Wayne Reliance G6101D Guide

Installation / Operation
Reliance™ S1 AST Model G6101D
Mechanical Registration Fleet Dispensers
920943
Rev E

READ THIS MANUAL BEFORE YOU BEGIN
Dispensers have both electricity and a hazardous, flammable, and potentially explosive liquid. Failure
to follow the below precautions and the Warning and Caution instructions in this manual may result in
serious injury or death. Read every tag attached to the dispenser before commencing installation.
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 cabinet
for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off when
servicing the dispenser. If applicable, 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 the product lines of dispensers 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, etc., otherwise equipment damage or personal
injury may occur.
USE ONLY GENUINE PARTS
For product liability to be valid, no changes may be made to the equipment without the written
consent of Wayne.
REGISTRATION OF SITE AND HOW TO CONTACT WAYNE
The equipment used at this site must be registered prior to contacting Wayne for warranty service.
Sites can be pre-registered prior to installation by a Wayne Authorized Service Organization (ASO)
via the on-line registration system OR through completing the Section 1 portion of the form, at the end
of this manual, and sending it to Wayne (for non-ASOs). Pre-registration of a site helps to expedite
warranty service in case it is needed. Please allow 2-3 days after receipt of the information for pre-
registration. Final registration, which requires all of the information pertaining to the site including
Start-Up date and equipment serial numbers, must be completed within 7 days of the completion of
the Start-Up using the same aforementioned methods.
Trouble with the installation of this product should be referred to your Wayne®ASO. An ASO with a
technician number can receive assistance by calling Wayne at Technical Support at:
1-800-926-3737
Customers, Installers or Distributors who are not an ASO, needing help with the operation or
installation of this product, should contact the Wayne Help Desk at:
1-800-289-2963 OR [email protected]
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.
Important information to consider, otherwise, improper installation and/or damage to
components may occur.
NOTE:
DANGER
WARNING
CAUTION
DANGER

920943 Rev E July 2014 i
Table of Contents
Title Page
1 INTRODUCTION …………..………………………………………………………………………. 1
1.1 Dispenser Covered …………..……………………………………………………………. 1
1.2 Model Designation Format – G6101.................…………………………………………… 2
1.3 Technical Information – G6101…………….…………….………………………………… 3
2 SITE DESIGN & PREPARATION ……………………………………………………………… 5
2.1 Local, State, and Federal Codes…………………………………………………………… 5
2.2 Safety Precautions …………………………………………………………………………. 6
2.3 Ethanol Installations………………………………………………………………………….. 7
2.4 Existing Installations ………………………………………………………………………… 7
2.5 Dispenser Anchoring and Piping ………………………….……………………….……… 7
2.6 Remote Dispenser Applications …………………………………………………………… 8
3 INSTALLATION ………….…………………………………………………………………………. 9
3.1 Equipment Inspection ……………………………………………………………………….. 9
3.2 Typical Site Layouts ………………………………….…………………………………….. 9
3.3 Electrical Wiring …………………………………………………………………………….. 12
3.3.1 General……………………………………………………………………………… 12
3.3.2 Electrical Termination Descriptions……………………………………………… 12
3.3.3 Circuit Breakers & Emergency Electrical Disconnect …………………………. 13
3.3.4 Grounding…………………………………………………………………………... 13
3.3.5 Wiring……………………………………………………………………………….. 13
3.3.6 Conduit……………………………………………………………………………… 14
3.4 Hose and Accessories Installation ………………………………………………………… 15
3.4.1 General……………………………………………………………………………… 15
3.4.2 Balance Vapor Recovery ……..………………………………………………… 15
4 START-UP …………………………………………………………………………………………… 17
4.1 Initial Checkout ………………………………………………………………………………. 17
4.2 Bleeding Product Lines (Remote Dispensers) …………..……………………………….. 17
4.3 Initial Delivery ……………………………………………………………………………….. 18
4.4 Dispenser Operating Sequence (Troubleshooting) ……………………………………… 18
4.5 Meter Check ……………….………………………………………………………………… 19
4.6 Voltage Test …………………………………………………………………………………. 19
4.7 Complete Installation ……………………………………………………………………….. 19
4.8 Complete Start-Up Report …………………………………………………………………. 19
5 OPERATION ………………………………………………………………………………………… 21
5.1 Safety Items You Should Know …………………………………………………………… 21
5.1.1 Portable Tanks and Containers …………………………………………………. 22
5.1.2 Health Note………………………………………………………………………….. 22
5.2 Dispenser Operation ………………………………………………………………………… 22

ii 920943 Rev E July 2014
Table of Contents, continued
Title Page
6 MAINTENANCE ………………………………………………………………………………..…… 23
6.1 Preventive Maintenance …………………………………………………………………… 23
6.2 Strainer/Filter ………………………………………………………………………………… 23
6.3 Cleaning and Corrosion Protection Instructions …………………………………………. 24
6.4 Vapor Recovery …………………………………………………………………………….. 24
6.5 Meter Maintenance Issues …………………………………………………………………. 24
6.6 Register Power Reset ………………………………………………………………………. 25
6.7 Register …………….………………………………………………………………………… 26
6.8 Pump Handle to Reset Linkage ……………………………………………………………. 27
6.9 How to Get Service on Your Pump ……………………………………………………….. 27
APPENDIX A - DIMENSIONS & BASE LAYOUTS …………………………….…………………… 29
G6101D/2JK Single Remote Dispenser ………………….………..……………………. 30
Shelf Mounting Dimensions………………………………….………..……………………. 31
Hose Mast Dimensions ……………..……………………….………..……………………. 32
APPENDIX B – ELECTRICAL RATINGS & WIRING DIAGRAMS …………………….………….. 33
Component Electrical Ratings ………..……………………………………………………. 33
G6101D/2JK Single Remote Dispenser ……………….……………………………….... 34
10:1 Reed Pulser Option ………..………………………………………………………….. 35
100:1 Electronic Pulser Option …………………………………………………………….. 35
APPENDIX C – WARRANTY REGISTRATION ……………………..…………………….………….. 37
C.1 Warranty Registration Instructions ……………………………………………………….. 37
C.2 Warranty Registration Definitions ………………………………………………… 37

920943 Rev E July 2014 1
1 INTRODUCTION
1.1 Dispenser Covered
This manual describes the installation and operation of the Wayne Reliance®S1 G6101D Mechanical
Registration AST (above-ground storage tank) Fleet Remote Dispenser. This dispenser displays volume
only. This series includes the following base model:
Model
Number Type Hoses Products Solenoid Valves
G6101D/ Single 1 1 1” (2.5 cm)
The G6101D includes the following options as standard: enhanced capacity - 1” piping [2 suffix], AC
junction box [J suffix], and hose hanger [K suffix]. Other optional equipment, also represented by model
number suffix designations, is shown in Section 1.2.
Any questions concerning the installation and operation of the dispensers that are not covered in this
manual should be referred to your local Wayne authorized service personnel or call the Wayne Help Desk
at 1-800-289-2963 or e-mail [email protected].
NOTE: Terminology Used in This Manual:
Dispenser(s):Generic term used to refer to any model in the Wayne Reliance Series.
Remote Dispenser(s): Models utilizing a submersible pump in the tank to
provide fuel to the dispenser.

2 920943 Rev E July 2014
1.2 Model Designation Format
Main Body / First Suffix / Second Suffix
A / BCDEFG / ZZZZZZZZ / YYYYYYYYYY
Prefix A Hydraulic Style E
Hydraulics Listed for up to E85 (Blank
for normal)
/
Main Body
B Model Series G Global
C Registration Type 6 Reliance Mechanical Fleet-Volume only
D Model Style 1 Shelf-Mount
E Flow Rate Capacity 0 Standard & High Capacity
F Hose & Product
Configuration 1 Single
G Hydraulic System D Remote Dispenser
/
First Suffix Z Standard
2 Enhanced Capacity (1” Piping)
J Explosion-Proof AC Junction Box
K Hose Hanger
7A 10:1 Pulser
7B 100:1 Pulser
8 Liter Measure
Z 230VAC 50/60 Hz Operation
/
J Hose Mast Kit
S All Stainless Steel Exterior Panels
S1 Stainless Steel Sides, Top, Bezel, &
Base w/ Painted Galvanneal Doors
S2 Stainless Steel Door
W1 Two-Stage Solenoid Valves (Standard)
Customer
Specs Not Shown in Model
Number Optional Paint Colors - Doors

920943 Rev E July 2014 3
1.3 Technical Information
Application: For dispensing low viscosity petroleum fuels - diesel, including biodiesel
blends up to 20%; kerosene; gasoline, including standard oxygenated
blends; AvGas; and jet fuel (check with fuel supplier for any metal flow
path restrictions for AvGas and jet fuel, you must install the appropriate
filters, water separators, etc. needed for the fuel type being used.) - from
aboveground or underground storage tanks in applications where only
volume measurement is required. Dispensers with the “E” Prefix utilize
nickel-plating, hard anodizing, stainless steel, black iron piping, special
elastomers and a special fuel filter. While standard dispensers are Listed
to handle Ethanol products up to an E10 blend, “E” prefix dispensers are
Listed for use with products up to E85. Use hanging hardware rated for
the available fuel type dispensed. Note: Dispenser has not been evaluated
for Biodiesel (up to 20%), AvGas and Jet Fuel by UL.
Performance: Up to 22 GPM (83 LPM) maximum test rate. Actual flow rates will depend
upon the installation conditions, dispenser accessories, and the size of the
submersible pump.
Register: Veeder Root VR101, 4-wheel, non-computer. Displays on one side of
dispenser. U.S. gallons measure standard. Optional liter measure. Non-
resettable accumulative totalizer displays up to 9999999.9 on primary
side.
Reset Veeder Root electric reset. 120VAC, 50/60 Hz standard. Optional
240VAC, 50/60 Hz.
Meter: Wayne 2PM 2-piston meter. Adjustable calibration.
Junction Box: Explosion-proof AC junction box standard for power, reset complete,
submersible connections, and optional pulser.
Strainer: 120-mesh; removable for cleaning.
Filter: Optional external filter adapter with standard 10-micron filter element.
(Note: User should make sure the element meets the application and replace with
the appropriate element as necessary.)
Inlet: 1 ½” (3.8cm) NPT.
Outlet: 1” (2.5cm) NPT. ¾” (1.9cm) reducer bushing supplied for ¾” hose
assemblies.
Flow Control Valve: 1” (2.5cm), 2 stage (1 stage on E Prefix models), 120 VAC Valve.
Standard.
Cabinet Galvannealed steel. Hinged front and rear doors. Optional Stainless
Steel.
Finish: Silver powder coat finish with blue powder coated doors. Optional black,
green, red, silver, white, or yellow powder coated doors.
Nozzle Boot and
Hook Fits standard U.L. interchangeable automatic nozzles. Works with Emco Wheaton A4015 short spout and Husky V balance vapor recovery short
spout nozzles without modifications.
Options: 10:1 or 100:1 pulser on Volume, external filter, hose mast, and stainless
steel panels and doors. Shelf bracket.
International Options: 230VAC Hz operation (valve/reset) and 50 Hz
operation and liter measure.
Hose and Nozzle
Accessories: Not included.
Approvals: Underwriter’s Laboratories C-UL-US Listed. Note: CUL Listing does not
cover E85 Listings.

4 920943 Rev E July 2014

920943 Rev E July 2014 5
2 SITE DESIGN & PREPARATION
2.1 Local, State, and Federal Codes
The Wayne Reliance Series models are only part of a fuel dispensing system. A fuel dispensing system
typically comprises equipment and safety devices from a variety of manufacturers. It is the responsibility
of the pump owner to have a qualified installer ensure that all of the necessary equipment and
accessories are included to meet the requirements of the application and all tanks (both underground and
aboveground), piping and fittings, check valves, leak detection and corrosion protection devices, wiring,
venting systems, filtration devices, safety valves, submersible pumps, etc. are installed in accordance
with the manufacturer’s instructions and in compliance with local and regional building codes and
requirements pertaining to private fueling facilities (or other locations where the pump may be installed).
These requirements may include references to the National Electrical Code (NFPA 70); Motor Fuel
Dispensing Facilities and Repair Garages (NFPA 30A); Flammable and Combustible Liquids Code (NFPA
30); 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.
Where local requirements do not specify applicable codes, Wayne recommends using the codes listed
above. These codes are comprehensive and detailed, often requiring 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 regulations and practices
be consulted before starting installation.
Pertinent information and codes are available from the following sources:
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]
(continued on next page)

6 920943 Rev E July 2014
United States Environmental Protection
Agency
Office of Underground Storage Tanks
401 M St., SW (05-400WF)
Washington, DC 20640
[phone] (Underground Storage Tanks)
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]
Western Fire Chiefs Association
5360 South Workman Mill Road
Whittier, CA 90601
[phone]
NOTE: Other regulatory codes may apply. Consult your local and regional code requirements to
determine which codes are applicable for your location.
2.2 Safety Precautions
NFPA 30A states that:
“When maintenance to Class I dispensing devices becomes necessary and such maintenance is
capable of causing 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 devices, to the pump serving the dispensing devices,
and to all of associated control circuits shall be shut off at the main electrical disconnect
panel.
The emergency shutoff valve at the dispenser, if installed, shall be closed.
All vehicular traffic and unauthorized persons shall be prevented from coming within 20 ft. (6
m) of the dispensing device1.”
Electric shock hazard! More than one disconnect switch may be required to de-energize the
pump 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
Regulations (29CFR1910), Control of Hazardous Energy Source (Lockout/Tagout).
1. Reprinted with permission from NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair
Garages 2000 Edition, Copyright ©2000, 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.
WARNING

920943 Rev E July 2014 7
2.3 Ethanol Installations
All Wayne dispensers are rated and Listed for use with Ethanol blends up to and including E10.
For blends that exceed E10, the dispenser must be supplied with the “E” prefix option. “E” prefix
dispensers are Listed for use up to and including E85 blends. The “E” prefix is only available on
remote dispensers. When considering an installation, all fluid handling components must be
rated for the type of fuel that will be dispensed. Piping connections for above E10 must use UL
Classified Saf-T-Lok Teflon pipe sealant.
Some alternative fuels and additives can degrade the dispenser performance and integrity if
the dispenser is not designed for that product. In addition, converting between fuel types
(especially between an alternative fuel to a standard fuel) can degrade can degrade the
dispenser performance and integrity. Before changing fuel types, always make sure that the
dispenser is designed for use with the new product. In addition, the dispenser should be
closely monitored for any sign of degradation or leaks after the conversion. This monitoring
should take place in the days, weeks and even a month after the conversion takes place. Leaks
can result related to the conversion which can create an environmental hazard.
2.4 Existing Installations
If the dispenser is to be installed on an existing installation, it is still the responsibility of the
installer to read and follow this installation manual in its entirety and make sure the existing
installation meets the requirements and satisfies local, state, and federal codes.
2.5 Dispenser Anchoring and Piping
This dispenser is designed to be shelf-mounted. The base of the dispenser contains four
bolt holes (7/16” holes for 3/8” bolts) for anchoring the dispenser to the shelf. Reference
Appendix A, Dimensions & Base Layouts, for dispenser dimensions and for the dimensions
for Wayne’s optional shelf bracket.
Vertical supply risers and electrical conduits must be located per the Installation Drawing.
Proper height must be maintained to avoid undue stress on the dispenser. See Section 3 for
wiring and conduit requirements. Reference Appendix B for Wiring Diagrams.
Supply piping should be selected and installed in accordance with local, state, and federal
regulations. The piping manufacturer’s instructions should be followed for the proper
trenching, connection, sealing, corrosion prevention, pressure relief, and leak detection and
containment. Inlet connections for Ethanol applications exceeding E10 must use schedule
40 pipe using UL Classified Saf-T-Lok Teflon pipe sealant.
For installations with balance vapor recovery, the vapor recovery system should be installed
in accordance with local, state, and federal regulations. The vapor recovery system
manufacturer’s instructions should be followed for the proper vapor splitter, return piping,
shear section, and hose accessories.
Wayne dispensers are specified to work at a maximum normal operating pressure of 50 PSI.
Normal operation can create pressure spikes which may exceed 50 PSI. These normal spikes
are easily handled by the dispenser. Wayne dispensers are designed and tested to withstand
pressures up to 250 PSI, for short durations, without rupture or permanent distortion. Certain
extreme conditions, such as installations with above-ground tanks and very long runs of pipe,
can create pressure spikes that may damage the dispenser and its accessories. If these
conditions exist, measures must be taken to reduce or dampen these pressure spikes to
prevent damage to the equipment.
WARNING
WARNING

8 920943 Rev E July 2014
2.6 Remote Dispenser Applications
To maximize flow, position the remote dispenser and tank as close together as possible and
minimize the number of turns in the piping. Consult the submersible pump manufacturer for
the proper sizing of the submersible pump, any necessary leak detection equipment, and
installation details.
Product piping must avoid the creation of vapor in the lines and deliver a minimum pressure
of 25 psi at the remote dispenser inlet when all dispensers connected to the same
submersible pump are operating. The dispenser’s maximum operating pressure is 50 psi.
A UL Listed, rigidly anchored emergency shutoff valve must be installed, in accordance with
the manufacturer’s instructions, in each supply line at the base of each dispenser.
NOTE: On E85 dispenser models, use shear valve part number 10P-0152E85 manufactured by
OPW.
WARNING

920943 Rev E July 2014 9
Union-Top Emergency
Shear Valves must be
used due to height
restrictions.
1-1/2" Supply
Line
(If Solenoid Valve
has pressure relief,
separate relief
valve is not needed.)
Shelf
Bracket
Model G6101D
Dispenser
Electrical
Conduit
1-1/2" Union-Top
Emergency
Shear Valve
Relief Valve
Expansion
Submersible
Pump Gate Valve
(Block Valve)
(Anti-Siphon)
Solenoid Valve
3 INSTALLATION
3.1 Equipment Inspection
Examine the shipment immediately upon arrival to make certain there has been no damage
or loss in transit. Make sure that all the component parts, including keys and any optional
equipment, are accounted for.
Check and save the Packing Slip, Bill of Lading, Invoice, and all other documents included in
the shipment.
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 Warranty.
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-resistant 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.
3.2 Typical Site Layouts
Figure 3-1 Submersible Site Layout
WARNING

10 920943 Rev E July 2014
Vacuum
Breaker
Suction Pump
with Vacuum
Breaker
1-1
2" Union-Top
Emergency
Shear Valve
Electrical
Conduit
Model G6101D
Dispenser
Shelf
Bracket
1-1
2" Supply
Line
Figure 3-2 Suction Pump Site Layout

920943 Rev E July 2014 11
UL Listed Balanced
Hose Breakaway
Vapor Recovery Equipment is
to be Installed According to the
Manufacturer's Instructions.
No Fluid Traps Should Exist
During the Fueling Sequence.
Return Line (Not Shown) Exits
Co-Axial Adapter and
Returns Fuel to the Tank.
Line Should be Pitched
Towards the Tank.
Outlet of Dispenser Piped to
Input of Co-Axial Adapter
Using Either Pipe, UL Listed Hose
Assembly, or a Combination of Both
UL Listed Co-Axial Adapter
Securely Mounted to Tank
or Bracket
Figure 3-3 Vapor Recovery Installation Guidelines

12 920943 Rev E July 2014
3.3 Electrical Wiring
3.3.1 General
Wayne recommends employing a qualified licensed electrician for all wiring.
A hazardous liquid is being handled, so it is extremely important to ensure that all wiring and
conduit is in accordance with all local, state and federal regulations, including, but not limited
to, the National Electrical Code (NFPA 70), NFPA 30, and NFPA 30A.
NOTE: U.L. requires that all electrical connections to the dispenser be made with threaded, rigid
conduit and properly sealed conductors. All dispensers and electrical connection boxes
must be grounded per NFPA 70.
3.3.2 Electrical Termination Descriptions
The following describes the electrical inputs and outputs utilized in the Wayne Reliance Series
and can provide assistance in interpreting the Wiring Diagrams in Appendix B.
3.3.2.1 Ground
A good ground ensures proper operation of the equipment and provides the necessary safety
factors. A ground wire must be connected between the unit’s AC junction box ground lug and the
main electrical service panel. One (1) earth ground connection is required per unit.
3.3.2.2 Dispenser Feed
The pump feed is a 115VAC [international (int’l) - 230VAC] input which is supplied to the
dispenser to activate the reset motor. Without power supplied to this line, the unit will not reset
when the pump handle is turned on. This feed is also connected to the input of one of the
internal switches of the electric reset. When the reset finishes its cycle, the 115VAC (int’l -
230VAC) input to the switch will be passed through as an output to power the solenoid valve,
and to power the submersible feed.
3.3.2.3 Reset Complete
When the reset finishes its cycle, the 115VAC (int’l – 230VAC) input to the switch is also passed
through as an output to the reset complete line. When connecting to a fuel management system,
the reset complete line may be required to indicate to the fuel management system when the
reset process is complete. When the handle is turned off, the signal returns to 0VAC. (This is the
same line used to turn on/off the solenoid valve. It is the orange wire in the AC junction box.)
This line is also used to power the solenoid valve on top of the AST for applications where one
dispenser is connected to the submersible.
3.3.2.4 Return
Commonly referred to as the neutral wire, the return is the AC current return line back to the
circuit breaker panel for all connected devices (reset motor and solenoid valve). The wire gauge
should match the gauge of the submersible feed.
3.3.2.5 Submersible Feed
The submersible feed is a 115VAC (int’l - 230VAC) output which is supplied from the reset to a
submersible starter relay for remote dispensers. When the reset finishes its cycle, 115VAC (int’l -
230VAC) is supplied to drive a starter relay.
3.3.2.6 Pulser
The pulser option provides a DC output that is used to communicate the quantity dispensed to
fuel management systems. The pulser transmits electrical signals (pulses) based on revolutions
of the register output shaft. The 10:1 pulser option is a reed pulser which transmits 10 pulses for
each unit of measure (gallon or liter). The 100:1 pulser is an electronic pulser which transmits
100 pulses for each unit of measure (gallon or liter).

920943 Rev E July 2014 13
3.3.3 Circuit Breakers & Emergency Electrical Disconnect
The power to the dispenser should be on a separate dedicated breaker. Two (2) dispensers
may be grouped together on a common breaker if the submersible pump has its own
breaker. It is not recommended to group more than two (2) remote dispensers to the same
breaker, because you lose the ability to isolate the power to the dispenser in case of
problems.
If multiple remote dispensers provide power to the same submersible pump, then the
dispenser breakers must be on the same phase of power or damage to the equipment may
result.
Both legs of any AC circuit must be broken.
Install the correct breaker size based upon the model and/or voltage setting.
In addition to the circuit breaker requirements, in accordance with local, state, and federal
regulations, the fueling site should include a clearly identified emergency electrical
disconnect switch that simultaneously removes power to all of the electrical equipment
installed in the hazardous classified areas of the fuel site, including, but not limited to, the
fuel dispensers, submersible pumps, and fuel management systems. The switch should be
located within a convenient distance of the fueling equipment and all employees and fuel
site users should be trained on the location and function of the emergency switch.
3.3.4 Grounding
All dispensers and electrical connection boxes must be grounded per NFPA 70.
Connect a ground wire between the AC junction box ground lug and the main electrical
service panel.
Make sure a ground rod is properly installed and wired to the ground bus strip of the main
electrical service panel in accordance with the National Electrical Code. Unless prohibited by
local regulations, it is recommended that the neutral and ground bus strips be tied together.
3.3.5 Wiring
All wiring should be UL-Listed, gasoline- and oil-resistant wire.
All AC wire terminations must be made in the AC junction box. Take care when handling the
junction box cover. Keep the mating flange clean and free of burrs and scratches. Make sure
all wire connections are tightly spliced and secured with a wire nut. 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.
3.3.5.1 Wire Size
For remote dispensers using a submersible starter relay, 12 AWG wire is recommended for
most applications for the control lines (pump feed, return, submersible drive). The wire
gauge for the submersible pump should be determined by the size of the motor and the
length of the run according to the manufacturer’s installation instructions.
The DC wire size for the optional pulser lines must be 18 AWG. Reference the installation
instructions of the fuel management system manufacturer regarding the ability to run the DC
wires with AC wires and the necessary wire specifications (shielding, etc.).

14 920943 Rev E July 2014
3.3.6 Conduit
Use UL Listed threaded, rigid, metal conduit and properly sealed connectors.
All threaded connections must be drawn up tight and have a minimum of five threads
engaged.
Do not use flexible conduit or knockout boxes.
When connecting to a fuel management system, consult the manufacturer’s instructions for
conduit requirements for AC and DC lines.
The following charts are provided as a guide to help determine the proper conduit sizes.
Step 1 Determine the square area for each wire by looking up the desired wire gauge on
the following chart and writing down the corresponding square area from the
Square Area column. Calculate the total area by adding up the square area for
each of the wires.
THHN/THWN Wire Areas
Wire Gauge Diameter Square Area in mm In
2
mm
2
18 .090 2.29 .007 4.1
14 .118 2.95 .011 6.8
12 .135 3.43 .014 9.2
10 .169 4.29 .022 14.5
8 .216 5.49 .037 23.7
6 .259 6.60 .053 34.2
4 .331 8.41 .086 55.5
3 .359 9.14 .102 65.6
2 .394 10.01 .122 78.7
Step 2 In the 25% Fill Area column in the table below, find the square area that is closest
to, without exceeding, the calculated total area. The value listed on the same row
in the Trade Size Conduit column is the diameter of the required conduit.
Trade Size Conduit Square Area
Trade Size
Conduit Internal Diameter Square Area 25% Fill Area
In mm in2mm2in2mm2
½” .629 16 .303 196 .076 49
¾” .826 21 .532 343 .133 86
1” 1.063 27 .862 556 .215 139
1 ¼” 1.378 35 1.50 968 .375 242
1 ½” 1.614 41 2.04 1314 .509 329
2” 2.087 53 3.36 2165 .839 541

920943 Rev E July 2014 15
3.4 Hose and Accessories Installation
3.4.1 General
Hose assemblies should be U.L. Listed and installed in accordance with the manufacturer’s
instructions.
Install the hose assembly after the dispenser is installed.
oTo ensure a proper joint, wash all cutting oil off the threads and use a U.L. Listed
gasoline-resistant pipe joint sealing compound.
oPlace the compound on male threads only; be careful not to get any excess compound
on the inside of the fittings.
oInstall the fixed end of the hose to the dispenser outlet; secure according to the
instructions of the sealing compound and hose manufacturer.
oInstall the nozzle, and other hose accessories – swivels, breakaways, etc. – on the hose
according to the manufacturer’s instructions.
NOTE: Do not use the joint sealant compound on balanced vapor recovery
accessories. Reference the manufacturer’s instructions.
NFPA code requires a Listed emergency breakaway device, designed to retain liquid on
both sides of the breakaway point, to be installed on each hose. 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.
NOTE: Models with “E” prefix, for dispensing up to and including E85, must use only the
following hose and accessories. All connections for these devices must use UL
Classified Saf-T-Lok Teflon pipe sealant:
OPW hose nozzle valves models: 21GE, 21GEA
OPW breakaway model: OPW 66V-0492
OPW swivel connector model: 241TPS-0492
Veyance Technologies hose assembly model: Flexsteel Futura Ethan-All
Use only UL Listed hoses, nozzles, breakaways, and other hose accessories. Continuity must
be present between the dispenser outlet and nozzle spout to prevent static discharge while
fueling. Continuity must be checked for the 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
or death.
3.4.2 Balance Vapor Recovery
The nozzle hook/boot assembly can accommodate an Emco Wheaton A4015 Short Spout or
a Husky V Short Spout nozzle without modification.
The vapor recovery installation should follow the instructions supplied by the manufacturer
for the vapor recovery components and should comply with all codes, both local and
national.
The discharge elbow can be oriented upwards for piping to an overhead splitter.
WARNING

16 920943 Rev E July 2014