1vista Service Blending - Non Blending 920160 - REV - A
1vista Service Blending - Non Blending 920160 - REV - A
1vista Service Blending - Non Blending 920160 - REV - A
Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Fail-
ure to follow the Warning and Caution instructions in this manual, may result in hazardous condi-
tion. Follow all rules, codes and laws that apply to your area and installation.
SAFETY PRECAUTIONS - OPERATION
Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an
emergency. Repair all leaks or defects immediately.
SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE
Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cab-
inet for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off
when servicing the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser
BEFORE beginning maintenance.
EQUIPMENT PRECAUTIONS
Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before
dispensing product. Always use the approved method for lifting the dispenser. Never lift by the
nozzle, sheet metal, valance, etc.
HOW TO CONTACT WAYNE
Title Page
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1. Sequence of the Dispensing Cycle (Non-Blenders) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1. Lift-to-Start Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2. Push-to-Start Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2. Sequence of the Dispensing Cycle (Blenders Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. Unit Prices/Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.1. Manually Setting Unit Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.2. Authorize Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.3. Setting A Fueling Point (Pump Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4. The Blending Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3. ELECTRONIC PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1. Display Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2. Lighted Cash/Credit Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3. Solenoid Drive Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4. Computer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1. Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5. Fault Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6. Intrinsic Safe Barrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7. Pulser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.7.1. Photocoupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.7.2. Pulser Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8. Proportional Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4. MECHANICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1. Nozzle Boot (Proximity “Reed” Switch Style Boot). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1.1. Lift-to-Start Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1.2. Push-to-Start Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5. HYDRAULIC PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1. Strainer and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.1. Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.2. Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2. Two Stage Solenoid Valve (Non-Blenders only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.1. Flow Control Valve “Off” No Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.2. Flow Control Valve “On” Slow Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.3. Flow Control Valve “On” Full Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3. Proportional Flow Control Valve (Blenders Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.3.1. Flow Control Valve “Off” No Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.2. Flow Control Valve “On” Slow Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.3. Flow Control Valve “On” Full Regulated Flow . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4. Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4.1. Meter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6. TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
iii
Title Page
7. COMPONENT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1. Electronic Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.1.1. Removing the Bezel From Vista Dispensers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.1.2. DEM In Service Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.1.3. Solenoid Drive Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.1.4. Computer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1.5. Intrinsic Safe Barrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1.6. Display Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1.7. Cash/Credit Interface Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7.1.8. Photocoupler/Pulser Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.1.9. Lift-to-Start Nozzle Boot Component Replacement . . . . . . . . . . . . . . . . . . . . . . 64
7.1.10. Push-to-Start Nozzle Boot Component Replacement . . . . . . . . . . . . . . . . . . . . . 65
7.1.11. Push-to-Start Membrane Switch Assembly Replacement. . . . . . . . . . . . . . . . . . 68
7.1.12. Back Lit Display Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.1.13. Electro-Mechanical Totalizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2. Hydraulic Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2.1. Diaphragm Replacement (Non-Blenders Only) . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2.2. Diaphragm Valve Replacement (Non-Blenders Only) . . . . . . . . . . . . . . . . . . . . 70
7.2.3. Actuator Replacement (Non-Blenders Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.2.4. Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2.5. Proportional Flow Control Valve Replacement (Blenders Only) . . . . . . . . . . . . 71
7.2.6. Check and Pressure Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 71
APPENDIX A. TROUBLESHOOTING FLOWCHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
APPENDIX B. SERVICE INFORMATION AND CONNECTOR PIN OUTS. . . . . . . . . . . . . . . . . 101
B.1. Dispenser Electronic Module (DEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
APPENDIX C. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY. . . . . . . . . . . . . . Inside Back Cover
FCC WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
LIST OF FIGURES
Title Page
Figure 2-1. Function Switches and Display Locations - Non Blender Shown . . . . . . . . . . . . . . . . . . . 6
Figure 2-2. Unit Price Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2-3. Proportional Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2-4. Fixed Ratio Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 3-1. Computer and Solenoid Drive Board (Non-Blender). . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 3-2. Computer and Solenoid Drive Board (Blender) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3-3. Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 3-4. Main Sale Display Showing Transaction Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 3-5. Main Sale Display Showing Transaction Counter and Fault Code . . . . . . . . . . . . . . . . . 20
Figure 3-6. Intrinsic Safe Barrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
iv
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Title Page
LIST OF TABLES
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vii
This manual describes the service of Wayne Vista series blending and non-blending dispensers that
have a 1 in the prefix of the model number. For example, 1/V390D1/GQY. Again these dispensers
can be identified by their model which begins with “1/V”. The basic troubleshooting methods and
service theory will remain the same for all models of dispensers which satisfy the above definition.
Any information which is specific to a particular model of dispenser will be shown as specific in
the text.
Any service problems which cannot be solved should be referred to Wayne Technical Support or
to the appropriate regional service office.
Wayne Technical Support 1-800-926-3737
Austin, TX 24 hours/7 days
Northeast Regional 410-546-6750
Service Office 8:30AM-5:00 PM Eastern
Salisbury, MD
Southeast Regional 770-988-3362
Service Office 8:30AM-5:00PM Eastern
Atlanta, GA
North Central Regional 312-693-7404
Service Office 8:30AM-5:00PM Central
Chicago, IL
South Central Regional 713-987-5442
Service Office 8:30AM-5:00PM Central
Houston, TX
Southwest Regional 714-952-1137
Service Office 8:30AM-5:00PM Pacific
Cypress, CA
Northwest Regional 510-328-0400
Service Office 8:30AM-5:00PM Pacific
San Ramon, CA
Mid-Atlantic Regional 410-691-2200
Service Office 8:30AM-5:00PM Eastern
Baltimore, MD
INTERNATIONAL OFFICES
Caribbean and Latin America (Voice) 410-546-6757
Service Office (FAX) 410-548-6968
Salisbury, MD
Mid-East and Africa (Voice) 44-1635-874881
Service Office (FAX) 44-1635-876633
United Kingdom
Far East (Voice) 65-734-4431
Service Office (FAX) 65-737-0219
Singapore
1
The general operation is very similar for all dispensers with model numbers beginning with 1/V.
2.1. SEQUENCE OF THE DISPENSING CYCLE (NON-BLENDERS)
* The submersible may have been energized in the previous step depending on the data setting in
programming Option 36. Refer to the Option Programming Manual part number 920205 for more
information.
3
• When the nozzle is removed from the nozzle boot or the Lift to Start lever is raised,
the constant +5 VDC that the computer supplies to the nozzle switch goes to ground.
At this point the lighted buttons (grade select or cash/credit, depending on the model)
will flash indicating that one of the buttons must be pressed.
• When one of the lighted buttons is pressed, the constant +5 VDC that is supplied to
the switch goes to ground. This signals the computer to begin its reset cycle.
• When the dispenser receives an Authorization signal either from the control system
or from the Authorize switch in the dispenser, the correct submersible pump relay
will be energized.*
• The computer performs a self test and flashes eights, blanks, then resets to zeros, on
the main sale display.
• After the dispenser resets, the proportional flow control valve(s) is energized with
just enough current to barely open the valve(s) and allow a slow flow.
After a small amount of fuel has been dispensed, the valve(s) is energized with
enough current to be in the fully open position and allow fast flow. During the sale,
the valve(s) will be continuously controlled with the proper amount of current to
provide the correct blend ratio and limit fuel flow rate to a maximum of 10 GPM.**
• In preset sales, the current received by the proportional flow control valve(s) is
reduced to the barely open position just prior to the final shut-off amount. The
valve(s) is then de-energized when the final amount is reached.
• When the nozzle is replaced in the nozzle boot, the nozzle switch goes back to the
constant +5 VDC, and the sale is complete.
* The submersible may have been energized in the previous step depending on the data setting in
programming Option 36. Refer to the Option Programming Manual part number 920205 for more
information.
** The maximum allowable flow rate in the United States is 10 gallons per minute.
4
Before any Wayne dispenser will reset two things must happen. First, the dispenser must have
unit prices set in it. Second, an authorization must be received from some source. Both the
unit prices and the authorization can be manually set at the dispenser, or set from a control
system. In order to manually set unit prices, set the authorize switch, or set the fueling point
the function switches must be accessed (see Figure 2-2). In order to access the function
switches complete the following steps:
• Lower the ad panel holder frame by pulling the holder frame out and down from the
top.
• This exposes the function switch access door; unlock this door and slide it to the left.
• The function switches which are located behind the door opened in the previous step
are: the Authorize (Self-Serve/Attend) switch, the Totals push-button, the Position
Select push-button, the Price Jog push-button, and the DCPT power switch (if the
dispenser is equipped with CAT’s)
2.3.1. Manually Setting Unit Prices
The following procedures need not be used if the dispenser is connected to a
control system. Refer to the operating procedures provided with the control
system for a complete description of unit price setting.
The Position Select push-button selects the position for which the unit price is to
be changed. The Price Jog push-button changes the price of the position selected.
The first closure of the Position Select push-button selects position “X” unit price
(credit price of Cash/Credit type dispenser) and will blank the Unit Price displays
for the position “Y”, “Z”, and “AA”. The unit price for position “X” is set as
follows:
The first closure of the Price Jog push-button causes the least significant digit or
tenths of cents position of the unit price to cycle (see Figure 2-2.). The digit will
cycle 0 through 9 until the switch is released. Each successive closure of the Price
Jog push-button will select and increment the next most significant digit.
Subsequent Position Select switch closures are defined in see Figure 2-1.
and 2-2. The unit price for each position may then be set as described previously.
FIGURE 2-1. FUNCTION SWITCHES AND DISPLAY LOCATIONS - NON BLENDER SHOWN. Always
lock the access door after using the function switches.
FIGURE 2-2. UNIT PRICE DISPLAY. The first closure of the Price Jog push-button causes the least
significant digit or tenths of cents position of the unit price to cycle.
6
Fifth Closure Original sale display returns. Credit unit price position “Z”
Sixth Closure ---------------------------- Cash unit price position “Z”
Seventh Closure ---------------------------- Credit unit price position “AA”*
Eighth Closure ---------------------------- Cash unit price position “AA”*
Ninth Closure ---------------------------- Original sale display returns.
* “AA” applies only to V490 models.
• The Position Select push-button is used to enter the fueling point setting
mode. The Totals push-button sets the fueling point number.
See Figure 2-1. for switch location.
• Press and release the Position Select push-button.
• To read the fueling point number, press and release the Totals switch.
• To set the fueling point number, press and hold the Totals push-button.
The least significant digit of the unit price display will cycle 0 through 9.
Release the Totals push-button when the correct number is displayed.
Press and hold the Totals push-button again and the next significant digit
will cycle 0 through 9. Release the Totals push-button when the correct
number is reached. Currently only the numbers 01 through 24 are valid
fueling points. If any other number is entered the control system will not
communicate with the dispenser computer.
• Press the Position Select push-button until the original sale display returns.
Note: In order for the dispenser to operate each fueling point must be set to a unique
number other than zero.
8
A blender has two grades of fuel (product) input to the dispenser. These two grades are the
LO and HI product inputs referred to as “feedstocks.”
The proportional blending dispenser uses the feedstock input grades to deliver three to
five grades (depending on model) outputs to the “nozzle.” Two of these grades are feed-
stock* and the other one to three (depending on model) are a blend mixture of some propor-
tion of the feedstock inputs. All grades are dispensed through the same hose and nozzle,
see Figure 2-3.
The fixed ratio blending dispenser uses the feedstock products to deliver three grade
outputs to the “nozzles.” Again, two of these three grades are the feedstock products*, but
unlike the proportional blender, the third grade or blended grade is delivered through a
separate hose and nozzle. Also, the feedstock grades are each individually delivered
through separate hoses and nozzles, see Figure 2-4.
In all blending dispensers, there are two separate sets of hydraulics. One for controlling the
LO octane product input and one for controlling the HI octane product input. In all
enhanced Vista blending dispensers (1/V models), whether it’s a proportional or fixed ratio
blender, the LO and HI product hydraulic systems each contain a proportional flow
control valve.
When any grade (LO, HI or blend) is selected, the blend ratio programmed into the
dispensers computer determines the percentage or proportion of HI product to be
dispensed. When the LO grade product is selected, the proportion or percentage of HI
product is 0%. When the HI grade product is selected, the percentage of HI product is
100%. When a blended grade is selected, a percentage of HI product (less than 100%) is
mixed with the remaining percentage of LO product, and the combined total (100%) deter-
mines the octane rating of the blended grade.
Knowing the percentage or proportion of HI, and thus LO, product to dispense and by
calculating the volume dispensed based on input signals from the pulsers, the computer
signals the solenoid drive board which in turn controls the proportional flow control valves.
Each proportional flow control valve continuously opens or closes, as directed by the sole-
noid drive board, to maintain the desired blend ratio and the maximum allowable flow
rate.**
* Some customer specific models may not dispense feedstocks. For example, one feedstock and four
blended grades may be dispensed.
** The maximum allowable flow rate in the United States is 10 gallons per minute.
9
TD00318-A
Nozzle
Hose Outlet
Where Mixing Actually
Takes Place
Computer and
Solenoid
Drive
Lo Product Hi Product
Proportional Flow Proportional Flow
Control Valve Control Valve
Electrical Connections
Mechanical Drive
Hydraulic Tubing
FIGURE 2-3. PROPORTIONAL BLENDING. The proportional blending dispenser uses the feedstocks to
create three to five end grades to be dispensed through the nozzle.
10
Hose Outlets
Outlet Valves
Lo Product Hi Product
Proportional Flow Computer and Proportional Flow
Control Valve Solenoid Control Valve
Drive
Mechanical Drive
Hydraulic Tubing
FIGURE 2-4. FIXED RATIO BLENDING. Each end grade is dispensed through a separate hose & nozzle.
11
There are five types of electronic components in the head of a Wayne dispenser.
• Display Board
• Computer Assembly
The hydraulics cabinet contains one or more of the following electronic or electrical components.
• Pulser assembly
The display boards are self-contained units which provide a visual display of sales infor-
mation (i.e., dollar amount, volume amount, unit prices). The actual display elements are
seven segment Liquid Crystal Displays (LCD’s). These elements are back lit with two 7W,
field replaceable, fluorescent lamps to improve their visibility in low lighting conditions.
The LCD’s are soldered to their printed circuit boards; therefore, they are not replaceable
in the field.
The display board receives its data from the computer assembly. The decoding circuits, and
the drivers for the LCD’s, are located on the display board.
The lighted cash/credit interface board performs three functions. First, is the switch inter-
face; that is all of the function and operational switch closures are sensed by this board and
then transmitted to the computer. Second, it supplies power to the lighted buttons on the
dispenser that require them (push to start, cash/credit and grade select). The transformer on
the board converts 110 VAC input to approximately 18 VRMS in order to power the switch
lamps. Third, the cash/credit Interface Board provides the drive circuits to increment the
Electro-mechanical Totalizer.
13
Located on this board is a fuse which fuses the AC input to the select board. If this fuse
should open, the push to start or cash/credit select switches will go blank; and the push to
start (or cash/credit or grade select) and function switches will not work. If the dispenser
requires that a push to start, cash/credit or a grade select switch be pressed it will not reset.
Once the select switch has been pressed the push-to-start signal must be received at the
push-to-start input connector J5 at nozzle on, if Pin 1 and Pin 2 are both open either must
be grounded and opened again for the dispenser to operate.
This board usually comes with a fixed address, however, it contains provisions to add a four
position DIP switch which must be set correctly in order for the display to operate.
The solenoid drive board primarily serves as an AC switching board. By utilizing solid state
relays, it controls AC power to the pump motor relays, and (in non-blenders) the two stage
actuator valves. Also, the solenoid drive board enables the correct pulser assembly by
switching the pulser select lines. In addition (in blenders), the blender solenoid drive board
provides DC pulse modulated signals to operated the proportional flow control valves.
Located on the solenoid drive board is a fuse (F1). This fuse controls all AC voltage
supplied to the solenoid drive board. If the fuse opens the dispenser will reset, but the AC
valves and relays will not be energized.
Blender solenoid drive boards have two additional protection devices: PF1 and PF2. These
are poly fuses that supply 24VDC power to the proportional flow control valves for side 1
and side 2, respectively. If one of the valve lines is overloaded, the poly fuse will open.
When the overload is removed, the poly fuse will close, and the circuit will reset and return
to normal operation. Blender solenoid drive boards contain a micro-processor and two
additional troubleshooting aids: two LEDs that indicate the state of communications to the
computer and to the valves. The LED labeled DS1 is the “Valve Enable” indicator and will
light steadily as soon as a grade is selected upon nozzle removal. This indicates that the
computer base Pump processor has enabled one or more valves on either side of the
dispenser. The other LED labeled DS2 is the activity indicator for the solenoid drive board
(SDB) micro-processor and will blink about every 2 seconds to indicate that, the processor
is functioning properly, and that communications have been established between the sole-
noid drive board processor and the computer base Pump processor. At power up, this lamp
will blink at a faster rate, and then pause, until the communications are established. A
steady On or a steady Off indicates that the SDB processor is not functioning properly.
14
The computer is a complete self-contained unit with a built in power supply and memory
retention device, see Figure 3-1. It is responsible for performing the following functions:
• Provides 5 VDC to, and monitors the return from, the handle switches.
• Monitors the two output lines from each pulser.
• Converts the data received from the pulsers into a volume amount.
• Calculates the sale dollar amount based on the selected unit price.
• Controls the solenoid drive board to switch on the correct submersible pump relays
and solenoid valves. It also switches the pulser select lines to enable the correct
pulser(s) by controlling the solenoid drive board.
• Maintains electronic product totals.
• Sends sale and product totals data to the control system via a two wire data loop.
• Monitors all dispenser functions, and when a problem is found, generates and stores
error codes.
The Duplex Computers is fused to protect itself from overvoltages and shorts. There are
two fuses on the computer:
• F1 fuses the input to the 5 VDC regulator on the computer board. If this fuse opens
the dispenser will look like it has been powered down.
• F3 fuses the main AC input to the computer; all power to the computer, solenoid
drive board, and the displays passes through the F3 fuse. If this fuse opens the
dispenser will look as if it has been powered down.
Note: F1 is a pico fuse. It physically looks very similar to a small resistor and is mounted
in a socket.
F3 is the more visible glass enclosed type fuse, however, it is insulated with heat shrink
tubing as required by UL.
On the Duplex II Computer there are two option jumpers which are be configured for
proper operation. These are labeled JP2 and JP3. A jumper is on the two pins closest to the
edge of the board on each connector for blending and single hose MGD applications.)
In addition to the jumper settings, there are programming options which must be set in order
for the Duplex II Computer to operate correctly. For programming information refer to the
manual: “Duplex II Computer Option Programming for 1/Vista Model Dispensers”, part
number 920205.
15
J4
J6
J9
J1 JP2
and
JP3
J3
J10
J2 J1 J5
J4
J11
CAP JP4
F1
JP1
F3
J14
J3 J13
F1
J1 -- Data Loop Both Sides J1 --Relay Select Side 1 (There is also a J1 Located on the
J3 -- AC Input computer; it is the data connector for both sides.)
J4 -- Displays Side-1 J2 --Relay Select Side 2
J5 -- Displays Side-2 J3 --Nozzle and Pulser Control Side-1 (1/V490 ONLY)
J6 -- Provides For RAM Clear J4 --Nozzle and Pulser Control Side-2 (1/V490 ONLY)
J8 -- (Not Shown) AC Output to Solenoid Drive Board
J9 -- Pulser Control Side-1 FUSES
J10--Pulser Control Side-2
J11--Nozzle Switches Both Sides F1 -- Solenoid Valves and Relay Selects
J13--Annunciator Connection
J14--Annunciator Connection
JP1 --
JP2 & JP3 -- Shunts Located Near Edge of Board for
Blender and Uni-Hose.
Shunts Located Toward Inside of
Board for MGD's.
JP4 --
FUSES
F1--Fuses the input to the 5 VDC regulator (LCD Displays)
F3--Fuses the AC input to the computer
FIGURE 3-1. COMPUTER AND SOLENOID DRIVE BOARD (NON-BLENDER). The computer is a
complete self-contained unit with a built in power supply and memory retention device.
16
DS2 DS1
J6
J9
J1 JP2
and
JP3
J10
J1
J5
J4
J J3 J11
4
J
2 F2
CAP JP4
JP1
F3 F1 J14
J3 J13
F1
J1 -- Data Loop Both Sides J1 --Relay Select (There is also a J1 Located on the
J3 -- AC Input computer; it is the data connector for both sides.)
J4 -- Displays Side-1 J2 --Pulser Select
J5 -- Displays Side-2 J3 --Porportional Valve Control 24 VDC Output
J6 -- Provides For RAM Clear J4 --Porportional Valve Power 24 VDC Input
J8 -- (Not Shown) AC Output to Solenoid Drive Board DS1-Valve Enable
J9 -- Nozzle Switch and Pulser Control Side-1 DS2-MPU Activity
J10--Nozzle Switch and Pulser Control Side-2
J11--Nozzle Switches Both Sides FUSES
J13--Annunciator Connection Side 1
J14--Annunciator Connection Side 2 F1 -- Relay Selects (AC Line Voltage)
JP1 -- F2 -- Porportional Valves (+24 VDC)
JP2 & JP3 -- Shunts Located Near Edge of Board for
Blender and Uni-Hose.
Shunts Located Toward Inside of
Board for MGD's.
JP4 --
FUSES
FIGURE 3-2. COMPUTER AND SOLENOID DRIVE BOARD (BLENDER). Blender Solenoid Drive
Boards also contain two LED’s which indicate the state of communications to the computer and to the valves.
17
• Error codes (Status 1) shut down the entire side of the dispenser until the
error is reset by cycling power to the computer or entering Option 99. (See
the Option Programming manual, part number 920205, for specific
programming functions.)
• Hydraulic codes (Status 2) shut down the nozzle position which was
affected by the error until the computer is reset by cycling power or by
entering Option 99.
• Service codes (Status 3) are recorded and displayed in Option 01, but do
not affect the operation of the dispenser.
• Disable codes (Status 4) are similar to service codes in that they do not affect the
operation of the dispenser; however, they are not recorded or displayed in
Option 01.
Disable Codes are Service Codes that have been disabled by the computer program or
by the Option 98 setting in option programming.
Note: Error and Hydraulic fault codes that have not been cleared via Option 99 or a power
cycle will continue to be displayed until the problem which caused them is remedied.
Error and Hydraulic codes are displayed every time the affected portion of the
dispenser is restarted by removing the nozzle from the nozzle boot and lifting a
lever or by pressing a start, grade select or cash/credit switch.
The format of the displayed fault codes is shown in Figure 3-3., Figure 3-4. and
Figure 3-5. The fault codes, their status, and descriptions are shown in
Table 3-1. When more than one number is shown in the Fault Code Status
column, it indicates that the Fault Code can be assigned either status. An
asterisk(*) next to a number in this column indicates the default status.
When the computer detects a fault, the sale currently in progress may be shut down.
Depending on the fault code status, the sale may not be shut down and, on the next reset, a
fault code will be displayed. The fault code is displayed only for the affected side of the
dispenser. In addition to the displayed fault code, a transaction counter number is also
displayed. The transaction counter number can be used as a troubleshooting aid to deter-
mine on which sale an error occurred and if that particular error is related to the reported
problem. This fault code, along with the new transaction counter number, will have a
format similar to that in Figure 3-3.
18
The transaction counter has a range of 00000 - 59999 and then rolls over to 00001. Each
side of the dispenser has a transaction counter. When Option 01 is entered the current trans-
action number for side 1 is shown in the Sale Money Display. The value of side 2 transac-
tion counter (if two fueling points) is shown in the Sale Volume Display. See Figure 3-4.
for an example. Pushing the Totals button while the transaction values are displayed causes
entry into the Fault Code History Display Mode. See Figure 3-5. for an example. As shown
the transaction number is displayed for each side along with the fault code for that transac-
tion number. The first fault code displayed is the most recent.
Pushing the Totals button cycles through the fault codes. This mode will display the last 16
fault codes detected by the dispenser’s computer since the last RAM clear (not 16 per side
but 16 total for that computer).
In order to reset the dispenser after an Error or Hydraulic fault, the initial problem must be
corrected and power to the computer cycled or Option 99 is entered. Until these conditions
are satisfied the fault code will continue to be displayed at the end of the reset cycle.
TD00362-A
F = Fault Source. This value identifies the fault source if the fault can be
linked to a particular hydraulic condition. The range is 0 - 7, "H" or "L".
The numeric values indicate positions (0 = none) while the letters
indicate blending feedstocks.
P = Product Source. This is the position that was selected at the time the
fault occurred. The range is 0 - 7, with 0 = no position selected.
FIGURE 3-3. FAULT CODE DISPLAY. The fault code will have a format similar to that shown.
19
Money
Volume
FIGURE 3-4. MAIN SALE DISPLAY SHOWING TRANSACTION COUNTERS. The transaction number
for Side 1 of the dispenser is shown in the Money Display and the transaction number for Side 2 is shown
in the Volume Display.
TD00364-A
Money
Volume
FIGURE 3-5. MAIN SALE DISPLAY SHOWING TRANSACTION COUNTER AND FAULT CODE. In
this example Fault Code 05 occurred on transaction number 00833 on side 1 of the dispenser.
20
21
The Intrinsic Safe Barrier (ISB) assembly is located in the electronic head of the dispenser.
Its function is to ensure that the amount of electrical energy introduced into the hydraulics
cabinet is within acceptable limits. This barrier uses resistors, fuses, transistors and zener
diodes to limit energy out of the barrier. In the dispensing cycle, when the operating lever
is lifted, the nozzle switch moves to the closed position. This causes the nozzle signal on
the computer base to go from a +5 VDC potential to zero or ground potential, which alerts
the microprocessor to begin a new sale if the dispenser has been authorized and the push-
to-start, cash/credit or grade select switch has been pressed. In addition to the nozzle switch
circuits, the pulser selects are also protected by the ISB assembly.
The ISB circuit board (see Figure 3-6.) contains current limiting resistors and voltage
limiting redundant (2 in parallel) zener diodes which will limit voltage potential to approx-
imately 6.2 VDC. This energy limiting circuit eliminates the possibility of arcs in the
hydraulic area of the dispenser.
The ISB assembly is a sealed assembly and must be repaired at the factory. The ISB circuit
board in the assembly is not replaceable in the field. The complete assembly shown in
Figure 3-6. must be replaced if the ISB board becomes inoperative. See Section 7 for
replacement procedures.
22
FIGURE 3-6. INTRINSIC SAFE BARRIER ASSEMBLY. The ISB ground connection shown must be made
directly to the dispenser chassis. The components of this assembly are not separately replaceable. If failure
occurs, replace the whole ISB assembly.
23
• Photocoupler
• Pulser Disc
3.7.1. Photocoupler
The photocoupler (see Figure 3-7. and Figure 3-8.) consists of two infrared
LEDs and two phototransistors, one for each LED. These four parts work
together to provide two separate pulse return lines to the computer. These pulse
return lines are labeled “pulse A” and “Pulse B”. The computer must receive the
pulses in an alternating sequence (i.e., Pulse A, Pulse B, A, B, A, B…). In this
way the computer can determine correct operation. If the computer detects too
many A or B pulses in a row it will assume that the photocoupler is defective,
shut down the sale and generate a fault code (see Table 3-1.). If the computer
senses that the meter is turning in the wrong direction, it will also shut down the
sale and generate a fault code. Figure 3-7. shows how the photocoupler is wired
for non-blending dispensers.
Blending dispensers combine two products to attain a mix with the desired
octane. This requires two photocouplers, one for each grade, to operate at the
same time. In these dispensers the LEDs in each photocoupler are wired in
series. Because of this, a problem in one of the photocouplers can cause symp-
toms to appear on the other. For instance if the LED in the LO product photo-
coupler was to become an open circuit, no voltage would be applied across the
LED in the HI product photocoupler. This would cause symptoms to appear on
the HI product as well as on the LO product photocouplers. Figure 3-8. shows
how the photocoupler is wired for blending dispensers.
24
FIGURE 3-7. NON-BLENDING PHOTOCOUPLER INTERNAL WIRING. The computer must receive the
pulses in an alternating sequence (i.e., Pulse A, Pulse B, A, B, A, B…) to determine correct operation.
FIGURE 3-8. BLENDING PHOTOCOUPLER INTERNAL WIRING. In a blending dispenser, two photocou-
plers operate simultaneously.
25
(Blenders only.) The proportional flow control valve is a pilot-operated, diaphragm sole-
noid valve. It has three main functions in the dispenser:
• Positive shutoff
• Blend ratio control
• Flow rate regulation*
Located between the meter and the hose outlet, the valve is controlled by a 24 VDC pulse
width modulated signal from the blender solenoid drive board. Normally closed, the pilot
opens by an amount proportional to the amount of current sent to the valve coil. As the pilot
raises off its seat, it reduces the pressure to the back side of the diaphragm causing it to lift
off of its seat as well. The same applies to the valve closing; the diaphragm follows the pilot
back to the closed position as the current to the coil is reduced. The computer continually
adjusts the current to the valves during a sale based on the desired blend ratio of the two
feedstocks and maximum allowable flow rate. The high and low products remain separate
until they are mixed at the hose outlet.
* The maximum allowable flow rate in the United States is 10 gallons per minute.
26
The nozzle boot assembly, used on the dispenser models covered in this manual, uses a
proximity “Reed” switch and magnet for ON/OFF dispenser activation. The nozzle boot
can be assembled in either the Lift-to-Start or the Push-to-Start configuration.
1. Authorize the dispenser and remove the nozzle from the nozzle boot. Lift
the nozzle hook lever fully upward to make sure the switch turns ON. An
ON switch will be indicated by the unit price displays of the unselected
products going OFF or displaying dashes.
2. Lower the Lift-to-Start lever to the down position and check that the switch
turns OFF. An OFF switch is indicated by the unit price displays of the unse-
lected products coming back ON.
4.1.2. Push-to-Start Version
The nozzle boot switch assembly (see Figure 7-9.) consists of a proximity reed
switch attached to the side of the nozzle boot casting and a magnetic actuator
shaft inserted into a spring-loaded flipper within the nozzle boot. When the
nozzle is removed, the flipper rotates and aligns the magnetic shaft with the
proximity switch, turning the switch ON. There is no adjustment for the switch.
1. Authorize the dispenser and remove the nozzle from the nozzle boot to
make sure the switch turns ON. An ON switch will be indicated by the
lighted Push-to-Start buttons and the unit price displays blinking.
2. Insert nozzle slowly into the nozzle boot and check that the switch turns
OFF. An OFF switch is indicated by the lighted Push-to-Start buttons
turning OFF and the unit price displays stop blinking.
27
The following section describes the operation of those hydraulic parts in Wayne dispensers which
perform some “act”. Simple flow tubes will not be discussed.
There are three basic hydraulic parts in Wayne dispensers as follows:
• Strainer and Filter
• Meter
The strainer and filter are mentioned in this document only because they may cause the
dispenser to deliver slowly. In some cases this may appear to be a service problem. In
reality the filter should be changed and the strainer cleaned on a regular basis.
Before removing the strainer or filter assembly, trip the impact valve and turn OFF the
circuit breaker for the associated submersible pump.
5.1.1. Strainer
If the underground installation is new, it may be necessary to clean the strainer
screen two or three times the first few days of operation to remove debris and
pipe dope. After this, occasional cleaning of the strainer is all that should be
required. The fuel filter should be changed whenever the strainer is cleaned.
The strainer is removed for cleaning by unfastening the cap. Place a container
under the cap to catch the product and sediment. Wash the screen in gasoline
and dislodge lint and other foreign particles with compressed air. Check for
leakage after reinstalling.
5.1.2. Filter
Like the strainer, in new installations it may be necessary to change the filter
frequently in the first few days of operation in order to ensure proper opera-
tion.The fuel filter is removed the same way an oil filter is removed from a car
engine. Place a container under the filter to catch the fuel. To install the new
filter, first apply a film of oil to the gasket and hand turn until the gasket contacts
the base. Then tighten one half turn. Open the emergency shear valve, turn the
submersible circuit breaker ON and check for leaks.
29
This section describes the operation of the Wayne two stage solenoid operated diaphragm
valve that does not have the built-in check and pressure relief function. This valve is used
in conjunction with a separate check and pressure relief valve (C&PR Valve).
The C&PR valve is located at the meter inlet. Once a delivery is complete and the
diaphragm valve is closed, the product pressure between the check valve and the nozzle
will be held at the pressure of the last delivery. If the pressure should build up due to
temperature rise in the hose or a car runs over the hose, the relief function of the C&PR
valve would relieve the pressure buildup. The relief valve is set to relieve pressure between
30-50 psi. The same C &PR valve is used in blenders and non-blenders.
The two stage AC operated solenoid diaphragm valve has two basic functions. It controls
all flow through the dispenser and acts as a positive shutoff valve.
The actuator is an electrically operated solenoid valve. It controls the diaphragm valve by
switching the diaphragm into and out of full flow and allowing a slower bypass flow around
the diaphragm.
The actuator coils control the actuator itself. When the coils are energized “poppets” inside
the actuator are moved to expose flow paths through the actuator.
Together these three parts will be referred to as the “flow control valve” throughout this
section.
The flow control valve performs three separate functions. It provides for slow product flow,
to be used in the slowdown at the end of preset sales and it allows for full product flow and
is the means for positive flow shutoff
In all Wayne non-blending dispensers using the two stage solenoid operated diaphragm
valve the general order of operation is the same. At the outset of a sale the slow flow coil
only is energized causing slow product flow to start. After a small amount of product is
delivered both coils are energized. This initiates full flow. For preset sales the dispenser
will switch back to slow flow at a pre-determined point.
30
The pressure in the inlet chamber and the outer chamber are equal at this point.
Because the area of the diaphragm material (5) exposed to the inlet chamber is
approximately half that exposed to the outer chamber, the force holding the
diaphragm closed is twice that which is trying to open it. Therefore, the
diaphragm material (5) remains in the closed position covering the outlet port.
When the delivery is complete both actuator coils are de-energized, allowing
the poppets to return to their rest position. This closes both ports in the actuator
and removes the pressure drain from the outer chamber. The pressure now
builds in the outer chamber until it equals that of the inlet chamber, at which
point the effects of the higher force caused by a larger area on the diaphragm
and the spring (10) pushes the diaphragm closed stopping flow.
31
7
10
3
OUTLET
4
TD00349-A
8 9
A B
INLET
LEGEND
1. Actuator
2. Passageway from inlet chamber to outer chamber
3. Passageway to the actuator inlet from the outer chamber
4. Actuator outlet
5. Diaphragm material
6. Cover A. Inlet chamber
7. Body B. Outer chamber
8. Slow flow poppet
9. Full flow poppet
10. Diaphragm return spring
FIGURE 5-1. FLOW CONTROL VALVE “OFF” NO FLOW. Flow control valve “Off” or no flow occurs when
the inlet to the valve is charged, but there is no flow required from the particular valve.
32
7
10
3
OUTLET
4
TD00350-A
8 9
A B
INLET
LEGEND
1. Actuator
2. Passageway from inlet chamber to outer chamber
3. Passageway to the actuator inlet from the outer chamber
4. Actuator outlet
5. Diaphragm material
6. Cover A. Inlet chamber
7. Body B. Outer chamber
8. Slow flow poppet
9. Full flow poppet
10. Diaphragm return spring
FIGURE 5-2. FLOW CONTROL VALVE “ON” SLOW FLOW. Flow control valve “On” slow flow occurs at
the beginning of all sales, and again at the end of preset sales.
33
7
10
3
OUTLET
4
TD00351-A
8 9
A B
INLET
LEGEND
1. Actuator
2. Passageway from inlet chamber to outer chamber
3. Passageway to the actuator inlet from the outer chamber
4. Actuator outlet
5. Diaphragm material
6. Cover A. Inlet chamber
7. Body B. Outer chamber
8. Slow flow poppet
9. Full flow poppet
10. Diaphragm return spring
FIGURE 5-3. FLOW CONTROL VALVE “ON” FULL FLOW. Flow control valve “On” full flow occurs during
the main portion of all sales.
34
OUTLET
TD00352-A
A OUTLET A
3 PORT
INLET
Indicates Part of Casting
LEGEND
2. Passageway from inlet chamber to outer chamber
3. Passageway to the actuator inlet from the outer chamber
A. Inlet chamber
Note: Item numbers 2, 3 and letter A are discussed in the text.
FIGURE 5-4. FLOW CONTROL VALVE WITH COVER AND CENTER CHAMBER REMOVED. Cutaway
as seen facing the valve cover.
35
(Blenders only.) The proportional flow control valve is a pilot-operated, diaphragm sole-
noid valve. It has three main functions in the dispenser:
• Positive shutoff
• Blend ratio control
• Flow rate regulation
Located between the meter and the hose outlet, the valve is controlled by a 24 VDC pulse
width modulated signal from the solenoid drive board. Normally closed, the pilot opens by
an amount proportional to the amount of current sent to the valve coil. As the pilot raises
off its seat, it reduces the pressure to the back side of the diaphragm causing it to lift off of
its seat as well. The same applies to the valve closing; the diaphragm follows the pilot back
to the closed position as the current to the coil is reduced. The computer continually adjusts
the current to the valves during a sale based on the desired blend ratio of the two feedstocks
and maximum allowable flow rate. The high and low products remain separate until they
are mixed at the hose outlet in proportional blenders or at the outlet valve in fixed ratio
blenders.
TD00310-A
FIGURE 5-5. PROPORTIONAL FLOW CONTROL VALVE. The valve is controlled by a 24 VDC pulse
width modulated signal from the solenoid drive board.
36
The proportional flow control valve controls flow and blend ratios in the dispenser. This
valve is used in conjunction with a separate check and pressure relief valve (C&PR valve).
The CP&R valve is located at the meter inlet. Once a delivery is complete and the
diaphragm valve is closed, the product pressure between the check valve and the nozzle
will be held at the pressure of the last delivery. If the pressure should build up due to
temperature rise in the hose or a car runs over the hose, the relief function of the C&PR
valve will relieve the pressure buildup. The relief valve is set to relieve pressure between
30-50 psi. The same C &PR valve is used in blenders and non-blenders.
The pilot operated proportional solenoid valve performs three basic functions in the
dispenser. It provides positive shutoff, regulates the ratio of blended feedstocks, and
controls the flow rate through the hydraulic path by limiting the maximum flow rate
through a given hose.
The pilot operated proportional flow control valve consists of two main parts:
The valve coil controls the operator of the valve. The coil is energized with a pulse width
modulated (PWM) signal that sends discrete “bursts” of current at a set frequency level.
When the coil receives this signal, the pilot inside the operator reacts to the changing
magnetic field and moves up and down depending on the amount of current through the
coil. The position of the pilot relative to the pilot orifice in the diaphragm controls the
amount of flow.
In all Wayne blending dispensers using this valve, the general order of operation is the
same. At the beginning of a sale, the coil is energized with a minimum current level,
allowing slow product flow to start. After a small amount of product is delivered, the coil
is energized with more current to initiate full regulated flow. For preset sales, the dispenser
will switch back to slow flow at a pre-determined point.
37
When the delivery is complete, the coil is de-energized, allowing the pilot to
return to its closed position. This allows pressure to build on the back side of the
diaphragm, forcing it to close and seal the outlet port thereby stopping flow.
5.4. METER
The meter is, in effect, a three-cylinder motor, using cylinders ‘B’ and ‘C’ and chamber ‘D’
as the three cylinders (see Figure 5-6.). Because the filling and discharging ports in the
valve are located 120° apart, and the port openings in the valve seat are at 120°, there is no
dead-center position in the meter. The operation of filling is continuous, in that before one
chamber is fully filled, the next one is in the process of starting to fill. The same procedure
applies to the discharging operation. The filling and discharging operations each occupy
180° of rotation. Measurement of flow is determined by the fact that the displacement of
each cylinder, together with the displacement from chamber ‘D’, represents a known quan-
tity, and the flow has a direct and substantially constant relationship to the rotation of the
output shaft.
By connecting the output shaft to the pulser assembly, the rotary movement of the meter
can be converted into pulses, which can in turn be counted by the computer. Calibration is
made possible by the incorporation of an adjusting knob on the top of the unit. Movement
of this knob causes the throw of the crank arm on the output shaft to be varied, so that the
speed at which the shaft rotates can be accurately adjusted to the known output of the meter.
38
FIGURE 5-6. METER CUTAWAY. The meter is, in effect, a three-cylinder motor, using cylinders ‘B’ and ‘C’
and chamber ‘D’ as the three cylinders
5.4.1. Meter Adjustment
While the dispensers leave the factory properly adjusted, rough handling in
transit or special installation conditions can change this. Therefore, before
placing the dispenser in operation, these items must be checked and adjusted, if
required.
If meter adjustment is required, the adjustment knob is located on the top of the
meter; see Figure 5-7. If the test can reads low, break the seal, lift the adjustment
knob and turn in a clockwise direction, viewing the knob from the top of the
meter. The lower portion of the knob is hexagonal and, in a normal position, the
portion of the knob is inserted in the output shaft assembly. There are 18 vertical
notches within the shaft, therefore, as the adjustment is made, the knob can be
felt to click over the leading edge of the notches. Each notch is equivalent to a
correction of approximately one cubic inch in five gallons. After the meter has
been adjusted and brought within tolerance, replace the seal wire and seal by
pinching the lead lock on the wire.
39
40
Many problems that appear to be the result of a defective computer are really caused by contami-
nation of the computer memory. Prior to replacing the computer for a first occurrence of a partic-
ular problem, a RAM clear should be initiated and the computer retested. If the computer functions,
it should not be replaced unless a second occurrence of the same problem results.
! WARNING
Electric Shock Hazard!
The above and following actions in this Section require that the electrical power to the
equipment be ON. Use wiring diagrams, connector drawings and other information
in this manual to identify the electrical connections and AVOID contact with the
electrical power. Failure to do so may result in severe injury or death.
To clear the RAM on the Duplex II computer use the following procedure:
1. Record all totals and all option programming.
2. Remove power from the board by removing connector J3.
3. Locate connector J6 and bridge (jumper) pins 3 & 5. Use jumper part number 129930. Pin
1 of J6 is located closest to the center of the board.
4. Apply power to the board by re-installing connector J3. The unit price display will show
“OP01” to indicate the option programming mode has been entered and Option 01 has been
selected.
5. Press the Price Jog push-button to go to Option 97 where the sale money display will show
XAB; AB being the right hand two digits.
6. Use the Totals push-button to change the value in the volume display to XBA. For example,
if the money display shows 06 in the right hand two digits, enter 60 in the right hand two digits
in the volume display.
7. Press the Price Jog push-button; a RAM clear will occur in a few seconds and the computer
will immediately enter Option 01.
8. Use the Price Jog and Totals push-buttons to reset the options as necessary and Save the new
settings with Option 99 set to 03.
9. Remove the security jumper.
10. Press the Price Jog and then the Position Select push-button to return the dispenser to the
normal operating mode.
Note: Reset the fueling point number and unit prices as necessary after performing this
procedure.
41
A. For other detailed information about faulty displays, see Figure A-20.
3. Data was corrupted then cleared by the Reset prices and or option programming. If problem contin-
computer. Check option 01 to verify. See ues to occur replace computer assembly.
programming manual part number
920205 for details.
42
2. Blown fuse on the lighted Cash/Credit Check F1 on the interface board and replace the board if the
Interface board. fuse is blown. If no fuse on board, replace board.
5. Defective display board or cable. Replace display board or cable to J1 on display board.
43
TABLE 6-8. COMPUTER RESETS BUT SUBMERSIBLE PUMP DOES NOT COME ON.
3. Non-Blender - Defective actuator coil. Non-Blender - Check coils for continuity; if open circuit
replace coil.
Blender - Defective proportional valve. Blender - Check coils for continuity; if open circuit replace
defective proportional valve.
44
1. Defective push to start or cash/credit Check the switch assembly and replace as necessary. See
switch assembly. Table 6-7., item #4.
2. Defective switch wiring. Check wiring harness and connectors between the suspect
switch assembly to the lighted cash/credit interface board.
Replace the wiring as necessary.
1. Defective wiring. Check the two wires in the DEM which are connected to the
two wire connector at the lower left corner of the DEM
(where the push to start switch normally is connected). Repair
or replace the wiring as necessary.
A. To clear the error message it is necessary to either cycle the power to the Duplex Computer or enter
option 99, change the data to 3 and exit option programming. Even if the problem is corrected the fault
code will continue to be displayed until one of these procedures is executed.
45
1. Solid state relay on solenoid drive board Check for 110VAC output (24VDC for blenders) to valve(s)
shorted. with handle off. If 110VAC (24VDC for blenders) is present,
replace solenoid drive board.
6. Defective proportional flow control valve Replace proportional flow control valve.
(Blenders only).
1. Computer found defective ROM chip dur- Clear error. If problem reoccurs replace computer assembly.
ing self test.
A. To clear the error message it is necessary to either cycle the power to the Duplex Computer or enter
option 99, change the data to 3 and exit option programming. Even if the problem is corrected the fault
code will continue to be displayed until one of these procedures is executed.
46
Pulser jitter.
4. Dust in housing.B Clean dust from housing and photocoupler. Adjust disc to
keep it from rubbing on photocoupler. Check for cracks in
housing, replace as necessary.
5. Disc tension is not correct. Check for missing wave washer. Install one if missing.
6. Air in system causing severe hydraulic Repair or replace faulty piping and purge all air from system.
shock.
8. Defective ISB assembly. Replace complete ISB assembly (board not separately
replaceable).
B. Dust blocking one phase of the photocoupler can cause the same symptoms as a defective photocoupler.
If dust is found in the housing do not replace the photocoupler unless the error reoccurs.
47
1. Operational error. If the dispenser presently transitions to fast flow and displays
volume, verify that Option 12 is set to appropriate time
period. Refer to programming manual, part number 920205
2. Defective computer assembly or ISB If problem occurs on all grades, replace computer assembly or
assembly. ISB assembly.
3. Defective pulser or ISB. If problem does not occur on all grades, check pulser and
replace as necessary or replace ISB assembly.
4. Defective wiring. Check wiring harness: ISB to pulsers and ISB to computer.
Replace necessary.
A. To clear the error message it is necessary to either cycle the power to the Duplex Computer or enter
option 99, change the data to 3 and exit option programming. Even if the problem is corrected the fault
code will continue to be displayed until one of these procedures is executed.
48
1. Disc tension is not correct. Check for missing wave washer on pulser shaft. Install as nec-
essary.
3. Defective diaphragm valve or propor- Install diaphragm repair kit or replace flow control valve.
tional flow control valve (Blender only).
1. Computer found scrambled data in option Check all option programming and set Option 99 to Data 03
programming. to clear error. Cycling power will not clear this error.
49
4. Shorted relay on solenoid drive board. If voltage is present (the same voltage as AC or DC input)
Check for AC output with dispenser off replace solenoid drive board.
(or DC output for blenders).
1. Totalizer fractional amounts that are Run additional product and monitor totals.
stored in memory after each sale have
been corrupted and reset to zero.
1. Computer missed incrementing at least Run additional product and monitor totals.
one volume unit on the electro-mechani-
cal totalizer.
50
1. Flow restricted on one end grade. Observe the low and high meters while dispensing to deter-
mine which grade is restricted. Verify any blend inaccuracy
using electronic totals. Check all valves and flow tubing for
obstructions. Clean strainer and change filter.
2. Defective solenoid drive board. Check that the DS1 LED on the drive board stays lit during
the sale and the DS2 LED blinks about every two seconds. If
either of these conditions fails, replace the Solenoid Drive
Board.
3. Faulty wire harness connected to coil. Check the wire harness connections to the valve coil wires
and the harness into J3 on the solenoid drive board. Verify the
voltage to the valve coils at 24 VDC when enabled. Replace
wire harness as necessary.
4. Defective proportional flow control valve. Replace proportional flow control valve.
1. Defective Solenoid Drive Board. Cycle power to dispenser. Replace solenoid drive board if
error continues to occur.
2. Defective Computer assembly. Replace computer assembly.
51
This section describes the procedures necessary to replace the major components in Wayne
dispensers.
7.1. ELECTRONIC COMPONENT REPLACEMENT
! WARNING
ELECTRIC SHOCK HAZARD!
Before removing any components as described in the following sections, electrical
power should be removed from the dispenser. More than one disconnect may be
required to remove power. Use a voltmeter to ensure AC power has been removed.
Failure to remove the power may result in severe injury or death.
Note: Before power is removed, totals should be read and recorded in case of memory alter-
ation.
When removing or installing one of the electronic components within the computer
housing, take care not to contact one component with another. Contact between compo-
nents might cause damage to the circuit board coating, circuit board tracks, or circuit
components.
Before replacing any components, servicing personnel should wear a static guard wrist
strap (Dresser part number 916962 or equivalent) securely attached to an earth grounding
point in order to prevent damage to electronic components due to static electricity.
Always keep replacement components in their anti-static shipping bags until they are
installed. Put replaced suspect components in the anti-static bags for return to the factory
in original packaging and fill out a return parts tag.
After having replaced a component, make a thorough visual inspection of your work to
ensure that:
53
1. Lower the ad panel holder frame by pulling the holder frame out and down
from the top.
2. Lowering the ad panel down toward you, exposes the function switch access
door and the thumbscrews or bezel locks which secure the bezel to the
dispenser.
3. Unscrew the thumbscrews, or unlock the bezel locks.
4. Pull the bottom portion of the bezel out toward you, then pull the bezel down
clear of the drip edge.
5. Use the reverse procedure to install the bezel.
7.1.2. DEM In Service Position
To gain access to the electronic components in the dispenser, put the DEM in
the service position by following the instructions in Figure B-1. and Figure B-
2. in Appendix B.
! WARNING
ELECTRIC SHOCK HAZARD!
Even though the dispenser control power is turned off voltage may still be present at
the solenoid drive board, this condition will continue until both J1 and J2 connectors
are removed from the solenoid drive board. For blenders the J1 connector must be
removed. Failure to remove the power may result in severe injury or death.
Replacing the solenoid drive board (see Figure 7-1.) requires the following
steps:
1. Turn the power to the dispenser OFF, and lock and/or tag the circuit breaker
in the OFF position.
2. Remove the bezel from the dispenser.
3. Place the DEM in the service position.
4. Disconnect all of the wiring harnesses (see Figure 7-1.) from the solenoid
drive board.
5. Remove the four (4) screws which secure the solenoid drive board to the
Duplex II computer.
54
FIGURE 7-1. REPLACING THE SOLENOID DRIVE BOARD (NON-BLENDER SHOWN). Even though
the dispenser control power is turned off voltage may still be present at the solenoid drive board. This
condition will continue until both J1 and J2 connectors are removed from the solenoid drive board.
55
When installing a Duplex II computer in a non-blending dispenser JP2 and JP3 must
have jumpers installed on the two pins closest to the center of the computer board.
1. Record the totalizer readings if the totalizer is functional.
2. Turn OFF the control power.
3. Put the appropriate switch in the data distribution box to bypass.
4. The computer is located behind and below the consolidated display on the
junction box side of the dispenser. To access the computer (see Figure 7-1.),
or solenoid drive board, disengage the two quarter turn screws located
above the left and right corners of the display. The Dispenser Electronic
Module (DEM) will then tilt out toward you to provide access to the internal
electronic components of the dispenser.
5. Disconnect all cables before removing the computer assembly. (The
connectors have two latches which must be squeezed to disengage them
from the board.)
6. Remove the screws securing the computer base assembly to the housing.
7. Lift the computer assembly out of the chassis.
8. Remove the solenoid drive board and install on the new computer assembly.
9. Install the new computer assembly and secure with the hardware removed
in Step 6.
10. Connect all cables to the computer assembly.
11. Set the switches in the data distribution box back to auto.
56
FIGURE 7-2. REPLACING THE DUPLEX II COMPUTER. The Dispenser Electronic Module (DEM) will tilt
out toward you to provide access to the internal electronic components of the dispenser.
57
58
FIGURE 7-3. INTRINSIC SAFE BARRIER ASSEMBLY. The ISB ground connection shown must be made
directly to the dispenser chassis.
TD00355-A
FIGURE 7-4. REPLACING THE INTRINSIC SAFE BARRIER ASSEMBLY. Placing both DEMs in the
service position allows for easy access to the Intrinsic Safe Barrier Assembly.
59
1 . L o o se n th e fo u r ( 4 ) scr e ws th a t
se cu r e th e d i a l fa ce to t h e d i sp l a y
TD00356-A
J1
2. D i s c onnec t the w i r i n g h a r n e ss
c onnec ted to J 1 on the d i sp l a y
boar d.
3 . Re mo ve th e fo u r scr e ws t h a t se cu r e
t h e d i sp l a y b o a r d t o th e DE M a n d
r e mo ve th e b o a r d .
FIGURE 7-5. REPLACING THE INTEGRATED DISPLAY BOARD. Remove the dial face from the display
by loosening the four screws in the corners of the dial face.
60
Di sc o n n e c t a l l o f th e conec t ors on t he
l i g h te d ca s h /cr e d i t b oard.
FIGURE 7-6. REPLACING THE LIGHTED CASH CREDIT INTERFACE BOARD. When servicing this
area, wire harnesses must be carefully placed to ensure proper operation.
61
62
FIGURE 7-7. EXPLODED VIEW PULSER ASSEMBLY. The cover must be properly attached to prevent
dust from entering.
63
1. Disconnect the nozzle switch connector and, if necessary, cut the wire tie securing the
switch wiring to the dispenser.
2. Remove the nozzle boot by removing the (2) lower hex screws that secure the boot to the
dispenser; removing the nozzle boot collar, and loosening the (2) upper allen screws.
3. Remove the retainer clip that secures the switch to the back of the boot casting and remove
the switch.
4. Install the new switch and secure with a new retainer clip making sure that the right hand
edge of
the switch aligns with the right hand edge of the casting flat mounting surface as viewed
from the
back of the boot.
5. Re-install nozzle boot and connect nozzle switch connector securing wires with wire tie if
applicable.
To replace the magnet or spring (see Figure 7-8.):
6. Disconnect the nozzle switch connector and, if necessary, cut the wire tie securing the
switch wiring to the dispenser.
7. Remove the nozzle boot by removing the (2) lower hex screws that secure the boot to the
dispenser; removing the nozzle boot collar, and loosening the (2) upper allen screws.
8. Raise the nozzle hook to the up position.
9. Remove the (2) 1/4-20 x 7/8 hex screws under the nozzle hook.
10. Remove the (2) #10 x 3/4 plascrews that screw into the back of the filler guide from the
back of the nozzle boot.
11. Remove the filler guide assembly containing the nozzle hook from the nozzle boot.
12. Remove the spring by unclipping it from the back of the filler guide.
13. Replace the magnet and/or spring as necessary.
14. Reassemble nozzle boot in reverse order.
15. Re-install nozzle boot and connect nozzle switch connector securing wires with wire tie if
applicable.
64
1. Disconnect the nozzle switch connector and, if necessary, cut the wire tie
securing the switch wiring to the dispenser.
2. Remove the nozzle boot by removing the (2) lower hex screws that secure the
boot to the dispenser; removing the nozzle boot collar, and loosening the (2)
upper allen screws.
3. Remove the retainer clip that secures the switch to the side of the boot
casting and remove the switch. Note: Some units, for a temporary period,
will have the switch secured, with (2) #4 screws, to a bracket mounted to the
side of the dispenser.
4. Install the new switch and secure with a new retainer clip.
5. Re-install nozzle boot and connect nozzle switch connector securing wires
with wire tie if applicable.
To replace the switch actuator assy (see Figure 7-9.):
1. If the boot is located to the right side of the dispenser, proceed with Step 2
below. If not, go to Step 4.
2. Disconnect the nozzle switch connector and, if necessary, cut the wire tie
securing the switch wiring to the dispenser.
3. Remove the nozzle boot by removing the (2) lower hex screws that secure the
boot to the dispenser; removing the nozzle boot collar, and loosening the (2)
upper allen screws.
4. Remove the lower part of the spring from the #10 -24 x 1/2 washer head
screw on the post on the side of the nozzle boot and remove the spring from
the switch actuator assy.
5. Pull the switch actuator assy out of the nozzle boot while holding the flipper.
6. Install new switch actuator assy by pushing into the nozzle boot, through the
flipper, until the switch actuator assy snaps into place.
7. Re-install spring to switch actuator assy and then to the post on the side of
the nozzle boot.
8. If applicable, re-install nozzle boot and connect nozzle switch connector
securing wires with wire tie if applicable.
65
66
February 1997
67
1. Remove the bezel and disconnect the wire harness connector from the
membrane switch assembly.
2. Remove the switch assembly cover on the front of the bezel by prying up
one end of the cover using a flat blade screwdriver.
3. Remove the switch assembly by unscrewing the eight (8) hex head screws
retaining the assembly on the back side of the bezel.
4. Install the new switch assembly using the hex head screws previously
removed.
5. Reinstall the switch assembly cover on the front of the bezel.
6. Reconnect the wire harness connector and replace the bezel.
7. Test for proper operation.
7.1.12. Back Lit Display Lamp Replacement
1. Remove the bezel from the dispenser.
2. Tilt the DEM down to its service position by disengaging the two quarter
turn screws located above the left and right corners of the display.
3. Disengage the finger lock screw that is now facing upward from behind the
display on either side of the DEM chassis.
4. Remove the bracket containing the lamp holder and lamp.
5. Install the new fluorescent lamp and reinstall the bracket.
6. Secure the DEM back in its original position.
7. Reinstall the bezel.
68
! WARNING
Before removing any components as discussed in the following sections, trip the
impact valve, and remove power to the submersible pump for the product in question
to prevent fuel spillage. Failure to do so could cause a possible fire hazard that may
result in serious injury or death.
! WARNING
Drain the fuel into an appropriate container and pour it into an underground tank to
prevent fuel drainage under and around the dispenser. Failure to do so could cause a
possible fire hazard that may result in serious injury or death.
7.2.1. Diaphragm Replacement (Non-Blenders Only)
1. Remove the four (4) bolts and the diaphragm cover.
2. Remove the diaphragm and discard. The center section and cover will be
reused. Note of the position of the disc and spring as they are removed so
they can be installed the same way.
3. The spring must be seated squarely in the spring cup so that it will stay in
place when the valve cover is installed.
4. Hand tighten the four (4) bolts, using a crisscross pattern until the bolt heads
just contact the valve cover. Continue this pattern increasing torque until all
bolts are fastened to a torque of 9-11 ft. lbs. This torque must not be
exceeded in order to keep the gaskets from deforming and covering the
ports.
5. Check operation and inspect for leaks.
69
70
The check and pressure relief valve is a non-serviceable assembly. If the new
valve fails, replace it. Failure Symptoms are: computer jump, crossflow or Error
Code 16.
Replacement Procedures:
71
72
73
FC-OO104-A
YES
NO
Is the
problem YES
corrected?
NO
Replace the
computer
assembly.
END
FC-00105-A
Use voltmeter to check
the cash/credit interface
board & wire harness
between board &
membrane switch assy.
See Appx B -pinout info.
Does
the harness
YES & cash/credit board
check good ?
NO
Is the
problem YES
corrected?
NO
Replace the
wiring harness.
Is the
problem YES
corrected?
NO
Replace the
computer.
END
75
Is 110VAC
(or 24VDC Replace the
blender only) present YES solenoid drive
when it should board.
not be?
NO
Is the
problem YES
corrected?
NO
Is the
problem YES
corrected?
NO
Replace the
computer.
END
Computer found
defective ROM chip
during self test.
Clear erroo.
Does the
error NO
reoccur?
YES
Replace computer.
END
77
2
Wayne Vac
Is dispenser Is LED on error. See
equipped with YES Wayne Vac control YES service manual
FC-00106-A
3
YES
NO
Repair/Repace
wiring or replace Replace photocoupler.
I S B a s s y.
NO YES
2
END
Is 110VAC
(or 24VDC NO Replace computer.
blender only)
present?
YES
Replace solenoid
drive board.
Is the
problem YES
corrected?
NO
Replace computer.
END
79
See Option 12
in the Duplex II
programming
manual.
Operational error
no corrective
action.
END
80
No
Yes
Is the problem with
all Grades ?
No
Operational error.
Replace pulser for Replace the Verify that Option 12
problem ISB assembly. is set to the appropriate
Grade/Hose. time period.
No No
END
NO NO
1
NO NO
1 1
Is there
enough tension Install wave washer
on the pulser NO if one is not present.
disc?
YES
YES
2 YES
YES
END
82
Computer found
scrambled data in
option programming.
Does the
error NO
reoccur?
YES
Replace computer.
END
83
Computer found
the totals data
to be corrupted
and reset the
data to zero.
Does the
error NO
reoccur?
YES
Replace computer.
END
84
Computer found
the unit price data
to be corrupted
and reset the
data to zero.
Re-enter
unit
pricess
Does the
error NO
reoccur?
YES
Replace computer.
END
85
NO
Is
there Replace
110 VAC or Solenoid
(24VDC blenders) YES
present? Drive
Board
NO
Is
the
problem YES
corrected?
NO
Replace the
computer assy.
END
NO
END
87
Corrupted
Electro-Mechanical
Totalizer data.
Totalizer fractional
amounts stored in
memory after each
sale have been
corrupted and reset to
zero (0).
Does the
error continue NO
to occur?
YES
Replace computer
assembly.
END
88
Electro-Mechanical
Totalizer overflow.
Does the
error continue NO
to occur?
YES
Replace computer
assembly.
END
89
Is
Problem YES
Corrected?
NO
While dispensing is
YES DS1 lit and DS2
blinking on the
Solenoid Drive
Board?
NO
Replace Solenoid
Drive Board
Is Problem
Corrected? YES
NO
On the solenoid Drive Board check connectors J3
(output to valve coils) and J4 (24VDC input). Repair
or Replace wire harness into J3 and/or replace
proportional flow valve as necessary .
Is Problem
Corrected? YES
NO
Replace Duplex II
Computer
END
Communications failure
between the Duplex II
computer and the
blender solenoid drive
board microprocessor.
Cycle power
to the dispenser.
Does the
error continue NO
to occur?
YES
Does the
error continue NO
to occur?
YES
Replace Duplex II
Computer
END
Check F1 and F3
fuses on the
computer. Replace
if defective.
Is there Is 110VAC
110VAC between present in
pins 1 and 2 on the NO NO Correct station wiring.
junction box
J3 connector? terminal 1?
YES YES
Repair/replace
Replace the display. defective internal
dispenser wiring.
Is the
problem YES
corrected?
NO
Replace the
computer.
END
FIGURE A-19. SALE DISPLAY AND UNIT PRICE DISPLAYS ARE BLANK.
92
FC-00122-A
missing segments,
or display appears
normal but frozen.
NO NO
NO
Is there
a jumper wire
across pins 8 & 9 of Replace
J5 connector on the computer
NO assembly.
Cash/credit
interface
board ?
YES Replace
this
wiring
Reseat connector to J2 on harness.
cash/credit interface board
and connector to J4 or J5
on computer assembly.
J4 is for side 1 display.
Check this cable for continuity
and replace it if defective.
Is the
NO problem YES
corrected ?
Is the
problem YES
corrected ?
NO
Check F1 fuse on
cash/credit interface board. Is the
If fuse is open replace the problem YES
board. If dispenser is not corrected ?
Push-to-Start model, the
board shoud be replaced
since F1 does not exist.
NO
YES YES
END
93
YES
Reseat connector J6
on cash/credit interface
board and check Is the
continuity of wiring problem YES
between J6 and switch. corrected?
Replace cable if
defective.
NO
Replace the
cash/credit
interface board.
Is the
problem YES
corrected?
NO
Replace the
computer assembly.
END
Reseat
connector J6 on
cash/credit interface
board.
Is the
problem YES
corrected?
NO
NO
Check continuity of
wiring between J6 on
cash/credit interface Is the
problem YES
board and each switch.
Replace cable if corrected?
defective.
NO
Replace the
computer assembly.
Is the
problem YES
corrected?
NO
END
Defective
Push-to-Start Is the
switch or wiring. problem YES
Correct as corrected?
necessary.
NO
NO
Defective handle
switch or wiring to
switch. Refer to the
proper wiring diagram
check for continuity at
plug on computer with
handle on.
YES YES
NO YES
YES
Is the
Replace the problem
computer. NO
corrected?
YES
END
product(s).
NO
C h e c k f o r : 1 1 0 VA C o u t p u t
from Solenoid Drive Bd to
relay(s) and AC valve(s)
if Non-Blender or
24VDC (J3) output to
valve(s) if Blender.
If Non-Blender, replace
solenoid drive board.
Is 110VAC If Blender, replace solenoid Is the
or ( 24VDC) NO problem YES
drive board if 24VDC is corrected?
present? present at J4. If not present
check F1 on 24VDC
power supply board. Replace
YES F1 if it is open and replaceable. NO
Check for: 110VAC
on relay select wires and If Non-Blender, replace
valve(s) in junction box if computer assembly.
Non-Blender or
If Blender, wiring harness
24VDC on proportional that comes with computer
valve(s) and 110 VAC on assy and/or computer assy
relay select wires if Blender. is faulty. Replace computer
assembly.
YES
Check actuator, or
proportional valve if
Blender, or relay coil
for continuity.
Replace
Is the
coil reading the actuator coil,
YES proportional valve if Blender,
an open circuit?
or the relay.
NO
Replace defective
actuator, relay, or
if Blender, the END
proportional valve.
NO YES
NO
NO
Replace the
computer(s).
END
98
Is
Electro-Mechanical YES
Totalizer Counting?
NO
Replace lighted
Cash/Credit interface
board
Is
Electro-Mechanical YES
Totalizer Counting?
NO
Replace
Duplex II Computer
Is
Electro-Mechanical YES
Totalizer Counting?
NO
Replace Wiring:
Electro-Mechanical Totalizer to Cash/Credit board J7.
or
Cash/Credit board J2 to Duplex II Computer J4(J5).
END
101
To move the DEM into service position preform the steps shown in Figure B-1. and B-2.
Once the DEM in tilted into the service position you will have access to all of the electronic
components in the dispenser. It may or may not be necessary to remove the bezel from the
rear of the dispenser to access the electronics on that side.
LOC AUTH ON
FIGURE B-1. DEM REMOVAL. To move the DEM into service position preform the steps shown.
102
Duplex II Computer
Tilt the upper edge of the DEM out toward you to expose the electronic components.
All wiring harnesses and the components on the rear of the dispenser have been
deleted for clarity.
FIGURE B-2. DEM IN THE SERVICE POSITION. Once the DEM in tilted into the service position you will
have access to all of the electronic components in the dispenser.
103
Connections
Pin 1-Fast Valve Nozzle AA
J3-Side 1
Pin 2-Slow Valve Nozzle AA
Pin 3-Relay Select Nozzle AA
Pin 4-Pulser Select Nozzle AA
Pin 1- Relay Select Nozzle X
Pin 2- Fast Valve Nozzle X
J1-Side 1 Connections
Connections
Pin 15- Slow Valve Nozzle Z Pin 1-Fast Valve Nozzle AA
J4-Side 2
Pin 2-Slow Valve Nozzle AA
Pin 3-Relay Select Nozzle AA
Pin 4-Pulser Select Nozzle AA
Pin 1- Relay Select Nozzle X
Pin 2- Fast Valve Nozzle X
J2-Side 2 Connections
NOTE: Pin connections which are not needed in a particular model of dispenser (for instance, the nozzle
Z switch in a V387 dispenser) will have no wire in that location.
104
J4-Proportional
Pin 3-Pump Relay Single Product*
Valve Power
Pin 4-Open Pin 1-(+24VDC)
Pin 5-Open Pin 2-Open
Pin 6-Open Pin 3-Ground
Pin 7-AC Valve Fast, Side 1*
Pin 8-AC Valve Slow, Side 1*
Pin 9-Open
Pin 10-AC Valve Fast, Side 2*
Pin 11-AC Valve Slow, Side 2*
Pin 12-Open
Pin 3-(+24VDC)
Pin 4-Proportional Valve Low, Side 1
Pin 5-Open
Pin 6-(+24VDC)
Pin 7-Proportional Valve High, Side 2
Pin 8-(+24VDC)
Pin 9-Proportional Valve Low, Side 2
J3-AC Input
Pin 6-Pulse "A" High Product Pin 2-Neutral
Pin 5-Pulse "B" Low Product Pin 3-Ground
Pin 9-Pulse "A" Low Product Pin 4-Open
Pin 7-LED "A" Pin 5-Open
Pin 4-LED "B"
*Only used on 1/V395D model series with additional "single hose" product.
Proportional Blender
105
J4-Proportional
Pin 2- Pump Relay High Product
J1- AC Valves & Relays Pin 3- Open
Valve Power
Pin 4- Open Pin 1-(+24VDC)
Pin 5- Open Pin 2-Open
Pin 6- Open Pin 3-Ground
Pin 7- AC Valve #1 Side 1*
Pin 8- AC Valve #2 Side 1*
Pin 9- AC Valve #3 Side 1*
Pin 10- AC Valve #1 Side 2*
Pin 11- AC Valve #2 Side 2*
Pin 12- AC Valve #3 Side 2*
SOLENOID DRIVE BOARD
Pin 1- Ground
J2-Product Select
Pin 9- Pulse "A" Low Product Pin 3-Side 2 High Product Handel Switch
Pin 7- LED "A" Pin 4-Side 2 Blend Product Handel Switch
Pin 4- LED "B"
106
107
PIN 5
PIN 8 PULSE "B" PIN 2
NOZZLE SW. FOR NOZZLE
POSITION Y SINGLE HOSE SWITCH
MGD COMMON
PIN 4 PIN 1
PIN 7
LED "B" NOZZLE SW.
LED "A" POSITION X
108
109
PIN 1
GROUND
PIN 2
PULSER
SELECT A
SIDE 1
PIN 3
PULSER
SELECT B
SIDE 1
PIN 4
PULSER
SELECT C
SIDE 1
PIN 5
KEY
PIN 6
PULSER
SELECT A
SIDE 2
PIN 7
PULSER
SELECT B
SIDE 2
PIN 8
PULSER
SELECT C
SIDE 2
PIN 9
GROUND
110
PIN 6 PIN 9
PIN 3 24 VOLTS DC PROPORTIONAL
24 VOLTS DC VALVE LO
SIDE 2
111
PIN 1
+24 VDC
INPUT
FROM
POWER
SUPPLY
PIN 2
PIN 3
GROUND
112
PIN 1
PIN 3 PIN 2 RELAY
SLOW VALVE FAST VALVE SELECT
NOZZLE X NOZZLE X NOZZLE X
RED WIRE RED WIRE WHITE-RED
WIRE
PIN 4
PIN 6 RELAY
FAST VALVE SELECT
NOZZLE Y PIN 5
NOT USED NOZZLE Y
BLACK- WHITE-
ORANGE BROWN
WIRE WIRE
PIN 7
PIN 9 PULSER
SLOW VALVE SELECT
NOZZLE Y PIN 8
NOT USED NOZZLE X
BLACK- VIOLET-
ORANGE BLACK
WIRE WIRE
PIN 12 PIN 10
FAST VALVE PULSER
PIN 11 SELECT
NOZZLE Z NOT USED
WHITE- NOZZLE Y
BLUE VIOLET-RED
WIRE WIRE
PIN 14 PIN 13
PIN 15 RELAY
SLOW VALVE PULSER
SELECT SELECT
NOZZLE Z NOZZLE Z
WHITE- NOZZLE Z
WHITE- VIOLETWIRE
BLUE BLACK
WIRE WIRE
FIGURE B-12. PINOUT CONNECTIONS TO NON- BLENDER SOLENOID DRIVE BOARD - J1 AND J2.
113
TD00344-A
TRANSFORMER
ON PUSH-TO-
START MODELS
ONLY J4
F1
J10
J1
J2
J7
J5
J6
114
TD00342-A
2 20 VOLTS DC
3 LED 5
4 20 VOLTS DC
5 LED 4
THE EVEN NUMBERED PINS (2,4,6, ETC.)
ARE THE 20 VDC SUPPLIED TO EACH 6 20 VOLTS DC
LIGHTED SWITCH; THE ODD NUMBERED
PINS (3,5,7 ETC.) ARE THE SWITCHED 7 LED 3
0 VDC WHICH CAUSE THE LIGHTS TO
BLINK. 8 20 VOLTS DC
9 LED 2
10 20 VOLTS DC
11 LED 1
12 20 VOLTS DC
13
14 20 VOLTS DC
15
16 20 VOLTS DC
115
TD00345-A
SETUP
AUTH
TOTALS
PUSH TO STOP
SWITCH DATA
COMMON
1 2 3 4 5 6 7 8 9
TD00346-A
5V 5V 5V 5V
116
1 2
5V 5V
FIGURE B-18. PINOUT CONNECTIONS TO LIGHTED CASH/CREDIT INTERFACE BOARD - J10.
TD00348-A
9 8 7 6 5 4 3 2 1
SELECT SWITCH 1
GND
NOT USED
SELECT SWITCH 5
GND
SELECT SWITCH 2
SELECT SWITCH 3
NOT USED
SELECT SWITCH 4
117
118
119
120
121
122
123
125
Written by S. G. Martin.
Formatted by S. N. Hart.
This manual was produced using Adobe® FrameMaker® on a Power Macintosh® 8100/80.
Manuals were electronically produced on a Xerox Docutech 135 Publishing System at 600 dpi.
This manual and the software described within are furnished under license and may be used or copied only in accordance with the
terms of such license.
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 license. Translation of this material to another language without express written
permission of Dresser Industries is prohibited.
The information in this publication is for informational use only and is subject to change without notice. The contents should not
be construed as a commitment by Dresser Industries, Inc. who assumes no responsibility or liability for inaccuracies that may appear
in this publication.
Wayne Division, Dresser Industries, Inc., is located at 124 West College Ave., Salisbury, MD 21804.
Dresser Industries’ general telephone number is (410)-546-6600.
The Documentation fax number is (410)-546-6753.
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
Seller warrants that new products and parts of its own design and manufacture when shipped, will
be of good quality and will be free from defects in material and workmanship and will conform to
applicable specifications. Work, when performed by Seller, will meet applicable work require-
ments. No warranty is made with respect to used or rebuilt equipment and with respect to products
not manufactured by Seller. Seller’s only obligation shall be to assign to Buyer, at the time of sale,
whatever warranty Seller has received from the manufacturer. Items such as but not limited to
lamps, electric motors, hoses, nozzles, hose swivels and safety impact valves are included in the
category referred to in the previous sentence. Seller’s recommendations with respect to the oper-
ation of Seller’s equipment are advisory only and are not warranted. All claims under this warranty
must be made in writing immediately upon discovery and, in any event, within twenty-four (24)
months from date of start-up, if a product is involved, or from completion of the applicable work,
if work is involved, or thirty (30) months from date of invoice (whichever shall occur first). (Pro-
vided however, that with respect to the Wayne Plus system, 2400 system, DL series dispensers,
and card readers, all claims must be made in writing within twelve (12) months from date of start-
up. With respect to receipts/totals printers, and any other printers or printing mechanisms, all
claims must be made in writing within ninety (90) days from date of start-up. Wayne Vista dis-
penser external metal panels will be free from defects due to rust and/or corrosion for a period of
forty-eight (48) months from date of dispenser start-up.) Defective and nonconforming items must
be held for Seller’s inspection and returned to the original f.o.b. point upon request. Seller’s war-
ranty on service parts, whether new or reconditioned, is ninety (90) days from the date of installa-
tion, or twelve (12) months from date of invoice, whichever first occurs. THE FOREGOING IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESSED, IM-
PLIED AND STATUTORY, INCLUDING WITHOUT LIMITATIONS, THE IMPLIED WAR-
RANTIES OF MERCHANTABILITY AND FITNESS.
Upon Buyer’s submission of a claim as provided above and its substantiation, Seller shall, at its
option either (I) repair or replace its product or work at the original f.o.b. point or location of pur-
chase products and/or parts or (II) refund an equitable portion of the purchase price.
Wayne Division, Dresser Industries Inc., P.O. Box 1859, Salisbury, MD 21802-1859, (410) 546-6600
Part No. 920160 Rev. A 2/97 ©1997 Dresser Industries, Inc. 50/2/97
920160 A