HI - HOSE CENTURY

INSTALLATION SUCTION PUMPS AND

OPERATION
REMOTE DISPENSERS

3/G3000
 INSTALLATION & OPERATION

HI - HOSE CENTURY SUCTION PUMPS

AND REMOTE DISPENSERS

3/G3000.

March 2003 Séries No 921193 Rev.C

Module “INSTALLATION & OPERATION”
Intelligent Global Electronics Module
Dresser Europe GmbH
Wayne Germany Dresser Inc.
All rights reserved.
Printed in Europe

No part of this publication may be electronically or mechanically reproduced, stored in a retrieval system, or
transmitted, in any form or by any means without express written permission of Dresser Inc. Translation of this
material to another language without express written permission of Dresser Inc. is prohibited.

The information in this publication is for informational use only and is subject to change without notice. The
contents should not be construed as a commitment by Dresser Inc. who assumes no responsibility or liability
for inaccuracies that may appear in this publication.

Séries No 921193 Rev.C March 2003

 WARNING

READ THIS MANUAL BEFORE YOU BEGIN

Dispensers have both electricity and 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.
Follow all rules, codes and laws that apply to your area and installation.

SAFTY PRECAUTIONS- INSTALLATION AND MAINTENANCE

Always make sure ALL power (motors and electronic head) 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 serving 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 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.

USE ONLY GENUINE PARTS.

For product liability to be valid no changes, completions or similar may be done in the equipment without the
written consent of Wayne.

HOW TO CONTACT WAYNE

Trouble with the installation and operation of the dispenser should be referred to your Wayne service
personnel or Wayne Technical Support.

INDICATORS AND NOTATIONS

Danger indicates a hazard or unsafe practice which, if not

DANGER avoided, will result in severe injury or possible death.

Warning indicates a hazard or unsafe practice which, if not

WARNING avoided, may result in severe injury or possible death.

Caution indicates a hazard or unsafe practice which, if not

CAUTION avoided, may result in minor injury.

Important information to consider, otherwise, improper

Note: installation and/or damage to components may occur.

Séries No 921193 Rev.C 1 March 2003

Séries No 921193 Rev.C 2 March 2003
 TABLE OF CONTENTS
1 INTRODUCTION.......................................................................................................... 8
1.1 Dispensers Covered...................................................................................................................... 8
1.2 Model Description ......................................................................................................................... 8
1.3 Model Designation Format ........................................................................................................... 9
1.4 Technical information ................................................................................................................. 10
1.5 Safety Precautions ...................................................................................................................... 11
1.6 Local, State and Federal Codes ................................................................................................. 11
1.7 Inspect The Equipment............................................................................................................... 11
2 GAS STATION PREPARATION ................................................................................ 12
2.1 Emergency Shutdown................................................................................................................. 12
2.2 Safety switch................................................................................................................................ 12
2.3 Emergency shut-off valve........................................................................................................... 13
2.4 Pipelines (Remote Pumps) (For UL markets) ........................................................................... 13
2.5 Check Valves (Suction Pumps Only) (For UL markets) .......................................................... 15
2.6 Connecting More Than One Pump To a Tank (Suction Dispensers) (For UL markets) ....... 15
2.7 Fill Pipe (For UL markets)........................................................................................................... 15
2.8 Venting (For UL markets) ........................................................................................................... 16
3 INSTALLING THE DISPENSER ................................................................................ 17
3.1 Cable drawing .............................................................................................................................. 20
3.1.1 Routing of power cables...................................................................................................... 20
3.2 Emergency shutdown ................................................................................................................. 20
3.3 Safety switch................................................................................................................................ 21
3.4 Submersible Pump Controls ...................................................................................................... 21
3.5 Multiple Dispenser Wiring .......................................................................................................... 22
3.6 Hose Installation (UL) ................................................................................................................. 22
3.7 Bleeding Product Lines (Remote Dispenser) ........................................................................... 23
3.8 Priming Suction Pumps.............................................................................................................. 23
3.9 Above Ground Storage Tanks.................................................................................................... 25
4 START-UP PROCEDURE ......................................................................................... 26
4.1 Hose Position Coding ................................................................................................................. 26
4.2 Nozzle Switch Check................................................................................................................... 27
4.3 Meter Check ................................................................................................................................. 28
4.3.1 Pumps Calibration............................................................................................................... 28
4.4 Link Belt Adjustment .................................................................................................................. 29
4.4.1 Z-profile belt ........................................................................................................................ 29
4.5 Adjusting Compact Pumping Unit ............................................................................................. 29
4.6 Fluorescent Lights ...................................................................................................................... 30
4.7 Totalizer Readings ...................................................................................................................... 30
4.7.1 Electro-mechanical volume totalizer (Option) ..................................................................... 30
4.7.2 Volume Totalizer Through Preset ....................................................................................... 30
4.8 Coalescent Filter Pump – Start Up Procedure ......................................................................... 31
4.9 Press Filter Pump – Start Up Procedure ................................................................................... 31

Séries No 921193 Rev.C 3 March 2003

5 COMPUTER OPERATION.........................................................................................33
5.1 Introduction ................................................................................................................................. 33
5.2 Programming functions ............................................................................................................. 33
5.3 Access to functions.................................................................................................................... 33
5.4 Exit (F00) ...................................................................................................................................... 35
5.5 Password Change (F33) ............................................................................................................. 36
5.6 Filling Modes (F01) ..................................................................................................................... 36
5.7 Checking the Electronics Totals (F11)...................................................................................... 36
5.7.1 Access to the statistic model .............................................................................................. 38
5.7.2 Mode “Statistics” ................................................................................................................. 39
5.8 Changing Unit price (F03) .......................................................................................................... 40
5.8.1 Changing prices on Side A ................................................................................................. 40
5.8.2 Changing prices on Side B ................................................................................................. 43
5.9 Pump Startup .............................................................................................................................. 45
5.9.1 Changing decimal points of unit price ................................................................................ 45
5.9.2 Changing decimal points of Paying Total ........................................................................... 47
5.9.3 Changing decimal points of Volume................................................................................... 48
6 DEMOUNTING ...........................................................................................................50
6.1 Preparations ................................................................................................................................ 50
6.2 Drain fuel from the pump ........................................................................................................... 50
7 OPERATION ..............................................................................................................51
7.1 Introduction ................................................................................................................................. 51
7.2 Portable Tanks and Containers................................................................................................. 51
7.3 Operation of the Preset (Option) ............................................................................................... 51
7.3.1 Twelve button keyboard ..................................................................................................... 52
7.3.2 Five button keyboard .......................................................................................................... 53
7.4 Health Note .................................................................................................................................. 54
7.5 Hazardous Zone Areas ............................................................................................................... 54
7.5.1 Hazardous Zone UL ........................................................................................................... 55
7.5.2 Hazardous Zone IEC .......................................................................................................... 56
7.6 How To Get Service On Your Dispenser .................................................................................. 57
8 PREVENTIVE MAINTENANCE .................................................................................58
8.1 Water Damage ............................................................................................................................. 58
8.2 Maintenance Guidelines............................................................................................................. 58
8.3 Cleaning of filters........................................................................................................................ 58
8.3.1 Inlet filter (Standard) ........................................................................................................... 59
8.3.2 Inlet filter (US)..................................................................................................................... 59
8.3.3 After filter cleaning: ............................................................................................................. 60
8.3.4 Coalescent Filter................................................................................................................. 60
8.3.5 Press Filter.......................................................................................................................... 60
9 ENGINEERING DRAWINGS......................................................................................61
9.1 Installation Instructions 3/G3000 .............................................................................................. 62
9.2 Electrical Installation Scheme 3/G3000P.................................................................................. 65
9.3 Electrical Installation Scheme 3/G3000D ................................................................................. 66
9.4 Installation Instruction of Models 3/G3397P/FC-FP ................................................................ 67
9.5 Installation Instruction of Suction Models ............................................................................... 68
9.6 Installation Instruction of Remote Models ............................................................................... 69
9.7 7151-C – Typical Electric Installation Scheme......................................................................... 70

Séries No 921193 Rev.C 4 March 2003

 FIGURES

Figure 1 Model Description ................................................................................................................................... 8

Figure 2 Model Designation Format ................................................................................................................... 10
Figure 3 Emergency chut-off valve ..................................................................................................................... 13
Figure 4 Decal..................................................................................................................................................... 17
Figure 5 Lifting the pump .................................................................................................................................... 18
Figure 6 Component Electrical Ratings .............................................................................................................. 19
Figure 7 Routing of power cables ....................................................................................................................... 20
Figure 8 Submersible Pump Relay Specifications.............................................................................................. 21
Figure 9 Priming Suction Pumps ........................................................................................................................ 23
Figure 10 Priming Suction Pumps (Duo with one twin meter) ............................................................................ 24
Figure 11 Location of Pipe Plugs in Pumping Unit. ............................................................................................ 25
Figure 12 Hose Position Coding for Century Series........................................................................................... 26
Figure 13 Calibration door .................................................................................................................................. 28
Figure 14 Z-profile belt........................................................................................................................................ 29
Figure 15 Compact Pumping Unit....................................................................................................................... 30
Figure 16 Remote controlHoofer Doofer............................................................................................................. 33
Figure 17 Hazardous Zone Diagram. (UL) ......................................................................................................... 55
Figure 18 Hazardous Zone Diagram (IEC) ......................................................................................................... 56
Figure 19 Inlet filters ........................................................................................................................................... 59
Figure 20 Strainer Assembly (US) ...................................................................................................................... 59

Séries No 921193 Rev.C 5 March 2003

HEALTH AND SAFETY REGULATIONS
When using inflammable liquids it is important that the following rules and regulations are followed:

Explosion hazard

Prohibited to smoke

Prohibited to take fire

Within a radius from the pump it is prohibited to smoke and light or enter fire.

Idle running is prohibited while fuelling.

Distribution box must be easily accessible and may not be blocked with goods or similar.

Always let specialists make electrical installations of all kinds. Special regulations are applied!

WARNING!
Never run a leaking pump!
(Failure to observe this information results in immediate danger to life.)

Please watch any leakage from pumps. If there is a leakage, cut the power to the pump (motors and electronic
head) and call Wayne After Sales Service.

Always follow the regulations regarding handling of petrol and oil, published by each oil company.

Always follow the special authority demands regarding the vapour recovery system.

Make sure that adequate functioning fire-extinguisher is in its place and not blocked.

WARNING!
ge which may result in electric shock or fire, disconnect the main power (motors and electronic head)
prior to any work

WARNING!
Action to be taken after elimination of short-circuits in components located behind the motor
protection: contactors and protective motor switches must be replaced.

To avoid incorrect function or that the pump is damaged, make sure that there is enough fuel in each tank.

Adequate personal safety equipment should be used by maintenance of the equipment (gloves, breathing
mask, glasses etc.).

Séries No 921193 Rev.C 6 March 2003

Product liability
For product liability to be valid no changes, completions or similar may be done in the equipment without the
written consent of Wayne.

Intended use
The pump is designed to move (pump) petrol, kerosene and diesel in correct quantities from tank to vehicle.

Product limitation
The pump is designed and approved for measuring of petrol, kerosene and diesel, all in accordance with type
approval.

Séries No 921193 Rev.C 7 March 2003

1 INTRODUCTION

1.1 Dispensers Covered

This manual describes the installation and operation of Hi - Hose Century dispensers. Hi - Hose
Century dispensers are designated by 3/G3000 model number series. These dispensers have
iGEM computer and either Lift-to-Start or Auto on nozzle boot configurations.

The 3/G3000 dispenser may be installed and operated as a stand-alone unit or as a component
part of a Wayne Management Control System. This manual provides installation and operation
information for 3/G3000 series dispensers operating as stand-alone units; however, information
concerning Wayne Control Systems is included where appropriate. Each side of the dispenser is
referred to as a fuelling point for connection to a control system. Single-sided dispensers are
designated by an "R" in the model number suffix and have only one fuelling point. Complete
installation and operation information for the appropriate Wayne Control System can be
obtained from the manuals provided with the system.

For programming the iGEM computer on these models, refer to the Programming Manual, Part
Number 921279.

A description of each model is shown in Figure 1 and the model number suffix designations are
defined in Figure 2.

1.2 Model Description

Configurations for Global “H”Style & Dispensers

Single Product
Pump and Dispenser
Two Hose

3/G3397 PFP
3/G3397 PFC 3/G3387 3/G3397 PFP – 3/G3397 PFC
Two Products
Pumps and Dispensers
Two Hose
3/G3388

Four Hose Four Hose

3/G3389 3/G3399
3/G3388 3/G3389 3/G3399

Multi-Grade
Pumps and Dispensers
Four Hose
3/G3498
Six Hose
3/G3390
Eight Hose 3/G3390 3/G3490 3/G3498
3/G3490
Figure 1 Model Description

Séries No 921193P Rev.C 8 March 2003

 1.3 Model Designation Format

Prefix / Main Body / First Suffix / Second Suffix

XXX / ABCDEF / ZZZZZZZZ/YYYYYYYY
Prefix
Electronic & 3 iGEM + iGHM
X
Hydraulic Configuration

Main Body
Model Series G Global A
3 Hi-Hose Century B

Model Style 3 1,2 or 3 products pump or dispenser

C
4 4 products pump or dispenser

Construction 8 Narrow body

D
9 Wide body

Nozzle & Product 7 Twin (Duo I), Lane Oriented

Configuration
8 Duo (Duo II), Lane Oriented E
9 Quadro, Lane Oriented
0 MGD, 3 or 4 products

Hydraulic System D Dispenser - Remote

F
P Pump - Self Contained

Activation Default - Lift -to-Start

A Auto On (not UL Listable) - Magnetic Activation
on Nozzle
A1 Auto On (not UL Listable) - Magnetic Activation
on Flipper
B Flow Indicator
D 3 Phase Operation
E Alcohol Densimeter (Brazil only)
G Filter (Remotes only)
J Explosion Proof J-Box
Z
O No EMT's - Electronic Totals Only - Default
One (1) EMT per Product

Stop Button P Stop Button - Electrical Interruption

P1 Stop Button - Computer Controlled Function

Preset S Preset - 16 button with dedicated display -

reserved
S1 Preset - 12 Button - Shared functions with
sales display
S2 Preset - 5 Button - Shared functions with sales
display

Séries No 921193 Rev.C 9 March 2003

2nd Suffix
Options 3 Quadro Dispenser LCD U. Price per each
Product - Default Sales U.P. LCD Only
B Drip Pan
D reserved for CAT option
E Export Crating
G 3 Pole Relay
H Hose Retractor

Communications Default is US Current Loop

I ISM - DART - Default is US Current Loop
I2 ISM - DART/IFSF - Default is US Current Loop
J Hose Mast
L Heating element and thermostat - Europe Only Y
K EMT per each hose - Default one (1) EMT per
product

Inlet Check Valve Default is No Inlet Check Valve

M Spring Loaded Inlet Check Valve
M1 Spring Loaded Inlet Check Valve with Bleeding
device
P Door Lock with unique keys per each unit -
Default 1290 Key Lock
U UL Approval - Default is IEC

Control Valves Default - Global Proportional Control Valves

W No Solenoids (Controls Suction Pump Relay -
No Preset) - Suction Only
Luis Hoyo 11/06/2000 Rev. D . W1 On/Off Solenoid Valves (No Preset)

Figure 2 Model Designation Format

1.4 Technical information

Surrounding environment
Corrosive outdoor environment, -30 C - +60 C, good ventilation. Must be located outdoors.

Product limitations
The product is designed and approved for measuring of petrol, kerosene, ethanol and
Noise
The noise level does not exceed 70 dB (A).

Weight
Between 116 and 450 kg depending on design.

Note!
Where referred “to UL Markets”, understand as markets where the standards follow the
American UL standards or similar.

Séries No 921193 Rev.C 10 March 2003

 Remark!
This product has no UL certification.

Power consumption
Maximum power consumption is between 850 W and 2400 W depending on the number of
motors.

1.5 Safety Precautions

For UL markets, NFPA 30A include 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 begins:
• Only persons knowledgeable in performing 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; and
• All vehicle traffic and unauthorized persons shall be prevented from coming within 20 feet
(6 m) of the dispensing device."

WARNING!
ELECTRIC SHOCK HAZARD! More than one disconnect switch may be required to de-
energize the dispenser. Use a voltmeter to make sure circuits in the dispenser are de-
energized. Failure to do so may result in serious injury.

WARNING!
Mind the rotating V-belt when the cover of the hydraulic unit is removed!

1.6 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). Therefore, it is strongly recommended a licensed engineer or contractor
familiar with local regulations and practices be consulted before starting installation.
For UL markets, these requirements are referenced in the National Electrical Code (NFPA 70);
the Automotive and Marine Service Station Code (NFPA 30A); the Flammable and Combustible
Liquids Code (NFPA 30); the Code of Federal Regulation, Title 40 (Protection of Environment),
Section 280 (40- CFR 280); and other codes.

1.7 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 transmit 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

Séries No 921193 Rev.C 11 March 2003

2 GAS STATION PREPARATION
By installation of fuel stations the rules and regulations of the authorities for each country must be
followed. You must always be updated regarding changes and completions of the rules.
Therefore, it is strongly recommended a licensed engineer or contractor familiar with local
regulations and practices are consulted before starting installation.
If the dispenser is to be attached to an existing underground installation, check the installation carefully.
The Wayne Division is not responsible for the improper operation of it due to accidents, abuse or faulty
installation.
All equipment must be installed in accordance with all applicable regulation as described in Section 1.6
page 11.
WARNING!
Follow strictly local installation instructions to avoid pipe/pump leakage that may cause
substantial fuel leakage.

2.1 Emergency Shutdown

To be able to stop an unrequested outflow of petrol, the electric control of the meters must be
connected in such a way that the flow can be stopped. This function should be designed as an
emergency shutdown. A reset of the emergency shutdown must not result in an automatic start
of the pump motor. The emergency shutdown is marked according to national standard and
should be located in such a way that it can easily be reached by the pump area supervisor. The
emergency shutdown must turn off the supply power in the electrical control center to all meter
cabinets. All concerned staff must be informed of the location and function of the emergency
shutdown."

2.2 Safety switch

The pump is not equipped with electric circuit breaker, but the same has to be installed in the
distribution board of the station.
Note!
"Every electrical supply must be supplied with a disconnecting device according to the
requirements in EN 60204-1."

Séries No 921193 Rev.C 12 March 2003

 2.3 Emergency shut-off valve
WARNING!
For remote dispensers, a Listed1, rigidly
anchored emergency shut-off valve must be
installed, in accordance with the manufacturer's
instructions, in each supply line at the base of
each dispenser. For a typical emergency valve
installation see Figure 1. Failure to install the
proper emergency shut-off valve will present a
hazardous condition that could result in serious
injury.

"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 Figure 3
on NRTL’s, see Title 29, Parts 1907 and 1910 of the Emergency chut-off valve
Code of Federal Regulations, Safety Testing or
Certification of Certain Workplace Equipment and
Materials.

2.4 Pipelines (Remote Pumps) (For UL markets)

Product piping 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. The dispenser's maximum operating pressure rating is 50 psi.
Dig a trench between the tanks and the dispenser foundation. The trench must be deep enough
to place the product line at least 18 inches (46 cm) below the surface of the ground at its highest
point (more in hot climates or high altitudes) and the slope upwards from the tank should be
approximately 1/4 inch per foot (1 cm lift per 48 cm length). The trench shall be as straight as
possible, avoiding curves in the line. If the distance from the tank to the dispenser is 60 feet
(18.2 m) or less, 1 1/2 inch (I.D.) pipe may be used; if the distance is greater than 60 feet (18.2
m), use 2 inch (I.D.) pipe to lessen friction. All piping must conform to local fire regulations.
Wayne recommends using new galvanized pipe and fittings for supply lines. Galvanized pipe is
also recommended for the fill and vent lines. The pipe used for the product line must be clean.
To clean it, rap it with a hammer to loosen excessive spelter and dirt, and then swab it out with a
rag soaked in mineral spirits. Pull the soaked rag though the pipe by attaching it to the end of a
long wire. Be careful to keep the pipe clean during its installation. All pipe threads should be
properly cut and each end of the pipe reamed. Clean the pipe of thread cutting and shavings.

Séries No 921193 Rev.C 13 March 2003

 To ensure tight pipe joints, wash all cutting oils off the threads and use a UL-Classified pipe joint
sealing compound, suitable for use in devices handling petroleum-based products. Place the
sealant on male threads only, being careful not to get excess inside the pipe or fittings when
making up Joints.
Use nothing but ground joint unions in underground pipe work. No gasket or pipe sealing
compound is required with this type of union. We recommend the use of at least one union in
the dispenser supply line for accessibility in the event of trouble developing later. This should be
placed as close to the tank as possible.
To prevent Zinc contamination of diesel fuels. It is recommended that all diesel fuel supply lines
be non metallic, UL-Listed, and Installed per the manufacturers recommendations.
Swing joints and universal joints, or flexible connections, should be used at the ends of all
horizontal runs, such as the pipe between the dispenser and the tanks. These aid in aligning the
dispenser inlets with the underground piping, and prevent leaks which might develop through
the settling of the tanks or heaving of the ground from heavy traffic or frost and thaw.
Block up the sloped section of products line, when installing in the trench to avoid settling. Take
particular care that the lines slope continuously upward from tanks to dispenser, otherwise
vapor traps may cause erratic dispenser operation. Test the lines for leaks before covering.
Breakaway devices should be used at the base of the dispenser so that damage to a dispenser
will not also damage the product line. Certain applications may require emergency shutoff
valves as a precaution against hazards due to fires and accidents, if these valves are required,
they must be installed in accordance with the manufacturer's instructions. The automatic closing
feature of the emergency shutoff valves should be tested at least once per year to ensure
proper operation.
Emergency shutoff valves and breakaway devices are examples of the requirements stated in
NFPA 30A, the Automotive and Marine Service Station Code. This equipment, as well as any
other safety devices required by NFPA 30 and NFPA 30A, must be installed and maintained per
the manufacturer's instructions.
When the dispenser has been connected and the pipe sealant is dry, the lines should be tested
for leaks. Be sure to properly plug any passages to the underground tank, otherwise,
over-pressurization of the tank will result in tank leaks.
To test underground lines, apply air pressure, in accordance with required local codes. While
the pressure is on the line, apply soap and water solution completely around each joint. A slight
leak will bubble when the solution is applied. This test must be performed /before the lines can
be track filled.
On existing underground lines, an air pressure test can be performed by applying a soap and
water solution to any visible joints in the line. To ensure a tight line, block any passages to the
tank and apply air pressure to the line. Pressure should remain on the line for at least one hour
with no loss in pressure, or in accordance with local codes. Also be sure to check unions and
impact valves for leaks on the inlet valves under all the dispensers, not just the one being
serviced.
Note!
Be certain to check local codes concerning line testing. In some areas a hydrostatic test
as well as air pressure test is mandatory.

Séries No 921193 Rev.C 14 March 2003

 2.5 Check Valves (Suction Pumps Only) (For UL markets)
Suction pumps require a check valve in the product lines to stop the product from draining back
into the tank. Wayne recommends that double poppet foot valves are used 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.
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 (4) inches (10 cm) 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 recommends the use of an extractable foot valve for easy and quick removal of the
check valve in the tank. The importance of keeping the end of the line in the tank at least four
(4) inches (10 cm) off the bottom of the tank cannot be overemphasized. Condensation 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.

2.6 Connecting More Than One Pump To a Tank (Suction Dispensers) (For UL
markets)
If you intend to connect more than one suction dispenser 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
systems normally require only one pump (submersible) to supply several dispensers; tanks
designed specifically for suction dispensers will have additional openings.
Where a tank is equipped with only one opening for a suction pump connection, Wayne does
not suggest the use of two or more pumps on one line; however, if this type of installation is
unavoidable, it is very important that a swing check valve be used in each suction line branch,
and that each valve be placed in the line as close as possible to the connection 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.

2.7 Fill Pipe (For UL markets)

If the fill pipe is used for the insertion of the gauge (dip stick to determine the amount of product
in the tank, it is important that this pipe be in a straight vertical position). The top of this pipe
should be protected with a fill box so that in freezing weather, the frozen ground will not pull the
tank flange loose from the tank.

Séries No 921193 Rev.C 15 March 2003

 2.8 Venting (For UL markets)
The tank must be vented, Wayne recommends conforming to the rules of the National Fire
Protection Association (NFPA). It is important that this vent line slopes slightly upward from the
tank, avoiding traps or pockets, and this line should be equipped with swing joints to prevent its
breaking due to settling or freezing. The top of the vent line should be at least 12 feet (366 cm)
above the ground and at least 5 feet (152 cm) away from chimneys, windows or other openings.
The vent outlet should be protected to minimize the possibility of blockage due to insects, nests,
etc.

Séries No 921193 Rev.C 16 March 2003

3 INSTALLING THE DISPENSER

A concrete foundation should be provided for the dispenser. Do not pour concrete around product or
electrical risers.
Do not leave any loose dirt inside the bottom of the dispenser. Dirt and dust blown around by the motor
fan or by the motion of the pulleys is likely to get attached to the V-Link belts and cause excessive wear
on the belts.
Rules and regulations
By installation of fuel stations the rules and
regulations of the authorities for each country must
be followed. You must always be updated regarding
changes and completions of the rules.

CAUTION!
Danger of tipping!
Follow the lifting instructions.
Note the point of balance.

Vertical supply risers and electrical conduits should be

located in accordance with the installation drawings for
the appropriate model. Proper height must be
maintained to avoid undue stress on the dispenser. To
install the dispenser, complete the following steps: Figure 4 Decal

Step 1
Remove the dispenser from its shipping carton. This should have already been done when the
equipment was inspected-refer to chapter 1.7"Inspect The Equipment" page 11.
Step 2
Unlock and remove the dispenser doors.
Step 3
Remove the shipping discs from the inlet unions.

NOTE!
Before performing the following steps, refer to the installation illustration (Drawing 1) page 62 for
retrofit sites or Installation illustration

CAUTION
When handling the dispenser, lift only by the base or main chassis. Do not lift by the nozzle boot,
hose outlet, operating lever or any external panels, this may result in dispenser damage and/or
personal injury.

Séries No 921193 Rev.C 17 March 2003

 Unload the pump on box Installation

1.5m(min.)
1.5m(min.)

Figure 5 Lifting the pump

WARNING!
Danger of tipping!
Bolt the pump on the base.
See attachment points in the ”Installation instruction” page 61!
Step 4
Raise the dispenser up even with the island and slide the dispenser onto the island. Position the
dispenser on the island in accordance with the dimensions shown on the appropriate engineering
drawing in chapter 9 page 61.
Step 5
Make all piping and conduit connections and anchor the dispenser to the island using anchor bolts. The
base of dispenser is provided with two bolt hole slots (3/4 inch by 1 1/2 inches) for anchoring the
dispenser to the island.

Séries No 921193 Rev.C 18 March 2003

 Step 6
a) Make electrical connections as shown on appropriate engineering instruction drawing in chapter 9
page 61 and verify that electrical power source(s) match the component electrical ratings shown in
Figure 6 Component Electrical Ratings and Figure 8 Submersible Pump Relay Specifications.
NOTE!
Wayne recommends employing a qualified licensed electrician for all wiring. A hazardous liquid
is being handled, therefore, it is extremely important to ensure that all wiring is in accordance
with the local rules, regulations, and codes discussed in Section 1.6 page 11, Local, State and
Federal Codes.
CAUTION
Wires must be marked (labeled) within six (6) inches (15 cm) prior to entering the conduit union
and also in the splice box to avoid component damage or shock hazard caused by incorrect
wiring connections.
b) If the dispenser will be operated with a Wayne Control System, make the DATA wire connections
as illustrated in the appropriate engineering drawing. These DATA wires are not required for full
service (stand-alone) dispenser operations, however, if a Wayne Control System will be installed
later, the DATA wires should be run at initial installation.
NOTE!
If the optional DATA wires are run they should not be physically connected to the DATA
terminals in the dispenser junction box or left open ended in the dispenser splice box. Instead
they should be properly terminated individually using wire nuts.

Component Electrical Ratings

Suction Pump Motor Options 1 HP, 50/60 Hz, 115/230V, 1 Phase
1 HP, 50/60 Hz, 230V, 3 Phase
1 HP, 50/60 Hz, 400V, 3 Phase
1 HP, 50/60 Hz, 230/400V, 3 Phase
Ballast Transformer Options 110VAC, 2x7W, 50/60 Hz
230VAC, 2x7W, 50/60 Hz
Figure 6 Component Electrical Ratings

Séries No 921193 Rev.C 19 March 2003

 3.1 Cable drawing
Cable ducts for low voltage and high voltage must be separated, to minimise the disturbances
(at least 50 cm between them).

3.1.1 Routing of power cables

Cables is to be routed along the

phased side of the pump as shown in
Figure 7.
They shall be fastened with three
appropriate cable-fasteners at the
plate.

Figure 7 Routing of power cables

3.2 Emergency shutdown

To be able to stop an unwanted outflow of petrol the electric control of the meters must be
connected in such a way that the flow can be stopped. This function should be designed as an
emergency shutdown. A reset of the emergency shutdown must not result in an automatic start
of the pump motor. The emergency shutdown is marked according to national standard and
should be located in such a way that it can easily be reached by the pump area supervisor. The
emergency shutdown must turn off the supply power in the electrical control centre to all meter
cabinets. All concerned staff must be informed of the location and function of the emergency
shutdown.

Séries No 921193 Rev.C 20 March 2003

 3.3 Safety switch
The pump is not equipped with electric circuit breaker, but the same has to be installed in the
distribution board of the station.

3.4 Submersible Pump Controls

Remote dispensers allow the use of a relay to interface to the submersible pump motor. Potter
and Brumfield relay No. PRD7AYO in a Listed magnetic motor controller assembly is
recommended. Relay specifications are listed in Figure 8 Submersible Pump Relay
Specifications.
A maximum of 24 fueling points may be connected to a single PRD7AYO relay; other relays
may have different limitations. All dispensers operating the same pump control relay must be
connected to the same circuit breaker, which may require multiple submersible pump control
relays for a submersible pump.
Ensure the submersible pump receives its power from its own separate Submersible Pump
Circuit Breaker as illustrated in the Typical Site Wiring Diagram 7151 -C in chapter 9 page 61.

Coil (120V) Control Voltage 120 VCA, 50/60 Hz

Coil Resistance 290 0 (Ohms) + 15%
Pull-in Characteristics Current - 0.085 Amp
Voltage - 75 VCA
Drop-out Characteristics Current - 0.085 Amp
Voltage - 55 VCA
Coil (240V) Control Voltage 240 VCA, 50/60 Hz
Coil Resistance 1100((Ohms) ( 15%
Pull-in Characteristics Current, - 0.043 Amp
Voltage - 204.0 VCA
Drop-out Characteristics Current - 0.043 Amp
Voltage - 144.0 VCA
Contact 25 Amps @ 240 VCA
Rating 20 Amps @ 277 VCA
1 HP @ 120/240 VCA
Figure 8 Submersible Pump Relay Specifications

Séries No 921193 Rev.C 21 March 2003

 3.5 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 can 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
chapter 9 page 70. 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 tied together at the Submersible Pump Control Relay Coil
terminal up to a maximum of 12 connections (24 fueling points). Where more than 12
connections activate the same submersible pump, additional relays should be used and the
contacts paralleled as illustrated in 7151-C, found in chapter 9 page 70. In larger installations,
dispensers can be separated into multiple groups.
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.

3.6 Hose Installation (UL)

Hose assemblies should be UL Listed and installed in accordance with the manufacturer's
instructions. To ensure a proper joint, wash all cutting oil off the threads and use a UL 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.
NFPA code requires that 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.
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.

Séries No 921193 Rev.C 22 March 2003

 3.7 Bleeding Product Lines (Remote Dispenser)
Make sure the power to the appropriate submersible pump is OFF.
NOTE!
To avoid severe damage to the dispenser, all air and air pockets must be bled from the
product trunk lines before attempting to dispense product.
To bleed air from a trunk line, remove the pipe plug from the safety impact valve on the
dispenser farthest from the storage tank.
Attach a flexible hose to the pipe plug opening in the safety impact valve. Energize the
appropriate submersible pump and allow the air to bleed out of the trunk line into a test can until
product flows into the test can. De-energize the submersible pump and replace the pipe plug.
Repeat the procedure for each product and each trunk line.

3.8 Priming Suction Pumps

Suction pumping units must be primed before their initial operation; it is not advisable to run any
type of internal gear pump dry during the priming process. Remove the cover and the check
valve and fill up with liquid in the pumping unit before starting the pump for the first time, see
picture.

Figure 9 Priming Suction Pumps

Séries No 921193 Rev.C 23 March 2003

 Remove the cover and
the check valve

Remove
the tube.

Figure 10 Priming Suction Pumps (Duo with one twin meter)

Séries No 921193 Rev.C 24 March 2003

 3.9 Above Ground Storage Tanks
When installing Wayne suction pumps in locations with above ground tanks and a pressure
regulator valve, a pipe plug with an orifice (Wayne part number 129881) must be added into the
pumping unit for optimum performance. Refer to the drawing Figure 11 Location of Pipe Plugs in
Pumping Unit.that shows where to add the pipe plug.

Above ground tank installations with a pressure regulator valve may not allow the pumping unit
to generate enough vacuum to keep the air chamber from over filling with fuel and allowing it to
discharge from the vent. The addition of this orifice plug will prevent this problem.

Pipe plug orifice

exploded view

Remove end cap to

install pipe plug

Prime plug

Figure 11 Location of Pipe Plugs in Pumping Unit.

The pipe plug is only required for above ground storage tanks.

Séries No 921193 Rev.C 25 March 2003

4 START-UP PROCEDURE

Power should be OFF. Always turn the dispenser control power circuit breaker OFF before accessing
the inside of the dispenser.

4.1 Hose Position Coding

In order to set up the dispenser properly, the installer has to understand hose position coding.
Unit Prices and Totals are given in hose position order; for an example of hose position coding
see Figure 4-1. When viewing the dispenser from the junction box side, the "X" hose position is
always the hose on the far left.

SIDE A SIDE A
NOZZLE 1A NOZZLE 1A NOZZLE 2A

DISPLAY X1A DISPLAY X1A / AA2A

X X Y Z AA
DISPLAY X1B DISPLAY Y1B / Z2B

NOZZLE 1B NOZZLE 1B NOZZLE 2B

SIDE B SIDE B
VIEW OF PULLEY VIEW OF PULLEY
MODEL 3/G3397 SUCTION & DISPENSER MODEL 3/G3498 SUCTION & DISPENSER
3/G3397P/FP 3G3397P/FC

SIDE A SIDE A
NOZZLE 1A NOZZLE 1A NOZZLE 2A

DISPLAY X1A DISPLAY X1A / AA4A

X X AA
DISPLAY X1B DISPLAY X1B / AA4B

NOZZLE 1B NOZZLE 1B NOZZLE 2B

SIDE B SIDE B

VIEW OF PULLEY VIEW OF PULLEY

MODEL 3/G3387 SUCTION & DISPENSER MODEL 3/G3399 SUCTION & DISPENSER

Figure 12 Hose Position Coding for Century Series.

These positions are critical for unit price programming from a system.

Séries No 921193 Rev.C 26 March 2003

 SIDE A SIDE A
NOZZLE 1A NOZZLE 1A NOZZLE 2A NOZZLE 3A

DISPLAY X1A DISPLAY X1A / AA4A

X AA X Y AA
DISPLAY AA4B DISPLAY X1B / AA4B

NOZZLE 1B NOZZLE 1B NOZZLE 2B NOZZLE 3B

SIDE B SIDE B
VIEW OF PULLEY VIEW OF PULLEY
MODEL 3/G3388 SUCTION & DISPENSER MODEL 3/G3390 SUCTION & DISPENSER

SIDE A SIDE A
NOZZLE 1A NOZZLE 2A NOZZLE 1A NOZZLE 2A NOZZLE 3A NOZZLE 4A

DISPLAY X1A / AA4A DISPLAY X1A / AA4A

X AA X Y Z AA
DISPLAY X1B / AA4B DISPLAY X1B / AA4B

NOZZLE 1B NOZZLE 2B NOZZLE 1B NOZZLE 2B NOZZLE 3B NOZZLE 4B

SIDE B SIDE B
VIEW OF PULLEY VIEW OF PULLEY
MODEL 3/G3389 SUCTION & DISPENSER MODEL 3/G3490 SUCTION & DISPENSER
Hose Position Coding for Century Series.
These positions are critical for unit price programming from a system.

4.2 Nozzle Switch Check

Check the operation of the nozzle switch as follows:
1. Remove the nozzle from the nozzle boot. Lift the drive handle in all the extension (if the
model is not auto-on), driving the micro switch in the receptacle. An “on” switch will be
indicated by the “displays”, showing 8 digits and, afterwards, the unit price and zero in the
“displays”, for “Volume” and “Total to pay”.
2. Lower the Lift-to Start lever to the down position (replace the nozzle in the nozzle boot, on
the Auto-on activated models) and check that the switch turns OFF.

Séries No 921193 Rev.C 27 March 2003

 4.3 Meter Check
NOTE!
Except at calibration/verification the power to the pulser should be turned off when
handling it.
4.3.1 Pumps Calibration.
Only one side of meter can be calibrated of each time. The valid calibration volumes are
5, 10 and 20 litres. A verification should be done after each calibration.
1. Wet the can and return the product to the
tank, letting the product drain for 10
seconds.
2. Identify the calibration door of the meter
that need calibration and remove the
respective seal.
3. Remove the nozzle corresponding to the
meter to be calibrated.
4. Actuate the handle of the nozzle boot (if it
is no “Auto-on”).
Figure 13 Calibration door
5. Observe that motor and the solenoid are
on. In the picture the calibration door
for the A-side is closed and the
6. Open the calibration door of the meter, door for the B-side is opened.
certifying the door is fully open.

7. Fill the can (5, 10 or 20 liters) up to the zero mark. Considering that the system is
not yet calibrated, the display will show a volume not totally corresponding to the
volume contained in the can.
8. Close the calibration door.
9. Observe if the motor and the solenoid are off.
10. Return the nozzle to rest position.
11. Empty the can.
12. If several meters supply one nozzle, repeat the procedure of steps 5 to 8 for the
next meter.
13. To check the calibration, fill the can until the display shows the correct volume. The
can volume shall now be within the limits approved by the authorities. On the
contrary, a new calibration shall be conducted.

Séries No 921193 Rev.C 28 March 2003

 4.4 Link Belt Adjustment
4.4.1 Z-profile belt

NOTE!
Use only antistatic Z-belts.

Check the tension on the Z-belts.

Deflection in cm = 1.5 x distance in m.
(See Figure 14 Z-profile belt)
Figure 14 Z-profile belt

4.5 Adjusting Compact Pumping Unit

The pumping unit in suction dispensers should be checked and, if required, adjusted; see Figure
If there is not enough delivery pressure, the pump will deliver product slowly. If the pump puts
out too much pressure, delivery of product will not increase, but increased noise and wear will
result, and an unnecessary load will be put upon the motor. The motor is thermally protected
and automatically shuts off when overloaded.
Step 1
Before deciding a pump adjustment is necessary, check and clean the strainer. To clean the
pumping unit strainer, remove the strainer cover and clean the strainer with compressed air.
Strainers often require cleaning frequently at station start-up, as materials such as pipe sealant
and dirt are flushed from the lines; after start-up, only occasional cleaning should be necessary.
Step 2
Install a Manometer (consult table) and check if the check and pressure relief valve is in the
2
range of 18 to 20 psi (124 to 138 kPa, or 1.3 to 1.4 kgf/cm ).
Step 3
To adjust the relief valve pressure, remove the adjustment cap (see picture)and turn the screw
inward (clockwise) to increase pressure, or back off the screw counter-clockwise) to decrease
pressure.

Séries No 921193 Rev.C 29 March 2003

 Install a
pressure gauge

Figure 15 Compact Pumping Unit

4.6 Fluorescent Lights

If the dispenser is lighted, turn on the light circuit breaker and ensure that all of the fluorescent
lights operate correctly. Replace any fluorescent light bulbs that fail to illuminate.

4.7 Totalizer Readings

Totals can be read off at the display for the respective pump sides. The pump must not be
activated, not even disengaged during this operation. Press the stop-key. Volumes for each
grade will be displayed for 5 seconds.
4.7.1 Electro-mechanical volume totalizer (Option)
There is a seven digit electro-mechanical volume totalizer located on the side of the
head. Read and record the totals. The initial readings must be given to the station
manager in order to maintain accurate station totals.
4.7.2 Volume Totalizer Through Preset
In the Preset, press the keys “1” and “2” simultaneously. The least significant six (6)
digits of the data value appear on the “Volume” display. The higher order non-zero digits
of the data value, if present, appear as blanks. In the “Unit price” display appear
corresponding nozzles. Ex. A1, B1, A2, B2, A3, B3, A4, B4.

Séries No 921193 Rev.C 30 March 2003

 4.8 Coalescent Filter Pump – Start Up Procedure
Before beginning the supply start up, check if the inlet valve 1 and outlet valve 3 are closed and
the by-pass valve 2 is open, and during at least one working day (or 2000 liters) the fuel shall be
recirculated, returning the above mentioned volume to the tank. After this line cleaning
procedure, put the valves in reverse position inlet 1 and outlet 3 opened and by-pass 2 closed.
CAUTION!
This recommendation for initial by-pass is important to increase the service life of the
filter.
WARNING!
The purge valve shall be open until the pressure vessel is full in order to facilitate the line
flow.

Figure Coalescent Filter

4.9 Press Filter Pump – Start Up Procedure

Before beginning the start up, check if inlet valve 1 is closed and by-pass valve 2 is open, and
during at least one working day (or 2000 liters) the fuel shall be recirculated, returning the above
recommended volume to the tank. After this line cleaning procedure, put the valves in reverse
form inlet 1 open and by-pass 2 closed.

Séries No 921193 Rev.C 31 March 2003

 WARNING!
This recommendation for initial by-pass is important to increase the working life of the
filter.

2
1

Figure Press Filter

Séries No 921193 Rev.C 32 March 2003

5 COMPUTER OPERATION

5.1 Introduction
You will need to access the maintenance mode in order
to program functions and/or view statistics. The function
and statistics data appear in the money, volume, and
unit price display windows.
The infrared interface is similar to a television remote
control. It has 16 buttons (see Figure 23). Use the
infrared interface to access dispenser functions. This
interface uses only the pump display for user feedback.
There is no additional display.

5.2 Programming functions

Change Unit Price (F03) page 40
Checking the Electronic Totals (S11) page 36
Pump Start up page 45
Exit Function page 35
Filling Modes (F01) page 36
Exit (F00) page 35
Password Change (F33) page 36
Access to Functions page 33

Note!
The Infrared interfaces only suitable for use in
unclassified (non-hazardous) locations. See Figure
Figure 16 Remote controlHoofer
24 Hazardous Zone Diagram. (UL) and Figure 25 Doofer
Hazardous Location Diagram (IEC).

5.3 Access to functions

Access the programming mode by pressing one of the following keys:
1 Station manager entry using station manager password.
2 Operator entry using operator password.
CLEAR Weights and Measures entry using weights and measures password.

Memory
Checksum

1 2
$ P-6 A99 3 4
5 6
L E-06E5 7 8
9 0
M C
Memory checksum
W&M part

Séries No 921193 Rev.C 33 March 2003

 The programming mode asks you for a password twice before allowing access to the functions.
A 10-second time-out is built into the password entry code.
After 3 seconds, the display shows:

1 2
$ PASS 1 3 4
5 6
L ------ 7 8
9 0
M C

When the word PASS 1 appears on the sale display, you have 10 seconds to start entering the
password. The timer restarts after you press a key. When you finish entering the password and
press ENTER (=M).
PASS 2 appears in the sale display window, prompting you to enter the password again.
The display will show:

1 2
$ PASS 2 3 4
5 6
L ------ 7 8
9 0
M C

Note1!
If you press nothing more, press <ENTER> (=M M) or press the wrong password, or there’s
no confirmation after pressing the password and the <ENTER> key, after about 10
seconds the computer will leave this function automatically.
Note 2!
If you press the wrong keys, press <CLEAR> (=C
C) key to erase the last digit you typed.
Press again the password to confirm and press <ENTER>

Séries No 921193 Rev.C 34 March 2003

 Press <ENTER>
The Display shows the function screen

Software version
Software date

1 2
$ 4.01 3 4
5 6
L 7.25.00 7 8
9 0
F-- M C

When you enter the programming mode, the unit price display windows show "F - - ", the money
display window shows the software version number, and the volume display window shows the
date of the software version. To edit or view specific functions, enter any function number using
the number keys and press ENTER. The corresponding number appears in the money display
window.

5.4 Exit (F00)

Use this function to select one of three maintenance mode exits.
Type 00
Press <ENTER> (=M)

1 2
$------ 3 4
5 6
L 7 8
9 0
F00 M C

.01 Do not exit and do not save changes

.02 Exit, but do not save changes
.03 Exit and save changes

Séries No 921193 Rev.C 35 March 2003

 5.5 Password Change (F33)
Dashes appear in the money display window, and the word PASS appears on the volume
display. When you begin editing, the money display goes blank and dashes appear instead of
the regular entries. Enter the new password twice. The sub-function numbers are defined as
follows:
.01 Station Manager Password, maximum of 6 characters (Use numbers only)
.02 Station Operator Password, maximum of 6 characters (Use numbers only)
.03 Weights and Measures Password, maximum of 6 characters (Use numbers only)

5.6 Filling Modes (F01)

Selected configuration parameters defined as follows:
.01 Serial Mode, dispenser controlled by site controller via serial link
.02 Stand Alone Mode, dispenser not supervised by a site controller
.03 Serial W&M Mode, same as 01 but volume decimal point format forced to .xxx volume units
.04 Stand Alone W&M Mode.

5.7 Checking the Electronics Totals (F11)

Access to functions, see page 33.
Press <ENTER>, and the display shows

Number of times the side B

motors were driven

1 2
$ 3 3 4
5 6
L 76 7 8
9 0
S-- M C

Number of times
the side A motors
were driven

Séries No 921193 Rev.C 36 March 2003

 Type 11
Press the <UP> or <DOWN> keys to enter statistical mode, and the display shows:

1 2
$------ 3 4
5 6
L 7 8
9 0
S 11 M C

Press <ENTER> to access the function and view the last dispensing.

1 2
$ 3 4
5 6
L 590.11 7 8
9 0
11.11 M C

The volume above are example.

Press <UP> to read the volume total of the other nozzle.

1 2
$ 3 4
5 6
L 54.91 7 8
9 0
11.12 M C

Séries No 921193 Rev.C 37 March 2003

 If you press <UP> will read the money totals of nozzle 1A

1 2
$ 3 4
5 6
L 5903.11 7 8
9 0
11.21 M C

To read other total press.

1 2
$ 21 3 4
5 6
L 82 7 8
9 0
M C
S--

Exit, see page 35.

5.7.1 Access to the statistic model
S11 – GENERAL TOTAL BY LOGICAL NOZZLE – SIDE A
Exemple: S.11.11

TN

11.11 Unit Price

Display

Statistic
Function
Side A

Séries No 921193 Rev.C 38 March 2003

 The substatistical numbers have the format “.TN” :
T = type of totals
1 = volume
2 = total in cash
3 = total in credit
4 = total on demand
5 = number of dispensing done with console
6 = number of dispensing done without console
N = number of the logical nozzle 0-8, where 0 = not configured

At least six (6) data digits shows up at the window “VOLUME”. The complement
of data digits different from “zero”, if any, shows at the window “TOTAL SALES”.
The decimal “zeros” are blank.
S12 – GENERAL TOTAL BY LOGICAL NOZZLE – SIDE B
The substatistical numbers have the format “.TN” :
T = type of totals
1 = volume
2 = total in cash
3 = total in credit card
4 = total on demand
5 = number of dispensings done with console
6 = number of dispensings done without console
N = number of the logical nozzle 0-8, where 0 = not configured

At least six (6) data digits shows up at the window “VOLUME”. The complement
of data digits different of “zero”, if any, shows at the window “TOTAL SALES”. The
decimal “zeros” are blank.
5.7.2 Mode “Statistics”
S01 – PARTIAL TOTALS (W/O SHIFT) PER LOGIC NOZZLE – SIDE A
At least six (6) data digits show up at the window “VOLUME”. The complement of
data digits different from “zero”, if any, shows at the window “TOTAL SALES”.
The non-significative “zeros” are blank.
PROCEDURE TO ERASE SHIFT TOTALS – SIDE A
- Access the function S01
- Press “ENTER” (the display shows UNIT PRICE the subfunction “1.11” and in
display VOLUME the registered volume)
- Press “#”(the display shows PAYING TOTAL “CLEAR” and in display VOLUME
“TOTALS”
- Press “ENTER” (the display shows PAYING TOTAL “PASS”)
- Type PASS 42
- Press “ENTER” (All shift totals are zeroed)

Séries No 921193 Rev.C 39 March 2003

 S02 – SHIFT TOTALS BY LOGICAL NOZZLE – SIDE B
The substatistical numbers have the format “.TN” :
T = type of totals
1 = volume
2 = total in cash
3 = total in credit card
4 = total on demand
5 = number of dispensings done with console
6 = number of dispensings done without console
N = number of the logical nozzle 0-8, where 0 = not configured
At least six (6) data digits show up at the window “VOLUME”. The complement of
data digits different of “zero”, if any, shows at the window “TOTAL SALES”. The
non-significative “zeros” are blank.
- Press “Next” to go forward
Exit, see page 35.

5.8 Changing Unit price (F03)

5.8.1 Changing prices on Side A
Access to functions, see page 33.
The Display shows the function screen
- Step 1 – Press 03 and press <ENTER>, and the display shows:

1 2
$------ 3 4
5 6
L 7 8
9 0
F03 M C

Séries No 921193 Rev.C 40 March 2003

 - Step 2 - Press <ENTER> and the display shows:

1 2
$------ 3 4
5 6
L 1.300 7 8
9 0
3.01 M C

Note!
To access the other unit price press <Next>.
Sub-Function 3.01 is responsible for changing unit price of fuel at nozzle 1 on side A,
and so on, according to the table below:

Sub-Function Nozzle Side

Credit Prices ( Position )
3.01 1 A
3.02 2 A
Sub-Function Nozzle Side
Cash Prices ( Position )
3.11 1 A
3.12 2 A

Pump Side Identification

Séries No 921193 Rev.C 41 March 2003

 Example: I have 2 pumps programmed to a unit price of $ 1.300 and want to change to
1.420

1 2
$------ 3 4
5 6
L 1.300 7 8
9 0
3.01 M C

Press the <#> key, the dotted part on paying total of display will be erased.

1 2
$ 3 4
5 6
L 1.300 7 8
9 0
3.01 M C

Press the desired value

Ex.: 1420

1 2
$ 1.420 3 4
5 6
L 1.300 7 8
9 0
3.01 M C

Séries No 921193 Rev.C 42 March 2003

 Press <ENTER>, and the display shows

1 2
$------ 3 4
5 6
L 1.420 7 8
9 0
3.01 M C

To change from one Sub-Function to another use the <NEXT> key (Ex.: from 3.01 to
3.02).
The same procedure applies to change the cash prices. ( Sub functions 3.11 to 3.12,
see table)
To save all changes follow the procedure of “F00” exiting, value 3. (see page 35)
5.8.2 Changing prices on Side B
Access to functions, see page 33.
- Step 1 – Press 04 and press <ENTER>, and the display shows:

1 2
$------ 3 4
5 6
L 7 8
9 0
F04 M C

- Step 2 - Press <ENTER>

1 2
$------ 3 4
5 6
L 1.300 7 8
9 0
4.01 M C

Séries No 921193 Rev.C 43 March 2003

 The Sub-Function 4.01 is responsible for changing unit price of fuel at nozzle 1 on side
B, and so on, according to the table below:

Sub-Function Nozzle Side

Credit Prices ( Position )
4.01 1 B
4.02 2 B
Sub-Function Nozzle Side
Cash Prices ( Position )
4.11 1 B
4.12 2 B

Example: I have 2 pumps programmed to a unit price of $ 1.300 and want to change to
1.420

1 2
$ 0.00 3 4
5 6
L 0.00 7 8
9 0
1.300 M C

Press the <#> key, the dotted part on paying total of display will be erased.

1 2
$ 3 4
5 6
L 1.300 7 8
9 0
4.01 M C

Séries No 921193 Rev.C 44 March 2003

 Press the desired value
Ex.: 1420
Press <ENTER>, and the display shows.

1 2
$------ 3 4
5 6
L 1.420 7 8
9 0
4.01 M C

To Change from one Sub-Function to another use the <NEXT> key (Ex.: from 4.01 to
4.02).
The same procedure applies to change the cash prices. (Sub functions 4.11 to 4.12, see
table page 44)
To save all changes follow the procedure of “F00” exiting, value 3. (see page 35)

5.9 Pump Startup

5.9.1 Changing decimal points of unit price
To change the number of decimal points of any unit price, you should enter the function
mode.
Access to functions, see page 33.
Note1!
If you press nothing more, press <ENTER> or press the wrong password, or
there’s no confirmation after press the password and the <ENTER> key, after
about 10 seconds the computer will leave this function automatically.
Note 2!
If you press the wrong keys, press <CLEAR> key to erase the last number you
typed.

Séries No 921193 Rev.C 45 March 2003

 Step 1- Select function 14 and press <ENTER> twice and the display shows:

1 2
$------ 3 4
5 6
L 1 7 8
9 0
14.00 M C

Step 2- Using the <NEXT> key, select Sub function 14.04, and the display shows:

1 2
$------ 3 4
5 6
L 3 7 8
9 0
14.04 M C

Note!
In this manual example, the unit price value is $1.000 (three decimal points).
Example of UP Function 14.04
1000 0
100.0 1
10.00 2
1.000 3

Séries No 921193 Rev.C 46 March 2003

 Press the <#> key, the dotted part of paying total will be erased.

1 2
$ 3 4
5 6
L 3 7 8
9 0
14.04 M C

Press the desired value and press <ENTER>.

Ex.: 2

1 2
$------ 3 4
5 6
L 2 7 8
9 0
14.04 M C

Press <ENTER> to return to function 14, press <CLEAR> to return to function menu,
and follow procedure at function F00, value 3 to save the changes.
To save all changes follow the procedure of “F00” exiting, value 3. (see page 35)
5.9.2 Changing decimal points of Paying Total
Function 14.02
- Step 1 – Select Function 14 and press <ENTER>, and the display shows:

1 2
$------ 3 4
5 6
L 1 7 8
9 0
14.00 M C

Séries No 921193 Rev.C 47 March 2003

 - Step 2 – Using the <NEXT> key, select Sub-Function 14.02, and the display shows:

1 2
$ ------ 3 4
5 6
L 2 7 8
9 0
14.02 M C

- Step 3 Press #
- Step 4 – Press the desired value and press <ENTER>, and the display shows:
Ex.: 1

1 2
$------ 3 4
5 6
L 1 7 8
9 0
14.02 M C

Press <CLEAR> to return to function 14 and follow as described at “Exiting functions

(Function zero)”. To save all changes follow the procedure of “F00” exiting, value 3. (see
page 35)
5.9.3 Changing decimal points of Volume
Function 14.03
- Step 1 – Select function 14 and press <ENTER>, and the display shows:

1 2
$------ 3 4
5 6
L 1 7 8
9 0
14.00 M C

Séries No 921193 Rev.C 48 March 2003

 - Step 2 – Using the <NEXT> key, select Subfunction 14.03, and the display shows:

1 2
$------ 3 4
5 6
L 2 7 8
9 0
14.03 M C

- Step 3 Press #
- Step 4 – Press desired value number and press <ENTER>, and the display shows:
Ex.: 3

1 2
$------ 3 4
5 6
L 3 7 8
9 0
14.03 M C

To save all changes follow the procedure of “F00” exiting, value 3. (see page 35)
NOTE:
The UL master-satellite models have a “satellite in use” indication in a display besides
the unit price, as show in the picture. Once the satellite nozzle is activated, the display
shows dashes going up.

1 2
$------ 3 4
5 6
L 3 7 8
9 0
14.03 M C

Séries No 921193 Rev.C 49 March 2003

6 DEMOUNTING
6.1 Preparations
Read chapter 2 page 12 and forward.
WARNING!
To prevent damage which may result in electric shock or fire, disconnect the main power
(motors and electronic head) prior to any work

6.2 Drain fuel from the pump

It is important that the pump is emptied of fuel before demounting.
Seal the inlet pipes with a flange with gasket. Depending on the pump model between one and
two pump units must be emptied and seal.
If needed, ask a transportation company for special regulations.

Séries No 921193 Rev.C 50 March 2003

7 OPERATION
7.1 Introduction
The dispensers are one or two inlet dispensers, with one or two outlets (depending on model).
Each side of the dispenser represents a fueling point.
The dispenser is equipped with one unit price per nozzle. Unit price must be set to operate. If
the dispenser is connected to a Management Control System, each dispenser must have a
unique fueling point number set for communication with a Management Control System.
Select the desired product. The dispenser is turned on by removing the nozzle from the nozzle
boot and lifting the operating lever (the lever is not lifted with the Auto-On models). The sales
display will show 8s, blanks and then reset to zero.
The pump motor starts at the end of the reset cycle and the solenoid valves open approximately
3-5 seconds later.
To complete the sale, lower the operating lever, replace the nozzle in the nozzle boot and the
pump motor will be switched OFF.

7.2 Portable Tanks and Containers

Portable containers of 12 gallons (45 liters) or less shall not be filled while they are in or on a
motor vehicle. Filling portable containers, especially when they are sitting on a non-conductive
surface such as a floor mat or a plastic bedliner in the back of a pick-up truck, can present a
possible safety hazard and should avoided as so stated in the following WARNING:
WARNING
FIRE HAZARD! The flow of gasoline through the dispenser nozzle can produce static
electricity, which can cause a fire if gasoline is pumped into an ungrounded gasoline
container. To avoid static buildup and the possible resulting serious injury:

• Place approved container on the ground. Do not fill the container in the vehicle or truck bed.
• Keep the nozzle in contact with the can or container while filling. Do not use an automatic
pump handle (latch-open) device.

7.3 Operation of the Preset (Option)

Dispensers with the preset option will have a preset keypad assembly installed in them. This
option allows the customer, or attendant, to input the amount of product desired, either in
volume or money, prior to the beginning of the sale. The following sections describe typical
operational scenarios using the preset option.

Séries No 921193 Rev.C 51 March 2003

 7.3.1 Twelve button keyboard

• Preset Operation
1 2
1. Pump Display shows last sale
3 4
2. Operator presses a digit key.
The display starts to blink
5 6
If this is a numeric key the number will be 7 8
indicated at the default panel (volume or money
panel), the other panel shows dashes. 9 0
If this is the C key, the display will switch to the M C
Money/Volume line, in case of money selected,
dashes are indicated on the volume panel.
Pressing the “M” key cancels the preset
operation.
3. Display will continue to blink showing the
entered numbers at one panel and dashes at
the other until the operator lifts the nozzle.
4. The display starts the reset cycle and stop
blinking.
5. The normal filling information will be indicated
at the display.
6. At the end of the sale the display shows the
sale (without blinking and showing the preset
entry).

Séries No 921193 Rev.C 52 March 2003

 7.3.2 Five button keyboard

• Preset Operation
Softkey 1
1. Pump display shows last sale 10 10
Softkey 2
2. Operator presses a digit key. 20 20
Softkey 3
The display starts to blink. 50 50
There are 3 fixed values of 10, 20 and 50.
C Softkey 4
Mon./Vol.
Multiple press of any of the fixed preset value
buttons will be added to the preset value. M Clear

For example, if the button 10 is pressed, 10 will be

indicated,
next if 50 is pressed, then 60 (10+50) will be
indicated,
next if 20 is pressed, then 80 will be indicated as
preset value at the display.
If this is a numeric key the number will be indicated
at the default panel (volume or money panel), the
other panel shows dashes.
If this is the C key, the display will switch to the
Money/Volume line, in case of money selected,
dashes are indicated on the volume panel.
Pressing the “M” key cancels the preset operation.
3. Display will continue to blink showing the entered
numbers at one panel and dashes at the other until
the operator lifts the nozzle.
4. The display starts the reset cycle and stop blinking.
5. The normal filling information will be indicated at
the display.
6. At the end of the sale the display shows the sale
(without blinking and showing the preset entry).

Séries No 921193 Rev.C 53 March 2003

 7.4 Health Note
Be advised that petroleum fuel and fuel vapors can damage your health.
Warning
Never run a leaking pump! Be careful with the environment and mind the skidding risk;
take care of leaching fuel immediately.

Adequate personal safety equipment should be used by maintenance of the equipment (gloves,
breathing mask, glasses etc.).

UNLEADED GASOLINE DIESEL OIL

May cause cancer.
Also danger ous: may cause
lung danger ous: may cause Possible risk of
lung damage if swallowed. irreversible effects.
Irritating to skin. Also danger ous:
may cause lung
Avoide exposure - obtain
damage if swallowed.
special instructiond before use.
In case of accident, or if you
feel unwell, seek medical
EXTREMELY advice immediately (show the
FLAMMABLE label where possible). After
contact with skin wash
Keep out of the reach of children.
immediately with soap and
water. After contact with skin wash immediately with
soap and water.
If swalloed do not induce If swallowed do not induce vomiting: seek
vomiting: Seek medical advice medival advice immediately.
emmediately. do not breath fumes or vapour.
Avoide release to the avoid release to the environment. Do not
environment. Keep out of the empty into drains.
reach of children. Do not
empty into drains.

Contains: Gasoline
Contains: Gas oil - unspecified
Benzene - unspecified

7.5 Hazardous Zone Areas

It is important to know the Hazardous Zone area around the dispenser as shown in Figure .
Zones Risk types Protection class Example
0 A risk area where explosive gas Exia In a tank.
mixture exists all the time or
during a long period.
1 A risk area where explosive gas Exd, Exe, Exib, Within the meter.
mixture may exist occasionally Exp, Exia, Exs, (within the hydraulic
during normal operation. Exm areas and pillar of
the pump, see
Figure 17 and
Figure 18.
2 A risk area where explosive gas Exd, Exe, Exib, see Figure 17 and
mixture is not expected to exist Exp, Exia, Exs, Figure 18.
during normal operation and, if it Exo, Exq, Exm
should exist anyway, in that case
seldom and during a short period
of time.

Séries No 921193 Rev.C 54 March 2003

 7.5.1 Hazardous Zone UL

Figure 17 Hazardous Zone Diagram. (UL)

Front and top views showing horizontal and vertical distances.

Séries No 921193 Rev.C 55 March 2003

 7.5.2 Hazardous Zone IEC

8” 8”
IP23

2”
IP54

IP67

IP54

0.8”
IP23

Figure 18 Hazardous Zone Diagram (IEC)

Séries No 921193 Rev.C 56 March 2003

 7.6 How To Get Service On Your Dispenser
Trouble with the operation of the dispenser should be referred to your local Wayne authorized
service personnel according with the table below.

Operation Name
Location Name Physical Address Mailing Address Phone
Wayne Brasil Estrada Do Timbó 126 +5521 2598 7722
Brasil Bonsucesso
Rio De Janeiro, 21061-280,
Brasil
Wayne Scandinavia Linhamnsvagen 109, +464 036 0500
Suécia Box 30049
Malmo
Suécia S-200 61
Wayne US – Austin 3814 Jarrett Way 512 388 8311
EUA Austin, TX, 78728-1212
EUA

Séries No 921193 Rev.C 57 March 2003

8 PREVENTIVE MAINTENANCE
8.1 Water Damage
It is recommended that the following precautions be taken to prevent water from getting inside
the dispenser:
If it is necessary to clean the dispenser, wipe it off with a damp cloth. Do not spray the dispenser
with water.
Do not use abrasive cleaners on the bezel. Use only mild soap and water with a soft cloth. Do
not use gasoline or other petroleum based products to clean the dispenser.
Before removing the bezel, wipe off any water lying along the top edge of the dispenser so it will
not run inside when the bezel is removed.
Care must be taken to prevent rain from getting inside if the bezels must be removed during
rainy weather.
Always remove snow and ice from the pump.

8.2 Maintenance Guidelines

A correctly installed, properly maintained dispenser, will seldom require emergency service.
Check the dispenser for internal and external leaks regularly. Check nozzles, swivels, hoses,
and joints for leaks and wear. Have all defects repaired immediately.
WARNING!
Never run a leaking pump!
(Failure to observe this information results in immediate danger to life.)
Test the tank for water regularly. Water in petroleum is not only a source of engine trouble, but
will also cause damage to the dispenser.
Do not abuse the hose by trying to stretch it to reach an automobile. This will cause early failure
at the couplings.

8.3 Cleaning of filters

A dirty strainer screen will slow down the delivery of petroleum. If the underground installation is
a new one, it may be necessary to clean the strainer screen two or three times the first few days
of operation to remove debris and pipe sealant. After this, occasional cleaning is all that should
be required.
NOTE!
Before removing the fuel filter or strainer assembly turn of the circuit breaker to the
pump.

NOTE!
Replacement fuel filters can be obtained from the vendor or from Wayne Division,
Dresser Industries, Inc.

1. Wash the screen in gasoline and dislodge lint and other foreign particles with compressed
air. Check for leakage after reinstalling.
2. All keylock cylinders and locking mechanisms should be periodically checked and
lubricated.

Séries No 921193 Rev.C 58 March 2003

 8.3.1 Inlet filter (Europe)

Remove the tube and filter (see Figure 19

Inlet filters). The filter can then be rinsed in
water and/or blown with pressure air.

Inlet filter

Figure 19 Inlet filters

8.3.2 Inlet filter (US) STRAINER

The strainer is removed for cleaning by

unfastening the cap; see Figure 20 CAP
Strainer Assembly (US). Place a
container under the cap to catch the
petroleum and sediment.

Figure 20 Strainer Assembly (US)

Séries No 921193 Rev.C 59 March 2003

 8.3.3 After filter cleaning:
Put on the power and check the functions. Make sure that there is no leakage.
WARNING!
Never run a leaking pump!
(Failure to observe this information results in immediate danger to life.)
8.3.4 Coalescent Filter
The filter elements of the coalescent filters consists of sets of filter elements and
separators. The filter element installed inside the separator is disposable and
manufactured with special components of pleated paper and coalescent material with
retention of solids of 1 to 5 microns and water separation e efficiency varying up to
99.7%, or approximately 100 ppm of residual water.
The separator is manufactured with steel screen covered with Teflon, water repellent,
with controlled pores, which does not hinder the water from passing through the screen,
directing it to the bottom of the pressure vessel.
WARNING!
The separators are reusable, but depend on the correct handling and maintenance.
- Do not crush and/or perforate the Teflon screen,
- Do not clean and/or wash the screen with solvents; water and soap are
recommended.

PRESSURE AND VACUUM CONTROL P1 AND P2.

Monitors the pressure or vacuum at the inlet of filter P1 and outlet P2. The initial
differential (P2 – P1), with new elements is approximately zero (0) as long as the
maximum flow indicated in the filter is obeyed.
The saturation indication is checked according to the pressure differential of 1.3 bar.
The final flow drop is proportional to the filter element saturation, and normally felt by the
operator.
8.3.5 Press Filter
The filter element of the press filters consists of a set of press plates, formed by frames
in special plastic fiber or aluminum, containing special paper boards of cotton linter
cellulose, with high solid retention power (5 microns) in free water.
PRESSURE CONTROL (P1) – MANOMETER
Monitors the inlet pressure of the press filter. Its initial indication, with new cardboards,
varies from 0 to 20 psi according to the model, and the cardboards shall be changed
when pressure reaches 30 psi above the initial pressure.
The durability of the various components depends directly on the change frequency of
the filter element.
WARNING!
For perfect equipment operation, change the cardboards as indicated.
The durability of the various components depends directly on the change frequency of
the cardboards.

Séries No 921193 Rev.C 60 March 2003

9 ENGINEERING DRAWINGS

This chapter contains engineering drawings for reference when installing and configuring dispensers.
The following drawings are included in this chapter:
Drawing 1 – Installation Instructions 3/G3000 – 1305476 Rev. A ........................................................... 62
Drawing 2 – Electrical Installation Scheme 3/G3000P – IN 2131 Rev. C................................................ 65
Drawing 3 – Electrical Installation Scheme – 3/G3000D – IN 2132 Rev. A............................................. 66
Drawing 4 – Installation Instruction of Model 3/G3397P/FC-FP – 1-306010 Rev. A............................... 67
Drawing 5 – Installation Instruction of Suction Model – 1-305532 Rev. D............................................... 68
Drawing 6 – Installation Instruction of Remote Model – 2-305532 Rev. D .............................................. 69
Drawing 7 – Installation Instruction of Suction Models ............................................................................ 70

Séries No 921193 Rev.C 61 March 2003

 9.1

LIGHTING

SET UP INSTRUCTIONS: COMPUTER FEEDING

1 – REMOVE THE DISPLAY ON BOTH SIDES E PLACE THEM OVER THE PUMP.
2 – INSERT THE WIRES THROUGH THE CABLE CLAMP.

Séries No 921193 Rev.C

COMMUNICATION
FEEDING
MOTOR CA
Installation Instructions 3/G3000

62
PUMP
CONTROLLER

Drawing 1 – Installation Instructions 3/G3000 – 1305476 Rev. A

SWITCHGEAR

RECOMMENDED CABLES’ LENGTH > OR = 2500 mm

March 2003
 VCA CABLE 230 AND VCA DATA COMMUNICATION CABLE
400
DESCRIPTION SPINDLE DESCRIPTION TYPE
TYPE CONNECTED TO TYPE CONNECTED TO

Séries No 921193 Rev.C

SWITCHBOARD PHASE (P) *4 PUMP
NEUTER (N) 10 TO SLOW CONTROL
PROTECTION 4000 TO
EARTH (PE) REFRACTIVE

PUMP COMPUTER PHASE (P)

NEUTER (N) DATA
PROTECTION PUMP
EARTH (PE)
SWITCHBOARD PHASE (P) *4
10 TO SLOW
NEUTER (N)
4000 TO
REFRACTIVE

LIGHTING PHASE (P)

PUMP NEUTER (N)

SWITCHBOARD LINE 1 (L1) *4

LINE 2 (L1) 10 TO SLOW

63
LINE 3 (L3)
PROTEC-TION EARTH 4000 TO
(PE) REFRACTIVE

MOTOR LINE 1 (L1)

LINE 2 (L1)
LINE 3 (L3)
PUMP PROTEC-TION EARTH
(PE)

NOTES:
*4 *1) THE CHOICE OF OUTER CABLE SHOULD BE EQUIVALENT TO CENELEC DOCUMENT HD-603-S1-3L (EKKj) AND
HD-627-S1 PART 4 C2 (FKAR-PG).
10 TO SLOW
*2) TRANSMITTING AND RECEIVING
4000 TO REFRACTIVE *3) IF A CABLE TYPE DIFFERENT THAN THE ONE RECOMMENDED S USED BY THE MAXIMUM “CPU “ UNITS AND
TO MEET IEC 60204-1 CLASS 5 THE MAXIMUM LENGTH OF THE CABLES, THE FUNCTIONALITY OF THE SERIAL COMMUNICATION WILL NOT BE
SECURE.
*5) THIS CONNECTION IS OPTIONAL.
*6) INSTALLATION WITHOUT A TERMINAL BOX.

March 2003
 TERMINALS BLOCK 166184 CONTACTORS
REF. CORRESPONDING CONNECTION SCHEME

INSTRUCTION FOR INSTALLATION WITH A INSTRUCTION FOR INSTALLATION WITHOUT A

CONNECTION BOX CONNECTION BOX

Séries No 921193 Rev.C

64
- “HIGH VOLTAGE“
CONNECTION BOX
- COMPUTER
- LIGHTING
- COMMUNICATION

REF. CORRESPONDING
CONNECTION SCHEME

SWITCHBOARD

SWITCHBOARD

March 2003
 9.2 Electrical Installation Scheme 3/G3000P
SINGLE-PHASE

GREEN/YELLOW GREEN/YELLOW

BLACK
BLACK
110 V
MOTOR 4 BLACK BLACK MOTOR

BLACK BLACK
110 V
COMPUTER BLUE BLACK MOTOR
BLACK
110 V
LIGHTING BLUE BLACK

GREEN BLACK MOTOR

COMMUNICATION
NATURAL

SINGLE-PHASE
THREE-PHASE

GREEN/YELLOW GREEN/YELLOW

BLACK BLACK

BLACK BLACK
MOTOR MOTOR
BLACK
BLACK

BLACK BLACK

COMPUTER BLUE
BLACK
MOTOR
BLACK BLACK

LIGHTING BLUE BLACK

GREEN BLACK
COMMUNICATION MOTOR
NATURAL BLACK

THREE-PHASE

GREEN/YELLOW GREEN/YELLOW

BLACK BLACK

BLACK BLACK
MOTOR MOTOR
BLACK BLACK

BLACK BLACK

COMPUTER BLUE BLACK

MOTOR
BLACK BLACK

LIGHTING BLUE BLACK

GREEN BLACK
COMMUNICATION MOTOR
NATURAL BLACK

CHECK THAT THE MOTOR IS CONNECTED ACCORDING TO LOCAL VOLTAGE.

Drawing 2 Electrical Installation Scheme 3/G3000P – IN 2131 Rev. C

Séries No 921193 Rev.C 65 March 2003

 9.3 Electrical Installation Scheme 3/G3000D

GREEN/YELLOW

PUMP BLACK BLACK PUMP

BLACK BLACK PUMP

COMPUTER BLUE

BLACK

LIGHTING BLUE BLACK PUMP

GREEN
COMMUNICATION
NATURAL

GREEN/YELLOW

PUMP BLACK BLACK PUMP

BLACK BLACK PUMP

COMPUTER BLUE

BLACK

LIGHTING BLUE BLACK PUMP

GREEN
COMMUNICATION
NATURAL

GREEN/YELLOW

PUMP BLACK
BLACK PUMP

BLACK BLACK PUMP

COMPUTER BLUE

BLACK

LIGHTING BLUE BLACK PUMP

GREEN
COMMUNICATION
NATURAL

CHECK THAT THE MOTOR IS CONNECTED ACCORDING TO LOCAL VOLTAGE.

Drawing 3 Electrical Installation Scheme – 3/G3000D – IN 2132 Rev. A

Séries No 921193 Rev.C 66 March 2003

 9.4 Installation Instruction of Models 3/G3397P/FC-FP

NOTAS

Drawing 4 – Installation Instruction of Models 3/G3397P/FC-FP – 1-306010 Rev. A

Séries No 921193 Rev.C 67 March 2003

 9.5 Installation Instruction of Suction Models

Drawing 5 – Installation Instruction of Suction Models – 1-305532 Rev. D

Séries No 921193 Rev.C 68 March 2003

 9.6 Installation Instruction of Remote Models

Drawing 6 Installation Instruction of Remote Models – 2-305532 Rev. D

Séries No 921193 Rev.C 69 March 2003

 9.7 7151-C – Typical Electric Installation Scheme

Drawing 7 Installation Instruction of Suction Models

Séries No 921193 Rev.C 70 March 2003

 UL markets:

NOTE: "This equipment has been tested and found to comply with the limits
for Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user
will be required to correct the interference at his own expense”.

Dresser Indústria e Comércio Ltda. Division Wayne – Estrada do Timbó, 126 – Bonsucesso
CEP: 21061-280 – Rio de Janeiro – RJ – Brasil – Tel.: (21) 2598-7722

March 2003 Séries No 921193 Rev. C