . . . . 9

2.6.4 Full Service (Stand-Alone) Dispenser Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.6.5 Multiple Dispenser Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.6.6 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6.7 Veeder-Root Vapor Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.6.8 Non-Dispenser Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.7 Hose and Hose Retractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.8 Bleeding Product Lines (Remote Dispensers). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.9 iMeter or Xflo™ Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.10 Balance Vapor Recovery System Installation Requirements . . . . . . . . . . . . . . . . . . . . . 16

2.10.1 Dynamic Back Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.10.2 Back Pressure System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.10.3 Nozzles Approved for Balance System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.11 Wayne Vac Vapor Recovery System Installation Requirements . . . . . . . . . . . . . . . . . . 18

2.11.1 Dispenser Vacuum Decay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.11.2 Wayne Pressure/Vacuum Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 IR Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.3 Logical Nozzle/Hose Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4 Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.5 Setting Unit Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.6 Setting Blend Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.7 Setting Fueling Point ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.8 Authorizing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.9 Initial Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.10 Disable Stand-alone Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

November 2008 Part No. 920559 Rev H

iii

Table of Contents (continued)

Title Page

3.11 Totalizer Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.11.1 Totalizer Readings by Product Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.11.2 Totalizer Volume Readings by Meter Position . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.11.3 Electro-Mechanical Totalizer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.12 Nozzle Boot Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.13 Annunciator Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

3.14 QCAT Dispensers Self-test and CAT Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.15 iX™ Pay Secure Payment Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.16 Wayne Vac Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.17 Audit Report Display Mode (For Weights & Measures Officials/Service Purposes Only) 33

3.18 IDPOS Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.19 iX™ CAT Dispensers Self-test and CAT Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.20 Bill Acceptor (BAC) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.1 Safety Items You Should Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.1.1 Portable Tanks and Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.1.2 Health Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.2 How To Get Service On Your Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3 Basic Dispenser Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.4 Operating the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.5 Restarting After Power Failure or Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.6 Cycling Power to Clear Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.7 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4.8 Resetting After All Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.9 Stand-alone Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.10 Printer Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.10.1 Changing Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.10.2 Paper Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.10 Hazardous Zone Area Classifications for Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.1 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.2 Filter/Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.3 Dispenser Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.4 Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

5.4.1 Wayne Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.4.2 Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.5 Meter Maintenance Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

APPENDIX A1 QCAT SELF-TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

APPENDIX A2 iX CAT SELF-TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

APPENDIX B INSTALLATION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

APPENDIX C LOCAL AUTHORIZE/STAND-ALONE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 73

APPENDIX D DISPENSER / BACKROOM INTERCONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 75

iv

Part No. 920559 Rev H November 2008

1 INTRODUCTION

This revision of the manual includes new installation footprint drawings. These drawings show the location
of the conduits for entering the new smaller junction box. The smaller junction box will be standard on pro­duction Ovation dispensers in November 2008. This junction box gives the installation personnel more
room to make inlet and conduit connections, and it also allows for bottom entry of conduits coming up out­side of the containment box.

1.1 Dispensers Covered

Ovation series dispenser models use the iGEM computer and, either the iMeter assembly with the Wayne
Intelligent Pulser (WIP), or the new Xflo
meter assembly have the letter X in the model number after the second / in the number, for example,
B23/4220D1/JKX/L. There is no difference in the installation and startup of these dispensers, with the only
exception being a one inch change in the location of the field conduit on those models that do not have a
junction box. On those models, the primary conduit location is moved from 1.37 to 2.37 inches off the cen­ter line towards the front of the dispenser. Components in a typical Xflo dispenser are shown in Figure 1-1.

E85 Ovation models have the letter E at the very beginning of the model number and use the Xflo meter
assembly. In addition to the noted change above for Xflo models, internal parts such as the Xflo meter, prod­uct tubes, and outlet castings, as well as external parts, such as pipes, pipe nipples, hoses, nozzles, break­aways and swivels that come into contact with the Ethanol fuel must be Ethanol compatible; they must be
either nickel-plated or stainless steel. Pipe nipples at the meter inlets need to be made of stainless steel.
Replacement filters should be 1 micron. The recommended filter for Wayne Ethanol dispensers is Cim-Tek's
Bio-Tek, 1 Micron filter. Standard gasoline dispensers commonly use filters rated at 10 microns.

™ meter assembly with the XWIP. Models with the new Xflo

The iGEM computer runs on software that can be downloaded by a laptop. Dispenser models with the Xflo
meter and XWIP use iGEM rev 46 or later pump software; servTerm version 5.4.2 or later is required for
servicing (loading the computer software or dispenser configuration template), however, this is not required
for installation/startup of the dispenser. If it becomes necessary to reload pump software, always use the lat­est version. Note: The XWIP case is blue and the iMeter WIP case is black; they are not interchangeable.

Computer function settings that are necessary for Ovation dispenser startup and operation, such as prices,
blending ratios, fueling point number, etc., are included in this manual. If additional information on function
settings and statistics is required, refer to the Ovation Dispenser Service manual, part number 920525-002.

Any questions concerning installation and operation of the dispenser that are not covered in this manual
should be referred to Wayne Technical Support (1-800-926-3737).

XWIP
Pulser

Xflo Meter Dome

Check Valves underneath
Cover Plates

Proportional
Valve and Coil

Figure 1-1 Location of Components in Lower Section. MGD, three Xflo Meters, side 2.

November 2008 Part No. 920559 Rev H

Filter

Product Inlet

1

1.2 Local, State, and Federal Codes

All tanks (both underground and above ground), piping and fittings, foot valves, leak detectors, cor­rosion protection devices, wiring, venting systems, etc., must be installed in accordance with the
manufacturer’s instructions and in compliance with local and regional building codes and require­ments pertaining to service stations (or other locations where the dispenser may be installed).

These requirements may include references to the National Electrical Code (NFPA 70), Automotive
and Marine Service Station Code (NFPA 30A); Flammable and Combustible Liquids Code (NFPA

30); Code of Federal Regulations, Title 40, Section 280 (40 CFR 280); United States Environmental
Protection Agency (U.S. EPA) Technical Regulations of 9-23-88 and U.S. EPA Financial Responsibil­ity Regulations of 10-26-1988.

Where local requirements do not specify applicable codes, Wayne recommends using the codes
listed above. These codes are comprehensive and detailed, often requiring interpretation to cover
unusual situations, and, therefore, the associated handbooks (where applicable) should also be con­sulted. (The handbooks are also available from the same sources.)

Due to the variety of locations encountered, further information on installation cannot be dealt with
in this document except as the codes relate directly to the installation of the dispenser. Therefore, it
is strongly recommended that a qualified engineer or contractor familiar with local regulations

and practices be consulted before starting installation.

Sources for various codes are listed on the following page.

2

Part No. 920559 Rev H November 2008

Pertinent information and codes are available from the following sources:

Association for Composite Tanks (ACT)

North State Street
Suite 720
Chicago, IL 60602
[phone] (for information requests)

Fiberglass Petroleum Tank and Pipe Institute

One SeaGate, Suite 1001
Toledo, OH 43604
[phone]

National Fire Protection Association (NFPA)

One Batterymarch Park
Quincy, MA 02269-9101
[phone]

Petroleum Equipment Institute (PEI)

Box 2380
Tulsa, OK 74101
[phone]

Underwriters Laboratories Inc.

333 Pfingsten Road
Northbrook, IL 60062
[phone]

United States Environmental Protection Agency

Office of Underground Storage Tanks
401 M St., SW (05-400WF)
Washington, DC 20640
[phone] (Underground Storage Tanks)

American Petroleum Institute (API)

1220 L Street, N.W.
Washington, DC 20005
[phone]

National Assoc. Corrosion Engineers

(NACE)
Box 218340
Houston, TX 77218
[phone]

National Leak Prevention Association

(NLPA)
685 Fields Ertel Road
Cincinnati, OH 45241
[phone] or 1-[phone]

Steel Tank Institute

P. O. Box 4020
Northbrook, IL 60065
[phone]

Underwriters Laboratories of Canada

7 Crouse Road
Scarsborough, Ontario, Canada N1R3A9
[phone]

Western Fire Chiefs Association

5360 South Workman Mill Road
Whittier, CA 90601
[phone]

U. S. Department of Labor,

Occupational Safety and Health Administration (OSHA)
Washington, DC 20402

• Call OSHA at [phone] to determine specific needs; OSHA rules
are covered by Title 29 of the Code of Federal Regulations (29 CFR.)

• Order OSHA publications from:
Government Printing Office (GPO)
Washington, DC 22304
[phone]

NOTE: Other regulatory codes may apply. Consult your local and regional code requirements to

determine which codes are applicable for your location.

November 2008 Part No. 920559 Rev H

3

1.3 SAFETY PRECAUTIONS

NFPA 30A states that:

“When maintenance to Class I dispensing devices becomes necessary and such maintenance may
allow the accidental release or ignition of liquid, the following precautions shall be taken before
such maintenance is begun:

• Only persons knowledgeable in performing the required maintenance shall perform the work.

• All electrical power to the dispensing device and pump serving the dispenser shall be shut off at
the main electrical disconnect panel.

• The emergency shut-off valve at the dispenser, if installed, shall be closed.

• All vehicle traffic and unauthorized persons shall be prevented from coming within 20 ft.(6 m)

of the dispensing device.

WARNING

Electric shock hazard! More than one disconnect switch may be required to de-energize the
dispenser for maintenance and servicing. Use a voltmeter to make sure ALL circuits in the
dispenser are de-energized. Failure to do so may result in serious injury.

1

”

Lockout/Tagout requirements of the U. S. Dept. of Labor, Occupational Safety and Health Adminis­tration (OSHA) may also apply. Refer to Title 29, Part 1910 of the Code of Federal Regulations
(29CFR1910), Control of Hazardous Energy Source (Lockout/Tagout).

NOTE: To prevent damage to components located in the hydraulic cabinet, dispenser doors should be

in place during rainy and/or icy weather conditions. Also, check the nozzle boot flipper for
freedom of movement. If ice has formed on the flipper, it should be cleared to prevent
unnecessary damage.

1. Reprinted with permission from NFPA 30A-90, Automotive and Marine Service Station Codes, Copyright
©1990, National Fire Protection Association, Quincy MA 02269. This reprinted material is not the complete
and official position of the National Fire Protection Association on the referenced subject, which is repre­sented only by the standard in its entirety.

4

Part No. 920559 Rev H November 2008

2 INSTALLATION

2.1 Inspect the Equipment

Examine the shipment immediately upon arrival to make certain there has been no damage or loss in
transit. Make sure that all the component parts, including keys and optional equipment (if any), are
accounted for. Check and save the Packing Slip, Bill of Lading, Invoice, and all other documents
included in the shipment. Damaged or lost equipment must be reported to the carrier. Any damage or
loss that may occur in transit is not covered under the Wayne/Dresser Warranty.

2.2 Island Construction, Dispenser Anchoring, and Piping

Product lines must avoid the creation of vapor in the lines and deliver a minimum pressure of 25 psi at
the dispenser inlet when all dispensers at the station dispensing the same product are operating.

A concrete foundation must be provided for the dispenser. Do not pour concrete around product lines or
electrical conduit risers.

Anchor bolts must be installed in the island to allow the dispenser to be bolted down in accordance with
NFPA requirements. The base of the dispenser contains six bolt hole slots (5/8 inch by 2 inch) for
anchoring the dispenser to the island. Use of all anchoring locations is re-commended. Position
the anchor bolts in accordance with the dimensions shown on the Installation Instruction drawing for the
dispenser model. These drawings are located in Appendix B.

Vertical supply risers and electrical conduits must be located per the Installation Instruction for the
appropriate model. Proper height must be maintained to avoid undue stress on the dispenser.

For E85 Ovation models, product piping, pipe nipples, etc., containing Ethanol fuel must be Ethanol
compatible. See the information in Section 1.1 on page 1.

For convenience, a 6” high pedestal is available to install under the dispenser base at locations where
there are no islands. The pedestal, shown in Figure 2-1, can be ordered separately. See the complete
assembly drawing 888813 in Appendix B.

Figure 2-1 Pedestal. See Note under the shear valve drawing on the following page.

November 2008 Part No. 920559 Rev H

5

2.3 Emergency Shut-off (Shear) Valves

WARNING

For remote dispensers, a Listed1, rigidly anchored emergency shut-off valve must be installed, in accor­dance with the manufacturer’s instructions, in each supply line at the base of each dispenser. For a typi­cal emergency valve installation see Figure 2-2. Failure to install the proper emergency shut-off valve will
present a hazardous condition that could result in serious injury.

Figure 2-2 Typical Emergency Valve Installation. The Emergency valve is designed to close the product line due

to shock or fire. The shear section, shown above, functions if the dispenser is knocked out of position.
NOTE: The shear valve must always be at the ground plane. The pedestal shown on the previous page, is con­sidered an extension of the dispenser, not the island.

Note: Wayne does not supply the meter inlet pipe nipple or the union shown above.

2.4 Vapor Return Piping

NFPA 30A Section 4-3-72 states that a vapor return pipe inside the dispenser housing shall have a shear sec­tion or flexible connector so that the liquid emergency shut-off valve will function properly. Wayne’s vapor
connections are secured to the chassis allowing for the use of a shear section.

Wayne dispensers provide 1" NPT pipe connections at the base of the dispenser for vapor return connections.
(See the installation foot print for location in Appendix B.) A minimum 1" riser at each dispenser is con­nected to a minimum 2" return piping to the underground tank. If more than six (6) fueling points are con­nected, then underground piping must be a minimum of 3". All lines should be sloped at a minimum of 1/8”
per foot (1/4” per foot preferred) from the dispenser to the tank to avoid liquid traps. Note: There is no vapor
recovery for the Ethanol product on E85 Ovation dispensers.

1. “Listed” means published on a list by a nationally recognized testing laboratory (NRTL) which is responsible for prod­uct evaluation and is acceptable to the authority having jurisdiction. Underwriters Laboratories, Inc. is one example
of a Nationally Recognized Testing Laboratory. For more information on NRTL’s, see Title 29, Parts 1907 and 1910
of the Code of Federal Regulations, Safety Testing or Certification of Certain Workplace Equipment and Materials.

2. Reprinted with permission from NFPA 30A-90, Automotive and Marine Service Stations Codes, Copyright 1990,
National Fire Protection Association, Quincy MA 02269. This material is not the complete and official position of the
National Fire Protection Association on the referenced subject, which is represented only by the standard in its
entirety.

6

Part No. 920559 Rev H November 2008

2.5 Lifting and Installing the Dispenser

Remove the shipping carton from the dispenser and, if the dispenser is equipped with an optional val­ance, survey the site to determine if it should be installed before or after the dispenser is set on the
island. Wayne recommends installing the valance after the dispenser is installed, if practical, to protect it
from installation damage. See the Valance Module drawing in the back of this manual.

Use door key (p/n 1-202022) to unlock and then remove the lower doors, see Figure 2-3 for location.

Install (2) eye-bolts in the dispenser top castings and lift the dispenser onto the island as per Lifting
Instructions drawing 888514-001 in Appendix B. When handling Ovation dispensers, lift only as per the
Lifting Instructions drawing contained in this manual. Do not lift by the electronic enclosure, nozzle
boot, or any external panels.

Bolt the dispenser into place (Section 2.2), remove the shipping discs from the meter inlets and connect
the product piping per the appropriate Installation Instruction drawing in Appendix B. When installing a
blending dispenser, make sure the Lo and Hi product inlets (and, if applicable, the single product inlet)
are correctly located.

To ensure tight, leak-proof connections when making piping connections, wash all cutting oils off the
threads and use a UL-classified pipe joint sealing compound, rated for use with petroleum-based prod­ucts.

WARNING

Explosive or flammable vapors may accumulate within the dispenser housing. All piping connec­tions in the final installation must be accurately fitted and all threaded joints tightly made up with a
Listed gasoline-resistant pipe joint compound. Put the compound on male threads only, being
careful not to get excess inside the pipe or fittings. Failure to perform the above will present a haz­ardous condition that could result in serious injury.

VGA
Screen

Upper Door
Locks

Lower Door
Locks (2)

Option

Figure 2-3 DOOR LOCK LOCATIONS. One door key fits upper and lower door locks.

November 2008 Part No. 920559 Rev H

Optional VGA display screen shown.

7

2.6 Electrical Wiring

2.6.1 General

Wayne recommends employing a qualified electrician for all wiring. A hazardous liquid is being handled, so it is
important to ensure that all wiring is in accordance with the National Electrical Code (NFPA 70) as well as all
federal, state and local regulations. Note: U.L. requires that all electrical connections to the dispenser be made
with threaded, rigid conduit and properly sealed conductors. Note: All dispensers and electrical connection
boxes must be grounded per NFPA 70.

2.6.2 Dispenser to Wayne Control System Interconnection

Dispenser installation wiring diagrams are provided in Appendix B. The system interconnection wiring diagrams
supplied are for reference purposes. Use these diagrams along with the wiring diagrams supplied with the control
system for laying out the system wiring requirements for a new site or when making changes to an existing one.

Two da t a wires to the Data Distribution Cabinet are required for the Wayne control system console operation.

Two da t a wires to the Site Controller Cabinet are required for dispenser card processing CAT operation.

Two da t a wires to the Site Controller Cabinet are required for Wayne TRAC operation.

One ethernet cable (gas and oil resistant) is required for dispensers equipped with the IDPOS or iX CAT option

from the switch in the dispenser to the switch in the building, see Section 2.6.6, Figure 2-5 and Figure 2-6. A UL

AWM Ethernet cable, Category 5 or higher, rated at least 300 V, 60 degrees C with a gasoline and oil resistant

jacket may be used. The conduit in the dispenser must be potted at the end of the installation.

Optional equipment wires, see Section 2.6.6.

NOTE: When data wires are installed, only the two data wires from the Data Distribution Cabinet used for pump control

are to be terminated at the dispenser’s terminal strip. The additional data wires should not be physically
connected to the data terminals on the dispenser’s terminal strip. Instead they should be properly terminated
individually using wire nuts.

Figure 2-4 shows the location of dispenser components that may need to be accessed during installation. If the
dispenser is not equipped with a junction box in the hydraulic cabinet, field wiring will terminate at the terminal
strip inside the electronic enclosure as shown in Figure 2-5 and the conduit fittings shown will be potted in the
field.

E-M TOTALIZERS

WIP PULSER

CHECK VALVES
(under Valve Plates
in iMeter Dome)

PROPORTIONAL

/

VALVE

VALVE COIL

JUNCTION BOX

PRODUCT INLET

FILETR/STRAINER
CASTING

Figure 2-4 Location of Components in Lower Section (iMeter model shown). Side 1.
See Appendix B for new footprint drawings with the smaller junction box (above) effective in November 2008.

8

Part No. 920559 Rev H November 2008

VAPOR
RECOVERY

OUTLET

WARNING

Electric Shock Hazard! No connections (including neutral) may be shared between groups of dispensers.
A separate Control Power Circuit Breaker must be provided for each group. Failure to do so may result in
serious injury.

2.6.3 Field Wiring for Dispensers Without a Junction Box

All field wiring must enter the Electronic Head via potted conduit/conduit fittings. When a dispenser
does not contain a junction box, the conduits must be potted in the field during dispenser installation.
Note: This also applies to the secondary conduit containing the Ethernet cable and the intercom call button/
speaker wires even if the dispenser does have a junction box since these wires do not connect in the junction
box.

1. Install (2) 3/4” field conduits from the UL approved seal-offs at the base of the dispenser to the conduit at
the vapor barrier as identified in Figure 2-5. One conduit will contain, as applicable, the Ethernet cable
and the intercom (call button and speaker) wires (low voltage - Class 2 circuits). The other conduit will
contain the pump power, relay selects, valance lighting and data wires (Power - Class 1 circuits).

Potted conduit for Ethernet and
Intercom Call Button/speaker wires only.

,

Note: With or without j-box,
this conduit now goes directly to the
seal offs under the dispenser to allow
for a straight run of Ethernet cable

from building switch to dispenser switch.

Terminal Block
used when junction box

is not installed.

MGD Wiring Shown.

Potted Fitting contains Pump Power,
Data, Relay Selects, Valance lighting

Note: Main potted fitting contains
intercom speaker wires (Brown pair)

These must run in separate underground

conduit along with the call button wires.

See optional equipment section.

Figure 2-5 Terminal Block Inside Electronic Enclosure. Field wiring connects to this terminal block when
the junction box shown in Figure 2-4 is not installed.

2. Clean conduit threads before connecting.

3. Pull continuous uninterrupted lengths of wires from the station electrical panels and control boxes to the
dispenser electronic head. Allow an extra 18” lengths past the vapor barrier fitting for terminating,
separating, potting and connecting to the terminal block. If installing iX CAT or IDPOS dispensers, allow
an extra 3 ft. of Ethernet cable past the top of the conduit in the vapor barrier.

4. From each conduit, separate the wires using 3-201623 Wire Separator Gasket. See Photo 1.

5. Roll separator gasket and wires into a cylinder and secure with electrical tape. Photo 2 and Photo 3.

6. Pull separator gasket and wires back through the conduit fitting (Photo 4) forming a dam in the conduit,
with the top of the separator down in the conduit past the dimple in the conduit.

November 2008 Part No. 920559 Rev H

9

2.6 Electrical Wiring, continued

7. Trim wires to appropriate length, terminate ends and connect to the terminal block as per Wiring Diagram
drawing 888445-001 located in the Appendix B of this manual. Note: Field wires are to be connected to
the lower terminals on the block.

8. Prepare the potting compound by pouring 4 oz. Rockite into an eight oz. paper cup.

9. Add 1-1/2 oz. of water.

10. Stir one to two minutes until reaching a consistency similar to pancake batter.

11. Pour mix into fitting and fill to within 1/8” of top of fitting (or top of conduit if the Ethernet conduit).

12. Close the service door.

13. Let fitting set for 12 hours. The wires must not be moved during this time.

Photo 1. Photo 2.

Photo 3. Photo 4.

10

Part No. 920559 Rev H November 2008

2.6.4 Full Service (Stand-Alone) Dispenser Wiring

For full service operation, make electrical connections as shown on the Installation Wiring Diagram in
Appendix B. The electrical connections illustrated are typical when additional like model dispensers are
used.

Data wires shown on the wiring diagram are for connecting the dispenser to the Data Distribution Cabi­net and the Site Controller Cabinet in a Wayne Control System. These data wires are not required for the
full service (stand-alone) dispenser. However, the six optional data wires and cable, whichever are
applicable, as described in Section 2.6.2, should be run at initial installation if a control system or
optional equipment is being installed or may be installed in the future.

Remote dispensers require a relay to control the submersible pump motor. These relays are available as
an option with the Wayne control system. If the dispenser is not connected to a Wayne control system, a
UL Listed magnetic motor controller assembly, constructed with Potter and Brumfield Relay No.
PRD7AYO (120) or equivalent, shall be used.

A maximum of 12 dispensers (24 fueling points) may be connected to a single PRD7AYO (120) relay;
other relays may have different limitations. All dispensers operating the same pump control relay must
be connected to the same circuit breaker; this may require multiple control relays for a submersible
pump.

Ensure that the submersible pump receives its power from its own separate circuit breaker as illustrated
in the Typical Site Wiring Diagram in Appendix B.

2.6.5 Multiple Dispenser Wiring

A primary requirement in dispenser installation wiring is to provide a means for disconnecting all power
connections, including the neutral, to the dispensers for safe shutdown and servicing of the units. Each
dispenser could be provided with a separate control Power Circuit Breaker. If this is not desirable or
practical, several dispensers can be grouped together and tied to the same Control Power Circuit Breaker
as illustrated in the Typical Site Wiring Diagram in Appendix B. A group of dispensers would then con­sist of all the dispensers and associated Submersible Pump Control Relay coils supplied by the same
Control Power Circuit Breaker.

When more than one dispenser within the group activates the same submersible pump, the Relay Select
lines may be commoned at the Submersible Pump Control Relay Coil terminal up to a maximum of 12
connections (24 fueling points). Where more than 12 connections activate the same submersible pump,
additional relays should be used and the contacts paralleled as illustrated in the Typical Site Wiring
Diagram.

In larger installations, dispensers can be separated into multiple groups.

November 2008 Part No. 920559 Rev H

11

2.6.6 Optional Equipment

Dispensers contain an extra pair of data wires in the junction box for Wayne TRAC as shown in
Figure 2-6 below. These wires are also identified in the installation wiring diagram in Appendix B.

Dispensers with the letter I in the model number will have an intercom call button.
Brown wires are speaker connections. Yellow wires are call button connections see Figure 2-6. Both
circuits are low voltage NEC Class 2 only.

Dispensers with a 3 or 6 in the main body of the model number indicates the dispensers are equipped
with iX CAT board option, VGA or QVGA, respectively. And, dispensers with the letter “L” in the 1st
suffix of the model number indicates iX Secure Keypad. All of these dispensers will require an unin-

terrupted run of Ethernet cable from the switch in the building to the switch in the dispenser elec­tronic head. These dispensers will need a secondary underground conduit for this cable and other
NEC Class 2 wiring as shown below. From the factory, these dispensers will contain a short section of
conduit that can be used for making the connection to the secondary conduit seal off under the dispenser.

NOTE: The field Ethernet cable and Intercom (Call Button and Speaker) wires (NEC Class 2) must be

installed via a separate underground conduit to the dispenser. The intercom/speaker and call button
wires should be terminated with wire nuts in the electronics head.

Call Button

Ethernet Cable for

iX CAT or

(NEC Class 2)
Underground Conduit

for Ethernet cable and
Intercom (call button
and speaker) wires only.

Note: This conduit now goes directly to the seal offs
under the dispenser to allow for a straight run of
Ethernet cable from building switch to dispenser switch.

IDPOS option

Secondary Conduit
in Electronic Head

Y

••

Y

Speaker

Junction Box

Electronic Head

Terminal Strip

BN pair

•

•

BU

OR

_

+

•

•

•

(NEC Class 1)
Underground Conduit
for Pump Power,

and Data,
Valance lighting
and relay select wires.

Speaker

Main Conduit in
Electronic Head

Data Wires for

Wayne TRA C

option

Wire Nut (typical)

Figure 2-6 Ethernet, Intercom Call Button and Speaker Wiring. Ethernet and Intercom (Call Button and
Speaker) wiring must run in a separate underground conduit to the dispenser.

2.6.7 Veeder-Root Vapor Flow Meter

Refer to the installation procedures in the Veeder-Root Manual No. 577013-796 Rev E (page 6, instruc­tion steps 11 and 12) supplied with dispensers equipped with the Veeder-Root option.

2.6.8 Non-Dispenser Equipment

Do not run wiring for any non-dispenser equipment, in the same conduit as the dispenser wiring; this
wiring must be run in a separate conduit.

12

Part No. 920559 Rev H November 2008

2.7 Hose and Hose Retractor

Hose assemblies should be U.L. Listed and installed in accordance with the manufacturer’s instructions. To
ensure a proper joint, wash all cutting oil off the threads and use a U.L. classified gasoline-resistant pipe joint
sealing compound. Place the compound on male threads only; be careful not to get any excess compound
inside fittings. Install the fixed end of the hose to the dispenser outlet; secure according to the instructions of
the sealing compound and hose manufacturers. Install the swivel end of the hose or other swivels to the noz­zle according to the manufacturer’s instructions.

Exception: Do not use the sealant on balanced or inverted hoses used with vapor recovery.

NFPA code requires a Listed emergency breakaway device, designed to retain liquid on both sides of the
breakaway point, must be installed on each hose dispensing Class I liquids; these devices must be installed
and maintained per the manufacturer’s instructions. Refer to your state and local codes for breakaway device
requirements that apply to your installation.

On E85 Ovation dispensers, all hoses, nozzles, breakaways, etc., containing the Ethanol fuel must be Ethanol
compatible. See the information in Section 1.1 on page 1.

On Wayne vapor recovery dispensers all hoses, nozzles, and breakaways, etc., must be CARB certified.

Hose Retractor: Caution!: On dispensers equipped with the Hose Retractor option, the hose clamp must
be mounted upstream 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.

Crossover Type
1 Hose per Side

Wayne Vac 14’ 0’’

Non-Vapor 3/4” 10’ 0’’ 10’ 0’’

Non-Vapor 5/8” 14’ 0’’ 14’ 0’’

WARNING

Use only Listed hoses and nozzles. Continuity must be present between the dispenser outlet and nozzle
spout to prevent static discharge while fueling. Continuity must be checked for each outlet/hose assem­bly to insure that the nozzle is grounded. Failure to do so may result in a hazardous condition that could
cause serious injury.

Loopback Type
1 Hose per Side

Loopback Type
2 Hose per Side

2.8 Bleeding Product Lines (Remote Dispensers)

NOTE: To avoid severe damage to the dispenser, all air and air pockets must be bled from the product trunk

lines before attempting to dispense product.

Step 1 Make sure the power to the appropriate submersible pump is OFF.

Step 2 To bleed air from a trunk line, remove the pipe plug from the safety impact valve on the dispenser

farthest from the storage tank. For pipe plug location see Figure 2-2 earlier in this section.

Step 3 Attach a flexible hose to the pipe plug opening in the safety impact valve. Energize the appropriate

submersible pump and allow the air to bleed out of the trunk line into a test can until product flows
into the test can. De-energize the submersible pump and replace the pipe plug. Repeat the procedure
for each product and each trunk line.

November 2008 Part No. 920559 Rev H

13

2.9 iMeter or Xflo™ Meter Calibration Procedure

Sufficient product must be run through each meter to thoroughly flush out all air and completely fill the system
prior to the calibration process.

Each meter assembly contains two meters. The WIP pulser (or XWIP for Xflo meter) contains two sets of sen­sors, one set for each meter. On the front of the pulser, there are two calibration doors, one for each meter in
the assembly. The door closest to the front of the dispenser controls calibration of the front meter and the other
door controls calibration of the rear meter.

(only one meter at a time can be calibrated).

assure the correct door is opened during the calibration process.

Dispensers have an operation mode setting that establishes the pulser’s calibration mode. This is set at the fac­tory in the dispenser template (Read Only function F16). The imeter and the Xflow meter are calibrated using
the same procedure as shown below.

Verification Accuracy:

1. Dispense some product into the test measure to wet the container and then drain the container thor­oughly, 10 seconds or more.

2. Dispense product into test measure until exactly 5 gallons (20 liters) are shown on dispenser display.
See Note 1.

3. Compare reading on site glass of test measure to dispenser display. Volume in test measure should be
within +/- 3 cu. in. (+/- 50 ml). See Note 2.

Only one door may be opened at one time during meter calibration

It is important to verify the product grade for each assembly to

4. If values are out of range, calibrate as described below.

Calibration:

1. Identify calibration door for meter in need of calibration.

2. Remove seal wire and pin to allow access to door.

3. Dispense some product into the test measure to wet the container and then drain the container thor­oughly, 10 seconds or more.

4. Open calibration door of meter to be calibrated. (Only one door can be opened at a time during the cali­bration process).

5. Dispense exactly 5 gallons (20 liters) into the test measure exactly to the “0” mark on the sight glass
(read the bottom of the meniscus).

6. Close the calibration door. (This now redefines the calibration factor in the pulser).

7. Empty the test measure (drain completely, 10 seconds or more) and verify accuracy as described above.

8. Seal calibration door.

Note 1: In the Liter mode, in addition to 20 liters, a 10 liter or 5 liter test measure may be used if required
by the application. However, you should check with your jurisdiction on Weights & Measures tolerance
requirements.

Note 2: For the U.S. and Canada, acceptance tolerance of ±3 cu.in. for a 5 gallon measurement and ± 50
ml for a 20 liter measurement is only required for newly installed, newly placed in service devices for 30
days. After 30 days, the tolerance is increased to ±6 cu.in. for 5 gallons and ±100 ml for 20 liters.

14

Part No. 920559 Rev H November 2008

Dispenser
Front
(Side 1)

iMeter

(Side 2)

Meter A

Meter B

(Side 2)

Pulser Connector
located inside of
cover

XWIP
Pulser
(Blue Case)

Check Valve
Covers

Xflo Meter

Meter B

Meter A

Dispenser
Front
(Side 1)

Figure 2-7 Meter Assemblies. The WIP and the XWIP are physically the same size, but have a different

Note:If for any reason the pulser is replaced, be sure the replacement pulser’s tabs snap

into place in the meter slots before tightening the two screws securing the pulser.

November 2008 Part No. 920559 Rev H

colored case because they are not functionally interchangeable.

15

2.10 Balance Vapor Recovery System Installation Requirements

2.10.1 Dynamic Back Pressure Testing

At initial installation, balance vapor recovery dispensers should have a dynamic back pressure test
performed at each nozzle to ensure there are no blockages in the vapor recovery system.

The dispenser should be connected to the underground and the hanging hardware (hoses, nozzles,
breakaways, etc.) should be installed.

The following test methods or equivalent methods can be used:

“ST-27 Gasoline Dispenser Facility Back Pressure.” Available from the California Bay Air
Management District via the Internet at http://www.baaqmd.gov/mop/vol4/v4index.htm

“TP201.4” Determination of Dynamic Pressure Performance of Vapor Recovery Systems of
Dispensing Facilities.” Available from the California Air Resources Board.

Maximum allowable dynamic back pressure for an individual dispenser nozzle using either test pro­cedure is listed below:

60 cu. ft. per hr. <
80 cu. ft. per hr. <

0.35 in. of water

0.62 in. of water

Note: Very low numbers for back pressure results may indicate a leak in the system and it should

be checked.

2.10.2 Back Pressure System Check List

Note: Check test equipment for up-to-date calibration stickers. Normal use of rotameters and
pressure gauges necessitates yearly calibration; calibration is also required if this equipment has
been dropped or mishandled.

1. Check test equipment for leaks prior to use. Pressurize with nitrogen supply (plug nozzle end of
the fill pipe). Adjust nitrogen until 50% on pressure gauge is reached. Close off supply. A pres­sure decay must not be more than 0.2 in. of water in five minutes.

2. If facility has a vapor pod (condensate pot), drain prior to testing.

3. Open dry break poppets.

4. Completely drain hoses and nozzles prior to test. A pulsating needle indicates fluid in the lines.
Re-drain if necessary.

5. The following information should be included on the field data sheet:

• Facility address and ID

• Pump number and grade ID

• Nozzle make and model

• Back pressure in inches of water

• Nitrogen flow rate

16

Part No. 920559 Rev H November 2008

2.10 Balance Vapor Recovery System Installation Requirements, continued

6. If back pressure readings are very low (less than .02 @ 20 CFH; 0.18 @ 60 CFH; 0.4 @ 100 CFH):

1. Check test fixture for tight seal at nozzle entry point.

2. Check bellows and face seal for tears.

3. Check vapor piping for leaks.

7. If back pressure readings are high:

1. Check hoses and nozzle bellows are completely drained.

2. Check dry break is open. (If only allowed to have one dry break open during the test, try all.)

3. Check vapor pod.

4. Check vapor impact valve to be open.

5. Check piping under dispenser. Should be a minimum of 1 inch diameter piping and fitting.

6. Check dispenser back pressure, disconnected from the underground and compare to dispenser base line
data.

7. Check hanging hardware separate from dispenser and compare to balance hardware matrix base line
data.

8. Check outlets, hose, and underground, for suspect blockage problems due to fitting bottomed out or
casting flashing. Flashing is aluminum edges left over when the casting was made. This should be your
last resort to diagnosing high back pressure readings since piping will have to be removed to look
inside the casting for flashing. A large amount of flashing would be required to affect readings.

2.10.3 Nozzles Approved for Balance System

The Ovation nozzle boot hook can be adjusted to accommodate different nozzles. Table 2-1 shows the nozzles
approved for use with a balance system and the hook position for each nozzle. Position 1 is the standard posi­tion. The hook is in position 1 in the accompanying photo. To change positions, remove the (4) screws shown,
slide the hook down to the new position, and reinstall the (4) screws to secure the hook to the boot.

Table 2-1 Nozzle and Nozzle Hook Position

NOZZLE HOOK POSITION

Emco Wheaton A4005 3

Emco Wheaton A4015 1

OPW 11VF47 4

Husky V Model 5010 and 5020 3

Husky V(short) Model 5110 and 5210 1

1/4-20
Screws (4)

November 2008 Part No. 920559 Rev H

17

2.11 Wayne Vac Vapor Recovery System Installation Requirements

2.11.1 Dispenser Vacuum Decay

At initial installation, Wayne Vac vapor recovery dispensers should have a 27” decay test performed on
each point to ensure there are no vapor leaks in the dispenser/hanging hardware - hose, nozzle, break­away, etc. This test is used to verify the dispenser/hanging hardware integrity so the vapor assist system
will operate at its peak performance.

The test should be performed with the proper hanging hardware installed on the dispenser and the dis­penser disconnected from the underground piping.

Connect the test equipment to the discharge of the vapor piping in the dispenser and apply 27” of water
vacuum to the vapor line. Then close off the vapor line and determine if the closed vapor system can
maintain the 27” of water vacuum.

The system should hold the vacuum for one minute. If it does not, apply 10” of water pressure to the sys­tem, soaping all connections to find the leak. Use a light soap solution; a heavy soap solution could mask
leaks. If the system piping is tight, check hanging hardware by bagging the nozzles and doing a vacuum
test again, while looking for the bags to deflate. The Wayne vacuum tester, as discussed below, is also
used to test nozzles for leaks.

2.11.2 Wayne Pressure/Vacuum Tester

The Wayne Pressure/Vacuum Tester, part number 1-921168-KIT, is available from Wayne to perform this
test. The Operation manual, part number 920372 included in the kit, explains the various tests that can
performed using both vacuum and pressure.

Additional information on these tests is contained in the Compliance Testing and Preventative Mainte­nance manual, part number 917947, supplied with each Wayne Vac equipped dispenser.

18

Part No. 920559 Rev H November 2008

3START-UP

3.1 Initial Checkout

Before applying power to the dispenser, double-check the wiring to make sure the wires are correctly routed
and terminated. Turn on the dispenser control power circuit breaker and the submersible pump or suction
pump motor circuit breakers. Make sure the dispenser comes on and all lights work. The dispenser displays
will show some numbers, usually the last sale run during factory test.

The dispenser template, which configures the dispenser, has been loaded in the dispenser and tested at the fac­tory. The dispenser will have the necessary data such as unit prices and blend ratios to allow the dispenser to
operate in stand-alone at installation to purge product lines and test operation. At start-up, the procedures in
this section should be performed in sequential order to ensure proper operation before the dispenser is
switched over to control system operation.

3.2 IR Remote Control

The Infrared Remote (IR) Control shown in Figure 3-1 is similar to a television remote control. It has
16 buttons and, when held close (12-18 inches) to the infrared eye located on the sales display board, is used
to access dispenser functions and statistics. The IR remote, as discussed in the following sections, is used to
set the clock, unit prices, fueling point IDs, blend ratios, and read electronic totalizers.

Figure 3-1 IR Remote Control. Hold remote close to the sales display to set the clock, unit prices,
blend ratios and fueling point ID, read totals, view error codes and other dispenser diagnostic functions.

November 2008 Part No. 920559 Rev H

19

3.3 Logical Nozzle/Hose Positions

The physical number of hoses on one side of the dispenser is not the same as the number of electronic hose
positions on that side. Unit prices and blend ratios are set in electronic hose position or logical nozzle order.
B23/3, B23/4 and B23/5 model Blenders each have 2 hoses per side and 3 inlets, but either 3, 4 or 5 grade
selects/logical nozzles as shown in Figures 3-2 A-C. Logical nozzles are assigned positions 1 through 7,
depending on the dispenser model as shown in Table 3-1.

Three product MGD models have one hose per side and three logical nozzles, which are positions: 1, 2, and

3. For these non-blending models, such as the R13/3, these products are shown as the X, Y, Z products in
Tab l e 3-1.

Logical nozzle positions for the Ovation models listed below are also shown in the examples in
Figures 3-2 and 3-3 on the following pages.

Table 3-1 Hose (Logical Nozzle) Positions Defined by Values of N.

Ovation Model
# begins with

B23/5 Two Hose (1+4)

B23/4 Two Hose (1+3)

B23/3 Two Hose (1+2)

B12/5 Single Hose 5 Grade

B12/4 Single Hose 4 Grade

B12/3 Single Hose 3 Grade

B12/2 Single Hose 2 Grade

R13/3 3 Grade

R22/2 2 Grade

Dispenser
Description

Blender

Blender

Blender

Blender

Blender

Blender

Blender

Non-Blender

Non-Blender

N=7 N=6 N=5 N=4 N=3 N=2 N=1

Lo
Feedstock

Lo
Feedstock

Lo
Feedstock

Lo
Feedstock

Lo
Feedstock

Lo
Feedstock

Lo
Feedstock

Lo-BL Mid-BL Hi-BL Hi

Lo-BL Hi-BL Hi

Lo-BL Hi-BL Hi

Feedstock

BL Hi

Feedstock

Hi
Feedstock

Feedstock

Feedstock

BL Hi

Feedstock

Hi
Feedstock

ZYX

Single
Grade

Single
Grade

Single
Grade

Y X

R11/1 1 Grade

Non-Blender

Model number designations are defined as follows:
B23/5 model, B = Blender, 2 = two hoses per side, 3 = three inlets, 5 = five grade selects.
R13/3 model, R = Regular piped non-blender, 1 = one hose per side, 3 = three inlets, 3 = three grade selects.

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Part No. 920559 Rev H November 2008

X

position

1

positions
6,5,4,3

positions
7,3

Model B23/5220D1 Model B12/2220D3

positions
7,6,5,4

position

1

positions
6,5,4

Model B23/4220D1 Model B12/4220D3

position

1

positions
6,4

positions
7,5,3

Model B23/3220D1 Model B12/3220D3

Figure 3-2 Blending Models.

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November 2008 Part No. 920559 Rev H