Wayne Ovation Installation & Operation Manual
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Wayne Ovation Installation & Operation Manual

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  • Page 1 Ovation Dispensers...
  • Page 2 HOW TO CONTACT WAYNE Technical questions related to the installation of the dispenser should be referred to Wayne Technical Support (1-800-926-3737). Customers needing help with the operation of the dis- penser should call the Wayne Help Desk (1-800-289-2963).
  • Page 3 Ovation Series Dispensers Installation & Operation November 2008 Part No. 920559 Rev H...
  • Page 4 November 2008 Part No. 920559 Rev H...

  • Page 5: Table Of Contents

    2.11.2 Wayne Pressure/Vacuum Tester ........
  • Page 6 Wayne Vac Motor Operation ........

  • Page 7: Introduction

    Components in a typical Xflo dispenser are shown in Figure 1-1. E85 Ovation models have the letter E at the very beginning of the model number and use the Xflo meter assembly. In addition to the noted change above for Xflo models, internal parts such as the Xflo meter, prod- uct tubes, and outlet castings, as well as external parts, such as pipes, pipe nipples, hoses, nozzles, break- aways and swivels that come into contact with the Ethanol fuel must be Ethanol compatible;...

  • Page 8: Local, State, And Federal Codes

    Protection Agency (U.S. EPA) Technical Regulations of 9-23-88 and U.S. EPA Financial Responsibil- ity Regulations of 10-26-1988. Where local requirements do not specify applicable codes, Wayne recommends using the codes listed above. These codes are comprehensive and detailed, often requiring interpretation to cover unusual situations, and, therefore, the associated handbooks (where applicable) should also be con- sulted.
  • Page 9 Pertinent information and codes are available from the following sources: 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.

  • Page 10: Safety Precautions

    1.3 SAFETY PRECAUTIONS NFPA 30A states that: “When maintenance to Class I dispensing devices becomes necessary and such maintenance may allow the accidental release or ignition of liquid, the following precautions shall be taken before such maintenance is begun: • Only persons knowledgeable in performing the required maintenance shall perform the work.

  • Page 11: Installation

    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. For E85 Ovation models, product piping, pipe nipples, etc., containing Ethanol fuel must be Ethanol compatible. See the information in Section 1.1 on page 1.

  • Page 12: Emergency Shut-Off Valves

    Wayne dispensers provide 1" NPT pipe connections at the base of the dispenser for vapor return connections. (See the installation foot print for location in Appendix B.) A minimum 1" riser at each dispenser is con- nected to a minimum 2"...

  • Page 13: Lifting And Installing The Dispenser

    Wayne recommends installing the valance after the dispenser is installed, if practical, to protect it from installation damage. See the Valance Module drawing in the back of this manual.

  • Page 14: Electrical Wiring

    2.6.1 General Wayne recommends employing a qualified electrician for all wiring. A hazardous liquid is being handled, so it is important to ensure that all wiring is in accordance with the National Electrical Code (NFPA 70) as well as all federal, state and local regulations.

  • Page 15: Field Wiring For Dispensers Without A Junction Box

    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. 2.6.3 Field Wiring for Dispensers Without a Junction Box All field wiring must enter the Electronic Head via potted conduit/conduit fittings.
  • Page 16 2.6 Electrical Wiring, continued 7. Trim wires to appropriate length, terminate ends and connect to the terminal block as per Wiring Diagram drawing 888445-001 located in the Appendix B of this manual. Note: Field wires are to be connected to the lower terminals on the block.

  • Page 17: Full Service (Stand-Alone) Dispenser Wiring

    Data wires shown on the wiring diagram are for connecting the dispenser to the Data Distribution Cabi- net and the Site Controller Cabinet in a Wayne Control System. These data wires are not required for the full service (stand-alone) dispenser. However, the six optional data wires and cable, whichever are applicable, as described in Section 2.6.2, should be run at initial installation if a control system or...

  • Page 18: Optional Equipment

    2.6.6 Optional Equipment Dispensers contain an extra pair of data wires in the junction box for Wayne TRAC as shown in Figure 2-6 below. These wires are also identified in the installation wiring diagram in Appendix B. Dispensers with the letter I in the model number will have an intercom call button.

  • Page 19: Hose And Hose Retractor

    Refer to your state and local codes for breakaway device requirements that apply to your installation. On E85 Ovation dispensers, all hoses, nozzles, breakaways, etc., containing the Ethanol fuel must be Ethanol compatible. See the information in Section 1.1 on page 1.

  • Page 20: Imeter Or Xflo™ Calibration

    2.9 iMeter or Xflo™ Meter Calibration Procedure Sufficient product must be run through each meter to thoroughly flush out all air and completely fill the system prior to the calibration process. Each meter assembly contains two meters. The WIP pulser (or XWIP for Xflo meter) contains two sets of sen- sors, one set for each meter.
  • Page 21 Dispenser Front (Side 1) iMeter (Side 2) Meter A Meter B Check Valve (Side 2) Covers Pulser Connector located inside of cover XWIP Pulser (Blue Case) Xflo Meter Meter B Meter A Dispenser Front (Side 1) Figure 2-7 Meter Assemblies. The WIP and the XWIP are physically the same size, but have a different colored case because they are not functionally interchangeable.

  • Page 22: Balance Vapor Recovery System Installation Requirements

    2.10 Balance Vapor Recovery System Installation Requirements 2.10.1 Dynamic Back Pressure Testing At initial installation, balance vapor recovery dispensers should have a dynamic back pressure test performed at each nozzle to ensure there are no blockages in the vapor recovery system. The dispenser should be connected to the underground and the hanging hardware (hoses, nozzles, breakaways, etc.) should be installed.

  • Page 23: Nozzles Approved For Balance System

    2.10.3 Nozzles Approved for Balance System The Ovation nozzle boot hook can be adjusted to accommodate different nozzles. Table 2-1 shows the nozzles approved for use with a balance system and the hook position for each nozzle. Position 1 is the standard posi- tion.

  • Page 24: Wayne Vac Vapor Recovery System Installation Requirements

    If the system piping is tight, check hanging hardware by bagging the nozzles and doing a vacuum test again, while looking for the bags to deflate. The Wayne vacuum tester, as discussed below, is also used to test nozzles for leaks.

  • Page 25: Start-Up

    START-UP 3.1 Initial Checkout Before applying power to the dispenser, double-check the wiring to make sure the wires are correctly routed and terminated. Turn on the dispenser control power circuit breaker and the submersible pump or suction pump motor circuit breakers. Make sure the dispenser comes on and all lights work. The dispenser displays will show some numbers, usually the last sale run during factory test.

  • Page 26: Logical Nozzle/Hose Position

    3. For these non-blending models, such as the R13/3, these products are shown as the X, Y, Z products in Table 3-1. Logical nozzle positions for the Ovation models listed below are also shown in the examples in Figures 3-2 and 3-3 on the following pages.

  • Page 27: Blending Models

    positions positions position 6,5,4,3 Model B23/5220D1 Model B12/2220D3 positions positions position 7,6,5,4 6,5,4 Model B23/4220D1 Model B12/4220D3 positions positions position 7,5,3 Model B23/3220D1 Model B12/3220D3 Figure 3-2 Blending Models. November 2008 Part No. 920559 Rev H...
  • Page 28 position position position Model R11/1220D1 Model R22/2220D1 positions 1,2,3 Model R13/3220D1 Figure 3-3 Non-blending Models. Part No. 920559 Rev H November 2008...

  • Page 29: Setting The Clock

    3.4 Setting the Clock The time and date is set in function F02 Clock Configuration. The sub-functions F02.00 is the time HH.MM, F02.01 is the date MM.DD and F02.02 is the year YY.YY. 1. Press ENTER PASS 1 (enter password) 2.
  • Page 30 3.5 Setting Unit Prices, continued Changing the Value of the Unit Price Type in the new unit price with at least three digits for three money display digits to be shown after the decimal point. For example, to set the new unit price to $1.50, type in 1500. Type in 1509 for $1.509 unit price.

  • Page 31: Setting Blend Ratios

    The procedure below is used to set the dispenser blend ratios. When enabled, the POS system verifies and confirms that its blend ratio data corresponds to the manually set blend ratios. The Wayne POS system will not allow fuel to be dispensed if these numbers do not match.
  • Page 32 For reference, the following is a 50% blend ratio setting for a single hose blender, Ovation model B12/3 xxxx, as listed in Table 3-1. Any unused position has to be set to 101 not 0.

  • Page 33: Setting Fueling Point Id

    3.7 Setting the Fueling Point ID The procedure below is used to set the pump fueling point address. The pump FPID should be input and saved before control is transferred to the POS system. Functions F05 and F06 are accessed to set the FPID on Side 1 and Side 2, respectively. To set the FPID, the desired FPID must be input and saved.

  • Page 34: Authorizing The Dispenser

    5. For dispensers equipped with Wayne Vac, verify that the correct vacuum pump motor is running when dispensing product. Verify by checking that air is being drawn through the vapor return hole(s) in each nozzle spout.

  • Page 35: Totalizer Readings

    3.11 Electronic Totalizer Readings 3.11.1 Totalizer Readings by Hose (Product) Position Each fueling point of the dispenser maintains electronic totalizers for both money and volume. Dispens- ers equipped for Cash/Credit operation also keep separate cash and credit totalizers by grade. Rather than mechanical totalizers, each position has an electro-mechanical totalizer for each feedstock.

  • Page 36: Totalizer Volume Readings By Meter Position

    3.11.2 Totalizer Volume Readings by Meter Position Meter volume totals are stored in statistical functions that are accessed using the remote control inter- face. The totals for Side 1 are stored in function S05 and those for Side 2 are stored in function S06. The value of the meter totals are stored in the sub-functions that take the format .M0, where M is the meter number.

  • Page 37: Electro-Mechanical Totalizer Operation

    Junction Box Table 3-2 Meter Positions for Ovation Dispensers 3.11.3 Electro-Mechanical Totalizer Operation Electro-Mechanical totalizers are standard on 3/Vista model dispensers. See Figure 2-4 for location. Electro-Mechanical totalizers are located on the junction box side of the dispenser. There is one totalizer for each meter.

  • Page 38: Nozzle Boot Switch Check

    3.12 Nozzle Boot Switch Check In the Ovation style nozzle boot, a proximity switch and a magnetic actuator are used for nozzle on/off operation. The proximity switch is attached to the back of the nozzle boot casting. The magnetic actua- tor is located inside the spring-loaded flipper, which is installed from the top front of the boot casting.

  • Page 39: Audit Report Display Mode (For Weights & Measures Officials/Service Purposes Only)

    Note: On standard Ovation dispensers, locate the BAM board inside the service door and set switch SW2 address to the CAT address, which is normally the fueling point ID. See the photo and table on the very last page in this manual for the switch settings.
  • Page 40 Insert Remove cash and cassette follow prompts Typical Screen Prompts Continue Unlock removing door cassette panel Open Unlock cassette cassette retrieve bills Reinsert Press cassette and hold down lever Re-lock cassette and door panel when done. Part No. 920559 Rev H November 2008...

  • Page 41: Operation

    Be advised that petroleum fuel and fuel vapors can damage your health. 4.2 How To Get Service On Your Dispenser Trouble with the operation of the dispenser should be referred to your local Wayne authorized service personnel or call the Wayne Help Desk at 1-800-289-2963.

  • Page 42: Basic Dispenser Requirements

    Section 3. If the dispenser is connected to a 2400 MCS, Wayne Plus or Nucleus POS system and you want to operate the dispenser in the stand-alone mode, independently from the control system, per- form the following steps: 1.

  • Page 43: Restarting After Power Failure Or Shutdown

    4.5 Restarting After Power Failure or Shutdown After loss of power, the display accurately displays the amount of the sale, in money and vol- ume, for approximately 15 minutes. When power is restored, all sales information returns to the displays. Any sales in progress will be ended; old sales should be paid and the dispenser reauthorized if more product is to be dispensed.

  • Page 44: Error Codes

    4.7 Error Codes Computer error codes can be displayed on the side of the dispenser where the error occurred by accessing the sub-functions S21.XX for Side 1 and S22.XX for Side 2, where XX is between 01 and 50 and represents the error/events records maintained by the computer program - with 01 being the most recent.

  • Page 45: Resetting After All Stop

    4.8 Resetting After All Stop This section applies to models connected to a Wayne Control system. Pressing the All Stop key on the 2400 MCS or Wayne Plus or Nucleus sends a signal to the dispenser computer to interrupt product flow. To resume product flow: •...

  • Page 46: Printer Paper

    7. Cut receipt, close and lock printer door. 4.10.2 Paper Specification The Clamshell printer in Ovation model dispensers uses the same thermal paper as the printer in Wayne 3/Vista series dispensers. For reference, our thermal paper specification is as follows: _____________ Basic weight: (gm./sq.
  • Page 47 4.10 Printer Paper, continued Pull Out From Top Figure 4-1 Loading Printer Paper. November 2008 Part No. 920559 Rev H...

  • Page 48: Hazardous Zone Area Classifications For Dispensers

    Figure 4-2 Hazardous Zone Area Classifications for Dispensers. Part No. 920559 Rev H November 2008...

  • Page 49: Operator Maintenance

    OPERATOR MAINTENANCE 5.1 Preventive Maintenance Adhere to the safety precautions on the inside cover and in Section 1.3 of this manual when performing pre- ventive maintenance. A correctly installed dispenser, given proper preventive maintenance attention, will sel- dom require emergency service. Take the following precautions: •...

  • Page 50: Filter/Strainer

    Replacement fuel filters should be UL recognized. Typically, gasoline fuel filters are rated at 10 Microns and Ethanol fuel filters are rated at 1 micron. For Ovation model dispensers with an E85 Ethanol grade(s), the recommended filter is Cim- Tek's Bio-Tek, 1 Micron filter.

  • Page 51: Dispenser Cleaning Procedures

    Wayne dispensers built prior to 2002 were painted with a standard paint. Cleaning these dispensers may require a higher level of cleaning (see cleaning levels below). In 2002 Wayne switched to using automotive grade paint on all painted surfaces of our dispensers. As such, they can be maintained in the same fashion as one would maintain your personnel vehicle.
  • Page 52 5.3 Dispenser Cleaning Procedures, continued • Level Three The third step, only for the most stubborn of stains, is to use mildly abrasive cleaners, such as Soft Scrub. Afterwards, be sure to wipe down the dispenser with a clean cloth and clean water.

  • Page 53: Vapor Recovery

    5.4 Vapor Recovery All hoses, nozzles, breakaways, etc., must be CARB certified for use on Wayne vapor recovery dispensers. 5.4.1 Wayne Vac See the Compliance Testing and Preventative Maintenance manual, p/n 917947. 5.4.2 Balance Tears or rips in the balance nozzle vapor bellows will cause the vapor system to be in non-compliance.
  • Page 54 Part No. 920559 Rev H November 2008...

  • Page 55: Appendix A1 Qcat Self-Test Procedure

    APPENDIX A1 OVATION QCAT SELF-TEST PROCEDURE The following are instructions for testing the CAT (Customer Activated Terminal) on the dispenser. QCAT SYSTEM SELF-TEST The following paragraphs provide instructions for testing and setting the address of the QCAT. During the self-test, the system is designed to pause 25 seconds for a response to self-test prompts. When the 25 second time limit expires, the system automatically advances to either the next self-test or returns to the on-line mode.
  • Page 56 CAT SELF TEST, continued Verify that the Keypad revision level is displayed on the screen. Step 3 Press ENTER to continue. Step 4 KEYPAD REV __ 1.3. CONFIGURE CARD READER When the system displays the prompt below, proceed as follows: *CONFIGURE CARD READER (Y/N) Answering YES to the prompt causes the screen to display the prompt below...
  • Page 57 Configure Card Reader, continued Offline msg: of Service (Y/N) Answer NO to the above prompt. Step 3 Answer the following prompts as they appear: Step 4 Fixed Length Scanner? (Y/N) SOFT KEY PRESENT? (Y/N) This prompt should be set to yes only if the dispenser has softkeys along side the QVGA display. On dispensers without softkeys, answer No to the above prompt, otherwise, the numeric keypad will not work when the dispenser is online.
  • Page 58 Self Test? (Y/N) Answering YES to the above prompt will begin the display, printer and card reader self test as discussed on the following pages. Answering NO to the above prompt will display the Exit prompt shown below. Exit Test Mode? (Y/N) Answer YES to the above prompt to exit and return the CAT to normal operation.
  • Page 59 1.4. DISPLAY SELF-TEST A series of actions appear on the screen for the display self-test. Two rows of black squares followed by numbers and letters scroll from right to left across the screen during the display self-test. At the prompt “Press Key”, press each of the Softkeys to verify they are active and installed cor- rectly.
  • Page 60 1.6. CARD READER SELF-TEST Any type of valid credit card can be used for the card reader test. The card reader self-test begins with the screen prompt shown below. INSERT CARD Insert the card. Step 1 Once the credit card is inserted into the card reader, the CAT computer reads data from the card.
  • Page 61 1.7. KEYPAD SELF-TEST Testing the CAT keypad requires the operator to select keys on the keypad and verify the informa- tion on the display screen. Refer to the Keypad Test table below. Complete the following steps to test the keypad. Press a key listed under the column heading Native Mode Key.
  • Page 62 1.8. SYSTEM MEMORY SELF-TEST A successful memory self-test will display the message below. MEMORY OK An unsuccessful memory self-test will display one of the following: “BIT 0" through “BIT 7". A BIT error message is an indication of a defective board in the CAT system. An example of a BIT error message that may appear on the display screen is shown below.

  • Page 63: Appendix A2 Ix Cat Self-Test Procedure

    Press reset button on the iX board. Note: A screen will be displayed showing “iX Ovation” with an activity bar moving across the bot- tom of the screen. When the activity bar has completed, the screen becomes dark briefly and...
  • Page 64 Ovation iX CAT Self Test Procedure, continued Press Yes or No at the “Want to Configure DM” prompt. If No is pressed, the self-test ends and the screen prompt sequence in step12 occurs. If Yes is pressed, the Orientation (VGA) or Contrast (QVGA) screen is displayed, see step 9.

  • Page 65: Appendix Binstallation Drawings

    APPENDIX B INSTALLATION DRAWINGS This revision of the manual includes new installation footprint drawings. These drawings show the location of the conduits for entering the new smaller junction box, which will be standard production on Ovation dispensers in November 2008.
  • Page 67 DISTANCE BETWEEN EYE BOLTS: 33.1”...
  • Page 68 INSTALLATION INSTRUCTION (page 1 of 2) - OVATION MODEL R13...
  • Page 69 INSTALLATION INSTRUCTION (page 2 of 2) - OVATION MODEL R13...
  • Page 70 INSTALLATION INSTRUCTION (page 1 of 2) - OVATION MODEL B23...
  • Page 71 INSTALLATION INSTRUCTION (page 2 of 2) - OVATION MODEL B23...
  • Page 72 INSTALLATION INSTRUCTION (page 1 of 2) - OVATION MODELS B12 AND R22...
  • Page 73 INSTALLATION INSTRUCTION (page 2 of 2) - OVATION MODELS B12 AND R22...
  • Page 74 INSTALLATION INSTRUCTION (page 1 of 2) - OVATION MODEL R11...
  • Page 75 INSTALLATION INSTRUCTION (page 2 of 2) - OVATION MODEL R11...
  • Page 77 2-7151-C TYPICAL SITE WIRING...

  • Page 78: Part No. 920559 Rev H November

    Part No. 920559 Rev H November 2008...

  • Page 79: Appendix Clocal Authorize/Stand-Alone Operation

    APPENDIX C LOCAL AUTHORIZE / STAND-ALONE OPERATION When the dispenser is not equipped with a Local Authorize Switch, the jumper (J7) shown below must be in place to enable Stand-alone operation. At new dispenser Startups, after product lines have been purged and dispenser operations checked, once the dis- penser is switched over to control system operation, the jumper should be removed as an extra security measure.
  • Page 80 Part No. 920559 Rev H November 2008...

  • Page 81: Appendix Ddispenser / Backroom Interconnections

    APPENDIX D SITE INTERCONNECTION DIAGRAMS November 2008 Part No. 920559 Rev H...
  • Page 82 Part No. 920559 Rev H November 2008...
  • Page 83 November 2008 Part No. 920559 Rev H...
  • Page 84 Part No. 920559 Rev H November 2008...
  • Page 85 November 2008 Part No. 920559 Rev H...
  • Page 86 Standard Ovation with Bill Acceptor Option. The BAM board is located just above the QCAT board on the inside of the service door. BAM Board SW2 switch positions BCD values with the LSD (0 or 1) to the left 1 2 4 8 16 32...
  • Page 87 The contents should not be construed as a commitment by Dresser, Inc. who assumes no responsi- bility or liability for inaccuracies that may appear in this publication. Dresser Wayne, Dresser, Inc., is located at 3814 Jarrett Way, Austin TX 78728. Wayne’s general telephone number is (512)-388-8311.
  • Page 88 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 Wayne, Dresser, Inc. 3814 Jarrett Way, Austin, TX 78728 (512) 388-8311 Part No.

This manual is also suitable for:

Ovation seriesOvation r13Ovation b23Ovation b12Ovation r22Ovation r11

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