Page 1 Installation & Operation Wayne Helix 4000 and 5000 Fuel Dispensers ™ Standard, Enhanced Capacity and Super-High Capacity Models WU017834 Rev 05 July 2023 Wayne Helix 5000 (left) and 4000 (right) Fuel Dispensers ™...
Page 2 North America, DFS references Wayne Fueling Systems LLC located in Austin, Texas. For Products from Brazil, DFS references Wayne Industria e Comercio Ltda. located in Rio de Janeiro, Brazil. For Products from the United Kingdom, DFS references Dover Fueling Solutions UK Ltd. located in Dundee, Scotland. For Products from China, DFS references Tokheim Hengshan Technologies Company, Ltd.
Page 3: Table Of Contents
3 SITE DESIGN AND PREPARATION..........17 3.1 E ....................17 XISTING NSTALLATIONS 3.2 D ....................17 ISPENSER ONFIGURATION 3.3 D ......................17 ISPENSER OCATION 3.4 S ......................... 17 UCTION UMPS WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 4 5.3.2 Logical Nozzle / Hose Positions .................. 37 5.3.3 Setting Unit Prices ....................... 39 5.3.4 Setting Blend Ratios ....................41 5.3.5 Setting the Fueling Point ID (FPID) ................44 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 5 OSE AND ETRACTOR 7.6 F ..................... 71 ILTER TRAINER EMOTE 7.7 F ..................... 72 ILTER TRAINER UCTION 7.8 P - DW-14 RS-232 P ............. 73 RINTER AINTENANCE RINTER WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 6 ..................... 139 LEND ATIO ETTINGS I.6 P ......................140 ROGRAM HANGE I.6.1 Program Change Menu ....................140 I.6.2 Printout for Program Change Events (Category 3 Only) ..........141 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 7 APPENDIX J GLOSSARY OF TERMS AND ACRONYMS ......150 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 8 Table of Contents WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 9: Introduction
Computer Programming Manual (P/N WM048524). 1.1 D ISPENSERS OVERED This manual covers Helix 4000 (narrow) and 5000 (wide) model dispensers excluding Ultra-High Capacity models, whose attributes can be determined by referring to the Model String Designation in Figure 1-1. The dispenser model number can be located on the serial number plate, receipts, or shipping documentation.
Page 10: Related Documents
Additionally, the CAN bus cable must be disconnected from the iGEM board before performing the bootstrap or the software download will fail. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 11: Parts Of The Dispenser
Figure 1-2 Helix 4000 Fuel Dispenser sales display volume display qVGA display softkeys printer lock card reader printer door keypad unit price display PTS buttons Figure 1-3 Dispenser Bezel WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 12: Safety Precautions
Quincy MA 02269. This reprinted material is not the complete and official position of the National Fire Protection Association on the referenced subject, which is represented only by the standard in its entirety. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 13: Trained
The use of safety cones, barricades or safety tape is highly recommended. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 14: Personal Protection
2.12 R EPLACEMENT ARTS Use only genuine Dover Fueling Solutions parts and retrofit kits on your Wayne dispenser. The use of alter- nate parts can create a hazardous situation, can violate local regulations, and could void warranty. 2.13 C HANGES TO THE...
Page 15: Portable Fuel Tanks And Containers
This area is generally the same as a Zone 2 area. Concrete Island 20 feet Class 1 Division 1 18 inches Class 1 Division 2 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 16: Site Warnings And Product Postings
Provide the nature of any injuries and any information about the victim that you can (age, etc.) ● Indicate if first aid is being provided ● Provide your name WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 17: Site Design And Preparation
Site Design and Preparation 3 SITE DESIGN AND PREPARATION The information in this section is a quick list of items to consider when preparing to install a Wayne dis- penser. Always refer to the other sections in this manual for additional details.
Page 18: Island Construction And Crash Protection
Helix 4000 and 5000 dispensers are supplied with 1-1/2 in. inlets. Use 1-1/2 in. piping for the 1-1/2 in. inlets if the distance to the tank is 60 feet or less. For distances greater than 60 feet, 2 in. piping is recommended to reduce friction.
Page 19: Emergency Shutoff Valve
The double-poppet emergency shut-off valve must be rigidly-secured according to manufacturer's instruction. The piping directly above the valve must be securely anchored and not able to rotate. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 20 NOTE! On E85 dispensers, use only shear valves approved for that fuel. For E85 models, use shear valve P/Ns 10P-0152E85 and 10P-4152E85 manufactured by OPW. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 21: Vapor Return Piping
Site Design and Preparation 3.11 V APOR RETURN PIPING Wayne dispensers provide 1 in. NPT pipe connections at the base of the dispenser for vapor return connec- tions. (See the applicable installation footprint for location in Appendix A, Installation Drawings, on page 79.) A minimum 1 in.
Page 22 Site Design and Preparation WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 23: Installation
Remove the hydraulic cabinet door from both sides of the dispenser. The side containing the Junction box (J-box) is Side A. ● Open the electronics cabinet doors on both sides of the dispenser. The side containing the Wayne iGEM board is Side A.
Page 24: Lifting And Installing The Dispenser
4.4 S IGNAGE Install the proper signage at the site as required by federal, state and local codes. This also includes the proper identification of products on the dispenser. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 25: Connecting Inlet Piping
Follow the manufacturer’s installation information supplied with the valve. Be careful to not create liquid traps that will prevent the flow of vapors back through the piping. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 26: Electrical Wiring
No connections (including neutral) may be shared between groups of dis- pensers. A separate Control Power Circuit Breaker must be provided for each group. Failure to do so may result in serious injury. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 27: Suction Pump Motor Switch
NOTE! The Dispenser Current Loop wiring may be installed in the same conduit containing the AC power wir- ing to the dispenser (NEC Class 1). WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 28: Payment Terminal To Control System Wiring - Ix Technology Platform
Wayne Connect – iX Pay EPP Payment Terminals and EMV Ready Payment Terminals (running as EPP or EMV devices) can be connected to the control device via 2 wire RS-485 connections through a Wayne Con- nect System. This method of connection also supports the ability to run media and EMV.
Page 29: Circuit Breakers
Use electrical tape to close the open end of the wire nut. After completing the wiring terminations, securely fasten the junction box cover using all of the supplied bolts. Make sure that any unused conduit entry open- ings are properly plugged. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 30: Wire Size
Table 4-2 Recommended Wire Size (AWG) - Control Wiring Distance (in feet) Current 1-25 26-50 51-75 76-100 101-150 151-200 201-250 251-300 2.5 A 5.0 A 7.5 A 10.0 A 12.5 A 15.0 A WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 31: Electrical Conduit
.512 2 in. 2.087 3.421 2207 .855 NOTE! The calculated conduit size may need to be increased to allow for long runs or a large number of bends. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 32: Dispenser Electrical Ratings
115 VAC 230 VAC 1 HP Pump Motor (per pump) 14.6 Control Electronics The following options add to the Control Electronics: Payment Option Wayne Connect Healy Vapor Recovery WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 33: Startup
The board is located on the bottom of the left wall of the dispenser if facing side A. Figure 5-1 Dispenser ON/OFF Switch on A/C Power Distribution Board WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 34: Pay ™ Secure Payment Platform Board Reset Button
A reset button is located on the iX Pay Secure Payment platform board. Refer to the following figure for but- ton location. This may be useful while performing the initial startup of the dispenser. Figure 5-2 iX Pay Platform Board Reset Button (iX Jade board shown) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 35: Configuration Of Basic Parameters Using The Infrared Remote Control (Irc)
ENTER When in Statistics Mode (S - - or S “xx” on Unit Price Display), the above commands work the same way. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 36: Set Clock Function
Type the current year in the format of YYYY - - - - - Current year in YYYY format 2.02 Press ENTER Press ENTER - - - - - F 02 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 37: Logical Nozzle / Hose Positions
1 Hose H(N/LU)24-21 LO-BL HI-BL Blender 1 Hose H(N/LU)25-21 LO-BL MID-BL HI-BL Blender 1 Hose H(N/LU)33-31 Non-Blender 2 Hose H(N/LU)34-32 Blender H(N/LU)35-32 2 Hose LO-BL HI-BL (4+1) Blender WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 38 Dual-Blender S2 + LO LO + HI H(W/LU)45-43 3 Hose (2+2+1) Dual-Blender S2 + LO H(W/LU)45-43 3 Hose S2 + LO S2 + LO (2+2+1) Dual-Blender (LO-BL) (HI-BL) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 39: Setting Unit Prices
---------------------------- ENTER New Credit Price NEXT Press # Existing Credit Price Type numbers - - - - - - 3.03 Noz 3 ---------------------------- ENTER New Credit Price NEXT WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 40 ---------------------------- ENTER New Cash Price NEXT Press # Existing Cash Price Type numbers - - - - - - 3.16 Noz 6 ---------------------------- ENTER New Cash Price NEXT WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 41: Setting Blend Ratios
Unit Price Logical Step Command Display Display Display Nozzle # Set Blending Ratios for Side A: Press ENTER PASS 1 Type the corresponding PASS- WORD PASS 2 Press ENTER WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 42 Set Blending Ratios for Side B: Press # Current 1 Type blend ratio Blend Ratio - - - - - - 18.21 Noz 1 ENTER ---------------------------- New Blend Ratio NEXT WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 43 - - - - - - 0.00 Press # Type 3 - - - - - - 0.00 ENTER CHANGE ENTER STORED Last Volume Current Last Sale Amount Unit Price Amount WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 44: Setting The Fueling Point Id (Fpid)
The procedure in the following table is used to set the dispenser Fueling Point (FP) address. Functions used to set Fueling Point IDs: Fueling Point ID Fueling Point ID Function F05 Function F06 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 45 - - - - - - 0.00 *2 = Exit and do not save changes *3 = Exit and save changes Press ENTER Press ENTER CHAnGE StorEd Current Price WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 46: Priming
Standalone Mode. Once the dispenser is switched to a POS Control System, the Local Authorize Switch should be removed. See Section 5.16, Security Precautions, on page 52. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 47: Initial Delivery
Check all piping and hose connections to make sure there are not any leaks. Turn the dispenser off by inserting the nozzle back into the nozzle boot. Repeat the steps in this section for each dispenser and all hoses. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 48: Meter Calibration - Wayne I Meter Or Xflo Fuel Meters
(into a 5 gallon prover). Consult Handbook 44 for full information. If the values are out of range, follow the calibration procedure. Repeat the verification procedure for each hose. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 49: Meter Calibration Procedure - Imeter Or Xflo
Empty the container back into the tank and let it drain for 10 seconds. Verify the accuracy by following the Accuracy Verification procedure. Seal the calibration door. Repeat the calibration procedure for each hose. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 50: Test Emergency Shear Valves
Repeat the above steps on the other side of the dispenser. If the keypad does not function as expected, refer to on page 98 to 12-Button Preset Keypad Configuration verify the keypad configuration. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 51: Payment Platform Configuration ( Optional )
ONFIGURATION OPTIONAL Connection details of the iX Pay Secure Payment boards and the SPM keypad are given in the Wayne Helix Service Manual, (P/N WU025076). For U.S. stations with EPP software, refer to the Wayne iX Pay Secure Payment Initial Startup Configuration for iX R2 or iX Jade Board (P/N W2940079).
Page 52: Security Precautions
Verify that the blank password is in place by entering into the Weights & Measure mode without any password required. ● .00: Service Engineer Password ● .01: Station Manager Password ● .02: Station Operator Password WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 53: Balance Vapor Recovery System Installation Requirements
Check dry break is open. (If only allowed to have one dry break open during the test, try all.) Check vapor pod. Check vapor impact valve to be open. Check piping under dispenser. Should be a minimum of 1 inch diameter piping and fitting. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 54 A large amount of flashing would be required to affect readings. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 55: Operation
NFPA 30A requires the dispenser to be “manually activated.” This requires a separate intentional oper- ation (Push to Start, Cash/Credit selection, or grade selection) after the nozzle is removed from its hang up position. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 56: Restarting After Power Failure Or Shutdown
Be certain to give the service personnel the amount at which the dispenser stopped and the exact error message given on the sales display. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 57: Error Codes
NEXT, the error buffer can be viewed completely. To exit, press CLEAR, then UP or DOWN. The Unit Price Display will show S—. Press ENTER three times to exit to the normal display. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 58: Electronic Totalizer Readings
1.12. The least significant six (6) digits of the data value appear on the volume display, while higher order non-zero digits of the data value, if present, appear on the money display. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 59: Totalizer Volume Readings By Meter Position
Electro-Mechanical totalizer is adjusted one whole increment; i.e., if five consecutive sales end with a fractional amount of .2, the Electro-Mechanical totalizer will not account for the fractions until after the fifth sale. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 60: Stand -Alone Operation
When enabled with the Maintenance Mode password option the SSA sensors will automatically re-arm one minute after the service door is closed. See Section 6.10.2 for more information. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 61 When enabled with the Maintenance Mode password option the SSA sensors will automatically re-arm one minute after the service door is closed. See Section 6.10.2 for more information. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 62: Recovering From Standalone Jumper Fail-Safe
Section 6.10.1 on page 64. NOTE! When enabled with the Maintenance Mode password option the SSA sensors will automatically re-arm one minute after the service door is closed. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 63: Smart Secure Access (Ssa)
F56.01 allows a technician to arm or disarm the door sensors, or to reset the door sensors after a breach, using only the Maintenance Mode password. See Section 6.10.2 on page 65. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 64: Arming Or Disarming Smart Secure Access (Ssa) Using A Oneshot Password
“Closed”. To clear the breach, close and secure the doors then access function 56. A new response code will be required. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 65: Arming Or Disarming Smart Secure Access (Ssa) Using Maintenance Mode
When finished, close and secure the doors. The switch will automatically re-arm after one minute and the dispenser will return to idle operation. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 66 Operation WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 67: Maintenance
Check the Nozzle Boot Switch operation to ensure that the flipper up inside the Nozzle Boot, or the up / down side level, depending on model, operates freely. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 68: Dispenser Cleaning
DFS uses automotive grade paint on all painted surfaces of our dispenser. As such, they can be main- tained in the same manner as one would maintain a personal vehicle. The cleaning process level for all Wayne dispensers is based on the amount of dirt or stains on the dispensers. We recommend starting with cleaning and moving to the second and third levels only as necessary.
Page 69 Periodic waxing of the dispenser surfaces is essential to maintain the original finish and inhibit corrosion. Painted surfaces should be waxed with an automotive wax or polish. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 70: Meter Maintenance
AINTENANCE All meters in the dispensers are determined to be calibratable when shipped from the factory. It is recommended that Wayne fuel meters be periodically checked for acceptable accuracy based on NCWM Handbook 44 under the General Code, G-UR.4, Maintenance Requirements and Liquid Measuring Device Code, Section 3.30.
Page 71: Filter / Strainer - Remote
The recommended gasoline and etha- nol fuel filters are rated at 10 micron. NOTE! On E85 dispenser models, use strainer cartridges marked “E85” manufactured by Central Illinois Mfg. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 72: Filter / Strainer - Suction
Failure to do so may result in a hazardous condition that can result in serious injury. Loosen the four screws and rotate the cover. Remove the cover and the attached filter. Replace the filter and reinstall the cover. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 73: Printer Maintenance - Dw-14 Rs-232 Printer
WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 74: Symptoms And Led Indicators
Green Orange Normal Operation Paper at End Paper Near End Blinking Fast Printhead Open Paper Loading Jam Blinking Paper Exit/Chute Jam Blinking Figure 7-3 DW-14 Printer Test Receipt WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 75: Loading Printer Paper
Remove the old core and place the new roll of paper into the tray so that the paper feeds from the top of the roll into the printer. Remove old core Install new roll Remove old paper core Insert new paper WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 76 Close the Printhead. The printer should advance the paper and generate a test receipt. Remove the test receipt, push the printer assembly back into the dispenser, then close and lock the printer door. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 77: Clearing Paper Jams
Close the Printhead. The printer should advance the paper and generate a test receipt. Remove the test receipt, push the printer assembly back into the dispenser, then close and lock the printer door. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 78: Balance Vapor Recovery Maintenance
ECOVERY AINTENANCE All hoses, nozzles, breakaways, etc., must be CARB certified for use on Wayne vapor recovery dispensers. Tears or rips in the balance nozzle vapor bellows will cause the vapor system to be in non-compliance. Replace or repair the nozzles as necessary.
Page 79: Appendix A Installation Drawings
WU007415 - Installation Drawing, Helix 5000, Remote, Sheet 3 WU007415 - Installation Drawing, Helix 5000, Remote, Sheet 4 WU007415 - Installation Drawing, Helix 4000 and 5000, Remote, Sheet 5 WU18653 - Installation Wiring Diagram - Remote Junction Box Terminal Strip Wiring - Remote...
Page 80 WM046631 - Helix Lifting Instruction, Sheet 1 635($'(5 %$5 &$3$&,7< 3281'6 NJ 0,1,080 /,)7,1* 675$36 /(1*7+ )((7 PP 0,1,080 &$3$&,7< 3281'6 NJ 0,1,080 63$&(5 %/2&.6 ,1&+(6 PP /21* [ :22' 25 27+(5 68,7$%/( 0$7(5,$/ ,1&+(6 PP 0$;,080 :,'( 3803 ,1&+(6 PP 0$;,080 1$552: 3803 >dZE d/s...
Page 81 WM046631 - Helix Lifting Instruction, Sheet 2 58%%(5 25 6,0,/$5 0$7(5,$/ %(7:((1 )25. $1' 723 %2; 72 3527(&7 7+( 3$,17(' 685)$&( )25. /,)7 &$3$&,7< 3281'6 NJ 0,1,080 ,1&+(6 PP 0$;,080 :,'( 3803 127( 63$&( %(7:((1 )25. ,1&+(6 PP 0$;,080 $1' 723 9$/$1&( 1$552: 3803 '85,1* /,)7,1*...
Page 82 WM046631 - Helix Lifting Instruction, Sheet 3 /E^dZhd/KE W> ^d> Z^ hEZE d, d, WhDW z D Eh >>z d/>d/E' d, WhDW ^>/',d>z ^>/ /d dK d, W> d&KZD 67((/%$56 3$//(7 3/$7)250 >dZE d/s hE>^^ EKd Kd,Zt/^ /DE^/KE^ Z /E...
Page 83 Instruction: Filter Orientation 7+( ),567 7:2 ),/7(56 6+28/' %( )$&(' 72:$5'6 7+( %6,'( $1' 7+( 7+,5' 21( )$&,1* $6,'( ,1 7+( 1$552: +(/,; 7+,6 ),/7(5 6+28/' %( $66(0%/(' 23326,7( 72 7+( 27+(5 7:2 ),/7(56 $6 6+2:1 )$&,1* %6,'( 7+( ),567 7+5(( ),/7(5 6+28/' %( )$&(' 72:$5'6 7+( $6,'( $1' 7+( 27+(5 ),/7(5 6+28/' %( $66(0%/(' $6 )$&,1* %6,'( ,1 7+( :,'( +(/,;...
Page 84 WU007415 - Installation Drawing, Helix 4000, Remote, Sheet 1 & & " T T " & & I T I & . T I > h & > h > / & / > & E > > >...
Page 85 WU007415 - Installation Drawing, Helix 4000, Remote, Sheet 2 " 8 " 2 T " " 2 x i l x i l t i s I T I > h & > h > / & / >...
Page 86 WU007415 - Installation Drawing, Helix 5000, Remote, Sheet 3 & & " T T " & & & . T I > h & > h > / & / > & E > > > & E &...
Page 87 WU007415 - Installation Drawing, Helix 5000, Remote, Sheet 4 " 8 " 2 T " I T I " 2 x i l x i l t i s " 2 > h & > h > / & / >...
Page 88 WU007415 - Installation Drawing, Helix 4000 and 5000, Remote, Sheet 5 > h & > h > / & / > & E > > > & E & / & > K & & K h &...
Page 89 WU18653 - Installation Wiring Diagram - Remote '(6&5,37,21 2) &+$1*( 1RW DOO FRQILJXUDWLRQV DUH 8/ /LVWHG 2QO\ WKRVH GLVSHQVHUV WKDW -81&7,21 ,17(5&20 EHDU D 8/ PDUN DUH &HUWLILHG 237,21 127(6 81/(66 27+(5:,6( 63(&,),(' $// (48,30(17 72 %( ,167$//(' ,1 $&&25'$1&( :,7+ 7+( 1$7,21$/ (/(&75,&$/ &2'( 1)3$ $1' 7+( $872027,9( $1' 0$5,1( 6(59,&( 67$7,21 &2'( 1)3$ $ 127( '$7$ $1' 5(/$<...
Page 90 Wayne TRAC TX / RX - option NC Blue Intercom Speaker + option NC White Intercom Speaker - option NC Blue Call Button + option NC Blue Call Button - WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 91 WU011861 - Installation Drawing, Helix 4000, Suction, Sheet 1 & & " T T " I T I & & & . T I D “ , ) S ) S ( ” .
Page 92 WU011861 - Installation Drawing, Helix 4000, Suction, Sheet 2 " 8 " 2 T " " 2 I T I I T I D “ , ) S ) S ( ” .
Page 93 WU011861 - Installation Drawing, Helix 5000, Suction, Sheet 3 & & " T T " & & & . T I D “ , ) S ) S ( ” .
Page 94 WU011861 - Installation Drawing, Helix 5000, Suction, Sheet 4 " 8 " 2 T " " 2 I T I D “ , ) S ) S ( ” .
Page 95 WU011861 - Installation Drawing, Helix 4000 and 5000, Suction, Sheet 5 D “ , ) S ) S ( ” .
Page 96 WU018654 - Installation Wiring Diagram - Suction '(6&5,37,21 2) &+$1*( 1RW DOO FRQILJXUDWLRQV DUH 8/ /LVWHG 2QO\ WKRVH GLVSHQVHUV WKDW -81&7,21 ,17(5&20 EHDU D 8/ PDUN DUH &HUWLILHG 237,21 127(6 81/(66 27+(5:,6( 63(&,),(' $// (48,30(17 72 %( ,167$//(' ,1 $&&25'$1&( :,7+ 7+( 1$7,21$/ (/(&75,&$/ &2'( 1)3$ $1' 7+( $872027,9( $1' 0$5,1( 6(59,&( 67$7,21 &2'( 1)3$ $ 127( '$7$ $1' 5(/$<...
Page 97 Main Conduit (Optional) NEUTRAL option NC Blue Intercom Speaker + option NC White Intercom Speaker - option NC Blue Call Button + option NC Blue Call Button - WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 98 Figure A-2 for the location of the CAN bus termination jumper, then refer to Appendix E, Dis- Settings, on page 113. penser CAN Bus Configuration / DIP Switch WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 99: Appendix B Site Interconnection Diagrams
Appendix B Site Interconnection Diagrams APPENDIX B SITE INTERCONNECTION DIAGRAMS Document Page # Backroom Installation Data Distribution Cabinet to Dispensers Pump Relay Installation Wiring Diagram Dispenser Card Processing (CATs) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 100 Backroom Installation...
Page 101 Data Distribution Cabinet to Dispensers...
Page 102 Pump Relay Installation Wiring Diagram...
Page 103 Dispenser Card Processing (CATs)
Page 104: Appendix C Hydraulic Configurations - Helix Models 4000 & 5000
H - Hi (fuel grade) S - Special PTS buttons / grade selects S1 - Special 1 (black = not used / no button) S2 - Special 2 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 105 Single-Sided: H(N/LU)11-110 S(L/LU)11-110 22-22: 2-PRODUCT NON-BLENDER H(N/LU)22-22 H(W/LU)22-22 S(L/LU)22-22 SIDE B SIDE B SIDE A SIDE A Single-Sided: Single-Sided: H(N/LU)22-22 H(W/LU)22-220 S(L/LU)22-220 Vista Equivalent: 399 Vista Equivalent: 389 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 106 Vista Equivalent: 390/U Narrow 44-4X: 4-PRODUCT NON-BLENDER (MULTI- & UNI-HOSE) H(W/LU)44-44 H(W/LU)44-42 SIDE B SIDE B SIDE A SIDE A Single-Sided: Single-Sided: H(W/LU)44-440 H(W/LU)44-420 Vista Equivalent: 490 Vista Equivalent: 490/U WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 107 SIDE A SIDE A SIDE A L B1 B2 H L B1 B3 H Single-Sided: Single-Sided: Single-Sided: H(W/LU)23-210 H(W/LU)24-210 H(W/LU)25-210 Vista Equivalent: 590/U Vista Equivalent: 595/U Vista Equivalent: 595/U WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 108 35-32: 4 + 1 BLENDER (NARROW) H(N/LU)35-32 H(N/LU)35-32 SIDE B SIDE B SIDE A SIDE A B2 H B1 L Single-Sided: N/A Single-Sided: N/A Vista Equivalent: 595 Vista Equivalent: 595 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 109 S+L (HI) S+L (LO) S+L S S+L (LO) S+L (HI) SIDE A SIDE A S+L L Single-Sided: N/A Single-Sided: N/A H(W/LU)35-330 H(W/LU)35-330 Vista Equivalent: N/A Vista Equivalent: N/A WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 110 S2+L (LO) S2+L S2+L (HI) SIDE A SIDE A SIDE A S2+L S2+L Single-Sided: Single-Sided: Single-Sided: H(W/LU)45-430 H(W/LU)45-430 H(W/LU)45-430 Vista Equivalent: N/A Vista Equivalent: N/A Vista Equivalent: N/A WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 111: Appendix D Helix Dispensers With A Compact Pumping Unit (Cpu)
Figure D-1 CPU Check Valves Suction pumps must be primed before their initial operation. It is not advisable to run any type of inter- nal gear pump dry during the priming process. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 112 If the motor pulley requires adjustment, loosen the set screw on the inside of the pulley which holds the key against the motor shaft. Align the pulley and retighten the set screw. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 113: Appendix E Dispenser Can Bus Configuration / Dip Switch Settings
CAN Bus termination ANT Board Side A components installed should NOT be terminated. already ON. There is no need to manually termi- SSA Controller nate. CAN to TTL Preset Keypad WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 114: Dispenser Configurations
The Dispenser Components columns list the boards (and combinations thereof) with CAN Bus that will most commonly be found on Wayne dispensers. The CAN Bus Termination Settings columns specify how the CAN Bus switch(es) should be set for those boards present on the dispenser.
Page 115 Appendix E Dispenser CAN Bus Configuration / DIP Switch Settings Table E-2 Helix Dispenser CAN Bus Configuration Matrix - Standard Dispensers Dispenser Components CAN BUS Termination Settings WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 116 Off Off Off Off Off On Yes Yes Off On Off Off Yes Yes On Off Off On Off Off Yes Yes Yes Yes On Off Off On Off Off WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 117: Can Bus Switch & Jumpers ( Example Settings )
DIP 1&2 = ON DIP 2-4 = OFF CAN to iX Blue (not terminated) (not terminated) iX Blue (terminated) Pins 1&2 (not terminated, shown, default) Pins Pins 2&3 (terminated) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 118: Appendix F Gen 1 Valance Installation
Attach the other valance end cap, but let it rest on the outer hooks. Do not secure this end. See figure at right. Attach side valance to fixed end valance, then loosely attach to the other end valance. See figure below. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 119 Secure the two side valances to the loose end valance, then secure the end valance with the two screws. Attach (snap in) the end cover on both ends of the valance. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 120: Appendix G Gen 2 Valance Installation
Appendix G Gen 2 Valance Installation APPENDIX G GEN 2 VALANCE INSTALLATION This section provides instructions for installing the Gen 2 valance on Wayne Helix fuel dispensers. ™ Table G-1 Required parts for valance installation Item Part Number Description Qty.
Page 121 (item 1) to the other end of the top panel. See Figure G-4. Figure G-4 Support brackets attached to first top panel WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 122 On the other side of the end panel, align the top slot with its retaining tab and push it onto its tab, then align the bottom slot and push it onto its tab. Push the end panel down to seat the tabs in the slots. See Figure G-6 right. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 123 See Figure G-8. Install four (4) screws (item 4) to secure the valance to the dispenser. See Figure G-8. Figure G-8 Valance installation on dispenser WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 124: Appendix H Weights And Measures Mode - Category 2 Only
Weights & Measures mode. The cabinet does not need to be opened to access this mode. Next Clear Enter Figure H-1 Infrared (IR) Remote Control PN WM002290 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 125: U L M
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Page 126: Unit Measure Measure
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Page 127: Pulse Output Menu
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Page 128: Automatic Temperature Compensation (Atc) Menu
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Page 129: Product Pressurization Menu
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Page 130: Programenu Change Menu
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Page 131: Meter Totals
(tx). You can press “Clear” at any time to move to the next upper menu item. 9ROXPH 7RWDOV 3UHVV 1H[W (QWHU 7RWDOL]HU &OHDU 1XPEHU 6HF 7LPHRXW 6LGH 0HWURORJLFDO 6HWWLQJV WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 132: Metrological Settings Menu
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Page 133: Metrological Configuration Parameter Definitions
Max. volume for selection of new product, 1-99 (units of 0.001 gals.) Suppress overflow of preset limit, 0-99 (units of 0.001 gals.) Preset/prepay slow down volume delta, 2-999 (units of 0.001 gals.) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 134 Volume digits to the right of the decimal point used in the amount calculation, 0-5 5=use volume decimal point as defined in F14.03 Money preset configuration Default price mode 1=Credit 2=Cash WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 135: Automatic Temperature Compensation (Atc) Testing
To verify the accuracy of the temperature probes, insert a Weights and Measures probe in the NPT test port next to the ATC temperature probe. Follow the steps above to see the temperature probe reading and verify it against the Weights and Measures probe. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 136: Appendix I Weights And Measures Mode - Category 2 Or 3
If the dispenser is operating in a Category 3 mode, pressing “4” on the remote keypad will cause the existing menu to print on the Payment Terminal printer. Next Clear Enter Figure I-1 Infrared (IR) Remote Control PN WM002290 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 137: U L M
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Page 138: Lelevantgally R Elevant
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Page 139: Printout For Legally Relevant Events (Category 3 Only)
PTS button. If the dispenser is not config- ured as a blender, this screen will not appear. Press “Enter”, “Clear” or “Next” to move to the “Program Change Menu”. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 140: Program Change
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Page 141: Printout For Program Change Events (Category 3 Only)
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Page 142: Meter Totalizers
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Page 143: Function Ettings M
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Page 144 Max. volume for selection of new product, 1-9 cl. Volume Unit Specific Con- Suppress overflow of preset limit, 0-99 cl. figuration Preset/prepay slow down volume delta, 5-399 cl. Forward pulse limit on idle/unused EIP, 1-99 cl. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 145 2=Access allowed Part 1 Standalone indication enabled (show 4 digits right of decimal place) 1=Yes 2=No Blank or dash unselected unit price displays on product selec- tion 1=Blank 2=Dash WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 146 Denomination ratio between money display and unit price dis- play 1=1/1 2=10/1 3=100/1 Sales Amount 4=1/10 Calculation 5=1/100 6=1/1000 Count by ones or fives in leas significant digit of money display 1=Ones 2=Fives WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 147 Totals display mode 0=Display totalizers per meter 1=display totalizers per logical nozzle Misc Config Part 2 2=display totals per meter 3=Display total per logical nozzle 4=Display WIP totalizers WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 148: Configuration
1=Anthem display Country code Alternate Display 0=US Configuration 1=International CAN FDDP display 0=Disabled 1=Enabled Local Software download through local serial port Software Download Remote Software download from remote location WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 149: Automatic
To verify the accuracy of the temperature probes, insert a Weights and Measures probe in the NPT test port next to the ATC temperature probe. Follow the steps above to see the temperature probe reading and verify it against the Weights and Measures probe. WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 150 Electronic Head - electronics cabinet EHPM electronic head and payment terminal WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 151 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 152 (pump) ground tank; not inside the dispenser residual something left over or remaining (as in residue) WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 153 User Interface universal joint a type of coupling Unit Price Display - shows the fuel price per gallon or per litre WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 154 Wayne Intelligent Pulser - device converts magnetic field from meter and sends digital pulses to computer. Used on iMeter. Xflo a type of meter manufactured by Wayne XWIP WIP used on Xflo meter WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 155 126 - Bonsucesso United States DD5 3RT Dundee Rio de Janeiro 21061-280 Tel +1 512 388 8311 United Kingdom Brasil Tel +44 (0)1382 598 000 Tel +55 21 2598 7722 WU017834 Rev. 05 July 2023 Wayne Fueling Systems | Dover Fueling Solutions...
Page 156 INSTALLATION & OPERATION Wayne Helix 4000 and 5000 Fuel Dispensers ™ Standard, Enhanced Capacity and Super-High Capacity Models WU017834 © 2023 Dover Fueling Solutions. All rights reserved. DOVER, the DOVER D design, DOVER FUELING SOLUTIONS, and other trademarks referenced herein are trademarks of Delaware Capital Formation, Inc./Dover Corporation, Dover Fueling Solutions...

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