DRESSER Wayne 4/Vista Series Guide

4/Vista Series
Suction Pumps and
Remote Dispensers
Including Ultra-High
Capacity Models
INSTALLATION
OPERATION
4/V387 Model Shown

READ THIS MANUAL BEFORE YOU BEGIN
Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Fail-
ure to follow the below precautions and the Warning and Caution instructions in this manual may
result in serious injury. Follow all rules, codes and laws that apply to your area and installation.
SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE
Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cabi-
net for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off when
servicing the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser
BEFORE beginning maintenance.
Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an
emergency. Have all leaks or defects repaired immediately.
EQUIPMENT PRECAUTIONS
Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before
dispensing product, otherwise, damage to the equipment may occur. Always use the approved
method for lifting the dispenser. Never lift by the nozzle boot, sheet metal, valance, etc., otherwise
equipment damage or personal injury may occur.
HOW TO CONTACT WAYNE
Operational problems with the dispenser after installation and startup should be referred to your
local authorized Wayne service personnel or the Wayne Help Desk at (1-800-289-2963).
Trouble with the installation and startup of the dispenser should be referred to Wayne Technical
Support (1-800-926-3737).
INDICATORS AND NOTATIONS
Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe injury
or possibly death.
Warning indicates a hazard or unsafe practice which, if not avoided, may result in severe
injury or possibly death.
Caution indicates a hazard or unsafe practice which, if not avoided, may result in minor injury.
NOTE: Important information to consider, otherwise, improper installation and/or damage to compo-
nents may occur.
DANGER
DANGER
WARNING
CAUTION

February 2009 Part No. 940008 Rev A
4/Vista Series
Suction Pumps and
Remote Dispensers
Including Ultra High Capacity Models
Installation & Operation

Part No. 940008 Rev A February 2009

Table of Contents
Title Page
iii
February 2009 Part No. 940008 Rev A
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Dispensers Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Local, State, and Federal Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 European Community CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Inspect the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Island Construction, Dispenser Anchoring, and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Vapor Return Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Check Valves (Suction Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Connecting More Than One Pump to a Tank (Suction Pumps) . . . . . . . . . . . . . . . . . . . . 7
2.6 Lifting and Installing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2 Full Service (Stand-Alone) Dispenser Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.3 Submersible Pump Control Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.4 Multiple Dispenser Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.5 Dispenser to Wayne Control System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.6 Dispenser Options - Intercom, CAT, Wayne Trac . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.7 Sales Display Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.8 Non-Dispenser Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7.9 Wires and Conduits - Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.9 Bleeding Product Lines (Remote Dispensers). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.10 Priming Suction Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.11 Above Ground Storage Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.12 Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.13 Balance Vapor Recovery System Installation Requirements . . . . . . . . . . . . . . . . . . . . . 16
2.13.1 Dynamic Back Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.13.2 Back Pressure System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.14 Wayne Vac Vapor Recovery System Installation Requirements . . . . . . . . . . . . . . . . . . 18
2.14.1 Dispenser Vacuum Decay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.14.2 Wayne Pressure/Vacuum Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.15 Healy Vapor Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Set the Clock in Function 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Nozzle Positions for Blenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Nozzle Positions for non-Blenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 IR Remote Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 Setting Unit Prices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7 Setting Blend Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8 Setting Fueling Point ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table of Contents (continued)
Title Page
iv
Part No. 940008 Rev A February 2009
3.9 Authorizing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.10 Initial Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.11 Check Nozzle Boot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.11.1 Lift-to-Start Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.11.2 Push-to-Start Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.12 Check V-link Belt (Suction Pumps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.13 Check Annunciator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.14 Check Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.14.1 Totalizer Readings by Product Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.14.2 Totalizer Volume Readings by Meter Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.14.3 Electro-Mechanical Totalizer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.15 Check Wayne Vac Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.16 Check Healy Vapor Recovery Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.17 Perform QCAT Self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.18 iX CAT Equipped Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.19 IDPOS Equipped Dispensers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.19 iX™ Pay Secure Payment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.20 Disable Stand-alone Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.21 Audit Report Display Mode (For Weights & Measures Officials/Service Purposes Only) 36
4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Safety Items You Should Know . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.1 Portable Tanks and Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.2 Health Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1.3 U.S. and International Hazardous Zone Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Dispenser Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.3 Dispenser Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.4 Restarting After Power Failure or Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.5 Cycling Power to Clear Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Resetting After All Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.7 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.8 Customer Activated Terminal (CAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9 Stand-alone Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Filter/Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3 Dispenser Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4.1 Wayne Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4.2 Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4.3 Healy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.5 Meter Maintenance Issue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6 How To Get Service On Your Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Table of Contents (continued)
Title Page
v
February 2009 Part No. 940008 Rev A
APPENDIX A QCAT SELF-TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
APPENDIX B - iX CAT SELF-TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
APPENDIX C ENGINEERING DRAWINGS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
APPENDIX D SITE INTERCONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
APPENDIX E HS4/VISTA ULTRA HIGH CAPACITY (UHC) MODELS . . . . . . . . . . . . . . . . . . . . . . 99

Table of Contents (continued)
Title Page
vi
Part No. 940008 Rev A February 2009

1
February 2009 Part No. 940008 Rev A
1 INTRODUCTION
1.1 Dispensers Covered
This manual explains the installation and operation of all 4/Vista series blending and non-blending
suction pumps and remote dispensers.
Non-blending dispensers included in this manual are the 4/V387, 4/V388, 4/V389, 4/V390, 4/V399,
and 4/V490 models.These dispensers are multi-grade dispensers, except for the 4/V387 single
grade model. The 80 series numbers in the models represent a narrow body dispenser, whereas,
the 90 series numbers in the models represent a wide body dispenser.
This manual also covers the HS4/V Ultra High Capacity (UHC) models in the HS4/V387, HS4/V388
and HS4/V389 model series and associated satellites. See Appendix E for these models.
Blending dispensers included in this manual are the 4/V580, 4/V585, 4/V590, 4/V591 and 4/V595
models. Blending dispensers combine the Low and High base products (end grades) to provide one
or more blended grades in addition to the end grades. The 4/V591 and 4/V595 models also have an
additional single product (non blended) grade, whereas the 4/V595/U does not.
4/Vista dispensers, referred to as 4V dispensers, use the iGEM computer to control the iMeter and
Intelligent Pulser (WIP). There is one iGEM computer for each dispenser and one iMeter module
for each base product. The iMeter module consists of two meters in one assembly and the WIP
pulser, where one of the meters is for side one of the dispenser and the other meter is for the same
product on side two.
4V models incorporate many of the features and options available in the Ovation models. QCAT
with QVGA display is standard on card reader equipped dispensers, while iX™CAT and iX™ Pay
Secure Payment are optional.
Table 1-1 gives a brief description of each 4V model.
Table 1-1 MODEL DESCRIPTIONS
Model Type Inlets Products Dispensed Hoses per Side
4/V387 non-blender 1 1 1
4/V388 non-blender 2 2 1
4/V389,
4/V399
non-blender 2 2 2
4/V390 non-blender 3 3 3
4/V390/U non-blender 3 3 1
4/V490 non-blender 4 4 4
4/V490/U non-blender 4 4 2
4/V580 blender 2 3 1
4/V585 blender 2 5 1
4/V590 blender 2 3 3
4/V590/U blender 2 3 1
4/V591 blender 3 3 blend, 1 nonblend 4
4/V595 blender 3 3-4 blend, 1 nonblend 2
4/V595/U blender 2 4-5 1

2
Part No. 940008 Rev A February 2009
1.1 Dispensers Covered, continued
The iGEM computer uses software that is uploaded by a laptop. Computer function settings nec-
essary for dispenser startup are included in this manual. If additional information on function set-
tings and statistics is required, refer to the iGEM Service manual, part number 920525.
4/V series dispensers may be operated as stand-alone units or as a component part of a Wayne®
Retail Control System or other pump controllers. This manual provides installation and operation
procedures for the dispenser. Information concerning Wayne control systems has been included
where appropriate in this manual, however, for complete installation and operation of the control
system, refer to the manuals provided with the control system.
Any questions concerning installation and startup of the dispenser that are not covered in this
manual should be referred to your authorized Wayne service personnel or Wayne Technical Sup-
port (1-800-926-3737). Operational problems with the dispenser after installation and startup
should be referred to your local authorized Wayne service personnel or the Wayne Help Desk at
(1-800-289-2963).
1.2 Local, State, and Federal Codes
All tanks (both underground and above ground), piping and fittings, foot valves, leak detectors,
corrosion protection devices, wiring, venting systems, etc., must be installed in accordance with
the manufacturer’s instructions and in compliance with local and regional building codes and
requirements pertaining to service stations (or other locations where the dispenser may be
installed).
These requirements may include references to the National Electrical Code (NFPA 70), the Auto-
motive and Marine Service Station Code (NFPA 30A); the Flammable and Combustible Liquids
Code (NFPA 30); the Code of Federal Regulations, Title 40, Section 280 (40 CFR 280); United
States Environmental Protection Agency (U.S. EPA) Technical Regulations of 9-23-88 and U.S.
EPA Financial Responsibility Regulations of 10-26-1988; and various other codes.
Where local requirements do not specify applicable codes, Wayne recommends using the codes
listed above. These codes are comprehensive and detailed, and often require interpretation to
cover unusual situations, and, therefore, the associated handbooks (where applicable) should
also be consulted. (The handbooks are also available from the same sources.)
Due to the variety of locations encountered, further information on installation cannot be dealt with
in this document except as the codes relate directly to the installation of the dispenser. Therefore,
it is strongly recommended that a qualified engineer or contractor familiar with local regula-
tions and practices be consulted before starting installation.
Pertinent information and codes are available from the following sources:

3
February 2009 Part No. 940008 Rev A
1.2 Local, State, and Federal Codes, continued
NOTE: Other regulatory codes may apply. Consult your local and regional code requirements to
determine which codes are applicable for your location.
Association for Composite Tanks (ACT)
North State Street
Suite 720
Chicago, IL 60602
[phone] (for information requests)
American Petroleum Institute (API)
1220 L Street, N.W.
Washington, DC 20005
[phone]
Fiberglass Petroleum Tank and Pipe Institute
One SeaGate, Suite 1001
Toledo, OH 43604
[phone]
National Assoc. Corrosion Engineers
(NACE)
Box 218340
Houston, TX 77218
[phone]
National Fire Protection Association (NFPA)
One Batterymarch Park
Quincy, MA 02269-9101
[phone]
National Leak Prevention Association
(NLPA)
685 Fields Ertel Road
Cincinnati, OH 45241
[phone] or 1-[phone]
Petroleum Equipment Institute (PEI)
Box 2380
Tulsa, OK 74101
[phone]
Steel Tank Institute
P. O. Box 4020
Northbrook, IL 60065
[phone]
Underwriters Laboratories Inc.
333 Pfingsten Road
Northbrook, IL 60062
[phone]
Underwriters Laboratories of Canada
7 Crouse Road
Scarsborough, Ontario, Canada N1R3A9
[phone]
United States Environmental Protection Agency
Office of Underground Storage Tanks
401 M St., SW (05-400WF)
Washington, DC 20640
[phone] (Underground Storage Tanks)
Western Fire Chiefs Association
5360 South Workman Mill Road
Whittier, CA 90601
[phone]
U. S. Department of Labor,
Occupational Safety and Health Administration (OSHA)
Washington, DC 20402
• Call OSHA at [phone] to determine specific needs; OSHA rules
are covered by Title 29 of the Code of Federal Regulations (29 CFR.)
• Order OSHA publications from:
Government Printing Office (GPO)
Washington, DC 22304
[phone]

4
Part No. 940008 Rev A February 2009
1.3 Safety Precautions
NFPA 30A states that:
“When maintenance to Class I dispensing devices becomes necessary and such maintenance
may allow the accidental release or ignition of liquid, the following precautions shall be taken
before such maintenance is begun:
• Only persons knowledgeable in performing the required maintenance shall perform the
work.
• All electrical power to the dispensing device and pump serving the dispenser shall be shut
off at the main electrical disconnect panel.
• The emergency shut-off valve at the dispenser, if installed, shall be closed.
• All vehicle traffic and unauthorized persons shall be prevented from coming within
20 feet (6 m) of the dispensing device.
1
”
WARNING
Electric shock hazard! More than one disconnect switch may be required to de-energize the dis-
penser for maintenance and servicing. Use a voltmeter to make sure ALL circuits in the dispenser are
de-energized. Failure to do so may result in serious injury.
‘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 of Federal Reg-
ulations (29CFR1910), Control of Hazardous Energy Source (Lockout/Tagout).
1.4 European Community Conformity Identification
1. Reprinted with permission from NFPA 30A-90, Automotive and Marine Service Station Codes, Copyright ©1990,
National Fire Protection Association, 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.

5
February 2009 Part No. 940008 Rev A
2 INSTALLATION
2.1 Inspect the Equipment
Examine the shipment immediately upon arrival to make certain there has been no damage or loss in
transit. Damaged or lost equipment must be reported to the carrier. Any damage or loss that may
occur in transit is not covered under the Wayne/Dresser Warranty.
Make sure that all the component parts, including keys and optional equipment (if any), are accounted
for. Check and save the Packing Slip, Bill of Lading, Invoice, and all other documents included in the
shipment.
2.2 Island Construction, Dispenser Anchoring, Piping and Emergency Valve
Product lines must avoid the creation of vapor in the lines and deliver a minimum pressure of 25 psi at
the dispenser inlet when all dispensers at the station dispensing the same product are operating.
A concrete foundation must be provided for the dispenser. Do not pour concrete around product lines
or electrical conduit risers.
Anchor bolts must be installed in the island for securing the dispenser in accordance with NFPA
requirements. Depending on the model, the base of the dispenser contains four to eight bolt hole slots
(5/8 inch by 2 inch) for anchoring the dispenser to the island. Wayne recommends using all available
slots. Install the anchor bolts in accordance with the dimensions shown on the Installation Instruction
drawing for the dispenser model. Installation drawings are located in Appendix C.
Vertical supply risers and electrical conduits must be located per the Installation Instruction for the
appropriate model. Proper height must be maintained to avoid undue stress on the dispenser.
WARNING
For remote dispensers, a Listed1, rigidly anchored emergency shut-off valve must be installed, in accor-
dance with the manufacturer’s instructions, in each supply line at the base of each dispenser.
See Figure 2-1 and Figure 2-2 for a typical emergency valve. Failure to install the proper emergency shut-off
valve will present a hazardous condition that could result in serious injury.
2.3 Vapor Return Piping
NFPA 30A Section 4-3-72states that a vapor return pipe inside the dispenser housing shall have a shear sec-
tion or flexible connector so that the liquid emergency shut-off valve will function properly. Wayne’s vapor con-
nections are secured to the chassis allowing for the use of a shear section.
Wayne dispensers provide 1" NPT pipe connections at the base of the dispenser for vapor return con-
nections. (See the installation foot print for location in Appendix C.) A minimum 1" riser at each dis-
penser is connected to a minimum 2" return piping to the underground tank. If more than six (6)
fueling points are connected, then underground piping must be a minimum of 3". All lines should be
sloped at a minimum of 1/8” per foot (1/4” per foot preferred) from the dispenser to the tank to avoid
liquid traps.
1. “Listed” means published on a list by a nationally recognized testing laboratory (NRTL) which is responsible for product
evaluation and is acceptable to the authority having jurisdiction. Underwriters Laboratories, Inc. is one example of a
Nationally Recognized Testing Laboratory. For more information on NRTL’s, see Title 29, Parts 1907 and 1910 of the
Code of Federal Regulations, Safety Testing or Certification of Certain Workplace Equipment and Materials.
2. Reprinted with permission from NFPA 30A-90, Automotive and Marine Service Stations Codes, Copyright 1990,
National Fire Protection Association, Quincy MA 02269. This 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.

6
Part No. 940008 Rev A February 2009
Figure 2-1 Typical Emergency Valve Installation. The Emergency valve is designed to close the
product line due to shock or fire. The shear section, shown above, functions if the dispenser is knocked
out of position. Note: Shear valves and unions are not supplied with dispenser.

7
February 2009 Part No. 940008 Rev A
2.4 Check Valves (Suction Pumps)
Suction pumps require a check valve in the product lines to stop product from draining back to
the tank. Wayne recommends double poppet foot valves inside the underground tank. The foot
valves should be the same size as the suction lines. Foot valves designed for handling petroleum
products are equipped with a coarse mesh strainer screen. The bottom of this screen is blocked
off so that the product enters the valve from the side.
Some installers prefer a double poppet check valve in the line just above the tank. If a check
valve is installed at the top of the tank, the end of the suction line in the tank should be equipped
with a suction pipe strainer. The suction pipe strainer is similar in construction to the bottom of the
foot valve and serves the same purpose.
A spring-loaded valve of any kind is not recommended. A good valve does not require a spring to
hold properly. Springs increase pumping resistance and may cause erratic operations. The valve
used should be one designed for use with petroleum products.
Examine the valve carefully and remove any blocks or other means used by the manufacturer for
protecting the valve in shipping. Clean the valve thoroughly with mineral spirits, because any dirt,
lint, or foreign matter between the poppet and the seat will cause it to leak. The valve should be
handled carefully, not dropped or thrown around. Never clamp the body of a check valve in a vise
or apply a wrench to any part other than the hexagonal end of the valve. If done, it may spring or
distort the valve, causing leakage or valve sticking.
Establish the length of the suction pipe in the tank to which the check valve will be attached,
keeping in mind that the bottom of the suction stub must be at least four inches (4") off the bottom
of the tank. The type of connection at the tank opening will have some bearing on the length of
this pipe. Sometimes, a tank reducing plug (double tapped bushing) is used. Wayne recom-
mends the use of an extractable foot valve for easy and quick removal of the check valve in the
tank. (See installation drawings in Appendix C.) The importance of keeping the end of the line in
the tank at least four inches (4") off the bottom of the tank cannot be overemphasized. Conden-
sation is constantly occurring inside the tank and creating water on the bottom. Checking tanks
regularly and keeping them clean reduces the risk of drawing water and debris into the lines and
dispenser.
It is a good idea to test for leaks in both the check valve and the pipe as an assembly before
installing them in the tank. Before installing the valve, pour petroleum into the check valve and
pipe assembly and let it stand for an hour or two to make sure the check valve seals properly.
2.5 Connecting More Than One Pump to a Tank (Suction Pumps)
If you intend to connect more than one suction pump to a tank, it is best to obtain a tank with
enough openings to provide each pump with a separate suction line. Tanks used in remote sys-
tems normally require only one (submersible) pump to supply several dispensers; tanks designed
specifically for suction pumps will have additional openings.
If a tank with only one opening is unavoidable, it is important that a check valve be used in each
suction line branch, and that each valve be placed in the line as close as possible to the connec-
tion leading to the main suction line coming from the tank. This is necessary to prevent a pump
from emptying the line leading to another pump instead of pulling the product out of the tank.

8
Part No. 940008 Rev A February 2009
2.6 Lifting and Installing the Dispenser
Remove the dispenser from its shipping carton. Survey the site and determine if any special installa-
tion requirements, such as a canopy, will affect the installation.
If the dispenser is equipped with an optional valance, survey the site to determine if it should be
installed before or after the dispenser is set on the island. Wayne recommends installing the valance
after the dispenser is installed, if practical, to protect it from installation damage.
4/Vista series dispensers must be lifted onto the island as per Lifting Instructions 1-7196-C and
installed as per the appropriate Installation Instruction drawing in Appendix C.
When handling 4/Vista dispensers, lift only as per the Lifting Instructions drawing contained in this
manual. Do not lift by the computer enclosure, nozzle boot, hose outlet, operating lever, or any exter-
nal panels.
After the concrete has hardened, the dispenser can be set on the island and firmly bolted into place
and the product lines connected. To gain access to the bottom section of the dispenser, unlock and
remove the doors by pulling out and over the nozzle boots. See Figure 2-2 for door lock location.
After removing, place the doors in an area where they will not be damaged.
When installing a blender dispenser, make sure the High and Lo product inlets (and, if applicable, the
single product inlet) are correctly located. Refer to the appropriate Installation Instruction drawing in
Appendix C.
When making piping connections, to ensure tight, leak-proof connections, wash all cutting oils off the
threads and use a UL-classified pipe joint sealing compound, rated for use with petroleum-based
products. Note that inlet unions and meter inlet pipe nipples are not supplied with the dispenser.
WARNING
Explosive or flammable vapors may accumulate within the dispenser housing. All piping connections in the
final installation must be accurately fitted and all threaded joints tightly made up with a Listed gasoline-resis-
tant pipe joint compound. Put the compound on male threads only, being careful not to get excess inside the
pipe or fittings. Failure to perform the above will present a hazardous condition that could result in serious
injury.
Figure 2-2 Dispenser Doors and Typical Emergency Shear Valve. Note: Shear valves and unions are not
supplied with the dispenser.

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February 2009 Part No. 940008 Rev A
2.7 Electrical Wiring
2.7.1 General
Wayne recommends employing a qualified electrician for all wiring. A hazardous liquid is being han-
dled, so it is important to ensure that all wiring is in accordance with the National Electrical Code
(NFPA 70) as well as all federal, state and local regulations. Note that U.L. requires that all electrical
connections to the dispenser be made with threaded, rigid conduit and properly sealed conductors.
NOTE: All dispensers and electrical connection boxes must be grounded per NFPA 70.
Review the location of the dispenser junction box, see Figure 2-3, as well as other parts of the dis-
penser that may need to be accessed during dispenser installation and start-up.
2.7.2 Full Service (Stand-Alone) Dispenser Wiring
For full service operation, make electrical connections as shown on the appropriate Installation
Wiring Diagram in Appendix C. The electrical connections illustrated are typical when additional like
model dispensers are used.
In addition to the required connections for full service operation, the Installation Wiring Diagrams also
show optional data wires for connecting the dispenser to the Data Distribution Cabinet and the Site
Controller Cabinet in a Wayne control system. These optional data wires are not required for full ser-
vice (stand-alone) dispensers, however, if a control system may be installed at a later time, the
optional data wires should be pulled at initial installation. See Section 2.7.5.
NOTE: If optional data wires are run for future use, they should not be physically connected to the data terminals in the
dispenser junction box. Instead they should be properly terminated individually using wire nuts.
2.7.3 Submersible Pump Control Relays
Remote dispensers require a relay to control the submersible pump motor. These relays are avail-
able as an option with the 2400 MCS, Wayne Plus and Nucleus systems. If the dispenser is not con-
nected to a 2400 MCS or Wayne Plus system, a UL Listed magnetic motor controller assembly,
constructed with Potter and Brumfield Relay No. PRD7AYO (120) or equivalent, shall be used.
A maximum of 12 dispensers (24 fueling points) may be connected to a single PRD7AYO (120) relay;
other relays may have different limitations. All dispensers operating the same pump control relay
must be connected to the same circuit breaker; this may require multiple control relays for a sub-
mersible pump.
Ensure that the submersible pump receives its power from its own separate circuit breaker as illus-
trated in the Typical Site Wiring Diagram 7151-C in Appendix C.
2.7.4 Multiple Dispenser Wiring
A primary requirement in dispenser installation wiring is to provide a means for disconnecting all
power connections, including the neutral, to the dispensers for safe shutdown and servicing of the
units. Each dispenser could be provided with a separate control Power Circuit Breaker. If this is not
desirable or practical, several dispensers can be grouped together and tied to the same Control
Power Circuit Breaker as illustrated in Typical Site Wiring Diagram 7151-C in Appendix C. A group of
dispensers would then consist of all the dispensers and associated Submersible Pump Control Relay
coils supplied by the same Control Power Circuit Breaker.
When more than one dispenser within the group activates the same submersible pump, the Relay
Select lines may be commoned at the Submersible Pump Control Relay Coil terminal up to a maxi-
mum of 12 connections (24 fueling points). Where more than 12 connections activate the same sub-
mersible pump, additional relays should be used and the contacts paralleled as illustrated in 7151-C.
In larger installations, dispensers can be separated into multiple groups.

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Part No. 940008 Rev A February 2009
2.7 Electrical Wiring, continued
WARNING
Electric Shock Hazard! No connections (including neutral) may be shared between groups of dispensers.
A separate Control Power Circuit Breaker must be provided for each group. Failure to do so may result in
serious injury.
Figure 2-3 Location of Components in the Dispenser (Typical). Locations may vary slightly with model.

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February 2009 Part No. 940008 Rev A
2.7 Electrical Wiring, continued
2.7.5 Dispenser to Wayne Control System Wiring
For connection to a 2400 MCS or Wayne Plus follow the installation instructions supplied with that
system. The installation wiring diagrams in Appendix C show two Data wires to the Data Distribution
Cabinet required for the 2400 MCS, Wayne Plus, or Nucleus pump control operation, and two Data
wires to the Site Controller for Card Processing and/or cash acceptor operation. In addition, two
Data wires are required for dispensers equipped with the Wayne TRAC option. System interconnec-
tion diagrams are supplied in Appendix D for reference. Use the diagrams in both Appendix C and D
as a group when laying out the system wiring requirements for a new site or when making changes
to an existing site.
A UL Listed magnetic controller assembly shall be used to control the remote pumping units.
NOTE: Data wires from the Wayne Control System may be installed in the same conduit containing the AC power
wiring to the dispenser (NEC Class 1).
2.7.6 Dispenser Optional Equipment
Installation wiring diagrams for optional dispenser equipment such as an intercom or lighted valance
are provided in Appendix C. All dispensers contain a pair of data wires for Wayne TRAC.
The letter “I” in the suffix of the dispenser model number indicates an intercom call button. As shown
in Figure 2-4, the Yellow wires are call button connections and the Brown wires are speaker connec-
tions. Both circuits are low voltage NEC class 2 only.
NOTE: Intercom/Speaker (NEC Class 2) must be installed via a separate conduit to the dispenser junction box.
The underground wiring for the intercom is terminated with wire nuts in the main junction box.
2.7.7 Sales Display Lights
The dispenser is delivered with the sales display lighting circuit connected to the control power cir-
cuit at the terminal strip in the dispenser junction box. The sales display lighting may be connected
to a separate circuit breaker by making a wiring change at the terminal strip in the junction box, refer
to the appropriate Installation Wiring Diagram in Appendix C.
See Section 2.7.9, Summary of Wiring and Conduits on the following page for number of wires
required for dispenser operation.
Figure 2-4 Intercom Speaker/Call Button and Ethernet Wiring. Intercom speaker and Call Button wiring
must run in a separate conduit to the dispenser.
Dispenser Junction Box
TB
BR
YY
BR
CALL BUTTON
SPEAKER
WIRE NUT
(TYP)
CONDUIT FOR
INTERCOM SPEAKER
AND CALL BUTTON
WIRES
CONDUIT FOR
AC POWER AND
DATA WIRES
•
BU OR
WAYNE TRAC
(Data Wires)
••
••
FIELD
FIELD

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Part No. 940008 Rev A February 2009
2.7 Electrical Wiring, continued
2.7.8 Non-Dispenser Equipment
Do not run wiring for any non-dispenser equipment, such as canopy lights, etc. in the same conduit as
the dispenser wiring; this wiring must be run in a separate conduit.
2.7.9 Summary of Wiring and Conduits
The following is a list of field wires and conduits required for typical dispenser operation. This list
includes wiring for the Wayne dispenser only and does not include additional conduits and wiring that
may be required for other equipment or devices at the island. Be sure to read the complete electrical
section on the previous pages for details and use the appropriate wiring diagram in the back of this
manual for the specific dispenser model being installed, i.e., 4/V490 models will have 4 relay select
wires.
Basic Dispenser: Optional Equipment:
2 Power wires (hot & neutral) 2 Intercom/Speaker wires
3 Relay select wires 2 Call button wires
1 Ground wire 2 Data wires (1pair) for Wayne Trac
2 Data wires (1pair) for iGEM 1 Ethernet cable for iXCAT or IDPOS
2 Data wires (1pair) for QCAT
1 Primary conduit (Data and Power wires), 1 Secondary conduit (Intercom/Speaker/Call button wires)
2.8 Hose Installation
Hose assemblies should be U.L. Listed and installed in accordance with the manufacturer’s instruc-
tions. To ensure a proper joint, wash all cutting oil off the threads and use a U.L. classified gasoline-
resistant pipe joint sealing compound. Place the compound on male threads only; be careful not to get
any excess compound inside fittings. Install the fixed end of the hose to the dispenser outlet; secure
according to the instructions of the sealing compound and hose manufacturers. Install the swivel end
of the hose or other swivels to the nozzle according to the manufacturer’s instructions.
Exception: Do not use sealant (pipe dope) on hoses used with vapor recovery vacuum assist sys-
tems, such as Wayne Vac or Healy systems. The sealant may become lodged in the vapor
pump.
NFPA code requires a Listed emergency breakaway device, designed to retain liquid on both sides of
the breakaway point, must be installed on each hose dispensing Class I liquids; these devices must
be installed and maintained per the manufacturer’s instructions. Refer to your state and local codes
for breakaway device requirements that apply to your installation.
All hoses, nozzles, and breakaways, etc., must be CARB certified for use on Wayne vapor recovery
dispensers.
WARNING
Use only Listed hoses and nozzles. Continuity must be present between the dispenser outlet and nozzle
spout to prevent static discharge while fueling. Continuity must be checked for each outlet/hose assembly
to insure that the nozzle is grounded. Failure to do so may result in a hazardous condition that could cause
serious injury.