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WM048527 Ae DEF
WM048527 Ae 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.
Note!
Indicates extra information or tip.
NOTICE!
CAUTION!
DANGER!
Note!
The graphics and pictures of dispensers contained in this manual may not be representative
of your actual dispenser(s).
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
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.
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'.
1.3 Software
Wayne Helix™ model dispensers are delivered pre-installed with software.
NOTICE!
WARNING!
WARNING!
WARNING!
WARNING!
WARNING!
Electric Shock Hazard!
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!
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!
3 Installation
3.2.6 Base
The pump is placed on an elevated island, in order to protect it from collisions.
WARNING!
WARNING!
anchor bolt
trip lever
(pull down to close valve) pipe plug for bleeding
product lines
product inlet
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.
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!
WARNING!
Danger of tipping!
CAUTION!
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.
3.7.1 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
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 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!
NOTICE!
4 Startup
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.
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 <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:
WARNING!
Important to change the passwords
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.
Note!
To exit and save changes use F00 Exit Function - option 3.
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 <ENTER>
The display shows:
The new Operating mode is show on volume display.
Note!
To exit and save changes use F00 Exit Function - option 3.
Access to Functions
The display shows the function screen.
- Step 1 – Press 03 and 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
Press the <#> key, the dotted part on paying total of display will be
erased.
Access to Functions
The display shows the function screen.
- Step 1 – Press 04 and 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:
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
Press the <#> key, the dotted part on paying total of display will be
erased.
Side A (F05)
Access to Functions
The display shows the function screen.
Press 05 and press <ENTER>, and the display shows:
Press <ENTER>
(the actual address is show on volume display)
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)
Press <ENTER>
To save all changes follow exit procedure of “F00” exiting, value 3.
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.
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.
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.
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.
5 Operation
WARNING!
Health Note
NOTICE!
HH.MM MM.DD.YY
CC.DD.NN C
Where: Where:
HH = hour MM = month
MM = minute DD = day
CC = error code YY = year
DD = device number C = filling count
NN = logical nozzle number
The complete description of the error codes is given in the Helix Service manual.
Computer errors are read by entering the Maintenance Mode and accessing the correct
statistical function and its sub-functions. Perform the following steps using the remote control.
Bold type denote remote control function; italicized type represents dispenser response.
Accessing the error code Sub-function
1 Press ENTER
2 PASS 1 (enter password)
3 Press ENTER
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.
6 Operator Maintenance
WARNING!
WARNING!
NOTICE!
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!
• 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.
7 Dissasembly - Recycling
WARNING!
WARNING!
Health Note
WARNING!
Danger of tipping!
8 Drawings
8.1.1 Zones
Zones Risk types Protection class Example
Alternative 1
Alternative 2
Alternative 3
Alternative 4
Alternative 1
Alternative 2
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.