DD1/350

INSTALLATION Remote Truck

Stop Dispensers
and Satellites

OPERATION
 ! WARNING

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. 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. Be sure to trip (close) the emergency valve(s) under the dispenser BEFORE beginning mainte-
nance.

SAFETY PRECAUTIONS - OPERATION

Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an emer-
gency. Have all leaks or defects repaired immediately.

EQUIPMENT PRECAUTIONS

Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before dispensing
product. Always use the approved method for lifting the dispenser. Never lift by the nozzle boot, sheet
metal, electronic head, etc.

HOW TO CONTACT WAYNE

Trouble with the installation and operation of the dispenser should be referred to your authorized Wayne
service personnel or Wayne Technical Support (1-800-926-3737).

INDICATORS AND NOTATIONS

Danger indicates a hazard or unsafe practice which, if not avoided, will result
! DANGER in severe injury or possibly death.

Warning indicates a hazard or unsafe practice which, if not avoided, may result
! WARNING in severe injury or possibly death.

Caution indicates a hazard or unsafe practice which, if not avoided, may result
! CAUTION in minor injury.

Note: Important information to consider, otherwise, improper installation and/or

damage to components may occur.

Part No. 917345-002 Rev A February 1999

 DD1/350
Remote Truck Stop Dispensers
and Satellites
Installation and Operation Manual

February 1999 Part No. 917345-002 Rev A

Part No. 917345-002 Rev A February 1999
 TABLE OF CONTENTS

Title Page

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. Dispensers Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. Local, State and Federal Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. Inspect the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. Island Construction, Dispenser Anchoring and Piping . . . . . . . . . . . . . . . . . . . . . . . 5
2.3. Master/Satellite Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4. Maintenance Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5. Weights And Measures Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6. Installing the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.7. Submersible Pump Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.8. Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3. START-UP PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1. Fueling Point I.D. (Pump Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2. Price Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3. Authorize Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4. Testing Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5. Bleeding Product Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6. Discharge Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7. Meter Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8. Operating Lever Check and Handle Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9. Fluorescent Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10. Totals Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2. DD1/Model Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3. Cycling Power To Clear Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4. Fault Detection And Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.2. Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.3. Fault Status Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4.4. Fault Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4.5. Totalizer Sequence Code Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5. Dispensers With Preset Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6. Restarting After Power Failure or All Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1. Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2. Proper Care of the Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
iii

February 1999 Part No. 917345-002 Rev A

APPENDIX A.- OPERATION OF THE PRESET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A.2. Preset Currency Sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
A.3. Preset Volume Sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A.4. Fill-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
APPENDIX B.- ENGINEERING DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY . INSIDE BACK COVER
FCC WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK COVER

LIST OF FIGURES

Figure 2-1. U.S. Hazardous Zone Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2-2. International Hazardous Zone Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2-3. Typical Emergency Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2-4. Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3-1. Computer Assembly Functions and Switch Locations . . . . . . . . . . . . . . . . . . . . . 13
Figure 3-2. Meter Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3-3. Operating Lever Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 3-4. Typical Electro-mechanical Totalizer Readings. . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 4-1. Data Distribution Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 4-2. Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 4-3. Main Sale Display Showing Transaction Counters . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 4-4. Main Sale Display Showing Transaction Counter and Fault Code . . . . . . . . . . . 26
Figure 5-1. Strainer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure A-1. Preset Keypad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure B-1. Installation Instructions - Models DD1/351 and DD1/357. . . . . . . . . . . . . . . . . . 34
Figure B-2. Installation Instructions - Models DD1/357 and DD1/358
(Master/Satellite Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure B-3. Installation Instructions - Model DD1/358 (Master/Satellite Unit) . . . . . . . . . . . 36
Figure B-4. Wiring Diagram - Installation - Models DD1/357 MIL/KR. . . . . . . . . . . . . . . . . 37
Figure B-5. Wiring Diagram - Installation - Models DD1/357 MIL/K . . . . . . . . . . . . . . . . . . 38
Figure B-6. Wiring Diagram - Installation - Models DD1/358 M1S . . . . . . . . . . . . . . . . . . . 39
Figure B-7. Satellite Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure B-8. Interconnection Wiring Diagram -
Site Controller to Remote Model DD/351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure B-9. Interconnection Wiring Diagram -
Site Controller to Remote Model DD/357 Series . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure B-10. 880062-31 Interconnection Diagram for Systems
With More Than 16 Fueling Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure B-11. 10196-B Dimensional Drawing - Inside Foot Print . . . . . . . . . . . . . . . . . . . . . . . 44

iv

Part No. 917345-002 Rev A February 1999

 LIST OF TABLES

Title Page

Table 2-1. Component Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 2-2. Submersible Pump Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 3-1. Unit Price Selection - Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 3-2. Totalizer Readings (Indication Displayed) - Single . . . . . . . . . . . . . . . . . . . . . . . 20
Table 3-3. Totalizer Readings (Indication Displayed) - Duo 2 . . . . . . . . . . . . . . . . . . . . . . . 20
Table 4-1. Fault Code Status and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

February 1999 Part No. 917345-002 Rev A

vi

Part No. 917345-002 Rev A February 1999

 1. INTRODUCTION

1.1. DISPENSERS COVERED

This manual covers truck stop dispensers, which means the dispensers are capable of oper-
ating at a higher flow rate than standard. This manual describes the installation and opera-
tion of “DD” 350 series remote dispensers. The “DD” refers to Duplex Computer.

The DD Series dispenser may be installed and operated as a stand-alone unit or as a compo-
nent part of a Wayne® Management Control System. This manual provides installation and
operation information for DD/350 series dispensers operating as stand-alone units;
however, information concerning Wayne Control Systems has been included where appro-
priate. Each side of the dispenser is referred to as a fueling point for connection to a control
system. Single-sided dispensers are designated by an “R” in the model number suffix and
have only one fueling point. Complete installation and operation information for the appro-
priate Wayne Control System can be obtained from the manuals provided with the control
system being installed.

Use the correct installation and wiring instructions as shown in Appendix B of this manual.

Each model is described in the following:

• DD/351 dispensers have one inlet (one product) and one hose and are island
oriented1.
• DD/357 dispensers have one inlet (one product) and two hoses and are lane
oriented2.
• DD/357M dispensers are lane oriented “Master” units which include plumbing and
controls for product flow to a “Satellite.”
• DD/357S dispenser are lane oriented satellite units. They must be used with a master
unit.
• DD/358MS dispensers are lane oriented combination master/satellite units. The “A”
side fueling point is set up as a master, the “B” side is set up as a satellite.
Any questions concerning installation and operation of the dispenser that are not covered
in this manual should be referred to your authorized Wayne service personnel or Wayne
Technical Support (1-800-926-3737).

1. Island oriented - Nozzle boot is located on side of dispenser and can fuel to either lane. A sale display for
each nozzle is located on both the front and back.
2. Lane oriented - Nozzle boot is located in door panel of unit and can only fuel one lane. Each nozzle boot
has its own sale display which can only be viewed from same lane as nozzle boot.
1

February 1999 Part No. 917345-002 Rev A

1.2. LOCAL, STATE AND FEDERAL CODES

All tanks (both underground and above ground), piping and all fittings, leak detectors,
corrosion protection devices, wiring, venting systems, etc., must be installed in accordance
with the manufacturers’ instructions and in compliance with local and regional building
codes and requirements pertaining to service stations (or other locations where the
dispenser may be installed).

These requirements may include references to the National Electrical Code NFPA 70, the
Automotive and Marine Service Station Code NFPA 30A, the Flammable and Combustible
Liquids Code NFPA 30, the Code of Federal Regulations, Title 40, Section 280 (40-CFR
280), United States Environmental Protection Agency (U.S. EPA) Technical Regulations
of 9-23-88 and U.S. EPA Financial Responsibility Regulations of 10-26-1988.

Where local requirements do not specify applicable codes, Wayne recommends using the
codes listed above. These codes are comprehensive and detailed, often requiring interpre-
tation to cover unusual situations, and, therefore, the associated handbooks, where appli-
cable, 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 sources listed on the following page.

Part No. 917345-002 Rev A February 1999

 Association for Composite Tanks (ACT) American Petroleum Institute (API)
North State Street 1220 L Street, N.W.
Suite 720 Washington, DC 20005
Chicago, IL 60602 (202) 682-8000
(301) 355-1307 (for information requests)
Fiberglass Petroleum Tank and Pipe Institute National Assoc. Corrosion Engineers
One SeaGate, Suite 1001 (NACE)
Toledo, OH 43604 Box 218340
(419) 247-5412 Houston, TX 77218
(713) 492-0535
National Fire Protection Association (NFPA) National Leak Prevention Association
One Batterymarch Park (NLPA)
Quincy, MA 02269-9101 685 Fields Ertel Road
(617) 770-3000 Cincinnati, OH 45241
(513) 489-9844 or 1-(800) 543-1838
Petroleum Equipment Institute (PEI) Steel Tank Institute
Box 2380 P. O. Box 4020
Tulsa, OK 74101 Northbrook, IL 60065
(918) 494-9696 (312) 498-1980
Underwriters Laboratories Inc. Underwriters Laboratories of Canada
333 Pfingsten Road 7 Crouse Road
Northbrook, IL 60062 Scarsborough, Ontario, Canada N1R3A9
(312) 272-8800 (416) 757-3611
United States Environmental Protection Agency Western Fire Chiefs Association
Office of Underground Storage Tanks 5360 South Workman Mill Road
401 M St., SW (05-400WF) Whittier, CA 90601
Washington, DC 20640 (213) 699-0541
(703) 308-8850 (Underground Storage Tanks)
U. S. Department of Labor,
Occupational Safety and Health Administration (OSHA)
Washington, DC 20402
• Call OSHA at (202) 523-8148 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
(202) 783-3238

Note: Other regulatory codes may apply. Consult your local and regional code requirements
to determine which codes are applicable for your location.

February 1999 Part No. 917345-002 Rev A

1.3. SAFETY PRECAUTIONS

NFPA 30A states that:

“When maintenance to Class I dispensing devices becomes necessary and such mainte-
nance may allow the accidental release or ignition of liquid, the following precautions shall
be taken before such maintenance is begun:

• Only persons knowledgeable in performing the required maintenance shall perform

the work.
• All electrical power to the dispensing device and pump serving the dispenser shall be
shut off at the main electrical disconnect panel.
• The emergency shut-off valve at the dispenser, if installed, shall be closed.
• All vehicle traffic and unauthorized persons shall be prevented from coming within
20 feet (6 m) of the dispensing device.1”

! WARNING
Electric shock hazard! More than one disconnect switch may be required to de-ener-
gize the dispenser 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-90, Automotive and Marine Service Station Codes, Copy-
right ©1990, National Fire Protection Association, Quincy MA 02269. This reprinted material is not the
complete and official position of the National Fire Protection Association on the referenced subject,
which is represented only by the standard in its entirety.
4

Part No. 917345-002 Rev A February 1999

 2. INSTALLATION

2.1. INSPECT THE EQUIPMENT

Examine the shipment immediately upon arrival to make certain there has been no damage
or loss in transit. Damaged or lost equipment must be reported to the carrier. Any damage
or loss that may occur in transit is not covered under the Wayne/Dresser Warranty.

Make sure that all the component parts, including keys and any optional equipment, are
accounted for. Check and save the Packing Slip, Bill of Lading, Invoice, and all other docu-
ments included in the shipment.

2.2. ISLAND CONSTRUCTION, DISPENSER ANCHORING AND PIPING

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.

A concrete foundation must be provided for the dispenser. Do not pour concrete around
product lines or electrical conduit risers.

Anchor bolts must be installed in the island, to allow the dispenser to be bolted down in
accordance with NFPA requirements. The base of the dispenser is provided with two 1”
bolt hole slots for anchoring the dispenser to the island. Position the anchor bolts in accor-
dance with the dimensions given on the appropriate Installation Instruction (engineering
drawing) in Appendix B.

Vertical supply risers and electrical conduits must be located per the installation instruction
for the appropriate model. Proper height must be maintained to avoid undue stress on the
dispenser.

Also it is important to know the Hazardous Zone area around the dispenser as shown in
Figure 2-1. and Figure 2-2.

! 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 2-3.
Failure to install the proper emergency shut-off valve will present a hazardous condi-
tion that could result in serious injury.

1. “Listed” means published on a list by a nationally recognized testing laboratory (NRTL) which is respon-
sible for product evaluation and is acceptable to the authority having jurisdiction. Underwriters Labora-
tories, Inc. is one example of a Nationally Recognized Testing Laboratory. For more information on
NRTL’s, see Title 29, Parts 1907 and 1910 of the Code of Federal Regulations, Safety Testing or Certifi-
cation of Certain Workplace Equipment and Materials.
5

February 1999 Part No. 917345-002 Rev A

 Unclassified Location
(Electronic Enclosure Area)

Vapor Barrier

48"
Island

18” Ground Level

Containment
Area (Pit)
18" 18"
20' 0" 20' 0"

U. S. Division 1 U. S. Division 2
Area where ignitable concentrations of Area where ignitable concentrations of
flammable gases, vapors or liquids can flammable gases, vapors or liquids are
exit all of the time or some of the time not likely to exist under normal operat-
under normal operating conditions. ing conditions.

20 FT. 20 FT.

DISPENSER

20 FT.

FIGURE 2-1. U.S. HAZARDOUS ZONE DIAGRAM. Front And Top Views Showing Horizontal And Verti-
cal distances
6

Part No. 917345-002 Rev A February 1999

 Unclassified Location
(Electronic Enclosure Area)

Vapor Barrier

1250 mm
Island

Ground Level

250
Containment
Area (Pit)
3000 3000
4250 mm 4250 mm

International Zone 1 International Zone 2

Area where ignitable concentrations Area where ignitable concentrations
of flammable gases, vapors or liquids of flammable gases, vapors or liquids
can exit all of the time or some of the are not likely to exist under normal
time under normal operating condi- operating conditions.
tions.

4250 mm 4250 mm

3000 mm 3000 mm

DISPENSER

3000 mm ZONE 2

ZONE 1

4250 mm

FIGURE 2-2. INTERNATIONAL HAZARDOUS ZONE DIAGRAM. Front and Top views showing horizon-
tal and vertical distances which are most common but may vary depending on country or jurisdiction.
7

February 1999 Part No. 917345-002 Rev A

FIGURE 2-3. TYPICAL EMERGENCY VALVE INSTALLATION. The emergency valve is designed to
close the product line due to shock or fire. The shear section, shown above, functions if the dispenser is
knocked out of position.

Part No. 917345-002 Rev A February 1999

2.3. MASTER/SATELLITE INTERFACE

The 350 series truck stop series is a high capacity flow rate dispenser. The satellite
dispenser is not a stand-alone unit and must be connected to the master unit for operation.
Flow to the satellite dispenser is controlled by the master dispenser computer and the
nozzle switch located in the satellite. The master dispenser must be ON in order for the
satellite to operate. Provisions are provided to prohibit simultaneous operation, if required
(see installation wiring diagrams). The satellite flow control valves are controlled by the
master.

A product supply line must be run between every master/satellite combination; see the
Installation Instructions in Appendix B.

2.4. MAINTENANCE SAFETY PRECAUTIONS

Safety precautions which should be observed are specified in the NFPA 30A. NFPA 30A
states that:

“When maintenance to Class I dispensing devices becomes necessary and such mainte-
nance may allow the accidental release or ignition of liquid, the following precautions shall
be taken before such maintenance is begun:

• Only persons knowledgeable in performing the required maintenance shall perform

the work.
• All electrical power to the dispensing device and pump serving the dispenser shall be
shut off at the main electrical disconnect panel.
• The emergency shutoff valve at the dispenser, if installed, shall be closed.
• All vehicle traffic and unauthorized persons
1
shall be prevented from coming within
20 feet (6 m) of the dispensing device. ”

! WARNING
More than one disconnect switch may be required to de-energize the dispenser for
maintenance and servicing. Do not take chances--use a voltmeter to make sure ALL
circuits in the dispenser are de-energized.
‘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-90, Automotive and Marine Service Station Codes, Copy-
right ©1990, National Fire Protection Association, Quincy MA 02269. This reprinted material is not the
complete and official position of the National Fire Protection Association on the referenced subject,
which is represented only by the standard in its entirety.
9

February 1999 Part No. 917345-002 Rev A

2.5. WEIGHTS AND MEASURES REQUIREMENTS

Local jurisdictions may have specific installation requirements for master/satellite

dispensers. Barriers may be required to prevent unauthorized use of the satellite nozzle.

2.6. INSTALLING THE DISPENSER

Remove the dispenser from its shipping carton. Survey the site and determine if any special
installation requirements, such as a canopy, etc. will affect the installation.

After the concrete has set, the dispenser can be set on the island and firmly bolted into place
and the product lines connected. To gain access to the bottom section of the dispenser,
unlock and remove the dispenser doors by lifting them straight up to clear the channel, and
then pulling forward.

Note: Remove the shipping discs from the inlet unions and connect the product piping.
Locate the dispenser on the island as shown on the appropriate installation instruction
(engineering drawing) in Appendix B, and make all piping and conduit connections. Attach
the base to the island using two anchor bolts in the holes provided, as shown on the appro-
priate installation instruction in Appendix B. When making piping connections, to ensure
tight, leak-proof connections, wash all cutting oils off the threads and use a U.L. classified
pipe joint sealing compound, rated for use with petroleum-based products.

Note: When handling the dispenser, lift only by the base or main chassis. Do not lift by the
computer enclosure, nozzle boot, hose outlet, operating lever or any external panels.
• 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.
For connection to a Wayne Control System follow the Installation Wiring Diagram
supplied with that system. However, an Interconnection Wiring Diagram is included in
Appendix B of this manual.

We recommend employing a qualified licensed electrician for all wiring. It is important,

because a hazardous liquid is being handled, that care be taken to ensure that all wiring is
in accordance with the National Electrical Code (NFPA 70) and also state and local rules
and regulations. See Table 2-1. for component electrical ratings.

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Part No. 917345-002 Rev A February 1999

 TABLE 2-1. COMPONENT ELECTRICAL RATINGS

Component Electrical Ratings

Control Power 120 VAC 1.5 Amps (per dispenser)

Nozzle Switch 12 VDC, 0.2 Amp or 28 vdc, 0.1 Amp
Solenoid Valves 120 VAC 60 Hz 8 Watts
Ballast 120 VAC 60 Hz 0.47 Amp

2.7. SUBMERSIBLE PUMP CONTROLS

Remote dispensers require a relay to interface to the submersible pump motor. Potter and
Brumfield relay no. PRD7AY0 (120) in a U.L. listed magnetic motor controller assembly
is recommended.

A maximum of 12 dispensers (24 fueling points) may be connected to a single PRD7AY0

(120) relay; other relays may have different limitations. All dispensers operating the same
pump control relay must be connected to the same circuit breaker. This may require
multiple submersible pump control relays for a submersible pump.

TABLE 2-2. SUBMERSIBLE PUMP RELAY SPECIFICATIONS

Coil Electrical Ratings

Control Voltage 120 VAC, 50/60 Hz

Coil Resistance 290 Ω (Ohms) ± 15%
Pull-in Characteristics

Current 0.040 Amp

Voltage 75 Volts
Drop-out Characteristics

Current 0.040 Amp

Voltage 55 Volts
Contact Rating for Potter and Brumfield PRD7AY0 (120)

25 A @ 240 VAC
20 A @ 277 VAC
1 HP @ 120/240 VAC

11

February 1999 Part No. 917345-002 Rev A

2.8. HOSE INSTALLATION

To ensure a proper joint, wash all cutting oil off the threads and use a good U.L. - classified
waterproof and petroleum-proof pipe joint sealing compound. Place the compound on male
threads only; be careful not to get any excess inside fittings. The hose bracket(s) supplied
mounts on the side panel/frame. Attach the bracket using the screws, lock washers and nuts
provided. Figure 2-4. illustrates the installation of the hose brackets.

NFPA 30A requires that a Listed emergency breakaway device, designed to retain liquids
on both sides of the breakaway point, be installed on the hose. These devices must be
installed and maintained per the manufacturer’s instructions.

Use only Listed hoses and nozzles.

FIGURE 2-4. HOSE BRACKET. The bracket is easy to attach to the side of the dispenser.

12

Part No. 917345-002 Rev A February 1999

 3. START-UP PROCEDURE

Power should be OFF. To use this dispenser with a control, follow the start-up instructions
provided with that particular system, referring to the procedures in this manual only as directed.
Note: Important: Weights and Measures regulations require the user to select the price used
in dual pricing applications by controls mounted on the dispenser. (See Figure 3-1.)
Always turn OFF all power to the dispenser prior to accessing the computer enclosure,
pulser enclosure and/or any junction box.

Note: Prior to removing bezels, installing and servicing personnel must wear a static control
wrist strap, Part No. 916962 or equivalent, securely attached to an earth grounding
point in order to prevent damage to electronic components due to static electricity. A
banana jack is located on the left side of each dispenser door to provide a grounded
attachment point for the wrist strap cord.
Remove dispenser bezels by removing two screws located on each bezel. Replace bezels
before powering up dispenser. Turn ON control power circuit breaker.

FIGURE 3-1. COMPUTER ASSEMBLY FUNCTIONS AND SWITCH LOCATIONS. For use with a control,
follow the start-up instructions with the system.

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February 1999 Part No. 917345-002 Rev A

3.1. FUELING POINT I.D. (PUMP NUMBER)

The following instructions apply only to installations incorporating the 2400 MCS or
Wayne Plus tied to each fueling point. Each “side” of the dispenser represents a fueling
point with each computer controlling one nozzle. A master/slave unit has one fueling point.
Each fueling point must be identified by a number for communication with a control
system.

The fueling point number is set as follows:

1. The PRICE JOG keyswitch is used to enter the fueling point setting mode. The
TOTALS switch (push-button) sets the fueling point number; see Figure 3-1. for switch
location.
2. Turn the PRICE JOG keyswitch ON, then OFF.
3. To read the fueling point number, press and release the TOTALS push-button.
4. To set the fueling point number, press and hold the TOTALS push-button. The two
least significant digits of the Unit Price display will cycle 01 through 24. Release the
TOTALS push-button when the correct fueling point number is displayed.
5. Cycle the PRICE JOG keyswitch until the original sale display returns.
3.2. PRICE SETTING

Unit prices must be set manually at the dispenser for stand-alone operation. The following
procedure should not be used if the dispenser is connected to a Management Control
System, because prices set with a Management Control System will override the manually
set prices. Refer to the operating procedures provided with the Management Control
System for a complete description of unit price setting when using these systems.

Note: The nozzle(s) must be in the nozzle boot(s) to set prices.

The closure of the Position Select key switch (turn and release) will enable the Price Jog
push-button to set unit price (the first closure will set the first unit price). Refer to
Table 3-1. for price selection.

1. The first closure of the Price Jog push-button (press and hold) causes the least signifi-
cant digit (commonly tenths of cents position) of the unit price to cycle.
2. The digit will cycle 0 through 9 until the switch is released. Each successive closure of
the Price Jog push-button will select and then increment the next most significant
(higher) digit.

14

Part No. 917345-002 Rev A February 1999

 TABLE 3-1. UNIT PRICE SELECTION - SINGLE

Price Jog Switch Closure Unit Price Digit Selected

First Closure Least Significant Digit (Commonly Tenths Of Cents)

Second Closure Next Most Significant (Higher) Digit (Commonly Cents)

Third Closure Next Most Significant (Higher) Digit (Commonly Tens Of Cents)

Fourth Closure Next Most Significant (Higher) Digit (Commonly Dollars)

3.3. AUTHORIZE SWITCH

The Authorize keyswitch (see Figure 3-1.) permits dispenser operation either with or
without console control. In the self service position (keyswitch turned counterclockwise),
the dispenser must be authorized by the console before each use. In the full service position
(keyswitch turned clockwise), the dispenser may be operated repeatedly without authoriza-
tion from the console. There is an Authorize keyswitch for each fueling point.

The switch may be used as a one time authorize by turning the keyswitch to the full service
position and back to the self service position (operating levers must be OFF). The dispenser
will operate one time following this sequence. When changing from full service to self
service, turn one of the operating levers ON, then OFF to avoid the one time authorize
condition.

Programming in the control system will determine the use of the Authorize keyswitch in
console control. Only one nozzle per fueling point may be used at a time.

Check that when the operating lever is lifted, the submersible pump motor is activated, and
at the end of the display reset (approximately three seconds) the solenoid valve(s) opens
(listen for an audible click of the valve(s).

Deliver product and check that the correct sale amount is displayed (volume times (X) unit
price ± 1/2 cent). Dispense at least 20 gallons (75 liters) of product to completely fill the
system and discharge all air from the line and dispenser.

3.4. TESTING LINES

Be certain to check local codes concerning line testing. In some areas a hydrostatic test as
well as an air pressure test is mandatory.

When the dispenser has been connected, the lines should again be tested for leaks.

15

February 1999 Part No. 917345-002 Rev A

3.5. BLEEDING PRODUCT LINES

Before dispensing product, remove the pipe plug from the safety impact valve on the
farthest dispenser in each product trunk line. 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 underground lines into a test can until product is dispensed. This bleeds the
air from the underground lines without damaging the dispenser. Always bleed the master
unit before the satellite unit.

Once the air is bled properly from each trunk line, product may then be slowly dispensed
through all other dispensers until lines are free of air. Attempting to dispense air through
a dispenser can severely damage components and cause pulser error.

3.6. DISCHARGE AIR

Deliver product and check that the correct sale amount is displayed (volume times (X) unit
price ± 1/2 cent). Dispense at least 20 gallons (75 liters) of product to completely fill the
system and discharge all air from the line and dispenser.

3.7. METER CHECK

The 350 Truck Stop dispenser has two meters connected in tandem to give a higher flow
rate. While the dispensers leave the factory properly adjusted, rough handling in transit or
special installation conditions can change this. Therefore, before placing the dispenser in
operation, these items must be checked and adjusted, if required. Either one or both meters
may need to be adjusted to obtain the correct overall calibration.

Check meter adjustment by dispensing a measured amount of product into a test can. If
meter adjustment is required, the adjustment knobs are located on the top of the meters; see
Figure 3-2. If the test can reads low or high, break the seal, lift the adjustment knob and turn
it clockwise (if the can reads low) or counter-clockwise (if the can reads high), viewing the
knob from the top of the meter. The lower portion of the knob is hexagonal and, in a normal
position, the portion of the knob is inserted in the output shaft assembly. There are
18 vertical notches within the shaft, therefore, as the adjustment is made, the knob can be
felt to click over the leading edge of the notches. Each notch is equivalent to a correction
of approximately one cubic inch in five gallons. After the meter has been adjusted and
brought within tolerance, (consult your local codes for meter adjustment regulations and
standards) replace the seal wire and seal it by pinching the lead lock on the wire.

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Part No. 917345-002 Rev A February 1999

FIGURE 3-2. METER ADJUSTMENT. After the meter has been adjusted and brought within tolerance,
install a seal wire and pinch the lead lock closed.

3.8. OPERATING LEVER CHECK AND HANDLE SWITCH SETTING

The operating lever is a spring over-center device that normally does not require adjust-
ment. When the operating lever is lifted just over center and then released, the lever will
spring to the fully-on position. Likewise, when the operating lever is lowered just over
center and then, released, the lever will spring to the fully-off position.

Note: Satellites only, Master units have switches on nozzle boots.

If setting the operating lever is necessary, push the nozzle support to the fully-on position
as shown in Figure 3-3. Snap the ball joint off the rod and turn it once or twice to lengthen
or shorten the rod as required.

Lengthening the rod will slow the turn on time of the pump; shortening it will turn the pump
on more quickly. Do not snap the ball joint back on to the rod yet. Hold it in place while
checking the accuracy of the setting.

To test the accuracy, slowly push the nozzle support toward the “down” or “off” position.
Note when the pump turns off. The pump must turn off at, or slightly past, the over-center
position. Be certain that the dispenser does not come on again when the nozzle support is
in the “fully-off” or “fully-down” position.

All moving parts of the nozzle boot should operate freely without binding or sticking. The
levers should click audibly during the up and down operation of the nozzle supports.
17

February 1999 Part No. 917345-002 Rev A

2.9. OPERATING LEVER CHECK AND HANDLE SWITCH SETTING, continued

FIGURE 3-3. OPERATING LEVER SETTING. Lengthening the rod will slow the turn on time of the pump;
shortening it will turn the pump on more quickly.

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Part No. 917345-002 Rev A February 1999

3.9. FLUORESCENT LIGHTS

Turn on the light circuit breaker and ensure that all of the fluorescent lights operate.
Replace any fluorescent light bulbs that fail to illuminate.

3.10. TOTALS SEQUENCE

Each fueling point of the dispenser maintains electronic totalizers for the money and
volume.

Totals automatically advance approximately every ten seconds after initial closure of the
Totals push-button. Subsequent closure of the Totals push-button also advances totals. The
dispenser computer retains totalizer data; the dispenser may be turned OFF at night or for
servicing without affecting totalizer readings.

Refer to Tables 3-2. and 3-3. for totalizer readings. Note that the table shows factory default
readings for dispensers operating in stand-alone mode.

Activate the Totals push-button and record the electronic money and volume totals. Read
and record the Electro-Mechanical Totalizer. All initial totalizer readings must be given to
the station manager to maintain accurate accounting. (See Figure 3-4.)
TD00020-A1

123456 123456 123456

LEFT MIDDLE RIGHT

FIGURE 3-4. TYPICAL ELECTRO-MECHANICAL TOTALIZER READINGS. Electro-Mechanical total-

izers display accumulated grade totals for both sides of a dispenser.

19

February 1999 Part No. 917345-002 Rev A

 TABLE 3-2. TOTALIZER READINGS (INDICATION DISPLAYED) - SINGLE

Totals Switch Indication

Closure Totals Displayed Displayed
First Closure Money Totals Position “X” C1
Second Closure Volume Totals Position “X” PR1
Third Closure Total Money All Products CC

TABLE 3-3. TOTALIZER READINGS (INDICATION DISPLAYED) - DUO 2

Totals Switch Indication

Closure Totals Displayed Displayed
First Closure Money Totals Position “X” C1
Second Closure Volume Totals Position “X” PR1
Third Closure Money Totals Position “Y” C2
Fourth Closure Volume Totals Position “Y” PR2
Fifth Closure Total Money All Products CC
w

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Part No. 917345-002 Rev A February 1999

 4. OPERATION

4.1. INTRODUCTION

Each side of the dispenser represents one fueling point, with one dispenser computer
servicing all nozzles on that side.

The Authorize keyswitch must be in the full service position, or the dispenser must be
authorized by a control system for the dispenser to operate.

To operate the dispensers independently from a control system, the following initial steps
must be performed:

1. In the data distribution box, switch the Auto/Bypass switch for the dispenser to the
Bypass position. See Figure 4-1.
2. Turn the Authorize keyswitch to the full service position (clockwise).
3. Cycle power (turn dispenser control power OFF, then ON.)
TD00301-A

Inside of Data Distribution Cabinet

Auto-Bypass
Switches

The 'Hose No.' inside the Data Distribution

TD00301-A
TD00301-A

Box refers to the fueling point number of

the dispenser side you want to control.
Auto means the dispenser is controlled by
the console; 'Bypass' means it is controlled
by the dispenser.

FIGURE 4-1. DATA DISTRIBUTION BOX. The Auto/Bypass switches connect or disconnect a dispenser
from the control system.

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February 1999 Part No. 917345-002 Rev A

4.2. DD1/MODEL SERIES

The DD1/model series dispenser is equipped with one unit price per nozzle. The dispenser
is turned ON by lifting the nozzle from its bracket and sliding the operating lever up. The
sale display shows all eights, then blanks and resets to zero. The submersible pump starts
at the beginning of the reset cycle and the solenoid valve(s) opens approximately 3 seconds
later.

At the end of the delivery, the operating lever is slid down to the OFF position and the
nozzle is replaced.

4.3. CYCLING POWER TO CLEAR FAULTS

If a fault in the dispenser is detected by the computer, an error message will be displayed
in the sale display. Be sure to make a note of the displayed error message. It may be
possible to restart the dispenser by the following sequence:

1. Make sure all nozzles are properly seated in the nozzle boot.
2. Turn the control power circuit breaker OFF for approximately five seconds. Turn the
control power circuit breaker ON.
3. Remove the nozzle from the nozzle boot. The dispenser should operate normally.
If it is not possible to restart the dispenser using this procedure, or if an error continues to
be displayed, consult appropriate service personnel. Be certain to give the service personnel
the amount at which the dispenser stopped and the exact error message, if any.

4.4. FAULT DETECTION AND REPORTING

4.4.1. Introduction
The purposes of the fault detection and reporting circuits in the Duplex II computer are as
follows:

• Monitor the operation of the dispenser.

• Identify a fault when it occurs.
• Categorize the severity of the fault.
• Take appropriate action depending upon the severity of the fault.
4.4.2. Clearing Faults
Once the cause of a fault is corrected the fault can be cleared from the display of the
dispenser by cycling power to the computer or by entering option 99. If the problem is
corrected but power is not cycled or option 99 is not entered the fault code will continue to
be displayed.

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Part No. 917345-002 Rev A February 1999

 4.4.3. Fault Status Descriptions
When a fault is detected, the Duplex II Computer records the Fault Status number (1,2 or
3). The Fault Status number indicates the action resulting from the fault as follows:

1. Error Code, error codes shut down the affected side of the dispenser until power is
cycled or option 99 is entered.
2. Hydraulic Code, hydraulic codes shut down the affected hydraulic system on the
specific side of the dispenser until power is cycled or option 99 is entered.
3. Service Code, service codes do not affect the operation of the dispenser but are
displayed in option 01.
The Fault Status column in Table 4-1. identifies the default status which is assigned to each
Code. When more than one number is shown in the Fault Status column, it indicates that
the status of that Fault Code is alterable. An asterisk next to a number indicates the default
value for the Fault Code.

For example, fault code 08 (Time Out Limit) has three numbers, 1/2/3, in the fault code
column. Therefore, you are given the option of assigning a status 1 (Error Code), 2
(Hydraulic Code), or 3 (Service Code) to Fault Code 08.

TABLE 4-1. FAULT CODE STATUS AND DESCRIPTIONS

Code Fault Code Description

03 1/2/3* Unit has overrun prepay/preset amount.

04 1* ROM checksum error.

05 1/2/3* Pulser error. (Set if jitter count exceeds limit).

06 1/3* Illegal current sensed in valve or relay output circuit.

08 1/2/3* Time out limit has been exceeded.

09 1* Five (5) consecutive no pulse time outs.

10 1/2/3* Reverse pulse limit has been exceeded.

11 1* Corrupted option data. the pump will not restart until option 99 is set to 03.
Cycling power will not reset this error.

12 3* Corrupted totals data; the totals were reset to zero.

13 3* Corrupted unit price data; the unit prices were reset to zero.

14 1/2/3* Forward pulses from illegal pulser exceeds limit. **

15 1/2/3* Jitter pulses from illegal pulser exceeds limit. **

16 1/2/3* Reverse pulses from illegal pulser exceeds limit. **

Note: An asterisk (*) in the Fault Code column indicates the default values.

23

February 1999 Part No. 917345-002 Rev A

 4.4.4. Fault Reporting
When the computer detects a fault, the sale currently in progress may be shut down.
Depending on the fault code status, the sale may not be shut down and, on the next reset, a
fault code will be displayed. The fault code is displayed only for the affected side of the
dispenser. In addition to the displayed fault code, a transaction counter number is also
displayed. The transaction counter number can be used as a troubleshooting aid to deter-
mine on which sale an error occurred and if that particular error is related to the reported
problem. This fault code, along with the new transaction counter number, will have a
format similar to that in (Figure 4-2.).

The transaction counter has a range of 00000 - 59999 and then rolls over to 00001. Each
side of the dispenser has a transaction counter. When Option 01 is entered the current trans-
action number for side 1 is shown in the Sale Money Display. The value of side 2 transac-
tion counter (if two fueling points) is shown in the Sale Volume Display. See (Figure 4-3.)
for an example. Pushing the Totals button while the transaction values are displayed causes
entry into the Fault Code History Display Mode. See (Figure 4-4.) for an example. As
shown the transaction number is displayed for each side along with the fault code for that
transaction number. The first fault code displayed is the most recent.

Pushing the Totals button cycles through the fault codes. This mode will display the last 16
fault codes detected by the dispenser’s computer since the last RAM clear (not 16 per side
but 16 total for that computer).

In order to reset the dispenser after a fault, the initial problem must be corrected and power
to the computer cycled or Option 99 is entered. Until these conditions are satisfied the fault
code will continue to be displayed at the end of the reset cycle.

4.4.5. Totalizer Sequence Code Display

The last fault code detected is displayed on the applicable side of the dispenser when the
totalizer read sequence is initiated unless:

Option 26 = 02 (Disable), or, since the last fault code was detected, Option 99
has been entered or power has been cycled.

4.5. DISPENSERS WITH PRESET OPTION

Dispensers may be equipped with an optional preset keypad. The preset keypad allows the
customer or attendant to enter the amount of product that they wish to dispense. For
complete operation instructions of the preset option, see Appendix A.

24

Part No. 917345-002 Rev A February 1999

 MAIN SALE DISPLAY
NNNNN = Transaction Counter in the range of
00000 - 59999
NNNNN.S S = Side 1 or 2. This is the side on which the code was
PF - CC.T detected.

T = Fault Code Status: 1 = Error 3 = Service

2 = Hydraulic 4 = Disable

CC = Fault Code number in the range of 00 - 99

F = Fault Source. This value identifies the fault source if the fault can be
linked to a particular hydraulic condition. The range is 0 - 7, "H" or "L".
The numeric values indicate positions (0 = none) while the letters
indicate blending feedstocks.

P = Product Source. This is the position that was selected at the time the
fault occurred. The range is 0 - 7, with 0 = no position selected.
FIGURE 4-2. FAULT CODE DISPLAY. The fault code will have a format similar to that shown.

25

February 1999 Part No. 917345-002 Rev A

 MAIN SALE DISPLAY

Money

Volume

FIGURE 4-3. MAIN SALE DISPLAY SHOWING TRANSACTION COUNTERS. The transaction number
for Side 1 of the dispenser is shown in the Money Display and the transaction number for Side 2 is shown
in the Volume Display.

MAIN SALE DISPLAY

Money

Volume

FIGURE 4-4. MAIN SALE DISPLAY SHOWING TRANSACTION COUNTER AND FAULT CODE. In this
example, Fault Code 05 occurred on transaction number 00833 on Side 1 of the dispenser (the junction box
side).

4.6. RESTARTING AFTER POWER FAILURE OR ALL STOP

The display accurately displays the amount of the sale in money and volume with the loss
of power for approximately 15 minutes. When power is restored, all sale information
returns to the displays. Any sales in progress will be ended.

26

Part No. 917345-002 Rev A February 1999

 5. PREVENTIVE MAINTENANCE

5.1. GUIDELINES

The safety precautions described in Section 1.3. apply to the following preventive mainte-
nance procedures. A correctly installed dispenser, given proper preventive maintenance
attention, will seldom require emergency service. Perform the following checks on a
regular basis:

• Check the dispenser for internal and external leaks regularly. Check nozzles, swivels,
hoses, and joints for leaks and wear. Have all defects repaired immediately.
• Do not abuse the hose by trying to stretch it to reach an automobile. This will cause
early failure at the couplings.
• 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.
• If the bezels must be removed during rainy weather, take care to prevent rain from
getting inside the dispenser.
• 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.
• Check the operating lever operation. If this does not operate easily, too much force
may be applied on the switch mechanisms, causing premature failure. The over-
center device must remain coated with a waterproof lubricant.
• The mechanical totalizer flex cable must be inspected for wear and remain coated
with waterproof lubricant.
• Periodically check and lubricate all key lock cylinders and locking mechanisms.
A dirty strainer screen will slow down the delivery of product. If the underground installa-
tion is a new one, it may be necessary to clean the strainer screen two or three times during
the first few days of operation to remove installation debris and pipe sealant. After this,
occasional cleaning is all that should be required.

! WARNING
Power to ALL dispensers should be turned OFF and the emergency shut-off valves on
the dispenser being serviced should be CLOSED before performing the following
procedure.
• Loosen strainer cap and allow the gasoline to drain into a plastic bucket until pressure
is relieved.
• Return any gasoline to appropriate underground tank.
• Remove the strainer for cleaning by unfastening the cap, see Figure 5-1. Place a
container under the cap to catch the petroleum and sediment. Wash the screen in
gasoline and dislodge lint and other foreign particles with compressed air. Check for
leakage after reinstalling.
27

February 1999 Part No. 917345-002 Rev A

FIGURE 5-1. STRAINER ASSEMBLY. Unfasten the cap for cleaning.

5.2. PROPER CARE OF THE DISPENSER

• Wash the dispenser frequently with a non-abrasive cloth and warm water mixed with
a mild household cleaner (such as dishwashing liquid). The dispenser should then be
wiped down with a clean wet cloth. Do not use a hose to rinse off the dispenser.

! WARNING
Do not direct pressurized water (even from a garden hose) at the dispenser.
Under no circumstances should power washers be used to clean the dispensers. (This
can force water into the electronic head and cause the dispenser to shut down.)

! WARNING
Do not use all-purpose cleaners on the surfaces of the dispenser. They may scratch the
clear plastic, as well as break down the corrosion resistance of painted and stainless
steel surfaces.

! WARNING
Do not use gasoline or other petroleum-based products to clean the dispenser.

28

Part No. 917345-002 Rev A February 1999

 • Exposure to contaminants can cause a discoloration of the stainless steel panels
(doors, column covers, etc.). If the discoloration persists after washing (as instructed
above), the use of an abrasive powder cleaner is very effective in restoring the orig-
inal shine.
Two cleaners in particular are very effective and practical to use: Zud Heavy Duty
Cleaner and Bar Keepers Friend. They can both be found in most hardware/grocery
stores. Follow the manufacturers' instructions for use and always rub in the direction of the
brush finish to prevent scratching the stainless steel.

• Periodic waxing of the dispenser surfaces is essential to maintain the original finish
and inhibit corrosion. Stainless steel surfaces should be polished with a non-abrasive
silicone wax. Painted surfaces should be waxed with an automotive wax/polish. We
recommend that these surfaces be waxed/polished at least three times a year.

29

February 1999 Part No. 917345-002 Rev A

30

Part No. 917345-002 Rev A February 1999

 APPENDIX A. - OPERATION OF THE PRESET

A.1. INTRODUCTION

Dispensers with the preset option will have a preset keypad assembly installed in them (see Figure
A-1.) 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.
The preset assembly cannot authorize a dispenser. In order for the dispenser to operate the
dispenser must be authorized either by a control system or by the self-serve/attend switch at the
dispenser. Even if a preset selection is made the dispenser will not reset until it receives an autho-
rize signal.

Currency
Volume

1 2 3 Currency/Volume

4 5 6 Fill

7 8 9 Clear

* 0 # Enter

FIGURE A-1. PRESET KEYPAD ASSEMBLY. The Preset may be installed either to the left or right of the
dial face. If the dispenser has CAT’s, the Preset will have to be on the right.

A.2. PRESET CURRENCY SALE

In order to preset a currency sale perform the following steps.

1. The preset will default to the currency mode; therefore, when the customer approaches
the dispenser the “Currency” arrow will be lit on the preset display.
2. Enter, on the numeric keypad, the monetary value of product desired.
3. Press the “Enter” key (this step is optional).
Note: The “Enter” function is to signal the software that keyboard entry has been
completed. This function can be done three ways:
4. Pressing the “Enter” key after keying in a value.
5. Lifting the nozzle after keying in a value.
6. Waiting six seconds after the last numerical entry is made.
31

February 1999 Part No. 917345-002 Rev A

 In either case, the function locks the keyboard and allows only the “Clear” key to function.
The “Clear” key can be used to clear the preset controller if the customer desires to change
the preset value.
The “Enter” function is not necessary if the unit is operating in the “no preset required”
mode. In this case, if “flow” is started before either of the aforementioned “enter” methods
has been invoked, the system locks the keyboard and looks to see if a preset value has been
entered. If no preset entries were made the pump will not automatically shut off. If a value
had been entered prior to “flow”, the pump will automatically shut off at that value.
7. Remove the nozzle from the nozzle boot and reset the dispenser. If you want to change
the preset amount, press “Clear” before fuel flows and enter the new amount.
8. Once the sale is complete replace the nozzle in the nozzle boot, and the preset readies
itself for a new sale.
A.3. PRESET VOLUME SALE

In order to preset a volume sale perform the following steps:

Step 1. The preset will default to the currency mode; therefore, when the customer
approaches the dispenser the “Currency” arrow will be lit on the preset display.
Press the “Currency/Volume” key to change the preset to the volume mode.
Step 2. Enter the volume amount desired.
Step 3. Press the “Enter” key (this step is optional).
Step 4. Remove the nozzle from the nozzle boot and reset the dispenser. If you want to
change the preset amount, press “Clear” before fuel flows and enter the new
amount.
Step 5. Once the sale is complete replace the nozzle in the nozzle boot, and the preset
readies itself for a new sale.
A.4. FILL-UP

In order to fill a tank using the preset perform the following steps:
1. The preset will default to the currency mode; therefore, when the customer approaches
the dispenser the “Currency” arrow will be lit on the preset display.
2. Press the “Fill” button on the preset.
3. Remove the nozzle from the nozzle boot and reset the dispenser. If you want to enter a
preset currency or volume amount, press “Clear” before fuel flows and enter the
amount.
4. Once the sale is complete replace the nozzle in the nozzle boot, and the preset readies
itself for a new sale.

32

Part No. 917345-002 Rev A February 1999

 APPENDIX B. ENGINEERING DRAWINGS

33

February 1999 Part No. 917345-002 Rev A

 34

Part No. 917345-002 Rev A

FIGURE B-1. INSTALLATION INSTRUCTIONS - MODELS DD1/351 AND DD1/357.

February 1999
February 1999
FIGURE B-2. INSTALLATION INSTRUCTIONS - MODELS DD1/357 AND DD1/358 (MASTER/SATELLITE UNIT).

35

Part No. 917345-002 Rev A

 36

Part No. 917345-002 Rev A

FIGURE B-3. INSTALLATION INSTRUCTIONS - MODEL DD1/358 (MASTER/SATELLITE UNIT).

February 1999
February 1999
FIGURE B-4. WIRING DIAGRAM - INSTALLATION - MODELS DD1/357 MIL/KR.

37

Part No. 917345-002 Rev A

 38

Part No. 917345-002 Rev A

February 1999
FIGURE B-5. WIRING DIAGRAM - INSTALLATION - MODELS DD1/357 MIL/K.
February 1999
39

Part No. 917345-002 Rev A

FIGURE B-6. WIRING DIAGRAM - INSTALLATION - MODELS DD1/358 M1S.
 FIGURE B-7. SATELLITE WIRING DIAGRAM.

40

Part No. 917345-002 Rev A February 1999

February 1999
FIGURE B-8. INTERCONNECTION WIRING DIAGRAM - SITE CONTROLLER TO REMOTE MODEL DD/351.

41

Part No. 917345-002 Rev A

 42

Part No. 917345-002 Rev A

FIGURE B-9. INTERCONNECTION WIRING DIAGRAM - SITE CONTROLLER TO REMOTE MODEL DD/357 SERIES.

February 1999
February 1999
FIGURE B-10. 880062-31 INTERCONNECTION DIAGRAM FOR SYSTEMS WITH MORE THAN 16 FUELING POINTS.

43

Part No. 917345-002 Rev A

 44

Part No. 917345-002 Rev A

FIGURE B-11. 10196-B DIMENSIONAL DRAWING - INSIDE FOOT PRINT. 350 Dimensions Same as 360
Model Series.

February 1999
 DD1/350 Series Remote
Dispensers Manual

This manual was produced using Adobe® FrameMaker® on a Power Macintosh® 8100/80.

Page design uses Times 12 and Helvetica 10 Fonts.

Manuals were electronically produced on a Xerox Docutech 135 Publishing System at 600 dpi.

Art was produced using Aldus® Freehand® and Adobe® PhotoShop®.

Copyright © 1999 Dresser Industries, Inc.
All rights reserved.
Printed in the United States of America.

FrameMaker® is a trademark of Frame Technology.

Power Macintosh® is a trademark of Apple Computer, Inc.

Adobe® PhotoShop® is a trademark of Adobe Systems, Inc.

This manual and the software described within are furnished under license and may be used or copied only in accordance with the
terms of such license.

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, except as permitted by such license. Translation of this material to another language without express written
permission of Dresser Industries 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 Industries, Inc. who assumes no responsibility or liability for inaccuracies that may appear
in this publication.

Wayne Division, Dresser Industries, Inc., is located at 124 West College Ave., Salisbury, MD 21804.
Dresser Industries’ general telephone number is (410)-546-6600.
The Documentation fax number is (410)-546-6753.
 WARRANTY AND LIMITATION OF REMEDY AND LIABILITY

Seller warrants that new products and parts of its own design and manufacture when shipped, will
be of good quality and will be free from defects in material and workmanship and will conform to
applicable specifications. Work, when performed by Seller, will meet applicable work require-
ments. No warranty is made with respect to used or rebuilt equipment and with respect to products
not manufactured by Seller. Seller’s only obligation shall be to assign to Buyer, at the time of sale,
whatever warranty Seller has received from the manufacturer. Items such as but not limited to
lamps, electric motors, hoses, nozzles, hose swivels and safety impact valves are included in the
category referred to in the previous sentence. Seller’s recommendations with respect to the oper-
ation of Seller’s equipment are advisory only and are not warranted. All claims under this warranty
must be made in writing immediately upon discovery and, in any event, within twenty-four (24)
months from date of start-up, if a product is involved, or from completion of the applicable work,
if work is involved, or thirty (30) months from date of invoice (whichever shall occur first). (Pro-
vided however, that with respect to the Wayne Plus system, 2400 system, DL series dispensers,
and card readers, all claims must be made in writing within twelve (12) months from date of start-
up. With respect to receipts/totals printers, and any other printers or printing mechanisms, all
claims must be made in writing within ninety (90) days from date of start-up. Wayne Vista dis-
penser external metal panels will be free from defects due to rust and/or corrosion for a period of
forty-eight (48) months from date of dispenser start-up.) Defective and nonconforming items must
be held for Seller’s inspection and returned to the original f.o.b. point upon request. Seller’s war-
ranty on service parts, whether new or reconditioned, is ninety (90) days from the date of installa-
tion, or twelve (12) months from date of invoice, whichever first occurs. THE FOREGOING IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESSED, IM-
PLIED AND STATUTORY, INCLUDING WITHOUT LIMITATIONS, THE IMPLIED WAR-
RANTIES OF MERCHANTABILITY AND FITNESS.

Upon Buyer’s submission of a claim as provided above and its substantiation, Seller shall, at its
option either (I) repair or replace its product or work at the original f.o.b. point or location of pur-
chase products and/or parts or (II) refund an equitable portion of the purchase price.

THE FOREGOING IS SELLER’S ONLY OBLIGATION AND BUYER’S EXCLUSIVE REM-

EDY FOR BREACH OF WARRANTY AND, EXCEPT FOR GROSS NEGLIGENCE OR
WILLFUL MISCONDUCT, THE FOREGOING IS BUYER’S EXCLUSIVE REMEDY
AGAINST SELLER FOR ALL CLAIMS ARISING HEREUNDER OR RELATING HERETO
WHETHER SUCH CLAIMS ARE BASED ON BREACH OF CONTRACT, TORT (INCLUD-
ING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER’S FAILURE
TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL
CLAIMS FOR DAMAGES OR OTHER RELIEF, INCLUDING BUT NOT LIMITED TO
CLAIMS BASED ON LATENT DEFECTS. IN NO EVENT SHALL BUYER BE ENTITLED
TO INCIDENTAL OR CONSEQUENTIAL DAMAGES. ANY ACTION BY BUYER ARISING
HEREUNDER OR RELATING HERETO, WHETHER BASED ON BREACH OF CONTRACT,
TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES,
MUST BE COMMENCED WITHIN ONE (1) YEAR AFTER THE CAUSE OF ACTION AC-
CRUES OR IT SHALL BE BARRED.
 "NOTE: This equipment has been tested and found to comply with the
limits for a 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 accor-
dance 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."

Wayne Division, Dresser Industries Inc., P.O. Box 1859, Salisbury, MD 21802-1859, (410) 546-6600
Part No. 917345-002 Rev A 2/99 ©1999 Dresser Industries, Inc. 200/2/99

917345-002 A