DRESSER Wayne 3/V390/U User manual

INSTALLATION
3/V390/U to 3/V590/U
Dispenser
Conversion Kit

Installation Manual for
3/V390/U to 3/V590/U Dispenser
Conversion Kit

i
June 2003 Part. No. 920680 Rev A
Table of Contents
Section 1: Before You Start
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Kit Overview and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.3 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.4 Returning Damaged Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Section 2: Removing Old Hardware
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Removal of Old Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Removal of Product Tubes and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Section 3: Installing New Hardware
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Installation of the New Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Testing the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Appendix A
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

ii
Part. No. 920680 Rev A June 2003
Table of Contents

1-1
June 2003 Part No. 920680 Rev A
Section 1
Before You Start
1.1 Introduction
This manual describes how to install the Wayne 3/V390/U to 3/V590/U Conversion Kit in a Vista
dispenser without Wayne Trac. Refer to the following table for identification of the retrofit kit.
Before retrofitting dispensers, any installation or modification must comply with the require-
ments of the National Electrical Code (NFPA 70), the Automotive and Marine Service Station
Code (NFPA 30A) and any other applicable codes.
WARNING: EQUIPMENT MUST BE SERVICED IN ACCORDANCE WITH NFPA30 AND
NFPA30(A) REQUIREMENTS. "LOCKOUT/TAGOUT" REQUIREMENTS OF THE U.S.DEPT.
OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) MAY
ALSO APPLY. REFER TO TITLE 29, PART 1910 OF THE CODE FEDERAL REGULATIONS
(29CFR1910), CONTROL OF HAZARDOUS ENERGY SOURCE (LOCKOUT/TAGOUT).
Important: You must wear an anti-static wrist strap (part number 916962 or equivalent)
securely attached to an earth ground when handling circuit boards, electronic
components or assemblies, or when reaching into the Site Controller or
dispenser computer enclosure. Do not use power tools.
Table 1-1 3/V390/U TO 3/V590/U Retrofit Kit
Part Number Kit Description
889336-001 CNVT 3/V390/U TO 3/V590/U

1-2
Part No. 920680 Rev A June 2003
Section 1: Before You Start
1.2 Kit Overview and Parts List
Refer to Photo 1 and the Parts List Table 1-2 below and make sure you have all the parts.
Table 1-2 889336-001 Kit Parts List
Item No. Part No. Description Qty.
1 001-202047-000 OUTLET PLUG 4
2 001-921130-000 O-RING 4
3 005-302140-HRN PULSER WIRE HARNESS 1
4 887344-002 VALVE CABLE ASS’Y 1
5 000-507284-000 BLT 5/16X3/4 HH 2
6 001-916931-000 WASHER 4
7 004-916931-000 WASHER 2
8 000-511883-000 NUT 5/16-18 2
9 883172-003 DECAL (not shown) 1
10 920680 INSTALLATION MANUAL 1
11 918195 INLET PLUG 1
12 122438 Lo OCTANE LABEL (not shown) 2
13 122439 Hi OCTANE LABEL (not shown 2
5
2
3
11 4
8
7
6
1
10
PHOTO 1. PARTS INCLUDED IN THE KIT

Section 1: Before You Start
1-3
June 2003 Part No. 920680 Rev A
1.3 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.
Caution: You must wear an anti-static wrist strap, part number 916962 when removing
electronic components from static packages. Attach the wrist strap 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.
Important: 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.
6. Check supplied graphics (such as ad panel and dial face graphics) prior to start of
installation.
1.4 Returning Damaged Components
Parts or components returned to the factory under warranty or for repair are subject to damage
if not packaged properly. Complete the following steps to return parts or components to the fac-
tory.
1. Place electronic components in an anti-static bag, then in the original shipping cartons for
return shipment to the factory.
Important: 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 covered under the original warranty. The customer or distributor will be
held responsible for the cost of repairs necessary to correct or replace the damaged parts.

1-4
Part No. 920680 Rev A June 2003
Section 1: Before You Start
1.5 Required Tools
Refer to Table 1-3 for a list of tools required to install the retrofit kit.
1.6 Power Ratings
Refer to Table 1-4 for power ratings for dispensers equipped with the Conversion kit.
Table 1-3 Required Tools
Quantity Description
1Phillips Screwdriver (medium and small)
1Slotted Screwdriver (medium and small)
11/4" to 3/4" Combo Wrenches
112" Cresent Wrench
1Channel Locks
13/8" Ratchet
11/4" to 3/4" 3/8" Drive Sockets
13/8" Ratchet Extension
1Ladder
1Metric Allen Wrench Set
1Electrical Tape
1Bezel Key
Table 1-4 Power Ratings
Circuits Powered Nominal
Voltage Amps
Dispenser Electronics 120 VAC, 60 Hz 7.4

2-1
June 2003 Part No. 920680 Rev A
Section 2
Removing Old Hardware
2.1 Introduction
This section explains how to remove the old hardware in preparation for the installation of the
conversion kit.
2.2 Removal of Old Components
To remove the old components from the dispenser, perform the following steps.
1. Record all totalizer readings and unit prices on the dispenser.
2. Remove all doors and place in a safe location.
3. Place the anti-static wrist strap on your wrist and attach the other end of the wrist strap to
an earth grounding point.
4. Unlock the bezel assemblies and disconnect the CAT power and data cables. Disconnect
the grade select cables and any other cables connected to the bezel for each side of the
dispenser.
5. Remove bezels and set aside.
6. Remove the top cover and right side outer column, shown in Figure 2-1. Save the
hardware for later use.

2-2
Part No. 920680 Rev A June 2003
Section 2: Removing Old Hardware
Figure 2-1 Outer Column Screw Locations
7. Close all emergency shut-off valves then try to dispense from each grade on both side 1
and side 2 of the dispenser, verifying that the valves are closed.
8. Turn off power to the dispenser.
Caution: Verify that all power sources have been turned off to the dispenser before
proceeding.
9. Remove the junction box cover.
10. Detach the ISB from the vapor barrier, disconnect the Pulser/Nozzle switch harness, p/n
2-302140-HRN, from the bottom of ISB. See Figure 2-2. Save ISB and all hardware for
later use.
11. Disconnect the Pulser/Nozzle switch harness, p/n 2-302140-HRN, from the pulsers and
nozzle switches then remove the harness from the vapor barrier. Save hardware for reuse.
12. Disconnect solenoid valve wires and remove cable assy p/n 887344-001. See Figure 2-3.
Top Cover
Right Side
Screw
Locations
Jucntion Box Side
Outer Column

Section 2: Removing Old Hardware
2-3
June 2003 Part No. 920680 Rev A
Figure 2-2 Disconnect Wire Harness from ISB
Figure 2-3 Remove Solenoid Valve Connections
ISB
Valve Conduit/
Potted Fittings
X1 and X2
valve
connections

2-4
Part No. 920680 Rev A June 2003
Section 2: Removing Old Hardware
2.3 Removal of Product Tubes and Valves
To remove the old product tubes from the dispenser, perform the following steps.
Important: Be sure that excess product is captured when removing product tubes and disposed of
properly.
1. Disconnect product tubes from the outlet assemblies, stabilizer bracket and solenoid valves, then
remove the (2) product tubes shown in Figure 2-4; right side as referenced from side 1.
2. Viewing meters left to right from side 1, remove the solenoid valves and conduit assemblies
attached to the right meter, Figure 2-5.
Figure 2-4 Product Tubes
Outlet
Vapor
Tube Stabilizer
Bracket
Recovery
Assembly
Right Side
Remove
(2) Product Tubes

Section 2: Removing Old Hardware
2-5
June 2003 Part No. 920680 Rev A
Figure 2-5 Right Meter
Remove
valve/conduit ass’y
on each side
Product tubes
removed
in Step 1.

2-6
Part No. 920680 Rev A June 2003
Section 2: Removing Old Hardware

3-1
June 2003 Part No. 920680 Rev A
Section 3
Installing New Hardware
3.1 Introduction
This section explains how to install the new hardware from the conversion kit into the dispenser
and electronic head.

3-2
Part No. 920680 Rev A June 2003
Section 3: Installing New Hardware
3.2 Installation of the New Hardware
To install the new components from the conversion kit, perform the following steps.
1. Lubricate the O-Rings from the kit p/n 1-921130 with vasoline and install onto the outlet
plugs p/n 1-202047. See Figure 3-1.
Figure 3-1 Outlet Plug with O-Ring
2. Install (2) outlet plugs in the right meter outlets.
3. Install (2) outlet plugs in the unused hose outlets at top of dispenser. See Figures 3-2 and
3-3.
Figure 3-2 Hose Outlet Left Side (Side 2)
O-Ring
Remove this tub
e
and install PLUG
here.

Section 3: Installing New Hardware
3-3
June 2003 Part No. 920680 Rev A
Figure 3-3 Hose Outlet Right Side (Side 1)
4. Install the new pulser/nozzle switch harness p/n 5-302140-HRN into the vapor barrier. See
Figure 3-4. Reuse hardware that was removed earlier and ensure that a washer is used
above and below the vapor barrier.
Figure 3-4 Pulser/Nozzle Wire Harness View From Side 2
5. Connect the pulser/nozzle switch harness to the ISB according to the labels on the
harness. Securely attach the ISB ground wire if removed and then re-attach the ISB to the
vapor barrier. See the wiring diagram 5-6632-D in Appendix A.
Remove this tube
and install PLUG.

3-4
Part No. 920680 Rev A June 2003
Section 3: Installing New Hardware
Figure 3-5 Pulser Cable Installation
6. Connect the new pulser/nozzle switch harness cable labelled HI to the middle pulser and
the cable labelled LO to the left pulser. Re-use grommet and cover removed earlier. See
Figure 3-5.
7. Connect the pulser/nozzle switch harness to the nozzle switch for side 1 and side 2
according to the label on the harness.
8. Install hardware from kit in the two holes in vapor barrier where the potted fittings/conduits
were located for the right meter valves. Install hardware in both holes per Figure 3-6.
9. Install the new valve power cable, p/n 887344-002, according to the wiring diagram
5-6632-D.
Figure 3-6 Hardware Stack-up for Vapor Barrier Seal
Pulser Cable Labe
l
Nozzle Switch
Cable
Pulser
Meter
-511883-
1-916931-
1-916931-
4-916931-
-507284-