Installation Manual IEC

Wayne Helix™ dispenser DEF

WM048527_DEF

Rev 12

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

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

Indicators and notations

Note!
Indicates extra information or tip.

NOTICE!

Highlights an essential element of a procedure to

help ensure accuracy, completeness, and appro-
priate performance.

CAUTION!

Indicates a potentially hazardous situation, which

if not avoided, could result in personal (non-lethal)
injury or equipment damage.

WM048527_DEF Rev 12 11/2018

 WARNING!

INDICATES A POTENTIALLY HAZARDOUS SIT-

UATION, WHICH, IF NOT AVOIDED COULD
RESULT IN DEATH OR SERIOUS INJURY.

DANGER!

INDICATES A HAZARDOUS SITUATION, WHICH,

IF NOT AVOIDED, WILL RESULT IN DEATH OR
SERIOUS INJURY.

Note!
The graphics and pictures of dispensers contained in this manual may not be representative
of your actual dispenser(s).

WM048527_DEF Rev 12 11/2018

 Table of Contents

Table of Contents

1 Introduction ......................................................................................................... 3
1.1 Dispensers covered ................................................................................ 3
1.2 DEF, AdBlue®, SCR, urea ...................................................................... 4
1.3 Software .................................................................................................. 4
1.4 Health and safety regulations ................................................................. 5
2 Associated equipments ....................................................................................... 7
3 Installation ........................................................................................................... 8
3.1 Inspect the equipment ............................................................................. 8
3.2 Installation recommendation ................................................................... 8
3.2.1 Installation preparations .................................................................................... 8
3.2.2 Final installation ................................................................................................ 8
3.2.3 Rules and regulations ....................................................................................... 8
3.2.4 Emergency shutdown ........................................................................................ 8
3.2.5 Safety switch ..................................................................................................... 9
3.2.6 Base .................................................................................................................. 9
3.2.7 Cable installation ............................................................................................... 9
3.3 Island construction, dispenser anchoring, and piping ............................. 9
3.4 Remote Dispenser Applications .............................................................. 9
3.5 Lifting and installing dispenser ................................................................ 11
3.6 Sealing of the pump towards the ground ................................................ 12
3.7 Electrical wiring ....................................................................................... 12
3.7.1 General ............................................................................................................. 12
3.7.2 Power supply / Power distribution in general .................................................... 12
3.7.3 Voltage stabilizer ............................................................................................... 13
3.7.4 Interference suppression ................................................................................... 13
3.7.5 Connection of other peripheral equipment ........................................................ 13
3.7.6 Dispenser to Control System connection .......................................................... 13
3.7.7 Full service (stand-alone) dispensers ............................................................... 14
3.7.8 Multiple dispenser wiring ................................................................................... 15
3.8 Bleeding product lines ............................................................................. 15
4 Startup ................................................................................................................. 16
4.1 Initial checkout ........................................................................................ 16
4.2 Programming .......................................................................................... 16
4.2.1 Introduction ....................................................................................................... 16
4.2.2 Access to Functions .......................................................................................... 16
4.2.3 Exit function (F00) ............................................................................................. 17
4.2.4 Password change (F33) .................................................................................... 18
4.2.5 Filling modes (F01) ........................................................................................... 20
4.2.6 Changing unit price (F03) .................................................................................. 21
4.2.7 Setting the fuelling point address (ID) ............................................................... 23
4.3 Authorizing the dispenser ....................................................................... 25
4.4 Initial Delivery .......................................................................................... 25

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Table of Contents

4.5 Electronic totalizer readings .................................................................... 25

4.5.1 Totalizer readings by hose (product) position ................................................... 25
4.5.2 Totalizer volume readings by meter position ..................................................... 27
4.5.3 Electro-mechanical totalizer operation .............................................................. 27
5 Operation ............................................................................................................ 29
5.1 Safety items you should know ................................................................ 29
5.2 Health Note ............................................................................................. 29
5.3 How to Get Service On Your Dispenser .................................................. 29
5.4 Basic dispenser requirements ................................................................. 30
5.5 Operating the dispenser .......................................................................... 30
5.6 Restarting after power failure or shutdown ............................................. 30
5.7 Cycling power to clear faults ................................................................... 31
5.8 Error codes ............................................................................................. 31
6 Operator Maintenance ........................................................................................ 33
6.1 Prover cans - contamination ................................................................... 33
6.2 Preventive maintenance ......................................................................... 33
6.3 Filter/Strainer .......................................................................................... 34
6.4 Meter Maintenance Issues ...................................................................... 35
7 Dissasembly - Recycling ..................................................................................... 36
7.1 Empty the fuel out of the pump ............................................................... 36
7.2 Dispenser recycling ................................................................................. 36
8 Drawings ............................................................................................................. 37
8.1 Classification scheme ............................................................................. 37
8.1.1 Zones ................................................................................................................ 38
8.2 Installation instruction ............................................................................. 39
8.3 Connection instruction ............................................................................ 55
8.4 Lifting instruction ..................................................................................... 97
8.4.1 Helix 1000 ......................................................................................................... 97
8.4.2 Helix 2000 ......................................................................................................... 99
8.4.3 Helix 6000 ......................................................................................................... 100

2 WM048527_DEF Rev 12 11/2018

 1 Introduction

1 Introduction

This manual covers general information about the installation, startup, and operation of the
Wayne Helix™ dispenser models specified in the Dispensers Covered section. This manual
also includes installation and footprint drawings that show locations of the product inlets and
conduits. Computer function settings that are necessary for Wayne Helix™ dispenser start-
up and operation such as setting prices, and fueling point adresses (ID's) are also included.
If additional information is required refer to the User's Manual (WM048521), Helix Service
Manual (WM048523), Parts Manual WM048522. Programming manual for iGEM - WM023838.
Any questions concerning installation and operation of the dispenser that are not covered in
this manual (and the User's manual WM048521) should be referred to Dover fueling solutions
after sales support.
Before you start to unpack, install or use the pump, please read applicable parts of the
manual and the User's manual. Consider all dangers, warnings, cautions and notes mentioned
in the manuals. Serious bodily injury and material damage may occur if you neglect this infor-
mation.
It is important that you:
• Keep this instruction manual, the User manual and other applicable documents as long
as the equipment is in operation.
• Pass it on to other owners or users of the equipment.
• Make any supplements or adjustments.

1.1 Dispensers covered

This manual covers the Wayne Helix™ DEF dispensers whose attributes can be determined
by referring to the model string designation below.
If the dispenser also manages fuels refers to a separate manual for this part of the meter.

WM048527_DEF Rev 12 11/2018 3

1 Introduction

a STYLE e NO. GRADES OUT 1 - 8 g NO. HOSES / NOZZLE POSITIONS PER SIDE
C = C-style If blender, count up +1 per each blending 1 digit = Symmetric. Same number, solution, and
H = H-style possibility between 2 grades flows on both sides A & B.
S = Small Style 2 digits = Asymmetric. Different number, solutions,
or flows on Sides A & B.
1st Digit = Side A
2nd Digit = Side B
b DESIGN
W = Wide
N = Narrow
H = High Hose
L = Low Hose
a b c de f g h NOTE: The last two positions shown here can contain
X ( X /X ) X X - X X X multiple digits

c ORIENTATION
ID = Island Dual Sided UI h BASIC TECHNICAL FEATURES
IS = Island Single Sided UI A = Additive
LM = Lane Mirrored B = Biodiesel
LU = Lane UnMirrored* C = CNG (Compressed Natural Gas)
D = DEF (Diesel Exhaust Fluid)
NO. E = Ethanol
f F = Fleet
HYDRAULIC
POSITIONS G = Enhanced Capacity
NO. GRADES H = Super-High Capacity
d 0-5
J = Ultra-High Capacity
IN
1-5 L = LPG (Liquified Petroleum Gas)
M = Media
P = Payment
R = Remote
S = Suction
T = Terminal
Example: U = 4 Users
H(W/LU)23-21PR V = Vapor Recovery
W = Main (Back-to-Back)
X = Back
Y = SAT Master (Satellite)
NOTE: The position prior to and Z = SAT Slave (Satellite)
following the slash '/' can contain
two (2) digits as shown in this
example. The 'L' & 'U' specify
'Lane' & 'UnMirrored'.

Figure 1.1: Helix Model String Designation

1.2 DEF, AdBlue®, SCR, urea

AdBlue®, generically known as DEF (Diesel Emission Fluid), is the registered trademark for
AUS32 (32.5% urea and 67.5% demineralised water by weight).
DEF is used in a process called Selective Catalytic Reduction (SCR) to reduce emissions of
oxides of nitrogen from the exhaust of diesel engined motor vehicles.
DEF is a very aggressive chemical fluid, however not flammable. Therefore it is extremely
sensitive to contamination from other fluids, metals etc. The only approved testing liquid
during production is distilled water that does not contaminate the urea product.
There are always distilled water remaining in valves and other fragile parts and as distilled
water have a freezing point of around 0º Celsius it means that equipment for DEF has to be
kept above freezing point during all phases of the transportation between the factory and to
the time of installation, when it is put into operation and primed with DEF.
If the DEF/distilled water in the dispenser is allowed to freeze, components in the dispenser
must be inspected for damage before the dispenser is placed back into service. Additives
may not be used in DEF to lower the DEF freezing point.
The AdBlue® trademark is currently held by the German Association of the Automobile In-
dustry (VDA), who ensure quality standards are maintained in accordance with ISO 22241
specifications.

1.3 Software
Wayne Helix™ model dispensers are delivered pre-installed with software.

4 WM048527_DEF Rev 12 11/2018

 1 Introduction

NOTICE!

If it becomes necessary to reinstall pump software,

always use the latest version.

1.4 Health and safety regulations

It is important that the following rules and regulations are followed:
• 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 goods
etc.
• Always ask a specialist to make electrical installations of any kind. Special regulations are
applicable!
• Please watch any leakage. If there is a leakage, cut the power to the pump and call Dover
fueling solutions After Sales Service.
• Always follow the regulations regarding handling of DEF, published by each oil company.
• 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 DEF in each
tank.
• Adequate personal safety equipment should be used during installation, dissasembly/re-
cycling, and maintenance of the equipment (gloves, breathing mask, glasses etc.).
• Only persons knowledgeable in performing the required maintenance shall perform instal-
lation and maintenance work. Dover fueling solutions cannot be held responsible for any
damages to persons and/or things deriving from an improper installation of the dispenser.
• The emergency shut-off valve at the dispenser, if installed, shall be closed during mainte-
nance work on the pump.
• All vehicle traffic and unauthorized persons shall be prevented from coming within 6m of
the dispensing device during installation or maintenance work on the pump.
• The customer has to make sure that DEF will not touch his skin during the filling. He also
has to make sure that DEF will not splash into his eyes.
The owner of the filling-station is responsible himself to show this with stickers or descrip-
tions on the pump.

WARNING!

Only authorised personnel may do installation.

WM048527_DEF Rev 12 11/2018 5

1 Introduction

WARNING!

Disconnect mains power prior to any work, to pre-

vent damage which may result in electric shock or
fire.

WARNING!

Electrical components under ATEX marked with

must not be repaired and should be re-

placed as complete spare part in case of opera-
tional functional failure.

WARNING!

Never run a leaking pump!

Be careful with the environment and mind the
skidding risk; take care of leaking fuel immediately.

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 cir-
cuits in the dispenser are de-energized. Failure to
do so may result in serious injury.

6 WM048527_DEF Rev 12 11/2018

 2 Associated equipments

2 Associated equipments

The pump is designed and approved for measuring DEF/Urea in accordance with type ap-
proval. It is a part of a complete system in a station and it communicates directly with both
outdoor and indoor equipment.

DANGER!

USE THIS DISPENSER ONLY FOR DIESEL EX-

HAUST FLUID (DEF)
DEF Dispensers are designed only for use with
Diesel Exhaust Fluid (DEF). Do not use this dis-
penser for motor fuels (such as gasoline) or any
other flammable or combustible liquids. Failure to
follow these requirements could result in a condi-
tion that leads to serious injury or death.

The equipment shall not be used in anything other than commercial or light industrial instal-
lations with respect to electromagnetic disturbance.
Please refer to each unit’s manual for information about each component in the system.

WARNING!

Observe strict compliance with local installation

instructions, to avoid pipe/pump leakage that may
result in substantial fuel leakage.

WM048527_DEF Rev 12 11/2018 7

3 Installation

3 Installation

3.1 Inspect the equipment

Examine the shipment immediately upon arrival to make certain there has been no damage
or loss in transit. Damaged or lost equipment must be reported to the carrier. Any damage
or loss that may occur in transmit is not covered by the Dover fueling solutions warranty.
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 docu-
ments included in the shipment.

3.2 Installation recommendation

3.2.1 Installation preparations

It is essential that care is taken during installation to eliminate the risk of damage and
scratches on cover panels.
We strongly recommend that hydraulic doors are removed and stored in a safe place during
all work.
This should be done before the pump is lifted from the transport pallet. Always make a visual
inspection already at this stage.
Before lifting the pump to the island, make sure that the surface is straight and flat to support
the bottom frame without bending it.

3.2.2 Final installation

Do not replace the hydraulic doors before all pipes and cables are connected and the bottom
frame has been fixed as recommended to the pump island.
Finally, remove the protective plastic film on different panels. Inspect the result to make sure
that the product is as expected by the customer.

3.2.3 Rules and regulations

The rules and regulations of the authorities in each country must be observed when fuel
stations are installed. You must always be updated regarding changes and additions to the
rules.

3.2.4 Emergency shutdown

The electric controls for the meters must be connected in such a way that the flow can be
stopped, so that an inadvertent outflow can be stopped. This function should be designed
as an emergency shutdown. A reset of the emergency shutdown must not result in an auto-
matic start of the pump. The emergency shutdown must be marked according to the national
standard and should be located in such a way that it can easily be reached by the pump area
supervisor. The emergency shutdown must turn off the supply power in the electrical control
centre to all meter cabinets. All staff concerned must be informed of the location and function
of the emergency shutdown.
The emergency stopping system, not included with the dispenser, must comply with national
regulations (for example EN 60204-1) keeping in consideration the 2014/34/EU Directive.

8 WM048527_DEF Rev 12 11/2018

 3 Installation

3.2.5 Safety switch

There is no safety switch on the pump, but this must be installed on the distribution box.

3.2.6 Base
The pump is placed on an elevated island, in order to protect it from collisions.

3.2.7 Cable installation

Cable ducts for mains voltage and low voltage (control) cables must be separated, to minimise
interference (at least 50 cm separation). Avoid excess wire loops in wells. This might cause
interference in the cables.

3.3 Island construction, dispenser anchoring, and piping

Product lines must avoid the creation of vapor in the lines and deliver a minimum pressure
of 25 psi at the dispenser inlet when all dispensers at the station dispensing the same product
are operating (remote pump system).
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. The base of the dispenser contains between 4
and 12 (depending on dispenser model) bolt hole slots for anchoring the dispenser to the
island. Position the anchor bolts in accordance with the dimensions shown on the Installation
Instruction drawings for the applicable dispenser model located in the back of this manual.

WARNING!

It is importan that all anchor bolts are used and

properly mounted as specified in section 3.3. Fail-
ure to secure the dispenser in the manner specified
may cause personal injury or equipment damage.

3.4 Remote Dispenser Applications

• Remote Dispensers: To maximize flow, position the remote dispenser and tank as close
together as possible and minimize the number of turns in the piping. Consult the sub-
mersible pump manufacturer for the proper sizing of the submersible pump, any necessary
leak detection equipment, and installation details.
• Remote Dispensers: Product piping must avoid the creation of vapor in the lines and de-
liver a minimum pressure of 25 psi at the remote dispenser inlet when all when all dis-
pensers connected to the same submersible pump are operating. The dispenser's maximum
operating pressure is 50 psi.

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3 Installation

WARNING!

Failure to install the proper emergency shut-off

valve will present a hazardous condition that could
result in serious injury. For remote dispensers, a
UL-Listed 1 , 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 emergen-
cy shut-off valve installation, refer to the figure
below.

dispenser inlet dispenser base frame

(1-1/2")

anchor bolt

valve actuator lever (1-1/2")

shear point
(should be level with
top of island)
top of concrete island

trip lever
(pull down to close valve) pipe plug for bleeding
product lines

product inlet

under pump cavity

The emergency shut-off 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.
Figure 3.1: Typical Emergency Valve Installation

1 "Listed" means published on a list by a nationally-recognized testing laboratory (NRTL) which is respon-
sible for product evaluation and is acceptable to the authority having jurisdiction. Underwriter Laboratories,
Inc. (UL) is one example of an NRTL. For more information on NRTL's, see Title 29, Parts 1907 and
1910 of the Code of Federal Regulations, Safety Testing, or Certification of Certain Worklplace Equipment
and Materials.

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 3 Installation

Note!
The emergency shut-off valve's shear point must always be at ground plane. The pedestal is considered
an extension of the dispenser, not the island.
The dispenser is not to be changed from its original application by switching fuel types once installed.
For example, if the dispenser is installed and used for gasoline/ethanol blends such as E85, the dis-
penser shall not be changed to traditional gasoline at a later date.
On E85 dispensers, use only shear valves approved for that fuel. For E85 models, use shear valve
part numbers 10P-0152E85 and 10P-4152E85 manufactured by OPW.

WARNING!
Risk of Injury!

Installation of a rotating emergency shear valve

instead of a rigidly-mounted emergency shut-off
valve will result in malfunction and possible injury.
The emergency shut-off valve must be rigidly-se-
cured according to manufactuer's instruction. The
piping directly above the valve must be securely
anchored and not able to rotate.

3.5 Lifting and installing dispenser

• Remove the shipping carton from the dispenser and, if the dispenser is equipped with an
optional valance, survey the site to determine if it should be installed before or after the
dispenser is set on the island. Dover fueling solutions recommends installing the valance
after the dispenser is installed, if practical, to protect it from installation damage.
• Remove dispenser hydraulic cabinet doors and store in a safe location until completion
of the installation.
Always use the original pallet including the bolts for proper fixation when moving a dis-
penser.
• Move the dispenser to a position adjacent to the island/sump box before removing the
fixation bolts.
• Using a method approved locally and adapted to domestic regulation, raise the dispenser
level with the island. See also "Lifting instruction" page 97.
• Manoeuver the dispenser into position on the island locating it in accordance with the
engineering drawing in chapter "Installation instruction" page 39.

WARNING!
Danger of tipping!

Please note that the centre of gravity is not in the

centre, and varies from one pump model to anoth-
er.

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3 Installation

CAUTION!

When handling the dispenser, lifting by the comput-

er enclosure, nozzle boot, hose outlet, operating
lever, or any external panels may result in dis-
penser damage and/or personal injury.

Bolt the dispenser into place, remove the shipping discs from the meter inlets, and connect
the product piping per the appropriate Installation Instruction drawing.
To ensure tight, leak-proof connections when making piping connections, wash all cutting
oils off the threads and use a classified pipe joint sealing compound.

3.6 Sealing of the pump towards the ground

It is important that the pump is sealed to the ground. A sealed drip tray must be installed so
that any leakage is diverted outside the pump. In this way the leak will be discovered at an
early stage. Through-holes for cable ducts, liquid tubes, gas pipes, bolts and cables in cable
ducts must be sealed with sealing compound. Due to the explosion hazard and the health
and safety regulations, the equipment must be designed so that DEF in gas or liquid form
cannot penetrate other tube systems, station buildings or other areas. The sealing compound
must be resistant to DEF/Urea and easy to mend after damage. The surface of the ground
plate must be even without too many irregularities.
We recommend "drip pan" (option, see drawings "Installation instructions") and Sikaflex
TankL, order number WM005290.

3.7 Electrical wiring

3.7.1 General
Dover fueling solutions recommends employing a qualified electrician for all wiring. A haz-
ardous substance is being handled, so it is important to ensure that all wiring is in accordance
with the local rules and regulations.

WARNING!
Grounding system

Verify proper functioning of grounding system.

3.7.2 Power supply / Power distribution in general

Install your power distribution so that it is easily accessible, clearly laid out, in accordance
with national regulations.
Label all cables to the power distribution in such a way that every other expert is able to un-
derstand the wiring.

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 3 Installation

Label fuses, circuit breakers, protective motor switches (if any) etc. Draw a wiring plan of the
electric distribution.
Remove all cables which are not needed from the power distribution.
Arrange fuses, motor protection switches etc. clearly according to function groups.
Ensure an even load dispatching on the 3 phases. Avoid an unbalanced load of the phases.
Note that high loads, for example motors from car washes, can cause substantial voltage
drops which may lead to interruptions.
Remember that motors, relays, contacts, fluorescent lighting etc. are inductances and that
these items have to be radio-shielded. Otherwise they would bring peak voltage disturbances
into the grid.
Remember to install an effective ground connection.
If possible, leave the address of the firm, which carried out the installation works, or the ad-
dress of the service company on the electric distribution.

3.7.3 Voltage stabilizer

• Have to be provided if voltage fluctuations higher than ±10% are expected.
• Have to be designed correctly and to be adjusted to match the system.
• All electronic components of the system have to be connected to the voltage stabilizer.
• In case of doubt Dover fueling solutions can recommend appropriate equipment.

3.7.4 Interference suppression

• Correct wiring of data cables.
• Interference suppression of all loads, switches and especially inductive loads which are
connected to the same network or distribution.
• Selection of suitable anti-interference devices.
• Defective loads must not be connected to the same network.
• When changing defective parts the wiring of the connection cables must be checked (the
original wiring must be maintained).

3.7.5 Connection of other peripheral equipment

• Is only possible after written approval of the connection by Dover fueling solutions.
• Interference suppression of all switches.
• Correct wiring of the data cables.

3.7.6 Dispenser to Control System connection

Dispenser installation wiring diagrams are provided in this manual. Use these diagrams along
with the wiring diagrams supplied with the control system for laying out the system wiring
requirements for a new site or when making changes to an existing one.
1 One data wire to the Data Distribution Cabinet are required for the Dover fueling solutions
control system console operation.
2 Two data wires to the Site Controller Cabinet are required for dispenser card processing
CAT operation.

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3 Installation

3 Two data wires to the Site Controller Cabinet are required for Wayne TRAC operation.
4 One ethernet cable (gas and oil resistant) is required for dispensers equipped with the iX
Pay terminal option from the switch in the dispenser to the switch in the building.
Power Wiring
Confirm that all wiring for outdoor equipment (line, neutral, relay select, etc.) is oil and
gasoline resistant.
Data Wiring
Confirm that all data wiring for outdoor equipment (communication lines) is oil and gas resis-
tant.

WARNING!

Electric Shock Hazard! No connections (including

neutral) may be shared between groups of dis-
pensers (remote pump). A separate Control Power
Circuit Breaker must be provided for each group.
Failure to do so may result in serious injury.

3.7.7 Full service (stand-alone) dispensers

For full service operation, make electrical connections as shown on the Installation Wiring
Diagrams. The electrical connections illustrated are typical when additional like model dis-
pensers are used.
Data wires shown on the wiring diagram are for connecting the dispenser to the Data Distri-
bution Cabinet and the Site Controller Cabinet in a Dover fueling solutions Control System.
These data wires are not required for the full service (stand-alone) dispenser. However, the
data wires and cable, whichever are applicable, should be run at initial installation if a control
system or optional equipment is being installed or may be installed in the future.
Remote dispensers require a relay to control the submersible pump motor. These relays are
available as an option with the Dover fueling solutions control system. If the dispenser is not
connected to a Dover fueling solutions control system. A maximum of 12 dispensers (24 fu-
eling 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.

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 3 Installation

3.7.8 Multiple dispenser wiring

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

3.8 Bleeding product lines

NOTICE!

To avoid severe damage to the dispenser, all air

and air pockets must be bled from the product
trunk lines before attempting to dispense product.

Perform the following steps:

1 Make sure the power to the appropriate submersible pump is OFF.
2 To bleed air from a trunk line, remove the pipe plug from the safety impact valve on the
dispenser farthest from the storage tank.
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.

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4 Startup

4 Startup

4.1 Initial checkout

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

4.2 Programming

4.2.1 Introduction
You will need to access the maintenance mode in order to program
functions and/or view statistics. The function and statistics data appear
in the money, volume, and unit price display windows.
The infrared interface is similar to a television remote control. It has
16 buttons. Use the infrared interface to access dispenser functions.
Point the remote control towards the A-side display. This interface
only uses the pump display for user feedback. There is no additional
display.

4.2.2 Access to Functions

Press the CRC button on the iGEM board.

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 4 Startup

Access the programming mode by pressing one of the following keys:

"1" Station manager entry using the station manager password.
"2" Operator entry using the operator password.

The programming mode 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 sale display, you have 10
seconds to start entering the password. The timer restarts after you
press a key. When you finish entering the password and press ENTER
(=E).
PASS 2 appears in the sale display window, prompting you to enter
the password again.
The display will show:

Note!
If you press nothing more, press <ENTER> (=E) or press the wrong password, or there is
no confirmation after pressing the password and the <ENTER> key, the computer will leave
this function automatically after about 10 seconds.

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

Press again the password to confirm and press <ENTER>

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

4.2.3 Exit function (F00)

Use this function to select one of three maintenance mode exits.

Press 00
Press <ENTER>
The display shows:

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4 Startup

Press <ENTER>
The display shows:

Press <#>
The display shows:
Select one of three maintenance mode exits:
01 = Do not exit and do not save changes
02 = Exit, but do not save changes
03 = Exit and save changes

Press <ENTER>
If you have entered 3
The display shows:

Press <ENTER>
The display shows:

4.2.4 Password change (F33)

The Helix dispenser is delivered with a set of default passwords for the different access/user
levels. These passwords are entered using the IR remote control in order be allowed access
to edit parameters.

WARNING!
Important to change the passwords

When installing the dispenser it is important to

change the passwords of these access/user levels
to something unique and secret only known to
those who are intended to access the dispenser
service menus.

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 4 Startup

Access to Functions
Select this function to change the password.
Press 33
Press <ENTER>
The display shows:

Press <ENTER>
the display shows:
Select the sub-function with <NEXT> :
33.00 Service Engineer Password (max. 6 characters)
33.01 Station Manager Password (max. 6 characters)
33.02 Station Operator Password (max. 6 characters)

Press <#>, the money display goes blank, enter the new password
(max. 6 characters), dashes appear instead of the regular entries.

Press <ENTER>
The display shows:

Enter the new password twice. Dashes appear instead of the regular
entries.

Press <ENTER>
If the password is correct, the dashes end “PASS” flashes.

Press <ENTER>
If the Password was changed, the dashes flash.

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4 Startup

Note!
To exit and save changes use F00 Exit Function - option 3.

4.2.5 Filling modes (F01)

Access to Functions
Select this function to change the Filling Mode.
Press 01
Press <ENTER>
The display shows:

Press <ENTER>
The display shows:
(the actual status is show on volume display)

Press <#> the amount display shows blanks.

Enter the new Filling Mode

(the new Operating mode is shown on amount display)
1 Serial Mode, dispenser controlled by site controller via serial link.
2 Stand Alone Mode, dispenser not supervised by a site controller.
3 Serial W&M Mode, same as #1, but 3 volume decimals.
4 Stand Alone W&M Mode, same as #2, but 3 volume decimals.
5 Serial W&M Mode, ATC, inspection of temperature compensation.
6 Stand Alone W&M Mode, ATC, inspection of temperature compen-
sation.

Press <ENTER>
The display shows:
The new Operating mode is show on volume display.

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 4 Startup

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

Note!
To exit and save changes use F00 Exit Function - option 3.

4.2.6 Changing unit price (F03)

If you have a system connected, its prices override the prices in the pump, and the prices
programmed in this sub-function are not taken into account.

Changing prices on side A

Access to Functions
The display shows the function screen.
- Step 1 – Press 03 and press <ENTER>, and the display shows:

- Step 2 - Press <ENTER> and the display shows:

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
so on, according to the table below:

Sub-Function Nozzle
Side
Credit Prices ( Position )

3.01 1 A
3.02 2 A

Sub-Function Nozzle
Side
Credit Prices ( Position )

3.11 1 A
3.12 2 A

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4 Startup

Example: I have 2 pumps programmed to a unit price of € 1.300 and

want to change to 1.420

Press the <#> key, the dotted part on paying total of display will be
erased.

Press the desired value.

Ex.: 1420

Press <ENTER>, and the display shows:

To change from one Sub-Function to another use the <NEXT> key
(Ex.: from 3.01 to 3.02).
The same procedure applies to change the cash prices. (Sub functions
3.11 to 3.12, see table)
To save all changes follow exit procedure of “F00” exiting, value 3.

Changing Prices on Side B

Access to Functions
The display shows the function screen.
- Step 1 – Press 04 and press <ENTER>, and the display shows:

- Step 2 - Press <ENTER> and the display shows:

Sub-Function 4.01 is responsible for changing unit price of fuel at nozzle 1 on side A, and
so on, according to the table below:

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 4 Startup

Sub-Function Nozzle
Side
Credit Prices ( Position )

4.01 1 B
4.02 2 B

Sub-Function Nozzle
Side
Credit Prices ( Position )

4.11 1 B
4.12 2 B

Example: I have 2 pumps programmed to a unit price of € 1.300 and

want to change to 1.420

Press the <#> key, the dotted part on paying total of display will be
erased.

Press the desired value

Ex.: 1420
Press <ENTER>, and the display shows.
To Change from one Sub-Function to another use the <NEXT> key
(Ex.: from 4.01 to 4.02).
The same procedure applies to change the cash prices. (Sub functions
4.11 to 4.12, see table above.)
To save all changes, follow exit procedure of “F00” exiting, value 3.

4.2.7 Setting the fuelling point address (ID)

Side A (F05)

Access to Functions
The display shows the function screen.
Press 05 and press <ENTER>, and the display shows:

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4 Startup

Press <ENTER>
(the actual address is show on volume display)

Type desired address (1 in this example)

Press <ENTER>, and the display shows:

Press <ENTER>
To save all changes follow exit procedure of “F00” exiting, value 3.

Side B (F06)

Access to Functions
The display shows the function screen.
Press 06 and press <ENTER>, and the display shows:

Press <ENTER>
(the actual address is show on volume display)

Type desired address (1 in this example)

Press <ENTER>, and the display shows:

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 4 Startup

Press <ENTER>
To save all changes follow exit procedure of “F00” exiting, value 3.

4.3 Authorizing the dispenser

The dispenser must be authorized before it will dispense product.
The dispenser filling mode is set in programming function F01. In stand-alone mode (not
connected to a control system), the dispenser is always authorized.
When connected to a control system, the system programming determines authorization.

4.4 Initial Delivery

To dispense product from a newly installed dispenser, make sure unit prices are set (as
previously described) and proceed as follows:
1 Authorize the dispenser.
2 Remove the nozzle, start the reset sequence and observe the reset cycle; make sure all
sales display and unit price display elements operate.
3 Check that when reset is started, the correct submersible pump motor is activated (Remote
dispenser).
4
NOTICE!
bleed prod lines

Make sure the product lines are properly bled

before dispensing any product through a remote
dispenser.
Make sure suction pumps are primed before
dispensing any product through a suction pump.

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

4.5 Electronic totalizer readings

4.5.1 Totalizer readings by hose (product) position

Each fueling point of the dispenser maintains electronic totalizers for both money and volume.
Dispensers equipped for Cash/Credit operation also keep separate cash and credit totalizers
by grade. Rather than mechanical totalizers, each position has an electro-mechanical totalizer
for each feedstock.

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4 Startup

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

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 4 Startup

4.5.2 Totalizer volume readings by meter position

Meter volume totals are stored in statistical functions that are accessed using the remote
control. The totals for Side 1 are stored in function S05 and those for Side 2 are stored in
function S06. The value of the meter totals are stored in the sub-functions that take the format
.M0, where M is the meter number. For example, M=5 for the high feedstock iMeter located
on Side 1 of a remote series blender. For Side 2 of the same meter, M=1.

Note!
There is no relationship between meter position and hose position.

Meter electronic totalizers are read by entering the Maintenance Mode and accessing the
correct function and associated sub-functions. Perform the following steps using the remote
control. Bold type denote remote control function; italicized type represents dispenser re-
sponse.
Accessing the Meter Volume Totalizer Sub-function for Side 1:
• Press ENTER
PASS 1 (enter password)
• Press ENTER
PASS 2 (enter password)
• Press ENTER. The unit price display will show F
• Press either UP or DOWN arrow to enter the statistics viewing mode. The unit price display
will show S— (indicating that a number needs to be selected)
• Press 05 to access S05
• Press ENTER. The unit price display will show S05 (indicating that the statistical function
has been accessed)
• Press ENTER to access the sub-functions of S05. The unit price display will show 5.10
(note here that M=1)
Consecutive pressing of NEXT will allow access to the next sub-function, incrementing the
value of M by (.1). For example, to access S05.20, press NEXT. The unit price display will
show 5.20. The value of the meter volume totals is shown in a format such that the least
significant six (6) digits of the data value appear on the volume display, while higher order
non-zero digits of the data value, if present, appear on the money display. Leading zeros
appear as blanks.
Quick Exit
1 Press the CLEAR key until the unit price display window shows S - - .
2 Press ENTER three times. This causes the maintenance mode task to immediately termi-
nate.

4.5.3 Electro-mechanical totalizer operation

Totalizers are optional on Helix dispensers. Electro-Mechanical totalizers are located on the
junction box side of the dispenser. There is one totalizer for each meter. The totalizer positions
on the bezel relate to the meter position numbers. The physical position of the totalizers, left
to right, on the bezel represent meter positions.

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4 Startup

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

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 5 Operation

5 Operation

Refer also to the User's Manual, WM048521.

5.1 Safety items you should know

• Know how to turn OFF power to the dispenser and submersible pumps in an emergency.
• Inspect regularly, 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. Never run a leaking pump.
• Test the Emergency (shear) valve, by opening and closing several times, at least once
per year.
• Use of automatic safety nozzles prevents the overfilling of fuel tanks and avoids spilling
fuel.
• Avoid tipping the nozzle downward which may cause the excess spilling of 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 the
station to shut OFF power to all station dispensers and submersible pumps in case of an
emergency.
• Hose retractor mechanisms, if anny, are spring loaded and can pose a possible injury.
• Care should be taken to prevent fuel spillage. If spillage occurs, clean-up immediately.
• Know the Hazardous Zone area around the dispenser. (see the users manual)

5.2 Health Note

WARNING!
Health Note

Be advised that contact with DEF/Urea and inhala-

tion of vapors can cause serious damage to your
health.

5.3 How to Get Service On Your Dispenser

Trouble with the operation of the dispenser should be referred to your local Dover fueling
solutions authorized service personnel or call the Dover fueling solutions Help Desk.

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5 Operation

NOTICE!

Any modification, repair, or service to the dispenser

not in accordance with the original design may in-
validate compliance with the equipment certifica-
tions such as CE Marking, UL, etc. Consult Dover
fueling solutions as necessary.

5.4 Basic dispenser requirements

Unit prices must be set and the dispenser must be authorized for the dispenser to operate.
If the dispenser is connected to a control system, each dispenser must have a unique fueling
point number set for communication with the system as discussed in Setting the fuelling point
address (ID) page 23.

5.5 Operating the dispenser

1 Authorize the dispenser via the Authorize switch on the dispenser or via the control system.
2 Remove the nozzle from the nozzle boot . The nozzle boot switch will turn on. The unit
price displays of the product.
3 The dispenser will reset and prepare for delivery. The sale display will show all eights,
then blanks, then the money and volume portion of the display will reset to zero.
4 Dispense product. (Pressing the optional Stop button will stop product flow only. The
nozzle boot switch must be cycled and the dispenser must then be reset before that side
of the dispenser can continue operation.)
5 Return the nozzle to the nozzle boot. The nozzle boot switch will turn off; the sale will be
complete and ready to pay.

5.6 Restarting after power failure or shutdown

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

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 5 Operation

5.7 Cycling power to clear faults

If a fault in the dispenser is detected by the computer, an error message will be displayed in
the sale display as described in Section 5.8 pare 31. Record the displayed error message.
It may be possible to restart the dispenser by the following sequence:
1 Ensure all nozzles are properly seated in the nozzle boot(s).
2 Turn the control power circuit breaker off for approximately ten seconds ore more; the
dispenser annunciator will sound. Turn the control power circuit breaker on; the dispenser
annunciator will sound again.
3 Authorize the dispenser.
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 service
personnel the amount at which the dispenser stopped and the exact error message given
on the sales display.

5.8 Error codes

Computer error codes can be displayed on the side of the dispenser where the error occurred
by accessing sub-functions S21.XX for Side 1 and S22.XX for Side 2, where XX is between
01 and 50 and represents the error/events records maintained by the computer program -
with 01 being the most recent. The computer can store up to 50 errors per side, continuing
to store errors beyond the 50th by cycling the error buffer with new errors inserted at the top
of the buffer. When this happens, an error is deleted at the bottom of the buffer for every new
error that is inserted in the top of the buffer. Only the last 50 errors are stored.
Errors are displayed in an alternating 2-page format. Information in the error pages is given
below.

Page 1 error information Page 2 error information

HH.MM MM.DD.YY
CC.DD.NN C

Where: Where:
HH = hour MM = month
MM = minute DD = day
CC = error code YY = year
DD = device number C = filling count
NN = logical nozzle number

The complete description of the error codes is given in the Helix Service manual.
Computer errors are read by entering the Maintenance Mode and accessing the correct
statistical function and its sub-functions. Perform the following steps using the remote control.
Bold type denote remote control function; italicized type represents dispenser response.
Accessing the error code Sub-function

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5 Operation

1 Press ENTER
2 PASS 1 (enter password)
3 Press ENTER
4 PASS 2 (enter password)
5 Press ENTER. The unit price display will show F
6 Press either UP or DOWN to enter the statistics viewing mode. The unit price display will
show S— indicating that a number needs to be selected.
7 Press 21 to access S21 (error data for Side 1 or A which is the junction box side)
8 Press ENTER. The unit price display will show 21.01, the first and most recent error data
for Side 1. The data will be displayed in the 2-page format described earlier, in an alternat-
ing sequence, at a 1 second per page rate.
9 Pressing NEXT accesses 21.02 and the display shows information for the second error
logged. By pressing NEXT, the error buffer can be viewed completely.
10 To exit, press CLEAR, then UP or DOWN. The unit price display will show S—.
11 Press ENTER three times to exit to the normal display.

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 6 Operator Maintenance

6 Operator Maintenance

WARNING!

Disconnect mains power prior to any work, to pre-

vent damage which may result in electric shock or
fire.

WARNING!

Maintenance operators are strictly forbidden to use

open flames or perform cutting, grinding, and
welding that may generate sparks, especially due
to the fact of the possible presence of gas.

6.1 Prover cans - contamination

NOTICE!

Prover cans designed and/or used for motor fuels

must not be used for measuring DEF nor should
DEF Provers be used for measuring motor fuels.
Contaminating the DEF with motor fuel can poten-
tially damage the vehicle’s SCR system.

6.2 Preventive maintenance

Adhere to the safety precautions on the inside cover and in Section 1.4 page 5 of this
manual when performing preventive maintenance. A correctly installed dispenser, given
proper preventive maintenance attention, will seldom require emergency service.
Take the following precautions:
1 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.

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6 Operator Maintenance

2 Be sure to trip (close) the emergency valve(s) under the dispenser BEFORE beginning
maintenance. See section 6.3 page 34 Filter/Strainer instructions.
3 Do not spray the dispenser with pressurized water. Pressurized water from a power
washer or even a garden hose may cause the water to enter the electronic enclosure.
4 Do not abuse the hose by trying to stretch it to reach an automobile. This will cause early
failure at the couplings.
5 Hose retractors: Do not abuse the hose by trying to stretch it to reach an automobile. This
will cause early failure at the couplings, cable or clamp. Check the hose retractor periodi-
cally for proper pull and retraction. Check the retractor cable periodically for frays or cuts.
Perform the following checks on a regular basis:
1 Check the dispenser for internal and external leaks regularly. Check nozzles, swivels,
hoses, filters, and joints for leaks and wear. Have all leaks or defects repaired immediately.
Never run a leaking pump.
2 Keep the dispenser clean at all times. Do not spray the dispenser with water. Use only
mild soap and water with a soft cloth. Do not use gasoline or other petroleum-based
products to clean the dispenser. Do not use abrasive cleaners on any part of the dispenser.
3 If the doors must be removed during rainy weather, take care to prevent rain from getting
inside the dispenser.

6.3 Filter/Strainer
A dirty strainer screen and/or fuel filter will slow down the delivery of product. If the under-
ground installation is new, it may be necessary replace the filter and clean the strainer screen
two or three times during the first few days of operation to remove installation debris and
pipe sealant. After this, filter replacement and strainer cleaning should be performed period-
ically.

WARNING!

Before removing the filter and strainer turn the

power to the dispenser and submersible pump off
and close the emergency shut-off valves on the
dispenser being serviced. Failure to do so may
result in a hazardous condition that can result in
serious injury. Loosen strainer cap or spin-on filter
slightly and allow DEF/Urean into a container.
Return product to the appropriate underground
tank.

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 6 Operator Maintenance

• The fuel filter is removed by unscrewing it (the same way an oil filter is removed from a
car engine). Place a container under the filter to catch the product and sediment. To install
the new filter, first apply a film of oil to the gasket and hand turn until gasket contacts base,
then tighten one half turn. Open the emergency shut-off valve(s) (remote pump), turn the
electrical power ON and check for leaks.

6.4 Meter Maintenance Issues

It is recommended that Dover fueling solutions Fuel Meters be periodically checked.
If adjustment need to be made, one would follow the prescribed procedure in the service
manuals for the respective equipment.

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7 Dissasembly - Recycling

7 Dissasembly - Recycling

WARNING!

Disconnect mains power prior to any work, to pre-

vent damage which may result in electric shock or
fire.

WARNING!
Health Note

Be advised that contact with DEF/Urea and inhala-

tion of vapors can cause serious damage to your
health.

WARNING!
Danger of tipping!

Please note that the centre of gravity is not in the

centre, and varies from one pump model to anoth-
er.

7.1 Empty the fuel out of the pump

It is important that there is no fuel in the pump before disassembly.
Blank the inlet pipes with a flange and gasket.
Between one and five pump units must be emptied and blanked, depending on the pump
model.
If necessary, ask a transport company for special regulations.

7.2 Dispenser recycling

The dispenser must be recycled according to the applicable regulations in the country where
it is installed.

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 8 Drawings

8 Drawings

8.1 Classification scheme

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8 Drawings

8.1.1 Zones
Zones Risk types Protection class Example

0 A risk area where explosive gas Exia In a tank.

mixture exists all the time or dur-
ing a long period.
1 A risk area where explosive gas Exd, Exe, Exib, Within the meter. (within
mixture may occasionally exist Exp, Exia, Exs the hydraulic areas and
during normal operation. column of he pump)
2 A risk area where explosive gas Exd, Exe, Exib,
mixture is not expected to exist Exp, Exia, Exs,
during normal operation and, if it Exo, Exq
should exist anyway, it will be in-
frequent and for a short period of
time.

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 8 Drawings

8.2 Installation instruction

WM053738 Wayne Helix™ 1000, IEC page 40
WM058840 Wayne Helix™ 6000 DEF, extra narrow, IEC page 43
WM059026 Wayne Helix™ 6000 B2B DEF, Remote IEC page 45
WM058981 Wayne Helix™ 6000 B2B DEF, Suction IEC page 49
The drawings are also available for download at Wayne's (Dover fueling solutions) ftp-server
or the Wayne Portal. Please contact your dealer for login information.

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8 Drawings

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 8 Drawings

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8 Drawings

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8 Drawings

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8 Drawings

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8 Drawings

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8 Drawings

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8 Drawings

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8 Drawings

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8.3 Connection instruction

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8.4 Lifting instruction

8.4.1 Helix 1000

Alternative 1

Alternative 2

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Alternative 3

Alternative 4

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8.4.2 Helix 2000

Alternative 1

Alternative 2

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8.4.3 Helix 6000

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 Installation Manual IEC

Wayne Helix™ dispenser DEF

Warranty
Any alternations or, additions to, or unauthorized work performed on the equipment without manufacturer’s express written
consent shall void any existing product warranty. Please see product warranty information for additional details.
Use only genuine parts.

This manual and any software described herein are furnished under the terms of sale or other applicable contract including any
license, and may be used or copied only in accordance with those terms.
No part of this publication may be electronically or mechanically reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, except as permitted by such terms. Translation of this material to another language without express
written permission from DFS is prohibited.
This publication is intended for informational purposes only and this material is subject to change without notice. Dover Fueling
Solutions has not made, and does not make, any representations or warranties of any kind, expressed or implied, with respect
to any information in the publication, including any warranty as to the accuracy, correctness, or completeness of any of the in-
formation. DFS shall not be responsible or liable for any damages or losses that occur asa result of the receipt and/or use of
the information contained herein.

Dover Fueling Solutions

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Tel: +44 (0)1382 598 000 Tel: +55 21 2598 7722

WM048527_DEF Rev 12 11/2018

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