Installation/Operation

Wayne Nucleus© Fusion

Site Controller Upgrade
July 2009 Part No. 940002 Rev. 4(B)
 Table of Contents
Title Page
1 PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 HOW TO USE THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5 RETURNING DAMAGED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 INSTALLATION LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

9 REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10 INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

11 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.1 Shutdown the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11.1.1 Sites with Wayne Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
11.1.2 Sites with Gilbarco Dispensers and no Veeder-Root BIR . . . . . . . . . . . . . . . . . . 13
11.1.3 Sites with Gilbarco Dispensers and Veeder-Root BIR . . . . . . . . . . . . . . . . . . . . . 14
11.2 Fusion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11.3 Programming the Nucleus System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
11.4 Programming the Fusion for Gilbarco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11.4.1 Gilbarco Blend Ratio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11.5 Veeder-Root BIR Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.5.1 Gilbarco Site with EDIM Installed in the Veeder Root . . . . . . . . . . . . . . . . . . . . . 21
11.5.2 Wayne Site with EDIM Installed in the Veeder Root . . . . . . . . . . . . . . . . . . . . . . 21
11.5.3 Wayne Site with CDIM Installed in the Veeder Root . . . . . . . . . . . . . . . . . . . . . . 21
11.6 Changing the Fusion Site Controller IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

12 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.0.1 Powering Fusion On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.0.2 Fusion Box Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

13 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.1 Fusion Site Controller Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.2 GRIB Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13.3 GRIB Jumper Configurations for Current Loop Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13.4 GRIB Jumper Configurations for 485 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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July 2009 Part No. 940002 Rev. 4(B)
iv
Part No. 940002 Rev. 4(B) July 2009
1 PRODUCT

Product Dresser Wayne Fusion Forecourt Controller

Application Nucleus Base 19 or better

Production Version Version x.xx

Current Build Version x.xx

Hardware Platform Wayne Proprietary Hardware

2 INTRODUCTION
The Fusion Forecourt Controller is an Ethernet-based device capable of supporting existing peripheral
devices that are currently supported through the SCC card. This manual explains how to install Fusion and
configure it for use with a Nucleus site controller.

3 HOW TO USE THIS DOCUMENT

By following the installation instructions and performing the steps in the sequence presented, you will be
assured of a successful install.

NOTE: This kit may require installation of several wiring and hardware assemblies. Any installation or
modification must comply with the requirements of the National Electrical Code (NFPA 70), the
Automotive and Marine Service Station Code (NFPA 30A) and any other applicable codes

NOTE: You must wear a static wrist strap, part number 916962 or equivalent, securely attached to an
earth ground, when handling any circuit board, electronic component or assembly, or when
reaching into the site controller or dispenser computer enclosure. Do not use power tools.

4 UNPACKING AND INSPECTION

Complete the following steps:

1. Before opening any cartons, count the number of cartons and verify the carton count against the
supplied packing list.
2. Inspect the cartons for damage made during transit.
3. File claim information with the carrier on the bill of lading.
4. Retain cartons suspected of damage for future claim purposes.

NOTE: You must wear an anti-static wrist strap, part number 916962 when removing electronic
components from static packages. Attach the wrist strap securely to an earth grounding point
to prevent possible damage from static electricity.

5. Remove all equipment from the shipping cartons and carefully inspect for visible damage.

NOTE: Any damage should be brought to the attention of the carrier and claims made immediately.
Return all equipment to the respective cartons for protection until actual installation is made.
Save all cartons until it is certain that return shipments are not required.

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July 2009 Part No. 940002 Rev. 4(B)
5 RETURNING DAMAGED COMPONENTS
Parts or components returned to the factory under warranty or for repair are subject to damage if not pack-
aged properly. Complete the following steps to return parts or components to the factory.

1. Place electronic components in an anti-static bag and in the original shipping cartons for return
shipment to the factory.

NOTE: If original shipping cartons are not available use a sturdy cardboard container and suitable
packing materials such as anti-static polyethylene foam or bubble pack, to ensure the
component is firmly packed.

2. Include a Return Parts Tag with the defective component describing the particular problem with
the part.
3. Make sure adequate insurance is provided when returning parts to the factory.

WARNING
If the parts or components arrive at our factory in a damaged condition and it is determined that
the damage is a direct result of inadequate or improper packaging, the damage will not be cov-
ered under the original warranty and the customer or distributor will be held responsible for the
cost of repairs necessary to correct or replace the damaged parts.

6 SAFETY INFORMATION
Read NFPA 30A and NFPA 70 (U.S. Installations)

Before installing the equipment, the installer must read, understand and follow this manual, NFPA 30A,
NFPA 70, and applicable federal, state and local codes and regulations. Failure to do so may adversely
affect the safe use and operation of the equipment.

CSA C22.1 (Canadian Installations)

For installation in Canada the installer must read and understand this manual, CSA C22.1 (Canadian Elec-
trical Code) and applicable federal, provincial and local codes and regulations.

Emergency Power Cutoff

NFPA30A require that an emergency power cutoff be installed. An emergency power cutoff is a single con-
trol that removes AC power from all site fueling equipment and submersible pumps. Make sure the control
is accessible, labeled clearly, and installed away from dispensers. Make sure all station employees know
where the Emergency Power Cutoff is located and how to operate it.

Electrical Circuits

Some of the procedures in this manual involve removal and connection of components during installation
or service. Remove power from the distribution box before executing these procedures.

Low Voltage

Do not be misled by the term "Low Voltage". Voltage potentials as low as 50 volts may cause death under
adverse conditions.

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Part No. 940002 Rev. 4(B) July 2009
High Voltage

High voltage of 110 volts AC is used for operation of this equipment. Death on contact may result if safety
procedures are not followed.

7 INSTALLATION LOCATION
Fusion equipment may be installed in a variety of locations, all the cabinets and required wireways must be
located in a non-hazardous area of an enclosed weather protected building.

Table 1: Mounting Location

Component Preferred Location Notes

Fusion Site Controller Back room; on wall near the - AC Power input required
wiring conduits for pumps - Ethernet input required
and CATs

Table 2: Space Requirements (in inches)

Component Width Height Depth

Fusion Site Controller 16 14 2

Dispenser conduit and Wiring requirements

Conduits used must be ¾ in. and the length of each conduit can be up to 330 feet from Fusion to the dis-
penser. Verify that approved wireways and threaded metallic conduit with tight connections are used, that
Data Link wiring is #18 AWG 600 Volt oil and gasoline resistant as a minimum.

Environmental Requirements

Ensure that all cabinets are located in an area that offers easy access for service, and free air space for
cooling, 6" away from other cabinets.

Care should be taken to ensure that the temperature of the cabinets does not exceed the operational
ranges of 0°C to 40°C (32°F to 104°F)

Preliminary Wiring

The site wiring must be completed before installation of a Fusion Forecourt Controller.

Data Link and CAT Wiring

Two pairs of data link wires must be installed from each dispenser to the location of the Fusion cabinet.
One pair for pump communication and one pair for CAT communication.

8 CONFORMITY WITH STANDARDS

Ensure that all National, State, and local standards and codes are observed in site preparations, wiring,
and installation.

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July 2009 Part No. 940002 Rev. 4(B)
Power Wiring

Confirm that all 120VAC to 240VAC wiring for outdoor equipment (line, neutral, relay select, etc.), is #14
AWG minimum (unless local codes call for 12 gauge), stranded, oil and gasoline resistant.

One conduit from the breaker panel to a dedicated outlet located near the Fusion Site Controller location is
required. The conduit must contain three 14 AWG wires; 110 to 240 VAC, Phase, Neutral and Ground. Do
not use electrical conduit to provide earth ground (earth ground does not exceed 5 ohms) The electrical
wiring for the Fusion dedicated outlet must be run through the Emergency Stop circuit at the site so that all
electrical power is cut to the dedicated outlet for Fusion whenever the Emergency Stop button is pressed.
Do not connect the Fusion power supply cord to any UPS.

The circuit powering the distribution box must not power other devices. This circuit must not share a con-
duit with wiring for devices drawing high amperage (compressor, freezer, etc.) or devices that are sources
of RFI (TV, microwave, intercom, etc.)

Data Wiring

Confirm that all data wiring for outdoor equipment (communication lines) is #18 AWG (minimum) stranded,
oil and gasoline resistant. Pump and CAT data wiring that attaches from the wiring trough to Fusion need
to be double shielded to satisfy NEC code for commercial use. Wayne recommends the use of the follow-
ing cable or equivelant for use as the pump and CAT communication wire for running between the wiring
trough and the Fusion box.

Product SKU: C2404.41.10

Product Description: Communication & Control Cable, Multi-Conductor, Unshielded, UL 2464, NEC Type CM (UL) c(UL), CSA
CMG, No. of Conductors: 4, Gauge Size (AWG): 18, Conductor/Strands: 16/30, Jacket: Gray PVC,
Temperature Range: -20°C to +80°C - Gray - 1000 Ft. Reel
Product Category: Electronics - Communication & Control Cable, Multi-Conductor - Unshielded-18 AWG & 20 AWG - Gray

Product Construction:
Conductor: 20 or 18 AWG fully-annealed, stranded tinned copper per ASTM B-33

Insulation: Color Code: See charts below

Premium grade color coded PVC per UL 1007

Jacket: PVC, gray

Temperature Range: -20ºC to +80ºC

Product Specification:

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Part No. 940002 Rev. 4(B) July 2009
 Product Specification:
No. of Conductors: 4

Conductor Size (AWG): 18

Conductor/Strands: 16/30

Jacket Color: Gray

Nominal Insulation Thickness 0.016

(in):

Nominal Insulation Thickness 0.41

(mm):

Nominal Jacket Thickness (in): 0.032

Nominal Jacket Thickness (mm): 0.81

Nominal Outside Diameter (in): 0.258

Nominal Outside Diameter 6.55

(mm):

Color Code: 1

Nominal C-C Capacitance 28.0

(pF/ft):

Standard Packaging: 1000' Non-returnable Wood Reels

Standard Package Quantity: 1

UPC #: 079407700875

NOTE: Existing wiring that runs from the wiring trough out to the dispensers do not need to be
modified since those wires are protected within the wiring trough or conduit.

Codes

Confirm that all equipment is installed in accordance with the National Electrical Code (NFPA 70), the auto-
motive and Marine Service Station Code (NFPA 30A), and any other applicable State and local codes.

9 REQUIRED TOOLS
Refer to Table 3 for a list of tools required to install Fusion.

Table 3: Required Tools

Quantity Description

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July 2009 Part No. 940002 Rev. 4(B)
 Table 3: Required Tools

1 Small Channel Lock pliers

1 Phillips Screwdriver Set (standard sizes)

1 Slotted Screwdriver Set (standard sizes)

1 Wire Cutters

1 Anti-static Wrist Strap

1 Needle Nose Pliers

1 Wire Strippers

16 to 32 Wire Nuts

1 Volt Meter

1 Diagonal Cutters

1 Standard Drill Bit Set

1 Drill

1 PC Feature Card Slot Blank

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Part No. 940002 Rev. 4(B) July 2009
10 INSTALLATION OVERVIEW

Figure 1 Backroom Installation

11 INSTALLATION PROCEDURE
When possible, mount the Fusion in the same location as the Data Distribution Cabinet for Wayne sites or
the Gilbarco Distribution box for Gilbarco sites. The previous diagram shows a typical placement of the
Fusion Unit.

NOTE: If mounting the Fusion to a concrete wall, you will need concrete bits and appropriate mounting
hardware.

NOTE: The Fusion mounting location may be require different placement than shown. Whenever
handling boards and components that are susceptible to damage from static electrical
discharge, BE SURE to wear an anti-static wrist strap.

IMPORTANT: The Fusion battery must be fully charged prior to site start-up otherwise Fusion will not boot.
Charge the battery prior to going to the site to avoid waiting on-site for the battery to charge. If
the battery is not fully charged, the system will beep three times every five seconds until the
battery charge is complete. Charge time is 4 hours for a full charge on an exhausted battery but
generally should only require a 2 hour charge.

11.1 Shutdown the Site

____ 1. Stop all pumps one at a time, allowing current customers to complete their transactions.
____ 2. Shutdown the site and tape off the pumps and run EOD.

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July 2009 Part No. 940002 Rev. 4(B)
____ 3. Go to Programming > System > Site. You will see the following screen.

Enable Fusion

IP Address

Port

Figure 2 Nucleus Programming Screen - Site

____ 4. In the Forecourt Hardware section, Enable Fusion and program the IP Address and Port.
____ 5. Click OK to save.
____ 6. Exit the Programming screen.
____ 7. Log off and shutdown all IPTs then log off and shutdown the Server.
____ 8. Disconnect the 883635-xxx cable from the SCC card on the back of the server.

11.1.1 Sites with Wayne Dispensers

Perform the following steps if you are installing at a site with Wayne dispensers.
____ 1. Disconnect other end of the 883635-xxx cable from Primary Distribution box, then remove the
cable.
____ 2. Open the server and remove the SCC board.
____ 3. Install a feature card blank and re-install the server cover.
____ 4. Run a CAT5 Ethernet cable from the Nucleus network switch to the data distribution box
location.
____ 5. Disconnect and remove the 860514-xxx cable that runs from the Data Distribution box to the
Primary Distribution box.
____ 6. Remove the Primary Distribution box from its mounting location.
____ 7. Open the Data Distribution box, remove the inside panel and verify the labeling of the pump and
CAT data wires.
____ 8. Disconnect pump and CAT wires from DD box.
____ 9. Disconnect pump and CAT wire conduit from DD box and remove the box.
____ 10. Extend discrete CAT and pump wire pairs from the wiring trough to the Data Distribution box
location for each dispenser if needed.

NOTE: CAT data wires may have been bundled together in parallel within the wiring trough. Un-bundle
the wire pairs and splice extensions if needed so that each discrete CAT wire pair reaches the

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Part No. 940002 Rev. 4(B) July 2009
 location of the Fusion box. Use double shielded wire specified in Section 8 for all exposed
wiring from the wiring trough to the Fusion box.

11.1.2 Sites with Gilbarco Dispensers and no Veeder-Root BIR

Perform the following steps if you are installing at a site with Gilbarco dispensers and no Veeder-
Root BIR.
____ 1. Disconnect other end of the 883635-xxx cable from Gilbarco Competitive Primary Distribution
box, then remove the cable.
____ 2. Disconnect and remove cable PN 886843-xxx and PN 886229-xxx.
____ 3. Remove the Wayne Competitive Primary Distribution Box.
____ 4. Open the case of the Gilbarco Distribution Box and label the pump and CRIND wire pairs that
are connected to P106 and P107 of the Pump and CRIND boards so that each pump and
CRIND has a set of discrete wire pairs identified. See Figure 3.
____ 5. Disconnect the pump and CRIND wire pairs from P106 and P107 of the pump board and from
the CRIND board.
____ 6. Extend discrete pump and CRIND wire pairs from the wiring trough to the Fusion Site Controller
mounting location for each dispenser. Splice additional wire to the wire pairs if needed.

NOTE: Splice extensions if needed so that each discrete CRIND wire pair reaches the location of the
Fusion box. Use double insulated wire specified in Section 8 for all exposed wiring from the
wiring trough to the Fusion box.

____ 7. Disconnect the transformer power supply from the Gilbarco Distribution Box and remove the
box from its mounting location.
____ 8. Open the server and remove the SCC board.
____ 9. Install a feature card blank and re-install the server cover.
____ 10. Run a CAT5 Ethernet cable from the Nucleus network switch to the Fusion Site Controller
location.

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July 2009 Part No. 940002 Rev. 4(B)
 Figure 3 Gilbarco Distribution Box

11.1.3 Sites with Gilbarco Dispensers and Veeder-Root BIR

Perform the following steps if you are installing at a site with Gilbarco dispensers and a Veeder-Root
BIR is installed.
____ 1. Disconnect other end of the 883635-xxx cable from Gilbarco Competitive Primary Distribution
box, then remove the cable.
____ 2. Disconnect and remove cable PN 886843-xxx. Leave the cable PN 886229-xxx connected up to
the UDB but disconnect the other end from the Competitive Primary Distribution Cabinet
____ 3. Remove the Wayne Competitive Primary Distribution Cabinet.
____ 4. Open the case of the Gilbarco Distribution Box and label the CRIND wire pairs that are
connected to P106 and P107 of the CRIND board so that each CRIND has a set of discrete wire
pairs identified. See Figure 3.
____ 5. Disconnect the CRIND wire pairs from P106 and P107 of the CRIND board.
____ 6. Extend discrete CRIND wire pairs from the wiring trough to the Fusion Site Controller mounting
location for each dispenser. Splice additional wire to the wire pairs if needed.

NOTE: Splice extensions if needed so that each discrete CRIND wire pair reaches the location of the
Fusion box. Use double insulated wire specified in Section 8 for all exposed wiring from the
wiring trough to the Fusion box.

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Part No. 940002 Rev. 4(B) July 2009
____ 7. Using the Wayne provided “Current Loop Dispenser Y cable”, plug one connector into the cable
from the Gilbarco CAB. Plug the other connector into the pump current loop DB9 on the
Gilbarco Distribution box.The remaining two current loop wires from the “Y” connector get
attached to a GRIB plug at pin 1(+) and pin 4(-). After the Fusion is mounted the plug will get
pluggged into Electronic Interface Board A - Channel 1. See Figure 4 and Figure 23.
____ 8. Open the server and remove the SCC board.
____ 9. Install a feature card blank and re-install the server cover.
____ 10. Run a CAT5 Ethernet cable from the Nucleus network switch to the Fusion Site Controller
location.

Wayne provided
Current Loop Dispenser Y cable

Figure 4 Fusion Installation with Gilbarco and BIR

11.2 Fusion Installation

____ 1. Select a Fusion Site Controller mounting location on the wall near where the Wayne Data
Distribution box was located or where the Gilbarco Distribution box was located. The Fusion
Site Controller mounting bracket should be mounted on the wall first, then the Fusion Site
Controller slides onto the mounting tabs or slots of the bracket. Orient the bracket/box so that

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July 2009 Part No. 940002 Rev. 4(B)
 the data wire connectors are located facing down. Fusion should be mounted in such a way that
there is visual access to the XMIT and RCV LEDs which are next to the GRIB connectors. The
opposite end of the box has the Status display LEDs and should also be visible.

Fusion mounting
bracket Bracket
mount
holes

Mounting
slots

Figure 5 Fusion Mounting Bracket

____ 2. After selecting a mounting location, attach the bracket to the wall by using two screws in the top
two screw holes first.
____ 3. For Wayne dispensers, route the pump data wires (2 pairs per connector) up to the pump GRIB
plugs beginning with Dispenser #1. Pump data wires can be connected as 4 fueling points per
plug. See Figure 24 and Figure 25.
____ 4. Route the CAT or CRIND data wires up to the CAT GRIB plugs beginning with Dispenser #1.
CAT data wires can be connected as 4 single CAT boards per plug or 2 dual CAT boards per
plug. See Figure 26 and Figure 27.

NOTE: The GRIB connectors for the Pumps (Current Loop) are located on the right-hand row of
connectors while the GRIB connectors for the Wayne CATs (RS485/422) are located on the left-
hand row of connectors. See Figure 20. If installing Gilbarco pumps then both the pumps and
CRINDS will use current loop. The GRIB boards will have different colors at the connector to
distinguish between the current loop and 485 versions.

____ 5. For Wayne dispensers, insert the GRIB plugs into the appropriate GRIB sockets on the rear
panel of the Fusion Site Controller beginning with the plug for Pump #1, #2, #3 and #4. See
Figure 23. Insert this plug into the Electronic Interface Board (EIB) A, Channel 1 socket. Insert
the remaining plugs into the appropriate sockets at Electronic Interface Board (EIB) A Channel 2
and so on for the remaining pumps.
____ 6. Insert the GRIB plugs into the appropriate GRIB sockets on the rear panel of the Fusion Site
Controller beginning with the plug for CAT #1, #2, #3 and #4. See Figure 21. Insert this plug into
the Electronic Interface Board (EIB) A, Channel 3 socket. Insert the remaining plugs into the
appropriate sockets at Electronic Interface Board (EIB) A Channel 4 and so on for the remaining
CATs.

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Part No. 940002 Rev. 4(B) July 2009
NOTE: Make a note of where all of the pumps and CATs are connected.

____ 7. Connect the CAT 5 ethernet cable that was run in step 4 to the Ethernet port on the Fusion Site
Controller. See Figure 20. Connect the other end of the cable to any available port on the
Nucleus Ethernet switch.
____ 8. Complete the wiring, secure the conduit, etc.
____ 9. Plug Fusion power brick into the dedicated120VAC power outlet which has been wired into the
Emergency Stop button, then plug the other end into the transformer input of the Fusion Site
Controller.

11.3 Programming the Nucleus System

If you are installing the Fusion Site Controller in an existing site where an SCC board was installed
in the Nucleus server then additional programming is needed to enable the Fusion Site Controller.

____ 1. Power up the Nucleus server and wait until you are at the logon screen.
____ 2. Log onto Nucleus with a level 4 access or higher.
____ 3. Log onto Nucleus with a Level 4 or higher.
____ 4. Go to Programming > System > Pump > Each. Select Pump # 1 and press the Modify button.
Press the Comm button to open the communications window. See below.

Figure 6 Pump Communications Window

____ 5. Program Pump # 1 according to which EIB and Channel that Pump # 1 was plugged into in
Section 11.2. Continue pump programming with the remaining pumps.
____ 6. Go to Programming > System > CAT > Each. Select CAT # 1 and press the Modify button.
Press the Communications button to open the communications window. See below.

Figure 7 CAT Communications Window

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July 2009 Part No. 940002 Rev. 4(B)
____ 7. Program CAT # 1 according to which EIB and Channel that CAT # 1 was plugged into in Section
11.2. Continue CAT programming with the remaining CATs.
____ 8. Shutdown and restart Nucleus when all the pumps and CATs have been programmed.

11.4 Programming the Fusion for Gilbarco

Fusion Programming should not be necessary if you are installing at a site with Wayne pumps since
the Fusion Site Controller comes with Wayne pumps configured by default. If you are installing at a
site with Gilbarco pumps then complete the following steps.
To access the Fusion Site Controller programming you can either log on using a laptop connected to
the Nucleus switch or you can get a OneShot password and log onto Nucleus as Level 6.
____ 1. Go to Programming (if using the Nucleus), and then click the Windows Start button > All
Programs > Internet Explorer.
____ 2. In the Explorer Address bar, type in 192.168.1.20 and press <enter>. The following Screen will
then be displayed.

Figure 8 Fusion Login Screen

____ 3. Enter the Admin in the Login field and leave the Password field blank. Press <enter> to
continue. The following window will be displayed.

Click Configuration
then select Generic

Figure 9 Fusion Programming Screen 1

____ 4. Click Configuration, and then select Generic. The following window will be displayed.

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Part No. 940002 Rev. 4(B) July 2009
 Select Scc Emulator from the
module pull-down

Figure 10 Fusion Programming Screen 2

____ 5. Select SCC Emulator from the module pull-down, then click Search. Scroll the display down to
show the List of Generic Parameters.The following window will be displayed.

Emulate Pumps

Pumps
Brand

Figure 11 Fusion Programming Screen 3

____ 6. Click Pumps Brand to open the following window where you select Wayne or Gilbarco from the
Param Value pull-down. See the following window,

Submit button

Param Value pull-down

Figure 12 Fusion Programming Screen 4

____ 7. Once the pump brand selection has been made, click the Submit button. The new configuration
will then be saved. See the following window.

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July 2009 Part No. 940002 Rev. 4(B)
____ 8. If you are installing a Gilbarco site, click on the Emulate Pumps option and set to Yes. See
Figure 11.

Send new Configuration

to Fusion

Figure 13 Fusion Programming Screen 5

____ 9. Click Send new Configuration to Fusion to download the new configuration to the Fusion Site
Controller. The following windows will then be displayed.

then

Figure 14 Fusion Programming Screen 6

____ 10. Click Close Windows to complete the process.
____ 11. Close the Internet Explorer window by clicking the X in the upper right corner.

11.4.1 Gilbarco Blend Ratio Programming

Gilbarco pumps use a different way of designating blend ratios than Wayne pumps. Gilbarco defines
the blend ratios as a percentage of low feedstock while Wayne defines blend ratios as a percentage
of high feedstock.
Another programming difference is how Gilbarco blenders handle pump operations when the POS
and the dispenser have different blend ratios set. Gilbarco blenders will communicate with the POS
and dispense fuel even if the blend ratios at the dispenser and POS do not match. In this case the
blend ratios programmed at the pump are valid.
Fusion programming contains a flag that controls whether Fusion checks for matching blend ratios.
The default is set to NO so no blend ratio checking will take place. If the site is experiencing
communications problems with the Gilbarco blenders and blend ratio programming is suspected, go
to the Fusion programming page located under Configuration > Devices > Pump. Access each
pump and verify that the value is set to NO.

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Part No. 940002 Rev. 4(B) July 2009
 Check Blend Ratios

Figure 15 Check Blend Ratio Flag

NOTE: This programming option only applies to Gilbarco blender programming. Wayne blenders are
not affected by this programming option.

11.5 Veeder-Root BIR Installations

If the site has a Veeder-Root Business Inventory Reconciliation (BIR) system installed then the
installation of Fusion is different depending on the hardware at the site.

11.5.1 Gilbarco Site with EDIM Installed in the Veeder Root

Use the existing UDB with the new Wayne EDIM cable.

11.5.2 Wayne Site with EDIM Installed in the Veeder Root

This configuration is currently under development. Eventually will support more than 12 fueling
points using EDIM.

11.5.3 Wayne Site with CDIM Installed in the Veeder Root

If using a CDIM in the current site you are limited to 6 dispensers. A 2nd CAB is needed if you have
more than 4 dispensers.
• CDIM has 3 connections for CABs and we can put 2 dispensers on each CAB connection at the CDIM.
• WDB has 2 channels w/ 4 disp per channel
• Each WDB channel can go via CAB to one CDIM connection
• After the Wayne EDIM software is developed, If more than 12 fueling points it will be less expensive
and less complex for site to simply buy an EDIM and cable than to purchase another CDIM

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July 2009 Part No. 940002 Rev. 4(B)
 Figure 16 CDIM Configuration with Fusion

11.6 Changing the Fusion Site Controller IP Address

The Fusion is pre-configured with an IP address of 192.168.1.20. If you need to change the IP
address you must use the following procedure.

1. Connect a display and a keyboard to the Fusion Site Controller and cycle power.
2. After the Fusion boots up, log in with the user ID of “ipchange" then use the password
"ipchange". See Figure 17.

Figure 17 Fusion Login and Password Prompt

3. The prompt on the screen will be “ip address:” Using the keyboard, enter the new IP Address
and press <enter>. See Figure 18.

22
Part No. 940002 Rev. 4(B) July 2009
 Figure 18 Fusion IP Address Entry Screen

4. Press <enter> again to confirm.

5. Press <enter> to accept the default Broadcast value.
6. Press <enter> to accept the default Gateway value.
7. Press <enter> to accept the default Name Server value.
8. Press <enter> to accept the default Netmask value.
9. Press <y> then <enter> to reboot.

NOTE:

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July 2009 Part No. 940002 Rev. 4(B)
24
Part No. 940002 Rev. 4(B) July 2009
12 TROUBLESHOOTING
After Fusion has been mounted and the system wiring has been completed, all of the pumps and CATs
should be online as shown in the Nucleus Sales screen. If pumps or CATs remain offline then double-
check for the correct polarity of the pump current loop. The CAT communication wiring should also be dou-
ble checked.

12.0.1 Powering Fusion On and Off

Note that after pressing the Fusion power button in order to power down, the Fusion power down
sequence actually can take up to a minute to complete. This is due to the internal battery backup of
Fusion which is shutting down in a controlled manner so that no file corruption occurs.

25
July 2009 Part No. 940002 Rev. 4(B)
 12.0.2 Fusion Box Components

CUPS Board Atom Board To GRIB 5-9 To GRIB 1-4

(ribbon cable pin 1 - 4) (ribbon cable pin 5 - 8)

Figure 19 Fusion Box Components

13 APPENDIX

13.1 Fusion Site Controller Rear Panel

The following diagrams show the Fusion Site Controller connections.

26
Part No. 940002 Rev. 4(B) July 2009
 Future EDIM
Connection

Serial
Power USB GRIB GRIB
Printer,
button ports RS485/422 Current Loop
HyperPIB
or Debug Board (CATs) Board (Pumps)
Transformer Ethernet DSM or
input port GSM only

Figure 20 Fusion Rear Panel (Wayne Dispenser Configuration)

13.2 GRIB Connectors

NOTE: Each GRIB Connector can connect with two dispensers (4 CATs)

Electronic Interface Electronic Interface

Board A Board B

Channel 3 Channel 4 Channel 3 Channel 4

XMIT LED

RCV LED

Pin 1 CATs CATs CATs CATs

Pin 4
1&2 (+) 1&2 (-) 3&4 (+) 3&4 (-)

Figure 21 GRIB Connectors - Nucleus CAT Configuration

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July 2009 Part No. 940002 Rev. 4(B)
NOTE: Each GRIB Connector can connect with two dispensers (4 CRINDS)

Electronic Interface Electronic Interface

Board A Board B

Channel 3 Channel 4 Channel 3 Channel 4

XMIT LED

RCV LED

Pin 1 CATs CATs CATs CATs

Pin 4
1&2 (+) 1&2 (-) 3&4 (+) 3&4 (-)

Figure 22 GRIB Connectors - Nucleus CRIND Configuration

28
Part No. 940002 Rev. 4(B) July 2009
NOTE: Each GRIB Connector can connect with two dispensers (4 fueling points)

Electronic Interface Electronic Interface

Board A Board B

Channel 1 Channel 2 Channel 1 Channel 2

XMIT LED

RCV LED

Pin 1 Pump 1&2 Pump 1&2

Pin 4
(+) (-)

OR

XMIT LED

RCV LED

Pin 1 Pump Pump Pump Pump Pin 4

1&2(+) 1&2(-) 3&4(+) 3&4(-)

Figure 23 GRIB Connectors - Nucleus Pump Configuration

29
July 2009 Part No. 940002 Rev. 4(B)
 Pin 4

-
Pump #1
+ Pin 1

Figure 24 GRIB Plug - Single Pump (Dispenser) Per Plug Configuration

- Pin 4
Pump #2
+

Pin 1
-
Pump #1
+

Figure 25 GRIB Plug - Two Pumps (Dispensers) Per Plug Configuration

Pin 4

-
Pin 1
CAT 1&2
+

Figure 26 GRIB Plug - One CAT Cable Per Plug Configuration

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Part No. 940002 Rev. 4(B) July 2009
 Pin 4
-
CAT or CRIND 3&4
+

Pin 1
-
CAT or CRIND 1&2
+

Figure 27 GRIB Plug - Two CAT or CRIND Cables Per Plug Configuration

Pin 4

-
CRIND #1
+ Pin 1

Figure 28 GRIB Plug - One CRIND Cable Per Plug Configuration

13.3 GRIB Jumper Configurations for Current Loop Board

Table 4: GRIB Jumper Configurations for Current Loop GRIB PCB Assy

CH1 CH2 CH3 CH4

Dispenser JP1 JP2 JP3 JP4
Wayne 2&3 2&3 2&3 2&3
Gilbarco 1&2 1&2 1&2 1&2

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July 2009 Part No. 940002 Rev. 4(B)
13.4 GRIB Jumper Configurations for 485 Board
Table 5: Channel 1

JP1 JP2 JP3 JP4 JP6 JP13 JP17 JP18 JP19

RS485 2&3 2&3 2&3 2&3 2&3 2&3 Off Off Off
RS422 1&2 1&2 1&2 1&2 1&2 1&2 Off Off Off
RS116 Off Off Off Off Off Off On On On

Channel 1 RS485/RS422 Echo Off (recommended)

ECHO JP5
On 2&3
Off 1&2

Table 6: Channel 2

JP7 JP8 JP9 JP10 JP12 JP14 JP20 JP21 JP22

RS485 2&3 2&3 2&3 2&3 2&3 2&3 Off Off Off
RS422 1&2 1&2 1&2 1&2 1&2 1&2 Off Off Off
RS116 Off Off Off Off Off Off On On On

Channel 2 RS485/RS422 Echo Off (recommended)

ECHO JP11
On 2&3
Off 1&2

Channel 3 RS485 Only Echo Off (recommended)

ECHO JP15
On 2&3
Off 1&2

Channel 4 RS485 Only Echo Off (recommended)

ECHO JP16
On 2&3
Off 1&2

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Part No. 940002 Rev. 4(B) July 2009
 Power Source

JP23
Power from USB 1&2
Power from Ext. 2&3
Source

33
July 2009 Part No. 940002 Rev. 4(B)
 Figure 29 GFC (Fusion) Wiring Diagram

34
Part No. 940002 Rev. 4(B) July 2009
 INSTALLATION/OPERATION

Wayne Fusion

Site Controller

Written by Tom Sigmon

This manual was produced on a personal computer using Adobe® FrameMaker® and Photoshop®
Page design uses Times New Roman and Arial Fonts
Manuals were electronically produced on a IKON Publishing System

Copyright © 2009 Dresser, Inc.

All rights reserved.
Printed in the United States of America.

Wayne, Nucleus and InSite are registered trademarks and iX is a trademark of Dresser, Inc.

IBM is a registered trademark of International Business Machines Corporation.

Adobe® FrameMaker® and Photoshop® are trademarks of Adobe Systems, Inc.

All other brand names and trademarks mentioned are the properties of their respective holders.

This manual and the software described within are furnished under license and may be used or copied only in accor-
dance 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, Inc. 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, Inc. who assumes no responsibility or liability for inaccuracies
that may appear in this publication.

Dresser Wayne, Dresser, Inc., is located at 3814 Jarrett Way, Austin TX 78728.
Wayne’s general telephone number is (512)-388-8311.
 NOTE: “This equipment has been tested and found to comply with the
limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio communi-
cations. Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be required to cor-
rect the interference at his own expense.”

Dresser Wayne, Dresser, Inc. 3814 Jarrett Way, Austin, TX 78728 (512) 388-8311
Part No. 940002 Rev. 4(B) ©2009 Dresser, Inc. 07/09