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Wayne Dresser Vista 1 Series Service Manual

Blending and non-blending remote dispensers
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  • Page 1 1/Vista Series Blending and Non-Blending Remote Dispensers...
  • Page 2 Always use the approved method for lifting the dispenser. Never lift by the nozzle, sheet metal, valance, etc. HOW TO CONTACT WAYNE Technical assistance is available at Wayne Technical Support (1-800-926-3737). INDICATORS AND NOTATIONS Danger indicates a hazard or unsafe practice which, if not avoided, will DANGER result in severe injury or possibly death.
  • Page 3 1/Vista Series Blending and Non-Blending Remote Dispensers Service Manual February 1997 Part No. 920160 Rev A...
  • Page 4 Part No. 920160 Rev A February 1997...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Title Page 1. INTRODUCTION ..............1 2.
  • Page 6 TABLE OF CONTENTS, continued Title Page 7. COMPONENT REPLACEMENT........... . 53 7.1.
  • Page 7 LIST OF FIGURES, continued Title Page Figure 3-7. Non-Blending Photocoupler Internal Wiring ........25 Figure 3-8.
  • Page 8 LIST OF FIGURES, continued Title Page Figure B-1. DEM Removal ............102 Figure B-2.
  • Page 9 LIST OF TABLES, continued Title Page Table 6-15. Fault Code 05 or 20............47 Table 6-16.
  • Page 10 viii Part No. 920160 Rev. A February 1997...

  • Page 11: Introduction

    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.
  • Page 12 Part No. 920160 Rev A February 1997...

  • Page 13: General Operation

    2. GENERAL OPERATION 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) 2.1.1. Lift-to-Start Models • When the nozzle is removed from the nozzle boot and the lever is lifted, the constant +5 VDC that the computer supplies to the nozzle switch goes to ground.

  • Page 14: Sequence Of The Dispensing Cycle (Blenders Only)

    2.1.2. Push-to-Start Models, continued • The slow valve coil is energized two to six seconds, depending on option program- ming settings, after the submersible pump relay is energized. • After a small amount of fuel has been dispensed, the fast valve coil is switched on and both coils are now energized together.

  • Page 15: Unit Prices/Authorization

    2.3. UNIT PRICES/AUTHORIZATION 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.

  • Page 16: Figure 2-1. Function Switches And Display Locations - Non Blender Shown

    2.3. .UNIT PRICES/AUTHORIZATION, continued 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.

  • Page 17: Table 2-1. Unit Price Switch Closure Definitions (Blenders)

    2.5.1. Manually Setting Unit Prices, continued TABLE 2-1. UNIT PRICE SWITCH CLOSURE DEFINITIONS (BLENDERS) The number of closures and unit price positions, and the order in which they appear may vary with each blender model. Position Select Position Selected Position Selected Switch Closure (Single Price Posting Dispenser) (Cash/Credit Type Dispensers)

  • Page 18: Authorize Switch

    2.3.2. Authorize Switch The Authorize switch permits dispenser operation with or without console control. In the self service position (toggle the switch down), the dispenser must be authorized by the control system before each use. In the full service position (toggle the switch up as shown in Figure 2-1.), the dispenser may be operated repeatedly without authorization from a control system.

  • Page 19: The Blending Process

    2.4. THE BLENDING PROCESS 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.”...

  • Page 20: Figure 2-3. Proportional Blending

    2.4. THE BLENDING PROCESS, continued Nozzle Hose Outlet Where Mixing Actually Takes Place Computer and Solenoid Drive Lo Product Hi Product Proportional Flow Proportional Flow Control Valve Control Valve Hi Product Meter Lo Product Meter Pulser Pulser Hi Product Inlet Lo Product Inlet "Feedstock"...

  • Page 21: Figure 2-4. Fixed Ratio Blending

    2.4. THE BLENDING PROCESS, continued Where mixing actually takes place for blended product. Lo Product Blend Product Hi Product Hoses and Nozzles Hose Outlets Outlet Valves Lo Product Hi Product Proportional Flow Computer and Proportional Flow Control Valve Solenoid Control Valve Drive Hi Product Meter Lo Product Meter...
  • Page 22 Part No. 920160 Rev A February 1997...

  • Page 23: Electronic Parts

    3. ELECTRONIC PARTS There are five types of electronic components in the head of a Wayne dispenser. • Display Board • Lighted Cash/Credit Interface Board • Solenoid Drive Board • Computer Assembly • Intrinsic Safe Barrier Assembly The hydraulics cabinet contains one or more of the following electronic or electrical components.

  • Page 24: Solenoid Drive Board

    3.2. LIGHTED CASH/CREDIT INTERFACE BOARD, continued 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.

  • Page 25: Computer Assembly

    3.4. COMPUTER ASSEMBLY 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. •...

  • Page 26: Figure 3-1. Computer And Solenoid Drive Board (Non-Blender)

    3.4. COMPUTER ASSEMBLY , continued MOUNTING SCREWS (4) COMPUTER BOARD SOLENOID DRIVE BOARD COMPUTER CONNECTOR DESCRIPTIONS SOLENOID DRIVE BOARD CONNECTOR DESCRIPTIONS J1 -- Data Loop Both Sides J1 --Relay Select Side 1 (There is also a J1 Located on the J3 -- AC Input computer;...

  • Page 27: Figure 3-2. Computer And Solenoid Drive Board (Blender)

    3.4. COMPUTER ASSEMBLY, continued MOUNTING SCREWS (4) COMPUTER BOARD SOLENOID DRIVE BOARD COMPUTER CONNECTOR DESCRIPTIONS SOLENOID DRIVE BOARD CONNECTOR DESCRIPTIONS J1 -- Data Loop Both Sides J1 --Relay Select (There is also a J1 Located on the J3 -- AC Input computer;...

  • Page 28: Fault Codes

    3.4.1. Fault Codes The fault codes generated by the Duplex II Computer are assigned a “status.” There are four types or Status as follows: Error codes, Hydraulic codes, Service codes and Disable codes. The definitions of each of these types are as follows: •...

  • Page 29: Figure 3-3. Fault Code Display

    3.5. FAULT REPORTING, continued 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.

  • Page 30: Figure 3-4. Main Sale Display Showing Transaction Counters

    3.5. FAULT REPORTING, continued MAIN SALE DISPLAY 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.

  • Page 31: Table 3-1. Fault Codes, Status, And Description

    Push-to-start jumper shorted but not configured for push-to-start. 1/2/3* Unit has overrun prepay/preset amount. ROM checksum error. 1/2/3* Pulser error or Wayne Vac error. (Set if jitter count exceeds limit) 1/3* Illegal current sensed in valve or relay output circuit. 1/2/3* Time out limit has been exceeded.

  • Page 32: Intrinsic Safe Barrier Assembly

    3.5. FAULT REPORTING, continued NNNNN.S Sale Money PF.20.BB Sale Volume NNNNN: Transaction Counter Side 1 or 2 Product Source (0-7) Fault Source (0-7, “H” or “L”) Fault Code 20 (Jitter pulse logging error) Maximum jitter count allowed 3.6. INTRINSIC SAFE BARRIER ASSEMBLY The Intrinsic Safe Barrier (ISB) assembly is located in the electronic head of the dispenser.

  • Page 33: Figure 3-6. Intrinsic Safe Barrier Assembly

    3.6. INTRINSIC SAFE BARRIER ASSEMBLY, continued 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. February 1997 Part No.

  • Page 34: Pulser Assembly

    3.7. PULSER ASSEMBLY The pulser assembly consists of two parts: • 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.

  • Page 35: Figure 3-7. Non-Blending Photocoupler Internal Wiring

    3.7. PULSER ASSEMBLY, continued 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.

  • Page 36: Proportional Flow Control Valve

    3.8. PROPORTIONAL FLOW CONTROL VALVE (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.

  • Page 37: Mechanical Parts

    4. MECHANICAL PARTS 4.1. NOZZLE BOOT (PROXIMITY “REED” SWITCH STYLE BOOT) 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. 4.1.1.
  • Page 38 Part No. 920160 Rev A February 1997...

  • Page 39: Hydraulic Parts

    5. HYDRAULIC PARTS 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 •...

  • Page 40: Two Stage Solenoid Valve (Non-Blenders Only)

    5.2. TWO STAGE SOLENOID VALVE (NON-BLENDERS ONLY) 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).

  • Page 41: Flow Control Valve "Off" No Flow

    5.2.1. Flow Control Valve “Off” No Flow Flow control valve “Off” or no flow (see Figure 5-1. and Figure 5-4.) occurs when the inlet to the valve is charged, but there is no flow required from the particular valve, as in the instance, where the submersible pump motor is running because another fueling point is being used.

  • Page 42: Figure 5-1. Flow Control Valve "Off" No Flow

    5.2. TWO STAGE SOLENOID VALVE (NON-BLENDERS ONLY), continued OUTLET Indicates High Pressure 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.

  • Page 43: Figure 5-2. Flow Control Valve "On" Slow Flow

    5.2. TWO STAGE SOLENOID VALVE (NON-BLENDERS ONLY), continued OUTLET Indicates High Pressure 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.

  • Page 44: Figure 5-3. Flow Control Valve "On" Full Flow

    5.2. TWO STAGE SOLENOID VALVE (NON-BLENDERS ONLY), continued OUTLET Indicates High Pressure 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.

  • Page 45: Figure 5-4. Flow Control Valve With Cover And Center Chamber Removed

    5.2. TWO STAGE SOLENOID VALVE (NON-BLENDERS ONLY), continued OUTLET OUTLET 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.

  • Page 46: Proportional Flow Control Valve (Blenders Only)

    5.3. PROPORTIONAL FLOW CONTROL VALVE (BLENDERS ONLY) (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.

  • Page 47: Flow Control Valve "Off" No Flow

    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.

  • Page 48: Flow Control Valve "On" Slow Flow

    5.3.2. 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. In this case the coil is energized with current bursts of shorter duration. This allows the pilot to slightly move off its seat, allowing slow flow through the pilot orifice leading to the valve outlet, but not relieving enough pressure to cause the diaphragm to open.

  • Page 49: Meter Adjustment

    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.

  • Page 50: Figure 5-7. Meter Adjustment

    FIGURE 5-7. METER ADJUSTMENT. Before placing the dispenser in operation, the meter must be checked and adjusted, if required Part No. 920160 Rev A February 1997...

  • Page 51: Troubleshooting Guide

    6. TROUBLESHOOTING GUIDE 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.

  • Page 52: Table 6-1. Sale And Unit Price Displays Are Blank

    TABLE 6-1. SALE AND UNIT PRICE DISPLAYS ARE BLANK. Probable Cause Corrective Action No power to computer. Check control power circuit breaker Check for AC between pins 1 and 2 of J3 connector. If not present check in J-box. If not present in J-box problem is in site wiring.

  • Page 53: Table 6-4. Unit Price Not Correctly Displayed

    TABLE 6-4. UNIT PRICE NOT CORRECTLY DISPLAYED. Probable Cause Corrective Action Loose or defective data cable. Re-seat or replace data cable. Defective computer. Replace computer assembly. TABLE 6-5. UNIT WILL NOT RESPOND TO ANY FUNCTION SWITCHES. Probable Cause Corrective Action Loose or defective wiring to switches.

  • Page 54: Table 6-8. Computer Resets But Submersible Pump Does Not Come On

    TABLE 6-7. COMPUTER WILL NOT RESET. (continued) Probable Cause Corrective Action Defective Cash/Credit Interface board. Check for signals to Cash/Credit Interface board. Replace board as necessary. Refer to the appropriate drawing in APPENDIX B. If blender, Blend ratios may not agree Set blend ratios to agree.

  • Page 55: Fault Code 02

    TABLE 6-10. ELECTRO-MECHANICAL TOTALIZER NOT COUNTING. Probable Cause Corrective Action Defective Electro-Mechanical totalizer Replace. Defective cash/credit interface board. Replace cash/credit interface board. Defective computer. Replace the computer assembly. Defective wiring to totalizer. Replace harness to J7 on the cash/credit interface board. Defective wiring between cash/credit Replace harness between J2 on cash/credit interface board interface board and computer.

  • Page 56: Fault Code 04

    TABLE 6-13. FAULT CODE 03. Probable Cause Corrective Action Unit has run over preset/prepay amount. 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.

  • Page 57: Table 6-15. Fault Code 05 Or 20

    Check LED on Wayne Vac Control board. LED should flash is equipped with Wayne Vac see correc- at power up and go OFF. If blinking see Wayne Vac service tive action, otherwise, proceed with manual part number 920023 for corrective action. If OFF probable cause Pulse Jitter.

  • Page 58: Table 6-16. Fault Code 06

    TABLE 6-16. FAULT CODE 06. Probable Cause Corrective Action Illegal current sensed in valve or relay circuit. Solenoid drive board has Replace solenoid drive board. defective solid state relay. Computer is holding solid Replace computer assembly. state relay on. TABLE 6-17. FAULT CODE 08. Probable Cause Corrective Action Operational error.

  • Page 59: Table 6-19. Fault Code 10 Or 21

    TABLE 6-19. FAULT CODE 10 OR 21. Probable Cause Corrective Action Reverse pulse. Disc tension is not correct. Check for missing wave washer on pulser shaft. Install as nec- essary. Debris holding diaphragm or actuator Repair as necessary. open. Defective diaphragm valve or propor- Install diaphragm repair kit or replace flow control valve.

  • Page 60: Table 6-23. Fault Code 14, 15 Or 16

    TABLE 6-23. FAULT CODE 14, 15 OR 16. Probable Cause Corrective Action Illegal pulse - a pulse was received from a “grade not selected.” Debris holding diaphragm, actuator, or Check/clean all valves. proportional flow control valve open. Defective diaphragm (Non-Blenders Install diaphragm repair kit.

  • Page 61: Table 6-26. Fault Code 51

    TABLE 6-26. FAULT CODE 51. Probable Cause Corrective Action Blend ratio error exceeded programmed Programming Option 52 should be set at 2% and Option 53 limits. should be set at 1.2 gallons. Reset if necessary. Flow restricted on one end grade. Observe the low and high meters while dispensing to deter- mine which grade is restricted.
  • Page 62 Part No. 920160 Rev A February 1997...

  • Page 63: Component Replacement

    7. COMPONENT REPLACEMENT 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.

  • Page 64: Removing The Bezel From Vista Dispensers

    7.1.1. Removing the Bezel From Vista Dispensers In order to access any of the electronic components the bezel must be removed; to remove the bezel perform the following steps: 1. Lower the ad panel holder frame by pulling the holder frame out and down from the top.

  • Page 65: Figure 7-1. Replacing The Solenoid Drive Board (Non-Blender Shown)

    7.1.3. Solenoid Drive Board Replacement, continued 6. Pull the solenoid drive board straight off of the computer. 7. Install the new board using the reverse of the procedure described above. 8. Test the dispenser for proper operation. D i scon nect a ll of t he wi ri ng connect ors on the sol en oi d dr i ve board.

  • Page 66: Computer Assembly Replacement

    7.1.4. Computer Assembly Replacement Note: The computer assembly and displays contain circuitry which is sensitive to static discharge. Keep the replacement computer assembly in the anti-static shipping bag until ready for use. Always place the suspect computer base in the anti-static shipping bag after replacement and return to the original packaging.

  • Page 67: Figure 7-2. Replacing The Duplex Ii Computer

    7.1.4. Computer Assembly Replacement, continued D isconn ect a ll of t he wi ri ng c o n n e c t o rs o n t he Dup lex com put er bo a rd . L o o s e n th e fo u r ( 4 ) s c re w s t hat s e c u re th e c o m p u t e r to th e D E M (th e s e a r e c a p ti v e s c re w s a n d s h o u l d n o t b e re m o v e d fr o m th e...

  • Page 68: Intrinsic Safe Barrier Assembly Replacement

    7.1.4. Computer Assembly Replacement, continued 12. Replace the DEM in its original position and turn the control power ON. 13. Program the dispenser as follows: a. Set the macro and all option programming. b. Set the unit prices (if stand-alone); or c.

  • Page 69: Figure 7-3. Intrinsic Safe Barrier Assembly

    7.1.5. Intrinsic Safe Barrier Assembly Replacement, continued FIGURE 7-3. INTRINSIC SAFE BARRIER ASSEMBLY. The ISB ground connection shown must be made directly to the dispenser chassis. Intrinsic Safe Barrier Assembly 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.

  • Page 70: Display Board Replacement

    7.1.6. Display Board Replacement 1. Remove the bezel from the dispenser. 2. Remove the dial face from the display by loosening the four screws in the corners of the dial face and then slipping it up and off of the display (see Figure 7-5.).

  • Page 71: Cash/Credit Interface Board Replacement

    7.1.7. Cash/Credit Interface Board Replacement 1. In order to access the cash/credit interface board remove the bezel from the dispenser and disengage the two quarter turn screws located above the display (see Figure 7-6.). This will allow the DEM to tilt out toward you allowing access to all internal electronic components in the dispenser.

  • Page 72: Photocoupler/Pulser Disc Replacement

    7.1.8. Photocoupler/Pulser Disc Replacement Note: Pulser discs are fragile. Care should be taken when removing the pulser components. 1. Remove the cover from the pulser assembly by inserting a small flat blade screwdriver into the narrow side of the cover where it connects to the mounting leg of the pulser bracket.

  • Page 73: Figure 7-7. Exploded View Pulser Assembly

    7.1.8. Photocoupler/Pulser Disc Replacement, continued FIGURE 7-7. EXPLODED VIEW PULSER ASSEMBLY. The cover must be properly attached to prevent dust from entering. February 1997 Part No. 920160 Rev A...

  • Page 74: Lift-To-Start Nozzle Boot Component Replacement

    7.1.9. Lift-to-Start Nozzle Boot Component Replacement Note: After replacing nozzle boot components, refer to Section 4. to check for proper operation. To replace the nozzle switch (see Figure 7-8.): 1. Disconnect the nozzle switch connector and, if necessary, cut the wire tie securing the switch wiring to the dispenser.

  • Page 75: Push-To-Start Nozzle Boot Component Replacement

    7.1.10. Push-to-Start Nozzle Boot Component Replacement To replace the nozzle switch (see Figure 7-9.): 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;...

  • Page 76: Figure 7-8. Nozzle Boot Assembly (Lift-To-Start)

    FIGURE 7-8. NOZZLE BOOT ASSEMBLY (LIFT-TO-START).

  • Page 77: Figure 7-9. Nozzle Boot Assembly (Push-To-Start)

    FIGURE 7-9. NOZZLE BOOT ASSEMBLY (PUSH-TO-START).

  • Page 78: Push-To-Start Membrane Switch Assembly Replacement

    7.1.11. Push-to-Start Membrane Switch Assembly Replacement The Push-to-Start, Cash/Credit, Grade Select switches, and associated LEDs are not separately replaceable. 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.

  • Page 79: Electro-Mechanical Totalizer Replacement

    7.1.13. Electro-Mechanical Totalizer Replacement 1. Remove Bezel. 2. Remove the two (2) pin connector from Electro-Mechanical totalizer. 3. Remove the two (2) phillips head screws that secure the Electro-Mechanical totalizer PCB to the bracket and remove the Electro-Mechanical totalizer. 4. Install new Electro-Mechanical totalizer using the two (2) screws previ- ously removed in Step 3.

  • Page 80: Diaphragm Valve Replacement (Non-Blenders Only)

    7.2.2. Diaphragm Valve Replacement (Non-Blenders Only) 1. Remove the three (3) bolts which secure the diaphragm valve to the strainer casting. 2. Remove the three (3) bolts which secure the diaphragm valve to the meter support. 3. Remove the two (2) bolts which secure the diaphragm valve to the rear of the junction box, and pull the diaphragm valve free.

  • Page 81: Meter

    7.2.4. Meter 1. Remove the four (4) bolts which secure the meter to the meter support. 2. Remove the meter. Note the position of the two (2) o-rings and replace with new ones in the proper location. Also, note there is a check and pressure relief valve between the meter and meter support.
  • Page 82 7.2.6. Check and Pressure Relief Valve Replacement, continued 3. Remove the two (2) meter seal o-rings (the larger o-ring on the inlet and the smaller o-ring on the outlet. 4. Remove the check pressure relief valve. 5. Install the new valve and replace the o-rings with new ones. Note: Do not pinch the o-rings against the meter support.

  • Page 83: Appendix A. Troubleshooting Flowcharts

    APPENDIX A. TROUBLESHOOTING FLOWCHARTS February 1997 Part No. 920160 Rev A...
  • Page 84 01 fault code. Push to start switch open or cash/credit switch shorted. Defective switch assy. Check by interchanging membrane switch assy with assy on opposite side of dispenser. Does the Replace membrane switch check switch assembly. good? Check with voltmeter, the lighted cash/credit interface board and the wire harness &...
  • Page 85 02 fault code. Pust to start option disabled but switch detected. Use voltmeter to check the cash/credit interface board & wire harness between board & membrane switch assy. See Appx B -pinout info. Does the harness & cash/credit board check good ? Replace the lighted cash credit interface board.
  • Page 86 03 fault code unit has run over preset amount. Check for 110VAC from solenoid drive board holding valve(s) open. Is 110VAC Replace the (or 24VDC solenoid drive blender only) present board. when it should not be? Check diaphragm (or porportional valve blender only) for leaks or debris holding it open.
  • Page 87 04 fault code. ROM error. Computer found defective ROM chip during self test. Clear erroo. Does the error reoccur? Replace computer. FIGURE A-4. FAULT CODE 04. February 1997 Part No. 920160 Rev A...

  • Page 88: Figure A-5. Fault Code 05 Or 20

    05 or 20 fault code. Normally Pulse jitter, but could be Wayne Vac error. Wayne Vac error. See Is LED on Is dispenser service manual Wayne Vac control equipped with p/n 920023 for board flashing ? Wayne Vac ? Wayne Vac...
  • Page 89 06 fault code. Computer sensed a valve or relay on when it should not Check the solenoid drive board for 110VAC (or 24VDC blender only) output to a valve or relay. Is 110VAC (or 24VDC Replace computer. blender only) present? Replace solenoid drive board.
  • Page 90 08 fault code. Time out limit exceeded. Dispenser was turned on but no product was despensed for more than the programmed time limit. See Option 12 in the Duplex II programming manual. Operational error no corrective action. FIGURE A-7. FAULT CODE 08. Part No.
  • Page 91 Fault Code 09. Five consecutive 08 fault codes. FC-OO100-A The no-pulse time out limit was exceeded on five consecutive sales. Does the dispenser now go into fast flow and display volume ? Is the problem with all Grades ? Operational error. Replace pulser for Replace the Verify that Option 12...

  • Page 92: Figure A-9. Fault Code 10 Or 21

    10 or 21 fault code. Reverse pulse error. Error Ensure that both occurs while submersible pumps Is the dispensing blend are operating at equal problem at proportional bypass pressures. corrected? blender? Correct as necessary. Check for leaking While flow control valves dispensing Is the on the opposite...
  • Page 93 11 fault code. Corrupted option programming. Computer found scrambled data in option programming. Check all option programming and clear error by setting Option 99 to data 03. Does the error reoccur? Replace computer. FIGURE A-10. FAULT CODE 11. February 1997 Part No.
  • Page 94 12 fault code. Corrupted totals data. Computer found the totals data to be corrupted and reset the data to zero. Check that sales are now being totaled correctll. Does the error reoccur? Replace computer. FIGURE A-11. FAULT CODE 12. Part No. 920160 Rev A February 1997...
  • Page 95 13 fault code. Corrupted unit price data. Computer found the unit price data to be corrupted and reset the data to zero. Re-enter unit pricess Does the error reoccur? Replace computer. FIGURE A-12. FAULT CODE 13. February 1997 Part No. 920160 Rev A...
  • Page 96 Fault code 14, illegal forward pulse. Forward pulse received from a grade not selected. Check diaphram valve (or flow control valve blender only) of the unselected product problem indicated by the fault source corrected? in the error code display. Look for leaks or debris holding it open.

  • Page 97: Figure A-14. Fault Code 15 Or 16

    Fault code 15 and 16, illegal reverse pulse. Reverse pulse received from a grade not selected. Check Submersible inlet pressure. If 40 psi or higher the CPR valve may be working properly. It is designed to relieve pressure in this range. Check for leaks at or after the meter of the unselected product indicated...
  • Page 98 Fault Code 30. 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 to occur? Replace computer assembly. FIGURE A-15. FAULT CODE 30. Part No. 920160 Rev A February 1997...
  • Page 99 Fault Code 31. Electro-Mechanical Totalizer overflow. The computer missed incrementing at least one volume unit on the Electro-Mechanical Totalizer. Does the error continue to occur? Replace computer assembly. FIGURE A-16. FAULT CODE 31. February 1997 Part No. 920160 Rev A...
  • Page 100 Fault Code 51. Blend raito error exceeded programmed limits. Option 52 should be set at 2%. Option 53 should be set at 1.2 gallons. Reset if necessary. Check for flow restriction on on END grade by observing LO and HI meters. Check all valves and tubing for obstructions.
  • Page 101 Fault Code 54. (Blenders only) Communications failure. Communications failure between the Duplex II computer and the blender solenoid drive board microprocessor. Cycle power to the dispenser. Does the error continue to occur? Replace the Blender Solenoid Drive Board. Does the error continue to occur? Replace Duplex II...

  • Page 102: Figure A-19. Sale Display And Unit Price Displays Are Blank

    Sale display and unit price displays are blank. Make sure control power circuit breaker is ON and power is present. Check F1 and F3 fuses on the computer. Replace if defective. Is there Is 110VAC 110VAC between present in Correct station wiring. pins 1 and 2 on the junction box J3 connector?

  • Page 103: Figure A-20. Displays Scrambled Or Missing Segments

    Display scrambled, missing segments, or display appears normal but frozen. Replace F3 on the Does computer assembly. Is the Do displays problem exist on After replacing, problem appear normal but both sides of verify that new F3 corrected ? frozen ? dispenser ? is still good.

  • Page 104: Figure A-21. Unit Will Not Respond To An Individual Function Switch

    Sale display is on; unit will not respond to an individual function switch, i.e., the totals switch works but the price jog does not. Use VOM to check switch for continuity when switch is on. Does the Replace the switch check defective switch.

  • Page 105: Figure A-22. Unit Will Not Respond To Any Function Switches

    Sale display on unit will not respond to any function switches. Reseat connector J6 on cash/credit interface board. Is the problem corrected? Replace the Is the cash/credit problem interface board. corrected? Check continuity of wiring between J6 on Is the cash/credit interface problem board and each switch.

  • Page 106: Figure A-23. Displays Are On But Unit Will Not Respond

    Displays are on but the unit will not reset. Defective Push-to-Start Is the switch or wiring. problem Correct as corrected? necessary. Blown fuse on, or defective, Is the cash/credit problem interface board. corrected? Correct as necessary. Defective handle switch or wiring to switch.

  • Page 107: Figure A-24. Dispenser Resets But Will Not Dispense Product

    Dispenser resets but will not dispense product(s). Check F1 fuse on Is the the solenoid drive problem board. Replace if it corrected? is open. C h e c k f o r : 1 1 0 VA C o u t p u t f r o m S o l e n o i d D r i v e B d t o r e l a y ( s ) a n d A C v a l v e ( s ) i f N o n - B l e n d e r o r...

  • Page 108: Figure A-25. Unit Price Showing 0.000

    Unit price showing 0.000. Ensure that the Is this dispensers in Is there the only question are not a control system fueling point with set to the same installed? 0.000 for unit fueling point prices? number. Manually set prices Are all Check the fueling in dispenser.

  • Page 109: Figure A-26. Electro-Mechanical Totalizer Not Counting

    Electro-Mechanical Totalizer not counting. Replace with new Electro-Mechanical Totalizer and dispenser product. Electro-Mechanical Totalizer Counting? Replace lighted Cash/Credit interface board Electro-Mechanical Totalizer Counting? Replace Duplex II Computer Electro-Mechanical Totalizer Counting? Replace Wiring: Electro-Mechanical Totalizer to Cash/Credit board J7. Cash/Credit board J2 to Duplex II Computer J4(J5). FIGURE A-26.
  • Page 110 Part No. 920160 Rev A February 1997...

  • Page 111: Appendix B. Service Information And Connector Pin Outs

    APPENDIX B. SERVICE INFORMATION AND CONNECTOR PIN OUTS February 1997 Part No. 920160 Rev A...

  • Page 112: Dispenser Electronic Module (Dem)

    B.1. DISPENSER ELECTRONIC MODULE (DEM) 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.

  • Page 113: Figure B-2. Dem In The Service Position

    Duplex II Computer Lighted Cash/Credit ISB ASSY. Interface Board Solenoid Drive Board Porportional Valve Power Supply (Blenders Only) 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.

  • Page 114: Figure B-3. Computer And Solenoid Drive Board Connector Pinouts (Non-Blenders)

    SOLENOID DRIVE BOARD Pin 1-Fast Valve Nozzle AA 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 Pin 3- Slow Valve Nozzle X Pin 4- Relay Select Nozzle Y Pin 6- Fast Valve Nozzle Y Pin 7- Pulser Select Nozzle X...

  • Page 115: Figure B-4. Computer And Solenoid Drive Board Connector Pinouts (Proportional Blenders)

    Pin 1-Pump Relay Low Product Pin 2-Pump Relay High Product Pin 3-Pump Relay Single Product* Pin 1-(+24VDC) Pin 4-Open Pin 2-Open Pin 5-Open Pin 3-Ground Pin 6-Open 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...

  • Page 116: Figure B-5. Computer And Solenoid Drive Board Connector Pinouts (Fixed Ratio Blenders)

    Pin 1- Pump Relay Low Product Pin 2- Pump Relay High Product Pin 3- Open Pin 1-(+24VDC) Pin 4- Open Pin 2-Open Pin 5- Open Pin 3-Ground Pin 6- Open 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*...

  • Page 117: Figure B-6. Pinout Connections To Duplex Computer Board - J3

    PIN 2 PIN 3 PIN 5 PIN 2 PIN 4 AC HOT EARTH AC NEUTRAL BLACK WIRE GROUND WHITE WIRE CONNECTION CONNECTION GREEN WIRE FIGURE B-6. PINOUT CONNECTIONS TO DUPLEX COMPUTER BOARD - J3. February 1997 Part No. 920160 Rev A...

  • Page 118: Figure B-7. Pinout Connections To Duplex Computer Board - J9 And J10

    PIN 9 PIN 3 PIN 6 NOZZLE SW. PULSE "B" PULSE "A" POSITION Z PIN 5 PIN 2 PULSE "B" PIN 8 NOZZLE NOZZLE SW. SWITCH SINGLE HOSE POSITION Y COMMON PIN 1 PIN 4 PIN 7 NOZZLE SW. LED "B" LED "A"...

  • Page 119: Figure B-8. Pinout Connections To Blender Solenoid Drive Board - J1

    PIN 1 PIN 3 PIN 2 PUMP RELAY PUMP RELAY PUMP RELAY PRODUCT A PRODUCT B PRODUCT C PIN 6 PIN 5 PIN 4 PIN 8 PIN 7 PIN 9 AC VALVE 2 AC VALVE 1 AC VALVE 3 SIDE 1 SIDE 1 SIDE 1 PIN 10...

  • Page 120: Figure B-9. Pinout Connections To Blender Solenoid Drive Board - J2

    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 PIN 6 PULSER SELECT A SIDE 2 PIN 7 PULSER SELECT B SIDE 2 PIN 8 PULSER SELECT C...

  • Page 121: Figure B-10. Pinout Connections To Blender Solenoid Drive Board - J3

    PIN 4 PIN 7 PIN 1 PROPORTIONAL PROPORTIONAL 24 VOLTS DC VALVE LO VALVE HI SIDE 1 SIDE 2 PIN 8 PIN 2 PIN 5 24 VOLTS DC PROPORTIONAL OPEN VALVE HI SIDE 1 PIN 6 PIN 9 PIN 3 24 VOLTS DC PROPORTIONAL 24 VOLTS DC...

  • Page 122: Figure B-11. Pinout Connections To Blender Solenoid Drive Board - J4

    PIN 1 +24 VDC INPUT FROM POWER SUPPLY PIN 2 PIN 3 GROUND FIGURE B-11. PINOUT CONNECTIONS TO BLENDER SOLENOID DRIVE BOARD - J4. Part No. 920160 Rev A February 1997...

  • Page 123: Figure B-12. Pinout Connections To Non- Blender Solenoid Drive Board - J1 And J2

    PIN 1 PIN 2 PIN 3 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 PIN 5 NOZZLE Y NOZZLE Y NOT USED BLACK- WHITE- ORANGE...

  • Page 124: Figure B-13. Connector And Fuse Locations On Lighted Cash/Credit Interface Board

    TRANSFORMER TRANSFORMER ON PUSH-TO- START MODELS ONLY J1 - CONNECTION TO MAIN SALE DISPLAY. J2 - DATA CONNECTIONS FOR THE DISPLAY CIRCUITRY FROM DUPLEX COMPUTER CONNECTIONS J4/J5. J3 - AC INPUT TO THE LIGHTED CASH/CREDIT INTERFACE BOARD. J4 - 20 VDC OUTPUT TO THE PUSH TO START SWITCH ASSEMBLY LEDS.

  • Page 125: Figure B-14. Pinout Connections To Lighted Cash/Credit Interface Board - J4

    PIN 1 20 VOLTS DC LED 5 20 VOLTS DC LED 4 THE EVEN NUMBERED PINS (2,4,6, ETC.) 20 VOLTS DC ARE THE 20 VDC SUPPLIED TO EACH LIGHTED SWITCH; THE ODD NUMBERED LED 3 PINS (3,5,7 ETC.) ARE THE SWITCHED 0 VDC WHICH CAUSE THE LIGHTS TO BLINK.

  • Page 126: Figure B-16. Pinout Connections To Lighted Cash/Credit Interface Board - J6

    SETUP AUTH SHOWN VIEWING THE CONNECTOR FROM ITS OPEN END AT THE EDGE OF THE PRINTED CIRCUIT BOARD. TOTALS PUSH TO STOP SWITCH DATA COMMON FIGURE B-16. PINOUT CONNECTIONS TO LIGHTED CASH/CREDIT INTERFACE BOARD - J6. EM TOT EM TOT BLENDER RIGHT LEFT...

  • Page 127: Figure B-18. Pinout Connections To Lighted Cash/Credit Interface Board - J10

    FIGURE B-18. PINOUT CONNECTIONS TO LIGHTED CASH/CREDIT INTERFACE BOARD - J10. FIGURE B-19. PINOUT CONNECTIONS TO LIGHTED CASH/CREDIT INTERFACE BOARD - J5. February 1997 Part No. 920160 Rev A...

  • Page 128: Figure B-20. Isb Assembly Connection Pinouts For Mgd

    FIGURE B-20. ISB ASSEMBLY CONNECTION PINOUTS FOR MGD . Refer to Table B-1. Part No. 920160 Rev A February 1997...

  • Page 129: Table B-1. Isb Assembly Connection Pinouts For Mgd

    TABLE B-1. ISB ASSEMBLY CONNECTION PINOUTS FOR MGD Connectors J2, J3 and J4 connect to wiring below the vapor barrier. Pinouts for those connectors are listed below. Connectors J1, J5, J6, J9, J10 and J11 connect to wiring within the pump head. Pinouts for those connectors are listed below. J2 Side 1 J3 Side 2 J4 Side 2...

  • Page 130: Figure B-21. Isb Assembly Connection Pinouts For Blender (Except X1/V590 6 Hose)

    FIGURE B-21. ISB ASSEMBLY CONNECTION PINOUTS FOR BLENDER (EXCEPT X1/V590 6 HOSE). Refer to Table B-2. Part No. 920160 Rev A February 1997...

  • Page 131: Table B-2. Isb Assembly Connection Pinouts For Blender (Except X1/V590 6 Hose)

    TABLE B-2. ISB ASSEMBLY CONNECTION PINOUTS FOR BLENDER (EXCEPT X1/V590 6 HOSE) Connectors J2, J3 and J4 connect to wiring below the vapor barrier. Pinouts for those connectors are listed below. Connectors J1, J5, J6, J9, J10 and J11 connect to wiring within the pump head.

  • Page 132: Figure B-22. Isb Assembly Connection Pinouts For X1/V590 6 Hose

    FIGURE B-22. ISB ASSEMBLY CONNECTION PINOUTS FOR X1/V590 6 HOSE). Refer to Table B-3. Part No. 920160 Rev A February 1997...

  • Page 133: Table B-3. Isb Assembly Connection Pinouts For X1/V590 6 Hose

    TABLE B-3. ISB ASSEMBLY CONNECTION PINOUTS FOR X1/V590 (6 HOSE) Connectors J2, J3 and J4 connect to wiring below the vapor barrier. Pin outs for those connectors are listed below. Connectors J1, J5, J6, J9, J10 and J11 connect to wiring within the pump head. Pin outs for those connectors are listed below. J2 - Side 1 J3 - Side 2 J4 - Side 2...
  • Page 134 Part No. 920160 Rev A February 1997...

  • Page 135: Appendix C. Wiring Diagrams

    APPENDIX C. WIRING DIAGRAMS Model Number Drawing Number 1/V390D, X1/V390D 1-6613-D 1/V395D/U, 1/V590D/U 2-6613-D 1/V580D, 1/V585D 2-6613-D 1/V390D/U 3-6613-D 1/V387D 4-6613-D 1/V389D, 1/V399D 5-6613-D X1/V590D 6-6613-D 1/V390D/R 7-6613-D 1/V395D/RU, 1/V590D/RU 8-6613-D 1/V580D/R, 1/V585D/R 8-6613-D 1/V390D/RU 9-6613-D 1/V387D/R 10-6613-D 1/V389D/R, 1/V399D/R 13-6613-D February 1997 Part No.
  • Page 147 Service Manual 1/Vista Written by S. G. Martin. Formatted by S. N. Hart. Review and technical assistance by Clyde W. Koenig and R. G. Bisker. This manual was produced using Adobe® FrameMaker® on a Power Macintosh® 8100/80. Page design uses Times 12 and Helvetica 10 Fonts. Manuals were electronically produced on a Xerox Docutech 135 Publishing System at 600 dpi.
  • Page 148 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.

  • Page 149: Warranty And Limitation Of Remedy And Liability

    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...
  • Page 150 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.

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