000-940002 - Fusion 500 Installation - Nucleus Rev 0G

Installation/Operation
Wayne Fusion 500 Forecourt System for the

Wayne Nucleus Point-of-Sale (POS) System
P/N 000-940002-
Rev 0G
DANGER
READ THIS MANUAL BEFORE YOU BEGIN
Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Fail-
ure to follow the below precautions and the Warning and Caution instructions in this manual may
result in serious injury. Follow all rules, codes and laws that apply to your area and installation.
SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE
Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cabi-
net for maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off
when servicing the dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser
BEFORE beginning maintenance.
Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an
emergency. Have all leaks or defects repaired immediately.
HOW TO CONTACT WAYNE
Problems with the installation of this kit should be referred to Wayne Technical Support (1-800-
926-3737).
INDICATORS AND NOTATIONS
Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe
DANGER injury or possibly death.
Warning indicates a hazard or unsafe practice which, if not avoided, may result in
WARNING severe injury or possibly death.
Caution indicates a hazard or unsafe practice which, if not avoided, may result in minor
CAUTION injury.
Important information to consider, otherwise, improper installation and/or damage to

NOTE:
components may occur.
Wayne Fusion 500 Forecourt System for the
Wayne Nucleus Point-of-Sale (POS) System
Installation/Operation
P/N 000-940002- Rev 0G August 2014 3

4 P/N 000-940002- Rev 0G August 2014
Table of Contents
Title Page
1 PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 DEFINITIONS AND ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 HOW TO USE THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 RETURNING DAMAGED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 INSTALLATION LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 INSTALLATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12.1 Shutdown the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12.1.1 Sites with Wayne Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
12.1.2 Sites with Gilbarco Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12.2 Wayne Isolation Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
12.3 Fusion V2 Forecourt System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
12.4 Changing the Fusion Site Controller IP Address . . . . . . . . . . . . . . . . . . . . . . . . 19
12.4.1 Using PuTTy to Change the IP Address . . . . . . . . . . . . . . . . . . . . . . . . 19
12.4.2 Using USB Maker to Change the IP Address . . . . . . . . . . . . . . . . . . . . . 20
12.5 Entering the Fusion Forecourt System Web UI . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.6 Gilbarco Blend Ratio Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.7 Fusion Installation using Veeder Root CDIM Configuration . . . . . . . . . . . . . . . 22
12.7.1 Connect the CABs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12.7.2 Connect the Dispensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12.7.3 Programming the System for Sites with Veeder-Root BIR . . . . . . . . . . . 24
12.8 Veeder-Root BIR Installations with EDIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12.9 Programming the Nucleus POS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
13 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 UPDATING FUSION FORECOURT SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . 36
P/N 000-940002- Rev 0G August 2014 v

Table of Contents (continued)
Title Page
14.1 Copy CD for Later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

14.2 USB Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
14.3 Verifying the Fusion Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
15 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
15.1 Fusion Forecourt System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
15.2 Fusion 500 Forecourt System Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
15.3 GRIB Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
15.4 GRIB Jumper Configurations for Current Loop Board . . . . . . . . . . . . . . . . . . . .46
15.5 GRIB Jumper Configurations for 485 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
15.6 Fusion 500 Forecourt System Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . .48
15.7 DIM Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
15.8 Converting Gilbarco Dispensers From MOC to Generic Control . . . . . . . . . . . .52
vi P/N 000-940002- Rev 0G August 2014

1 PRODUCT
Product Wayne Fusion 500 Forecourt System

Application Nucleus POS System Base 19 or better
Production Version Version 3.1.10
Hardware Platform Wayne Proprietary Hardware
2 INTRODUCTION
The Fusion 500 forecourt system is an Ethernet-based device capable of supporting existing peripheral
devices that are currently supported through the SCC card. This manual explains how to install the Fusion 500
forecourt system and configure it for use with a Nucleus POS system.
3 DEFINITIONS AND ACRONYMS

BIR Business Inventory Reconciliation - Veeder-Root term to describe Tank Monitoring feature
that compares tank inventory versus gallons sold and reports any discrepancies.
CAB Cable Adaptor Box (current loop to 422 converter box used in Veeder Root BIR solution)
CAT Customer Activated Terminal (Wayne Outdoor Card Processing Hardware)
CDIM Current Loop Dispenser Interface Module - Veeder-Root h/w board that exposes current
loop interface between Tank Gauge and the Fusion forecourt system for BIR reporting.
CF Compact Flash - the Fusion forecourt system currently uses 4G Industrial Grade
CRIND Card Reader In-Dispenser (Gilbarco Outdoor Card Processing Hardware)
CUPS Connector Uninterruptible Power Supply (power supply and battery backup board on the
Fusion forecourt system)
DOA Dead on Arrival
EDIM Electronic Dispenser Interface Module - Veeder-Root h/w board that exposes serial interface
between Tank Gauge and the Fusion forecourt system for BIR reporting.
EOD End of Day - business close of day
GNU GNUs Not Unix; an open source project to develop Unix-like software and operating
systems
GPL GNU General Public License
GRIB Global Rectangular Interface Board (interface board for pumps/CATs/CRINDs)
GSM Gilbarco Security Module (h/w device for Gilbarco debit encryption)
ISD In-Station Devices (Veeder-Root and other 3rd party system that perform BIR)
JRE Java Runtime Environment
OPIE One-time Passwords In Everything
PADSS Payment Application Data Security Standard - security standard to protect cardholder data.
PCI Payment Card Industry - in charge of PADSS
PIE Progressive International - box that controlled Gilbarco Dispensers with SCC board for the
Nucleus POS system
SBC Single-Board Computer (Nova Atom Motherboard)
SCC Serial Communication Controller (Fusion 500 forecourt system replaces this PCI card)
UFW Uncomplicated Firewall - Linux Ubuntu firewall
P/N 000-940002- Rev 0G June 2014 7

4 HOW TO USE THIS DOCUMENT
By following the installation instructions and performing the steps in the sequence presented, you will be
assured of a successful install.
NOTE: This kit may require installation of several wiring and hardware assemblies. Any installation or modification
must comply with the requirements of the National Electrical Code (NFPA 70), the Automotive and Marine
Service Station Code (NFPA 30A) and any other applicable codes
NOTE: You must wear a static wrist strap, part number 916962 or equivalent, securely attached to an earth ground,
when handling any circuit board, electronic component or assembly, or when reaching into the site
controller or dispenser computer enclosure. Do not use power tools.
5 UNPACKING AND INSPECTION

Complete the following steps:
1. Before opening any cartons, count the number of cartons and verify the carton count against the supplied
packing list.
2. Inspect the cartons for damage made during transit.
3. File claim information with the carrier on the bill of lading.
4. Retain cartons suspected of damage for future claim purposes.
NOTE: You must wear an anti-static wrist strap, part number 916962 when removing electronic components from
static packages. Attach the wrist strap securely to an earth grounding point to prevent possible damage
from static electricity.
5. Remove all equipment from the shipping cartons and carefully inspect for visible damage.
NOTE: Any damage should be brought to the attention of the carrier and claims made immediately. Return all
equipment to the respective cartons for protection until actual installation is made. Save all cartons until it
is certain that return shipments are not required.
6 RETURNING DAMAGED COMPONENTS

Parts or components returned to the factory under warranty or for repair are subject to damage if not
packaged properly. Complete the following steps to return parts or components to the factory.
1. Place electronic components in an anti-static bag and in the original shipping cartons for return shipment
to the factory.
NOTE: If original shipping cartons are not available use a sturdy cardboard container and suitable packing
materials such as anti-static polyethylene foam or bubble pack, to ensure the component is firmly packed.
2. Include a Return Parts Tag with the defective component describing the particular problem with the part.
3. Make sure adequate insurance is provided when returning parts to the factory.
WARNING
If the parts or components arrive at our factory in a damaged condition and it is determined that the dam-
age is a direct result of inadequate or improper packaging, the damage will not be covered under the origi-
nal warranty and the customer or distributor will be held responsible for the cost of repairs necessary to
correct or replace the damaged parts.
7 SAFETY INFORMATION
Read NFPA 30A and NFPA 70 (U.S. Installations)
8 P/N 000-940002- Rev 0G June 2014

Before installing the equipment, the installer must read, understand and follow this manual, NFPA 30A, NFPA
70, and applicable federal, state and local codes and regulations. Failure to do so may adversely affect the safe
use and operation of the equipment.
CSA C22.1 (Canadian Installations)
For installation in Canada the installer must read and understand this manual, CSA C22.1 (Canadian Electrical
Code) and applicable federal, provincial and local codes and regulations.
Emergency Power Cutoff
NFPA30A require that an emergency power cutoff be installed. An emergency power cutoff is a single control
that removes AC power from all site fueling equipment and submersible pumps. Make sure the control is
accessible, labeled clearly, and installed away from dispensers. Make sure all station employees know where
the Emergency Power Cutoff is located and how to operate it.
Electrical Circuits
Some of the procedures in this manual involve removal and connection of components during installation or
service. Remove power from the distribution box before executing these procedures.
Low Voltage
Do not be misled by the term "Low Voltage". Voltage potentials as low as 50 volts may cause death under
adverse conditions.
High Voltage
High voltage of 110 volts AC is used for operation of this equipment. Death on contact may result if safety
procedures are not followed.
8 INSTALLATION LOCATION
Fusion forecourt system equipment may be installed in a variety of locations; all cabinets and required
wireways must be located in a non-hazardous area of an enclosed weather protected building.
Table 8-1 Mounting Location
Component Preferred Location Notes

Fusion V2 Forecourt System Back room; on wall near the - AC Power input required
wiring conduits for pumps - Ethernet input required
and CATs
Table 8-2 Space Requirements (in inches)
Component Width Height Depth

Fusion V2 Forecourt System 22 4 16
Dispenser conduit and Wiring requirements

Conduits used must be in. and the length of each conduit can be up to 330 feet from the Fusion forecourt
system to the dispenser. Verify that approved wireways and threaded metallic conduit with tight connections
are used, and that Data Link wiring is #18 AWG 600 Volt oil and gasoline resistant as a minimum.
Environmental Requirements
Ensure that the Fusion V2 forecourt system cabinet is located in an area that offers easy access for service and
is situated a minimum of 6" away from other equipment cabinets. Orient the Fusion forecourt controller so that
the ventilation slots are on the top or bottom when wall mounting. This is to allow free air flow across the unit
for cooling and to provided proper visual access to the communication LEDs.
NOTE: The mounting instructions above are important and must be adhered to for proper operation.
Care should be taken to ensure that the temperature of the cabinets does not exceed the operational ranges of
0C to 40C (32F to 104F)
P/N 000-940002- Rev 0G June 2014 9

Preliminary Wiring
The site wiring must be completed before installation of the Fusion V2 Forecourt System.
Data Link and CAT Wiring
Two pairs of data link wires must be installed from each dispenser to the location of the Fusion forecourt
system. One pair for pump communication and one pair for CAT communication.
9 CONFORMITY WITH STANDARDS

Ensure that all National, State, and local standards and codes are observed in site preparations, wiring, and
installation.
Power Wiring
Confirm that all 120VAC to 240VAC wiring for outdoor equipment (line, neutral, relay select, etc.), is #14 AWG
minimum (unless local codes call for 12 gauge), stranded, oil and gasoline resistant.
One conduit from the breaker panel to a dedicated outlet located near the Fusion forecourt system location is
required. The conduit must contain three 14 AWG wires; 110 to 240 VAC, Phase, Neutral and Ground. Do not
use electrical conduit to provide earth ground (earth ground does not exceed 5 ohms).
The circuit powering the distribution box must not power other devices. This circuit must not share a conduit
with wiring for devices drawing high amperage (compressor, freezer, etc.) or devices that are sources of RFI
(TV, microwave, intercom, etc.).
Emergency Stop Circuit
It is recommended that the electrical wiring for the Fusion forecourt system dedicated outlet be run through
the Emergency Stop circuit at the site so that all electrical power is cut to the dedicated outlet whenever the
Emergency Stop button is pressed. Do not connect the Fusion forecourt system power supply cord to any
UPS. The Emergency Stop Circuit wiring should be configured according to local electrical regulations.
Data Wiring
Confirm that all data wiring for outdoor equipment (communication lines) is #18 AWG (minimum) stranded, oil
and gasoline resistant. Pump and CAT data wiring that attach from the wiring trough to the Fusion forecourt
system need to be double insulated to satisfy NEC code for commercial use. Wayne recommends the use of
the following cable or equivalent for use as the pump and CAT communication wire for running between the
wiring trough and the Fusion forecourt system.
NOTE: Existing wiring that runs from the wiring trough out to the dispensers do not need to be modified since
those wires are protected within the wiring trough or conduit.
10 P/N 000-940002- Rev 0G June 2014

Codes
Confirm that all equipment is installed in accordance with the National Electrical Code (NFPA 70), the
automotive and Marine Service Station Code (NFPA 30A), and any other applicable State and local codes.
10 REQUIRED TOOLS
Refer to Table 10-1 for a list of tools required to install the Fusion 500 forecourt system.
Table 10-1 Required Tools
Quantity Description
1 Small Channel Lock pliers
1 Phillips Screwdriver Set (standard sizes)
1 Slotted Screwdriver Set (standard sizes)
1 Wire Cutters
1 Anti-static Wrist Strap
1 Needle Nose Pliers
1 Wire Strippers
16 to 32 Wire Nuts
1 Volt Meter
1 Diagonal Cutters
1 Standard Drill Bit Set
1 Drill
1 PC Feature Card Slot Blank
11 INSTALLATION OVERVIEW
14.00
Earth Ground at
Electrical Panel
&USION6
19.5 &ORECOURT
3YSTEM
Ethernet Cable to Firewall
3.5 "
A C O utlet
wired to
Class 2 Environment Data wires from pumps
Emergency
Stop button
A C P ow er w iring for F usion
A C P ow er B r i c k
Figure 11-1 Backroom Installation - New Site
P/N 000-940002- Rev 0G June 2014 11

14.00
Earth Ground at
Electrical Panel
&USION6
19.5 &ORECOURT
3YSTEM
Ethernet Cable to Firewall
3.5 "
A C O utlet )SOLATION"OX
wired to
Class 2 Environment Data wires from pumps
Emergency
Stop button
A C P ow er w iring for F usion
A C P ow er B r i c k
Figure 11-2 Backroom Installation - Existing Site
12 INSTALLATION PROCEDURE
When possible, mount the Fusion V2 forecourt system in the same location as the Data Distribution Cabinet
for Wayne sites or the Gilbarco Distribution box for Gilbarco sites. Figure 11-1 shows the typical placement of
the Fusion forecourt system.
NOTE: If mounting the Fusion forecourt system to a concrete wall, you will need concrete bits and appropriate
mounting hardware.
NOTE: The Fusion forecourt system mounting location may be require different placement than shown. Whenever
handling boards and components that are susceptible to damage from static electrical discharge, BE SURE
to wear an anti-static wrist strap.
12.1 Shutdown the Site

1. Stop all pumps one at a time, allowing current customers to complete their transactions.
2. Shutdown the site and tape off the pumps and run EOD.
3. Go to Programming > System > Site. You will see the following screen.
Enable Fusion
IP Address
Port
Figure 12-1 Nucleus POS System Programming Screen - Site
12 P/N 000-940002- Rev 0G June 2014

4. In the Forecourt Hardware section, enable Fusion and program the IP Address and Port.
NOTE: IP Address and Port programming should be done according to the site schema or network layout
determined by the customer.
5. Click OK to save.
6. Exit the Programming screen.
7. Log off and shutdown all IPTs then log off and shutdown the Server.
NOTE: If you are converting an existing Nucleus POS system installation to the Fusion forecourt system, perform
the following steps to remove the original Nucleus POS system hardware. Otherwise, skip to step 11.
8. Disconnect the 883635-xxx cable from the SCC card on the back of the server.
9. Open the server and remove the SCC board.

NOTE: DO NOT REMOVE the SCC board if the server is a Fujitsu A or M platform, or is an IBM 741 or 742 SC/
IPT. The presence of this board is required to properly complete Gold Copy should the system require
reinstallation.
NOTE: The credit card host network is connected at Port C on the back of the IBM 74x server. Reconnect the
internal connection from port C to serial port C on the riser card using cable PN 890720-001, and remove the
cable that went from port C to the SCC board. See the following figure.
Serial Port C
Figure 12-2 IBM 743 Riser Card

A 9 pin serial host network cable is then used to connect from Port C on the Nucleus POS system to the Host
Modem. The serial port should also be configured by using the Port configuration function.
10. Install a feature card blank and re-install the server cover.
11. Run a CAT5 ethernet cable from the Nucleus POS system network switch to the data distribution box
location.
NOTE: The maximum recommended CAT5 ethernet cable length is 100 meters or 330 feet.
12.1.1 Sites with Wayne Dispensers

Perform the following steps if you are installing at a site with Wayne dispensers.
NOTE: If this is a new Nucleus POS system installation, skip to step 9. If you are converting an existing Nucleus
POS system installation to the Fusion V2 forecourt system, perform the following steps to remove the
original Nucleus POS system hardware.
P/N 000-940002- Rev 0G June 2014 13

1. Disconnect other end of the 883635-xxx cable from Primary Distribution box, then remove the cable.
2. Disconnect and remove the 860514-xxx cable that runs from the Data Distribution box to the Primary
Distribution box.
3. Remove the Primary Distribution box from its mounting location.
4. Open the Data Distribution box, remove the inside panel and verify the labeling of the pump and CAT data
wires.
5. Disconnect pump and CAT wires from the DD box.
6. If present, relocate the stations existing DUKPT Security Module (DSM) to a location near the planned
Fusion V2 forecourt system mounting location.
7. If the site has a Veeder-Root BIR connected to the DD box, connect one end of the cable from the
Gilbarco CAB into the 4th GRIB plug at pin 3(+) and pin 4(-). After the Fusion 500 forecourt system is
mounted, the plug will get plugged into Electronic Interface Board A - Channel 4. See Figure 15-10.
8. Disconnect pump and CAT wire conduit from DD box and remove the box.
9. Extend discrete CAT and pump wire pairs from the wiring trough to the planned location of the Wayne
Data Isolation box mounting location for each dispenser if needed.
NOTE: CAT data wires may have been bundled together in parallel within the wiring trough. Un-bundle the wire
pairs and splice extensions if needed so that each discrete CAT wire pair reaches the location of the Wayne
data isolation box. Use double insulated wire as specified in Section 9 for all exposed wiring from the wiring
trough to the Data Isolation box.
12.1.2 Sites with Gilbarco Dispensers

Perform the following steps if you are installing at a site with Gilbarco dispensers.
NOTE: If this is a new Nucleus POS system installation, skip to step 4. If you are converting an existing Nucleus
POS system installation to the Fusion 500 forecourt system, perform the following steps to remove the
original Nucleus POS system hardware.
1. Disconnect other end of the 883635-xxx cable from Gilbarco Competitive Primary Distribution box, then
remove the cable.
2. Disconnect and remove cable PN 886843-xxx and PN 886229-xxx.
3. Remove the Gilbarco Competitive Primary Distribution Box.
4. Open the case of the Gilbarco Distribution Box and label the pump and CRIND wire pairs that are
connected to P106 and P107 of the Pump and CRIND boards so that each pump and CRIND has a set of
discrete wire pairs identified. See Figure 12-3.
NOTE: If this is a new Nucleus POS system installation, you MUST convert Gilbarco dispensers from MOC to
Generic control before they can communicate with the Fusion forecourt system. Refer to Section 15.8 on
page 52 for instructions.
14 P/N 000-940002- Rev 0G June 2014

Wire Nut to Field Wiring
Wire Nut to Field Wiring
To
Transformer 4O0UMPS 4O0UMPS %NABLEOR %NABLEOR 4O#2).$3 4O#2).$3
$ISABLE0UMPS $ISABLE#2).$3
P107
P106
P101
P107
P101
P106
0UMP"OARD *0AND #2).$"OARD
*0AND 4O$"0UMP *0SETFOR
' 3)4%
*0SETFOR #OMMUNICATIONS
47)
*0SETFOR *0SET *0SET 4O$"#2).$ *0SETFOR *0SET *0SET
#ABLE 0UMPSAND#2).$3 FOR" FOR" 0UMPSAND#2).$3 FOR" FOR"
)NSTALLJUMPER #OMMUNICATIONS
)NSTALLJUMPER ON*0 #ABLE
ON*0
Figure 12-3 Gilbarco Distribution Box

5. Disconnect the pump and CRIND wire pairs from P106 and P107 of the pump board and from the CRIND
board.
6. For each dispenser extend discrete pump and CRIND wire pairs from the wiring trough to the Wayne Data
isolation box mounting location. Splice additional wire to the wire pairs if needed.
NOTE: Splice extensions if needed so that each discrete CRIND wire pair reaches the location of the Wayne data
isolation box. Use double insulated wire specified in Section 9 for all exposed wiring from the wiring trough
to the Fusion forecourt system.
7. If present, relocate the stations existing Gilbarco Security Module (GSM) to a location near the planned
Fusion V2 forecourt system mounting location.
8. If the site has a Veeder-Root BIR connected to the Gilbarco Distribution box, connect one end of the cable
from the Gilbarco CAB into the 4th GRIB plug at pin 3(+) and pin 4(-). After the Fusion V2 forecourt system
is mounted, the plug will get plugged into Electronic Interface Board A - Channel 4. See Figure 15-10.
9. Disconnect the transformer power supply from the Gilbarco Distribution Box and remove the box from its
mounting location.
10. For Gilbarco Encore 300 and Gilbarco Encore 500 dispensers, the Zero Previous Transaction
programming at the dispenser must be changed to improve nozzle joggle performance issues. The tech
needs to change when the Zero Previous Transaction function is performed; from Before the Lamp Test
to After the Lamp Test.
Gilbarco Encore 300
a. Go to Function Code 18: Zero Previous Transaction After Pump Handle Operation
0 = Zero after lamp test *
1 = Zero before lamp test
b. Change the programming from 0 to 1
Gilbarco Encore 500
a. Go to Command Code 48: Zero Previous Transaction
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1 = After lamp test *
2 = Before lamp test
b. Change the programming from 1 to 2
12.2 Wayne Isolation Box

The Fusion V2 forecourt system is rated for use in a Class2 environment. To maintain this classification the
Wayne Isolation Box has been designed to protect the data inputs by running the data lines through a bank of
Zener diodes which will clamp any high voltage and blow the fuse.
Existing site wiring will determine whether or not the Wayne Isolation box should be installed. If the site has
been constructed so that pump and/or the CAT/CRIND data wires do not share a conduit with the dispenser
power wiring, then the data wires can be considered Class 2 components and the installation of the Wayne
isolation box is not necessary.
However, if the pump and/or the CAT/CRIND data wires share a conduit at any point with the dispenser power
wiring then that environment is considered Class 1 and the Wayne Isolation box is required.
If the Wayne Isolation Box is required then mount the box near to where the Fusion V2 forecourt system is
located so the three foot pigtails can reach from the isolation box to the Fusion V2 forecourt system. Connect
according to the following diagram.
12.3 Fusion V2 Forecourt System Installation

1. Select a Fusion 500 forecourt system mounting location on the wall near where the Wayne Data
Distribution box, or the Gilbarco Distribution box, was located. The Fusion 500 forecourt system mounting
bracket should be mounted on the wall first, then the Fusion 500 forecourt system slides onto the
mounting tabs or slots of the bracket. Orient the bracket/box so that the data wire connectors are located
facing down. The Fusion 500 forecourt system should be mounted in such a way that there is visual
access to the XMIT and RCV LEDs which are next to the GRIB connectors. The opposite end of the box
has the Status display LEDs and should also be visible.
Mounting
bracket
Mounting
pins
Bracket
mount
holes
Figure 12-4 Fusion Forecourt System Mounting Bracket

2. After selecting a mounting location, attach the bracket to the wall by using two screws in the top two
screw holes first.
3. Connect a ground wire from the ground lug on the back of the Fusion box to an earth ground at the
electrical panel.
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4. For Wayne dispensers, route the pump data wires (2 pairs per connector) up to the pump GRIB plugs
beginning with Dispenser #1. Pump data wires can be connected as 4 fueling points per plug. See
Figure 15-8 and Figure 15-9.
5. Route the CAT or CRIND data wires up to the CAT or CRIND GRIB plugs beginning with Dispenser #1. CAT
data wires can be connected as 4 single CAT boards per plug or 2 dual CAT boards per plug. See
Figure 15-11 and Figure 15-12.
NOTE: In versions of Base code (Base 20 or less), the Nucleus POS system does NOT support Channels D-1 and D-
2, the last 2 GRIB ports on the second GRIB board. Code has been added in Base 21 to support 32 pumps;
however, there is a limitation due to the load on the current loop. Each GRIB port can support 2 loads which
could translate to 4 fueling points (if using dual-sided dispensers) or only 2 fueling points (if using single-
sided dispensers). Thus, you can run into problems if the right combination of dual-sided and single sided
dispensers. There is a patch that can be applied to sites on code prior to Base 21 that can get access the
last two GRIB ports corresponding to D-1 and D-2. Some older Wayne pump computer bases could only
program addresses up to 24. For limitations such as this, when connecting the 25th fueling point or load,
restart pump addressing with 1 and plug the corresponding GRIB plug into EIB D-1 and EIB D-2 of the GRIB.
NOTE: Some Gilbarco dispenser addresses go from zero (no jumpers) to 15. The 16th address must begin again
with zero (no jumpers). This is acceptable addressing as long as two pumps with the same address are not
on the same channel.
NOTE: The GRIB connectors for the Pumps (Current Loop) are located on the lower row of connectors while the
GRIB connectors for the CATs (RS485/422) or CRINDS (Current Loop) are located on the upper row of
connectors. See Figure 15-2. The GRIB boards will have different colors at the connector to distinguish
between the current loop and 485 versions. If installing Gilbarco pumps then both the pumps and CRINDS
will use current loop.
NOTE: If a Veeder-Root BIR is not used at this site then remove the resistor that is installed on the GRIB plug for
Channel 4 of the current loop GRIB and the pins 1 and 2 can then be used for additional pump
communications.
6. For Wayne dispensers, insert the GRIB plugs into the appropriate GRIB sockets on the rear panel of the
Fusion 500 forecourt system beginning with the plug for Pump #1, #2, #3 and #4. See Figure 15-7.
7. Insert this plug into the Electronic Interface Board (EIB) A, Channel 1 socket. Insert the remaining plugs into
the appropriate sockets at Electronic Interface Board (EIB) A Channel 2 and so on for the remaining pumps.
NOTE: If the site uses a Veeder-Root BIR in the CDIM configuration, then the last port(s) on the GRIB board(s) will
be used for CAB communications. See Figure 12-16 through Figure 12-18.
8. Insert the GRIB plugs into the appropriate GRIB sockets on the rear panel of the Fusion 500 forecourt
system beginning with the plug for CAT #1, #2, #3, and so on. See Figure 15-5. Insert this plug into the
Electronic Interface Board (EIB) A, Channel 3 socket. Insert the remaining plugs into the appropriate
sockets at Electronic Interface Board (EIB) A Channel 4 and so on for the remaining CATs.
NOTE: Make a note of where all of the pumps and CATs are connected.
9. If the site uses a Veeder-Root BIR in the EDIM configuration, connect the serial cable from the BIR to the
DB9 EDIM connector on the Fusion 500 forecourt system. See Figure 15-2.
10. If connecting a DSM, then plug the DSM cable to the appropriate port on the back of the Fusion 500
forecourt system. See Figure 15-2.
NOTE: The DB9 connector on the Fusion 500 forecourt system is NOT a full RS-232 DB9 connector. The
pin layout is as follows:
1 - Ground 4 - DTR
2 - TXDA 7 - Ground
3 - RXDA 9 - Reset
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The DSM requires pins 3(+) and 4(-). Since the Fusion 500 forecourt system does NOT supply power to the
DSM, any existing cable must be replaced with cable PN WU002290-001, which also requires power
adapter PN WU002344-001. See Figure 12-5.
a. Connect the WU002344-0001 cable to the two-pin connector of WU002290-001.

b. Connect the DB9 connector of WU002290-001 (attached to WU002344-001) to the DSM, and the
other DB9 connector to the DSM serial port on the Fusion 500 forecourt system.
c. Plug WU002344-0001 into a power outlet.
Connect to DSM
AC Transformer Connect to DSM

WU002344-0001 connector on
Fusion
Figure 12-5 DSM Cable PN WU002290-001

11. If connecting an Enhanced Gilbarco GSM, then the cable configuration can use either of the following two
methods. Verify that the end-to-end cable connections (GSM to Fusion forecourt system) result in the
following pin out:
NOTE: You may have to remove pins 1,6, and 8 from the Gilbarco adapters (Q13180-04)
* 2 to 2
* 3 to 3
* 7 to 7
* 9 to 9
a. Method 1 - Use two Gilbarco DB9 to CAT5 adapters (PN Q13180-04) connected together via a straight
through CAT5 cable. One end connects to the Fusion forecourt system using a DB9 female to DB9
female gender bender and the other end connects to the Enhanced GSM.
DB9 Female to
Fusion Female Gender Enhanced
Bender GSM
PN Q13180-04 CAT5 PN Q13180-04

CAT5 to DB9 Cable CAT5 to DB9
Connector Connector
Figure 12-6 Enhanced GSM Cable Connection Method 1
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b. Method 2 - Connect the GSM to a Gilbarco adapter (PN Q13180-04B). Next, connect the Gilbarco
CAT5 cable (PN Q13850-10) to that adapter and connect the other end into a Gilbarco DB25 to CAT5
adapter (PN Q13180-22B). Attach the 9 pin to 25 pin adapter then connect the Wayne 9 pin to 9 pin
cable. The other end of the ribbon cable connects to the Fusion forecourt system.
DB9 Male to DB25

Enhanced
Gilbarco CAT5 Cable Female adapter
GSM
PN Q13850-10
Gilbarco Adapter
PN Q13180-04B
Gilbarco Adapter
PN Q13180-22B
Fusion
Wayne 9 pin to 9 pin
Ribbon Cable
PN 887721-001
Figure 12-7 Enhanced GSM Cable Connection Method 2

12. Connect the CAT 5 ethernet cable that was run in Section 12.1 step 11 to the Ethernet port on the Fusion
500 forecourt system. See Figure 15-2. Connect the other end of the cable to any available port on the
Nucleus POS system Ethernet switch.
NOTE: If you are converting a Nucleus POS system site to the Fusion 500 forecourt controller, the existing
GSM cable should be compatible.
13. Complete the wiring, secure the conduit, etc.
14. Plug the Fusion 500 forecourt system power brick into the dedicated 120VAC power outlet which has been
wired into the Emergency Stop button, then plug the other end into the transformer input of the Fusion 500
forecourt system.
15. If the IP Address entered in Section 12.1 step 4 is different than the Fusion forecourt systems default
address of 192.168.1.20, refer to Section 12.4 to change the IP address.
16. If the site has Gilbarco dispensers, perform the following steps:
a. Enter the Fusion forecourt system Web UI. Refer to Section 12.5 for instructions.
b. Program the Fusion 500 forecourt system for Gilbarco Blend Ratios. Refer to Section 12.6.
17. If the site uses a Veeder-Root BIR, program the Fusion 500 forecourt system to communicate with the BIR.
For CDIM BIRs refer to Section 12.7.
For EDIM BIRs refer to Section 12.8.
18. Program the Nucleus POS system to communicate with the pumps and CATs/CRINDs.
If this is a new installation, refer to the Nucleus POS system installation manual for your site.
If you are converting an existing Nucleus POS system installation to the Fusion 500 forecourt system,
refer to Section 12.9.
12.4 Changing the Fusion Site Controller IP Address

The Fusion forecourt system is pre-configured with an IP address of 192.168.1.20. If you need to change the IP
address you must use one of the following procedures.
12.4.1 Using PuTTy to Change the IP Address

1. To access the Fusion forecourt system through the putty software go to the Start menu, look up the Putty
Shortcut and click on it. If needed, the Putty software is available for download from ASONet.
2. To start a session you have to complete the Host Name or IP address field and click Open.
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Figure 12-8 PuTTY Configuration Window
3. The profile of this user will start a session in the IP change script where you can add the new values and
restart the Fusion forecourt system to apply the changes.
4. Log in with the user ID of ipchange then use the password ipchange. See Figure 12-9.
Figure 12-9 Fusion Login and Password Prompt

5. The prompt on the screen will be ip address: Using the keyboard, enter the new IP Address and press
<Enter>. See Figure 12-10.
Figure 12-10 Fusion IP Address Entry Screen

6. Press <Enter> again to confirm.
7. Press <Enter> to accept the default Broadcast value.
8. Press <Enter> to accept the default Gateway value.
9. Press <Enter> to accept the default Name Server value.
10. Press <Enter> to accept the default Netmask value.
11. Press <Y> then <Enter> to reboot.
12.4.2 Using USB Maker to Change the IP Address

The USB Maker utility can be used to change the Fusion forecourt system IP address using a USB key.
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1. First obtain the USB Maker utility from the ASONet and load it on your laptop.
2. Insert the USB key into your laptop and execute StartUSBMaker.bat, The following window will then be
displayed.
Figure 12-11 USB Maker Window

3. Select the Network Configuration tab; enter IP Address, Permission and USB Drive. Permission of "One
Time" will direct the USB to be used only once. If "Every Time" is selected, then every time this USB is
used it will change the IP address - be careful when selecting this option!
4. Press the Submit button. You should get a successful notification. Now the USB key is ready to be used.
5. Remove the USB key from your laptop and insert into the Fusion forecourt system.
6. The system will beep once after a few seconds indicating the process has started.
7. After a few more seconds, the system will beep 4 times indicating success (3 low tones indicates failure).
After the IP change, the Fusion forecourt system automatically restarts the network with the new IP address.
There is no need to reboot the Fusion forecourt system.
As with all the USB Fusion operations, a log file is written to the USB key. Please review this logfile under
\DresserWayne\Fusion\usb.log for detailed information.
12.5 Entering the Fusion Forecourt System Web UI

To access the Fusion forecourt system programming you can either log
on using a laptop connected to the Nucleus POS system switch, or you
can get a One Shot password and log onto the Nucleus POS system as
Level 6.
1. Go to Start > All Programs > Internet Explorer.

2. In the Internet Explorer address bar, type in the Fusion forecourt
systems IP Address (default is 192.168.1.20) and press <Enter>.
The screen pictured to the right is then displayed.
3. Enter the Admin in the Login field and enter the default Login and
Password. Press <Enter> to continue.
Figure 12-12 Fusion Login Screen
12.6 Gilbarco Blend Ratio Programming

Gilbarco pumps use a different way of designating blend ratios than Wayne pumps. Gilbarco defines the blend
ratios as a percentage of low feedstock while Wayne defines blend ratios as a percentage of high feedstock.
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When using the Fusion forecourt system, the Nucleus POS system programming under Cash Register > Fuel
> Grade > Modify > Feedstock defines blend ratios as a percentage of high feedstock for both Wayne and
Gilbarco dispensers.
Another programming difference is how Gilbarco blenders handle pump operations when the POS and the
dispenser have different blend ratios set. Gilbarco blenders will communicate with the POS and dispense fuel
even if the blend ratios at the dispenser and POS do not match. In this case the blend ratios programmed at
the pump are valid.
Fusion forecourt system programming contains a flag that controls whether the system checks for matching
blend ratios. The default is set to NO so no blend ratio checking will take place. If the site is experiencing
communications problems with the Gilbarco blenders and blend ratio programming is suspected, go to the
programming page located under Configuration > Devices > Pump. Access each pump and verify that the
value is set to NO.
Check Blend Ratios

Figure 12-13 Check Blend Ratio Flag
NOTE: This programming option only applies to Gilbarco blender programming. Wayne blenders are not affected
by this programming option.
12.7 Fusion Installation using Veeder Root CDIM Configuration

If you are installing the Fusion forecourt system in a site which utilizes a Veeder-Root BIR (Business Inventory
Reconciliation) system, the following instructions will guide you through configuring the system to work with
the Fusion forecourt system. The CDIM (Current Loop Dispenser Interface Module) has three communications
ports but the only ones that are used are Port 1 and Port 2.
Port 1
Port 2
Port 3
Figure 12-14 Veeder-Root CDIM Ports

Each CDIM port is attached to one (1) CAB (Cable Adapter Box) which can handle up to 16 Fueling Positions.
If a site has more than 16 Fueling Positions then a second CAB is required.
When connecting 12 Fueling Positions and a CAB to a single Current Loop GRIB configuration, the CAB will
plug into Port 4 at pins 3(+) and 4(-). Pins 1 and 2 are not used. This leaves Port 1, Port 2 and Port 3 as
connection points for the current loop wires coming from the dispensers. See Figure 12-16.
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When connecting 16 Fueling Positions and a CAB to a dual Current Loop GRIB configuration, the CAB will plug
into Port 14 at pins 3(+) and 4(-). Pins 1 and 2 are not used. This leaves Port 1, Port 2 Port 3 and Port 4 as
connection points for the current loop wires coming from the dispensers. See Figure 12-17.
When connecting 24 Fueling Positions and 2 CABs to a dual Current Loop GRIB configuration, the CABs will
plug into Ports 13 and 14 at pins 3(+) and 4(-). Pins 1 and 2 are not used. This leaves Ports 1 through 4, and
Ports 11 and 12 as connection points for the current loop wires coming from the dispensers. See Figure 12-18
12.7.1 Connect the CABs

1. Disconnect the CAB communications cable(s), which are connected to either a Wayne or Gilbarco
Distribution box. (Make a note of the polarity of the wires when disconnecting).
2. Attach the CAB communications wire(s) to a GRIB plug. See the example below.
- Pin 4
Pin 3
BIR
+
Figure 12-15 GRIB Plug

3. Insert the GRIB plug into Port 4 of Current Loop GRIB #1 for 12 dispensers, or into Port 14 of Current Loop
GRIB #2 for 16 dispensers.
4. If there are two CABs then the CAB GRIB plugs are inserted into Current Loop GRIB #2 at Ports 13 and 14.
See Figure 12-18.
See the following configuration examples for options when connecting the CABs.
Figure 12-16 One CAB - 12 Fueling Points
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Figure 12-17 One CAB - 16 Fueling Points
Figure 12-18 Two CABs - 24 Fueling Points
12.7.2 Connect the Dispensers

1. Connect the dispenser with the lowest Fueling Point number to the Current Loop GRIB #1 beginning with
Port #1. See Section 15.3. Continue plugging dispensers into GRIB ports 2 and 3.
2. If there are 2 CABs at the site then continue plugging any additional dispensers into the next set of GRIB
plugs on Current Loop GRIB #2.
12.7.3 Programming the System for Sites with Veeder-Root BIR

1. Access the Fusion forecourt system Web UI. Refer to Section 12.5 on page 21. The following window will
be displayed.
24 P/N 000-940002- Rev 0G June 2014

Click Configuration
then select Generic
Figure 12-19 CDIM Programming Screen 1

2. Click Configuration, and then select Generic. The following window will be displayed.

3. Select BIR Port from the module pull-down, then click Search. Scroll the display down to show the list of
BIR Port Parameters.The following window will be displayed where you verify that the BIR port is set to
Enabled.
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4. Click Port to open the following window. Use the drop-down to select the BIR CAB port address as
/dev/gribport4 (when the CAB is plugged into port 4), /dev/gribport14 (when the CAB is plugged into
port 14), or /dev/gribport13 (when the CAB is plugged into port 13). See the following window.

5. If you are installing a site that has 2 CABs, then you will need to program the communication for the
second CAB. Click Second Port and the following window will be displayed.
IMPORTANT: If the "Second Port" is not used, then the "Second Port Pump" MUST be set to '0'

6. Using the drop-down, select the second BIR CAB port address as /dev/gribport14 then click Submit.
14
26 P/N 000-940002- Rev 0G June 2014

7. When using a second BIR CAB, click on Second Port Pump to program the fueling point address of the
pump that is plugged into Current Loop GRIB #2 - Port 11 then click Submit.

8. Click Send new Configuration to Fusion to download the new configuration to the Fusion forecourt
system. The following windows will then be displayed.
then

9. Click Close Windows to complete the process.
10. Navigate to HOME > Configuration > Others > Reboot Fusion.
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11. Select the Reboot Fusion button and the following is displayed:

The system will stop processes, shutdown the operating system and then reboot.
12.8 Veeder-Root BIR Installations with EDIM

If the site has a Veeder-Root Business Inventory Reconciliation (BIR) system installed then the Fusion
forecourt system installation varies depending on the hardware at the site. The BIR cable plugs into the DB9
EDIM connector on the Fusion forecourt system. See Figure 15-2
The Electronic Dispenser Interface Module (EDIM) solution sends commands from the Fusion forecourt
system to the EDIM over a serial link by capturing pump control data and sending it to the EDIM module in the
Veeder-Root. A serial communication channel and a Tank Monitor must be defined in the Fusion forecourt
system (via the Web UI) to enable this feature.
1. Log into the Web UI, using Internet Explorer, and navigate to HOME > Configuration > Devices >
Communications.
Figure 12-29 EDIM Programming 1

2. Select Add to bring up the next screen where you enter BIR1 then select Serial and click OK.
Figure 12-30 EDIM Programming 2
28 P/N 000-940002- Rev 0G June 2014

3. The following window is then displayed where the BIR1 programming values are set.
Figure 12-31 BIR1 Programming

Set the following values:
Baud Rate: 9600
Device ID: BIR1
Parity: ODD
Word Len: 7
Port ID: /dev/ttyS2 (COM3, the 3rd Serial Port - this is case sensitive and zero based!)
Stop Bits: 1
4. Leave the other values unchanged and press Apply Changes.
5. Next, Add a Tank Monitor by going to HOME > Configuration > Devices > TankMonitor and clicking Add.
The following window will then be displayed.
Figure 12-32 Tank Monitor Programming 1
P/N 000-940002- Rev 0G June 2014 29

6. Enter 1 and select Veeder from the pull-down and then press OK. The following window will be displayed.
Figure 12-33 Tank Monitor Programming 2

Set the following values:
Communications: BIR1
Send Transactions: YES
7. Leave the other values unchanged and press Apply Changes then click Close Windows to exit.
8. Reboot the Fusion forecourt system for the changes to take effect.
9. Plug in the serial connection between the Fusion forecourt system and the Veeder-Root EDIM and pump
volume data and totals are now sent to the EDIM.
12.9 Programming the Nucleus POS System

If you are installing the Fusion 500 forecourt system at an existing Nucleus POS system site, additional
programming is needed to enable the Fusion 500 forecourt system.
1. Obtain a One Shot access password if needed.
30 P/N 000-940002- Rev 0G June 2014

2. Go to Programming > System > Port Configuration and the following window will be displayed.
Figure 12-34 Port Configuration

3. Use the pull-down for COM3 and program for EXTERNAL_MODEM.
4. Click OK to exit.
5. Go to Programming > System > Pump > Each. Select Pump # 1 and press the Modify button. Press the
Comm button to open the communications window. See below.
Figure 12-35 Pump Communications Window

6. Program Pump # 1 according to which EIB and Channel that Pump # 1 was plugged into in Section 12.3.
Continue pump programming with the remaining pumps.
7. Go to Programming > System > CAT > Each. Select CAT # 1 and press the Modify button. Press the
Communications button to open the communications window. See below.
Figure 12-36 CAT Communications Window
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8. Program CAT # 1 according to which EIB and Channel that CAT # 1 was plugged into in Section 12.3.
Continue CAT programming with the remaining CATs.
9. Shutdown and restart the Nucleus POS system when all the pumps and CATs have been programmed.
32 P/N 000-940002- Rev 0G June 2014

13 TROUBLESHOOTING
After the Fusion 500 forecourt system has been mounted and the system wiring has been completed, all of the
pumps and CATs should be online as shown in the Nucleus POS system Sales screen. If pumps or CATs remain
offline then double-check for the correct polarity of the pump current loop. The CAT communication wiring
should also be double checked.
NOTE: Note that after pressing the Fusion 500 forecourt system power button in order to power down, the
power down sequence actually can take up to a minute to complete. This is due to the Fusion forecourt
systems internal battery backup which is shutting down in a controlled manner so that no file corruption
occurs.
NOTE: While troubleshooting, never disconnect/connect a USB port on the SBC while power is on!!! You can
easily fry the GRIB board. If the light on the GRIB comes on but does not blink, then it could be zapped.
Make sure you have SCC Emulator code loaded and not Console or HyperPIB.
* Verify that you have SCC Emulator code installed in the Fusion forecourt system and not Console or
HyperPIB code.
If you have trouble getting your pumps and CATs online:
* Make sure you have the right IP address programmed in the Nucleus POS system. If not, program the
correct address and reboot the Nucleus POS system.
* Can you ping the Fusion forecourt system from the Nucleus POS system? Try a ping - if it doesn't
work, then nothing will ever communicate. Check wiring into switch and connections.
* Make sure your switch/hub is not a 1G switch. The CUPS board in the Fusion forecourt system cannot
handle this. To troubleshoot this, connect the LAN cable from the hub directly into the Ethernet
connector on the ATOM board (you have to open the Fusion forecourt system to do this). If the light
comes on and you can ping it, then you may need another hub or your cable from the CUPS to the
ATOM board is bad.
If you have trouble getting your pumps online:
* Check polarity of pump wiring into current loop board. If only one pair of pump wires are connected,
then it should be connected on either end of the connector (the two in the middle are left unused).
* If the yellow light on the bottom is solid, that means you have an open circuit and don't have a current
loop connection.
* If no lights are blinking on the GRIB ports, then nothing is communicating.
* With the Fusion forecourt system running, make sure the GRIB light is blinking (open the box and look
for a flashing LED). If the light is turned on but not blinking then you may have a bad current loop GRIB.
* Make sure the jumper settings are correct for Gilbarco v. Wayne (one jumper for each GRIB port). See
Section 15.4 on page 46 for complete details.
* Make sure your pump channel programming is correct - see Channel/GRIB port map as defined in
Section 15.3 on page 41.
* Make sure your pump programming is correct - Gilbarco pumps now must program VRB and VRB+ as
required.
* If you can get some of your pumps online and not others, then you could have a bad port on GRIB. Try
moving the pumps to another GRIB, reprogram the Nucleus POS system and reboot.
* Make sure the BIR port is not in conflict with an existing GRIB port. The BIR cannot be used on the
same port as pumps are connected or you will have communication problems.
If your pumps/CATs are going online and offline repeatedly:
* Make sure there is nothing else on the hub/switch that is interfering with the Fusion forecourt system
and the Nucleus POS system. If an older POS console with the same IP address as the Fusion
forecourt system is still connected to the hub, this can cause the pumps/CATs to go offline. Verify that
all devices on the network have unique IP addresses.
* If the Fusion forecourt system crashes, it will restart immediately; however, while it is restarting the
pumps will be offline. Take logs and look at watchdog.log to see if the Fusion forecourt system is
constantly going up and down.
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If you have trouble getting your CATs or CRINDs online:
* For Wayne, check polarity of wiring into 485 GRIB.
* For Gilbarco, check polarity of wiring into current loop GRIB. If only one pair of pump wires are
connected, then it should be connected on either end of the connector (the two in the middle are left
unused).
* If no lights are blinking on the GRIB ports, then nothing is communicating.
* With the Fusion forecourt system running, make sure the GRIB light is blinking (open the box and look
for a flashing LED). If the light is turned on but not blinking then you may have a bad current loop
GRIB.
* For Gilbarco CRINDs make sure the jumper settings are correct for Gilbarco v. Wayne (one jumper for
each GRIB port). See Section 15.4 on page 46 for complete details.
* Make sure your CAT channel programming is correct - see Channel/GRIB port map as defined in
Section 15.3 on page 41.
* For Wayne CAT's, the 485 board must have Echo turned OFF. Jumper JP5 must be set to 1-2. Pin 1 is
identified by the square solder on the back of the board. JP5 pin 1 is also closest to GRIB port. Check
the jumper settings for JP11, JP15, and JP16 by referring to the tables in Section 15.5 on page 46.
If you have trouble with the ATOM Board:
* There are two lights. When powered on, one is solid. When the Fusion forecourt system software
application is running, the other light blinks about once per second. This blinking light will blink much
faster during shutdown mode. Both lights are off when fully powered down. At this time, it is safe to
power back on.
* At power up time, you should hear two beeps followed by another beep. If not, this board is bad or
somehow the BIOS got stuck in ATX mode. To get it out of ATX mode, follow these procedures:
. . . .
. . . .
pins 1 3
1.) At the top is a jumper called F_PANEL_1. Turn on the power to the Fusion forecourt system and
immediately short out PINs 1 and 3:
2.) Short out these pins at startup, that will reset the board and you should here two beeps followed
by another beep. If that doesn't work, then your motherboard is DOA.
34 P/N 000-940002- Rev 0G June 2014

If you have trouble with USB-GRIB cables and pin-outs:
* The ATOM board has 6 USB ports on 3 sets of connectors:
* USB1 and USB2 are reserved and hard-coded for GRIB ports. Each set of 8 pins provide 2 USB ports
(although the connector has room for 10 pins, there should be 2 pin connectors not used that should
hang off the board). Looking at the diagram above, USB1 and USB2 are the top two USB connections
and provide input for 4 USB ports. These correspond to the 4 GRIBs. The pin-outs correspond to
specific GRIB ports as follows:
.... Corresponds to GRIB ports 1-4 (USB1 on SBC)


.... 1st USB port on back panel (USB3 on SBC)

.... 2nd USB port on back panel (USB3 on SBC)
If you have trouble with USB key:

* If the USB drive isn't recognized (i.e. no beep on insert), your Fusion 500 forecourt system could be
missing the internal cable which runs from the USB3 connector on the SBC to the USB connectors on
the CUPS (J5/J8). Or possibly, you don't have the latest SCC software installed (containing the USB
generic update).
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Rebooting from the Web UI
If you are already in the Web UI, there is an easy way to reboot the Fusion forecourt system. Doing it this way
alleviates having to wait 30 seconds when using the power button.
* Navigate to HOME > Configuration > Others > Reboot Fusion:
* Select the Reboot Fusion button and the following is displayed:
* The system will stop processes, shutdown the operating system and then restart everything.
14 UPDATING FUSION FORECOURT SYSTEM SOFTWARE

Software updates can be done using the existing Nucleus POS system Copy CD for Later functionality or by
utilizing a USB Key to deliver the updates. Copy CD for Later is the preferred method while using the USB Key
is the secondary method.
14.1 Copy CD for Later

Use the Copy CD for Later feature to transfer files from a CD to the Fusion forecourt system. The operation
is very similar to the normal Copy CD for Later that a site would use for updating the Nucleus POS system.
Be aware that at the conclusion of the copy process, the dispensers will go offline for several minutes as the
software is updated. Pick a slow time at the station before beginning the update.
1. From the Nucleus POS system, stop all pumps one at a time as the customers finish their transactions.
2. Press the application button and select Copy CD for Later.
36 P/N 000-940002- Rev 0G June 2014

3. Open the CD tray, insert the update CD and then close the tray. Press OK to continue. The following screen
will be displayed.
4. A notification is displayed informing the user that a Fusion forecourt system update is about to take place
and that the pumps will be offline during this process. Press Yes to continue.
5. If any errors are encountered during the copy process then the following notification will be displayed.
Otherwise, the update will proceed and the Fusion forecourt system will restart using the updated
software.
14.2 USB Key

The Fusion forecourt system supports software updates using a USB Key. Using the proper setup program, a
user can copy update files to the USB along with a directive file (which dictates to the Fusion forecourt system
to update software). This program allows a technician or ASO to quickly update software with a pre-loaded
USB key. Like the Copy CD for Later method, pump communication will be lost during the update.
To create a directive file on the USB key perform the following steps.
1. Download the USBMaker 2.0 folder from the ASONet and copy to your laptop.
P/N 000-940002- Rev 0G June 2014 37

2. Execute StartUSBMaker.bat, the following window will then be displayed.
3. Select the Software Update tab. Press the Upload button and select the location of the software
updates. Set Permission and USB Drive location.
4. Setting the Permission to "One Time" will direct the USB to be used only once. If "Every Time" is
selected, then every time this USB is used it will update software - be careful when selecting this
option!
5. Press Submit. You should get a Successful notification. Now the USB key is ready to be used.
Successful
notification
6. Now, remove the USB key from you laptop and insert into the Fusion forecourt system.
7. The system will beep once after a few seconds indicating the process has started.
8. After a few more seconds, the system will beep 4 times indicating success (3 low tones indicates failure).
9. The Fusion forecourt system will install new software and restart. You will lose pump communication
during this process!
NOTE: As with all the USB Fusion operations, a log file is written to the USB key. Please review this logfile under
\DresserWayne\Fusion\usb.log for detailed information.
14.3 Verifying the Fusion Version

After loading a new version of the Fusion forecourt system, or to check the current version you can print a
Configuration Report from the Nucleus POS system.
1. Go to Programming > Reports > Configuration.
38 P/N 000-940002- Rev 0G June 2014

2. A Configuration Report will print which contains a section titled Fusion Version Information which looks
similar to the following.
Fusion Version Information
ForecourtManager-3.1.5
SCC Emulator- 3.1.10
Gilbarco- 1.2.36
Wayne- 1.2.58
Grib- 105E6
Figure 14-1 Configuration Report - Fusion Version Information
P/N 000-940002- Rev 0G June 2014 39

15 APPENDIX
15.1 Fusion Forecourt System Components
CUPS Board Atom Board To GRIB 6-9 To GRIB 1-4

(ribbon cable pin 1 - 4) (ribbon cable pin 5 - 8)
Figure 15-1 Fusion Forecourt System Components
40 P/N 000-940002- Rev 0G June 2014

15.2 Fusion 500 Forecourt System Rear Panel
The following diagrams shows the Fusion 500 Forecourt System connections.
EDIM GRIB
Connection DSM or RS485/422 Boards for Wayne CATs
GSM only or Current Loop Boards for Gilbarco
CRINDS
Serial
Power USB GRIB
Printer,
button ports Current Loop
HyperPIB
Boards (Pumps)
Transformer Ethernet or Debug
input port
Figure 15-2 Fusion 500 Forecourt System Rear Panel (Wayne Dispenser Configuration)
15.3 GRIB Connectors

NOTE: For Wayne sites with 16 computer bases, the following Nucleus port assignments are used
---------- CATS ---------

Electronic Interface Electronic Interface Electronic Interface Electronic Interface
Board C Board D Board A Board B
Channel 3 Channel 4 Channel 3 Channel 4 Channel 3 Channel 4 Channel 3 Channel 4
---------- PUMPS ---------

Figure 15-3 GRIB Connectors for 16 Computer Bases - Wayne Dispensers
P/N 000-940002- Rev 0G June 2014 41

NOTE: For Gilbarco sites with 16 computer bases, the following Nucleus POS system port assignments are used
---------- CRINDS ---------

---------- PUMPS ---------

Figure 15-4 GRIB Connectors for 16 Computer Bases - Gilbarco Dispensers
NOTE: Each GRIB Connector can connect with two dispensers (4 CATs)
Electronic Interface Electronic Interface

Board A Board B
Channel 3 Channel 4 Channel 3 Channel 4
XMIT LED
RCV LED
Pin 1 CATs CATs CATs CATs

Pin 4
1&2 (+) 1&2 (-) 3&4 (+) 3&4 (-)
Figure 15-5 GRIB Connectors - Nucleus POS System CAT Configuration
NOTE: Each GRIB Connector can connect with two dispensers (4 CRINDS)
42 P/N 000-940002- Rev 0G June 2014

Board A Board B
XMIT LED
RCV LED
Pin 1 CATs CATs CATs CATs

Pin 4
1&2 (+) 1&2 (-) 3&4 (+) 3&4 (-)
Figure 15-6 GRIB Connectors - Nucleus POS System CRIND Configuration
NOTE: Each GRIB Connector can connect with two dispensers (4 fueling points)
P/N 000-940002- Rev 0G June 2014 43

Board A Board B
XMIT LED
RCV LED
Pin 1 Pump 1&2 Pump 1&2

Pin 4
(+) (-)
OR
XMIT LED
RCV LED
Pin 1 Pump Pump Pump Pump Pin 4

1&2(+) 1&2(-) 3&4(+) 3&4(-)
Figure 15-7 GRIB Connectors - Nucleus POS System Pump Configuration
Pin 4
-
Pump #1
+ Pin 1
Figure 15-8 GRIB Plug - Single Pump (Dispenser) Per Plug Configuration
44 P/N 000-940002- Rev 0G June 2014

- Pin 4
Pump #2
+
Pin 1
-
Pump #1
+
Figure 15-9 GRIB Plug - Two Pumps (Dispensers) Per Plug Configuration
- Pin 4
BIR
+
Pin 1
Figure 15-10 GRIB Plug Used for BIR communication in Channel 4
Pin 4
-
Pin 1
CAT 1&2
+
Figure 15-11 GRIB Plug - One CAT Cable Per Plug Configuration
P/N 000-940002- Rev 0G June 2014 45

Pin 4
-
CAT or CRIND 3&4
+
Pin 1
-
CAT or CRIND 1&2
+
Figure 15-12 GRIB Plug - Two CAT or CRIND Cables Per Plug Configuration
Pin 4
-
CRIND #1
+ Pin 1
Figure 15-13 GRIB Plug - One CRIND Cable Per Plug Configuration
15.4 GRIB Jumper Configurations for Current Loop Board

Table 15-1 GRIB Jumper Configurations for Current Loop GRIB PCB Assy
CH1 CH2 CH3 CH4

Dispenser JP1 JP2 JP3 JP4
Wayne 2&3 2&3 2&3 2&3
Gilbarco 1&2 1&2 1&2 1&2
15.5 GRIB Jumper Configurations for 485 Board

Table 15-2 Channel 1
JP1 JP2 JP3 JP4 JP6 JP13 JP17 JP18 JP19

RS485 2&3 2&3 2&3 2&3 2&3 2&3 Off Off Off
RS422 1&2 1&2 1&2 1&2 1&2 1&2 Off Off Off
RS116 Off Off Off Off Off Off On On On
46 P/N 000-940002- Rev 0G June 2014

Table 15-3 Channel 2
JP7 JP8 JP9 JP10 JP12 JP14 JP20 JP21 JP22

RS485 2&3 2&3 2&3 2&3 2&3 2&3 Off Off Off
RS422 1&2 1&2 1&2 1&2 1&2 1&2 Off Off Off
RS116 Off Off Off Off Off Off On On On
Channel 1 RS485/RS422 Echo Off

(recommended)
ECHO JP5
On 2&3
Off 1&2
Channel 2 RS485/RS422 Echo Off

(recommended)
ECHO JP11
On 2&3
Off 1&2
Channel 3 RS485 Only Echo Off

(recommended)
ECHO JP15
On 2&3
Off 1&2
Channel 4 RS485 Only Echo Off

(recommended)
ECHO JP16
On 2&3
Off 1&2
Power Source
JP23
Power from USB 1&2
Power from Ext. 2&3

Source
P/N 000-940002- Rev 0G June 2014 47

5 4 3 2 1
KB1 6P J8 10P LED1
June 2014
WU001817 J7 10P LED2
8P USB5 & USB6 KYBD&Mouse Activity Pwr
Audio
VGA Bot
Top
8P USB3 & USB4 (Heart
Beat)
8P
USB1 & USB2
D
SINGLE BOARD COMPUTER D
CN2 LINUX OS
Rev 0G
RJ45 LAN2 2P 4P SATA2 EBX FORM FACTOR
NOVA ADAM
WU001261
Figure 15-14 FSN-2 (Fusion T/BA1B1/x/x) Wiring Diagram

RJ45 LAN1
J2
WU002111 COOLER
10P COM1 CN1 2P 4P SATA1 PWR 4P
WU001421
WU001421
WU002708-0001
WU001274
P/N 000-940002-
WU001266 10P COM2
WU001258
10P COM3
WU001307
2P 3P 3P 3P 3P 10P COM4 8P 10P

J2 2P
7P
J3
J18 J19 J20 J22 J24 F_PANEL1 DIO1

+24V
+5V ,5AMP
+5V Out
J17
Pwr
PS Section +5V LED
10P
CUPS PCB ASSY
C C
Battery
+24V LED
WU000995
UPS Section BAT RDY LED

J12
15.6 Fusion 500 Forecourt System Wiring Diagrams
2P
USB1_A
USB1_B
BAT EN LED
Charger
These two Boards are Stacked

PF LED
J13
& Power Fail

2P
4P 3P 4P 3P 2P 10P 10P
J5 J7 J6 J7 J8 J9 J10
USB AUX PWR
WU001269 USB AUX DSM Chn3 Chn4
SBC 422/ 422/
J11
PWR
PWR C/10 LED WU000813 116 116
4P
9P
J5
Reset
GRIB Current Loop
J16 LED1 Charge LED J21 Wayne/Gil 30/40 ma WU000922
GRIB top
6P ACT DC IN 10P
COM1 RS485/422/116
J8
+24V LED Bot

5P
J23
LED GIL/TOK 4 CHNL 4 CHNL
2P
WU001229
B
OUT J14 10P 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL B
J9 5P COM2
+24V 2-WIRE DSM/MSM/GSM
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4 J1 J2 J3 J4
J6 2P
DSM or MSM 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16
J10
DB9 J1 2P-Jack J4 2P USB USB RJ45 DB9 DB9 WU001265

PINS SKT Option 4P 4P 4P 4P 4P 4P 4P 4P
COM 3 To 2nd bot top Top bot
TWO DISPENSERS EACH CH

Box
PWR TO +24V USB 6 USB 5 COM 2 COM 1
TWO DISPENERS EACH CH

SW/LED GRN OPTION OPTION
To CATS 1-16
External
Not on PCB Supply
GSM
or
To FP 1-16
DSM/MSM
To POS System
CAT 5 WIRE
A A
NOTE: FP Numbers are based on IGEM or DUPLEX Title
FUSION T/BA1B1/x/x
PUMP Computers in Dispensers ( 2 FP per IGEM or DUPLEX)
Size Document Number R ev
B 89XXXXX-XXX X4
FUSION SYSTEM Date: Tuesday, January 11, 2011 Sheet 1 of 1
5 4 3 2 1
48
5 4 3 2 1
KB1 6P J8 10P LED1

WU001817 J7 10P LED2
Audio
VGA Bot
Top
8P USB3 & USB4
(Heart
Beat)
8P
USB1 & USB2
D
CN2 LINUX OS
2P 4P
P/N 000-940002-
RJ45 LAN2 SATA2 EBX FORM FACTOR
NOVA ADAM
WU001261 WU001585
RJ45 LAN1
J2
WU002111 10P COOLER
COM1 CN1 2P 4P SATA1 PWR 4P
10P WU002708-0001
Rev 0G
COM2
10P
COM3
10P
8P 10P
WU001421
WU001421
2P 3P 3P 3P 3P COM4
WU001274
J2 2P
7P
J3
WU001258
+24V
WU001307
+5V ,5AMP
Pwr
June 2014
J17
C PS Section +5V LED C
+5V Out
10P
+24V LED
WU001266
Battery
2P
J12
BAT EN LED
WU000995
Charger
USB1
USB2
WU001266
PF LED
CUPS PCB ASSY

& Power Fail
2P
J13
4P 3P 4P 3P
J5 J7 J5 J7
USB AUX PWR USB AUX PWR
WU001269
SBC
PWR C/10 LED Reset WU000813 WU000813
4P
9P
J11
J5
GRIB Current Loop GRIB Current Loop
J16 LED1 Charge LED J21 Wayne/Gil 30/40 ma Wayne/Gil 30/40 ma
6P ACT DC IN 10P
+24V LED COM1 Bot Bot
5P
J8
LED GIL/TOK 4 CHNL 4 CHNL
OUT
2P
J23
B J14 10P 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL B
J9 5P COM2
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4 J1 J2 J3 J4
1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16
WU001229
DB9 J1 2P-Jack J4 2P USB USB RJ45 DB9 DB9
J10
PINS SKT
J6 2P
4P 4P 4P 4P 4P 4P 4P 4P
Box
PWR USB 6 USB 5 COM 2 COM 1
Not on PCB
GSM
TO +24V or
External DSM/MSM
Supply
Figure 15-15 FSN-3 (Fusion T/BA1A/x/x) Wiring Diagram

To POS System
CAT 5 WIRE
To Dispensers 1-8
TWO DISPENERS EACH
To Dispensers 9-16
TWO DISPENERS EACH
A A
Title
FUSION T/BA1A/x/x

B 89XXXXX-XXX X4
5 4 3 2 1
49
June 2014
5 4 3 2 1
KB1 6P J8 10P LED1
WU001817 J7 10P LED2
Audio
VGA Bot
Top
8P USB3 & USB4
(Heart
Rev 0G
Beat)
8P
USB1 & USB2
WU002111 SINGLE BOARD COMPUTER
Figure 15-16 FSN-6 (Fusion T/BA2A2/x/x) Wiring Diagram

D D
CN2 LINUX OS
NOVA ADAM
WU001261 WU001585
P/N 000-940002-
RJ45 LAN1
J2
COOLER
WU001421
WU001421
WU002708-0001
WU001274
WU001258
10P COM2
WU001258
10P COM3
WU001307
2P 3P 3P 3P 3P 10P COM4 8P 10P

J2 2P
7P
J3

+24V
+5V ,5AMP
+5V Out
J17
Pwr
PS Section +5V LED
10P
CUPS PCB ASSY
C C
Battery
+24V LED
WU000995

J12
2P
USB2
BAT EN LED WU001266
USB3
USB4
USB1
Charger WU001266 WU001266 WU001266
PF LED
J13
& Power Fail

2P
4P 3P 4P 3P 4P 3P 4P 3P
J5 J7 J5 J7 J5 J7 J5 J7
USB AUX PWR USB AUX PWR USB AUX PWR USB AUX PWR
WU001269
SBC
J11
PWR C/10 LED WU000813 WU000813 WU000813 WU000813
4P
9P
J5
Reset
GRIB Current Loop GRIB Current Loop GRIB Current Loop GRIB Current Loop
J16 LED1 Charge LED J21 Wayne/Gil 30/40 ma Wayne/Gil 30/40 ma Wayne/Gil 30/40 ma Wayne/Gil 30/40 ma
6P ACT DC IN 10P
COM1
J8
+24V LED Bot Bot Bot Bot

5P
J23
LED GIL/TOK 4 CHNL 4 CHNL 4 CHNL 4 CHNL
2P
WU001229
B
OUT J14 10P 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL B
J9 5P COM2
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4 J1 J2 J3 J4 J1 J2 J3 J4 J1 J2 J3 J4
J6 2P
1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16
J10

PINS SKT 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P

Box

TWO CRINDS EACH CH

TO CRINDS 1-16
To FP 1-16
TWO CRINDS EACH CH

Not on PCB
FP 17-24
To CRINDS 17-24
GSM
or
DSM/MSM
TO +24V
External
TO BIR
To
Supply To POS System
CAT 5 WIRE
A A
24 Fueling Points (PUMPS & CRINDS) MAX.
Title
Plus One BIR FUSION T/BA2A2/x/x
B 89XXXXX-XXX X3
5 4 3 2 1
50
5 4 3 2 1
KB1 6P J8 10P LED1

WU001817 J7 10P LED2
Audio
VGA Bot
Top
8P USB3 & USB4
(Heart
Beat)
8P
USB1 & USB2
D
WU002111 CN2 LINUX OS
P/N 000-940002-
NOVA ADAM
WU001261
RJ45 LAN1
WU001266 J2
COOLER
WU001266 WU002708-0001
10P COM2
Rev 0G
10P COM3
10P 8P 10P
WU001421
WU001421
2P 3P 3P 3P 3P COM4
WU001274
J2 2P
7P
WU001258
J3
+24V
WU001307
+5V ,5AMP
Pwr
J17
C PS Section +5V LED C
June 2014
+5V Out
10P
+24V LED
Battery
2P
J12
BAT EN LED
WU000995
Charger
PF LED
CUPS PCB ASSY

USB3
USB4
USB1
USB2
& Power Fail
2P
J13
4P 3P 4P 3P 2P 10P 10P 4P 3P 4P 3P 2P 10P 10P
J5 J7 J6 J7 J8 J9 J10 J5 J7 J6 J7 J8 J9 J10
USB AUX PWR USB AUX PWR
WU001269 USB AUX DSM Chn3 Chn4 USB AUX DSM Chn3 Chn4
SBC PWR 422/ 422/ PWR 422/ 422/
PWR C/10 LED Reset WU000813 116 116 WU000813 116 116
4P
9P
J11
J5
GRIB Current Loop GRIB Current Loop
J16 LED1 Charge LED J21 Wayne/Gil 30/40 ma WU000922 Wayne/Gil 30/40 ma WU000922
GRIB top GRIB top
6P ACT DC IN 10P
+24V LED COM1 Bot RS485/422/116 Bot RS485/422/116
5P
J8
LED GIL/TOK 4 CHNL 4 CHNL 4 CHNL 4 CHNL
OUT
2P
J23
B J14 10P 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL 2 DISPENSERS/CHNL B
J9 5P COM2
+24V 2-WIRE DSM/MSM/GSM WU001265
2AMP +24V J6-J7 Ethernet J15 J1 J2 J3 J4 J1 J2 J3 J4 J1 J2 J3 J4 J1 J2 J3 J4
1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16 1-4 5-8 9-12 13-16
WU001229
J10
PINS SKT
J6 2P
DSM or MSM 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P 4P

Option
Box
Not on PCB
GSM
TO +24V or
External DSM/MSM
Supply
TO FP 1-16
To CATS 17-32
To CATS 1-16
To FP 17-32
To POS System
CAT 5 WIRE
A A
Figure 15-17 FSN-9 (Fusion T/BA2B2/x/x) Wiring Diagram

Title
FUSION T/BA2B2/x/x
NOTE: FP Numbers are based on IGEM or DUPLEX
PUMP Computers in Dispensers ( 2 FP per IGEM or DUPLEX) B 89XXXXX-XXX X4
5 4 3 2 1
51
15.7 DIM Quick Reference Chart
15.8 Converting Gilbarco Dispensers From MOC to Generic Control

1. Open the junction boxes at one pump and verify that the labeled wire pairs from the pump and CRIND
electronics connect to wiring from the conduit. The wiring emerging from the conduit should connect to
wire pairs inside the station.
2. Connect the pump and CRIND wiring as needed for separate pump and CRINDcommunication. Table 15-
4 lists the junction box wiring connections required for generic control.
NOTE: If the conduit does not contain adequate wiring, additional cabling may need to be installed.
Table 15-4 Dispenser Junction Box Connections for Generic Control
Pump Data Loop CRIND Data Loop
MPD-3 (3-Grade) A09 SP6

A019 SP7
MPD3-(4-Grade) A09 SP13

A019 SP16
MPD-3 Pro Blender A09 SP6

A019 SP7
The Advantage Series A9 B9

A19 B19
IMPORTANT: Perform steps 3 through 12 below to establish communications to one dispenser first, and
then repeat the steps for each of the remaining dispensers.
3. Modify the existing or new splitter cable according to the type of dispenser (Pre-Advantage or Post-
Advantage series) according to the instructions and tables in the Gilbarco Dispenser Installation manuals
for your particular dispenser.
52 P/N 000-940002- Rev 0G June 2014

4. Remove connector P262A on A-Side CRIND logic board.
5. Disconnect connector P264 on both CRIND Logic boards.
6. Remove MOC CRIND firmware and replace Z180-equipped logic boards with generic firmware version
60.4.20 or higher. The current version supplied by Gilbarco is 60.4.40. See also the Wayne 3rd Party
Hardware Certification List (Part No. 920670)
7. Change jumper settings on the CRIND logic boards. These changes only apply to Gilbarco T17764 boards:
a. Watchdog Timer (JP1) ON
b. JP10 OFF
c. MOC/generic jumper (JP14) ON
d. JP15 OFF
e. JP16 ON
NOTE: Do not modify the address jumpers.
8. Install jumpers on the cold-start jumpjacks located on the CRIND logic boards.
9. Restore power to the dispenser.
10. Remove the cold-start jumpers from the CRIND boards when prompted to do so by CRIND display
messages. (i.e. REMOVE COLD START JUMPER.) The message will appear in 2 to 3 minutes.
11. If the dispensers have color or monochrome Infoscreen LCD displays, complete the following procedure:
NOTE: The minimum firmware version on the LCD Controller in dispensers equipped with color
Infoscreens is 10.1.25. Upgrade the firmware if the firmware version is below the minimum. The firmware
version displays on all Infoscreens when the dispenser is power cycled.
a. Power off the dispensers.
b. For both color and monochrome Infoscreens, install a cold-start jumper on jumpjack JP2 on the LCD
controller board.
c. Power up the dispenser.
d. When a message is displayed indicating that memory has been cleared, then power down the
dispenser.
e. Remove the jumper from JP2.
12. Modify pump addresses through the programming keypad to match the CRIND address settings
(Command mode 12, function mode 1). This should be done by a technician familiar with Gilbarco pump
programming.
NOTE: In generic mode, the pump addresses must match the CRIND addresses. In MOC mode, pump
side A is always addressed to 7, and side B is set to 11.
P/N 000-940002- Rev 0G June 2014 53

54 P/N 000-940002- Rev 0G June 2014
INSTALLATION/OPERATION
Fusion 500 Forecourt System
2014 Wayne Fueling Systems.

Printed in the United States of America.
This manual and any software described herein are furnished under the terms of sale or other applicable contract in-
cluding any license, and may be used or copied only in accordance with those terms.
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 terms. Translation of this material to another language with-
out express written permission from Wayne Fueling Systems is prohibited.
This publication is intended for informational purposes only and this material is subject to change without notice. Wayne
Fueling Systems has not made, and does not make, any representations or warranties of any kind, expressed or im-
plied, with respect to any information in the publication, including any warranty as to the accuracy, correctness, or com-
pleteness of any of the information. Wayne Fueling Systems shall not be responsible or liable for any damages or losses
that occur as a result of the receipt and/or use of the information contained herein.
Wayne and the Wayne logo are trademarks or registered trademarks of Wayne Fueling Systems in the United
States and other countries. Other names are for informational purposes and may be trademarks of their respective own-
ers.
Wayne is located at 3814 Jarrett Way, Austin TX 78728.

Waynes general telephone number is (512)-388-8311.
This product
NOTE: complies
This withhas
equipment Part 15 of
been the FCC
tested and rules
foundand regulations.
to comply Operation
with the limits forisasubject
Class A
todigital
the following
device, pursuant to Part 15 of the FCC Rules. These limits are designed to and
two conditions: (1) This product may not cause harmful interference, (2)
provide
this product must
reasonable accept
protection any interference
against received, including
harmful interference when the interference
equipment isthat may cause
operated in a
undesired
commercialoperation.
environment. This equipment generates, uses, and can radiate radio frequency
energy
Note: and,
This if not installed
equipment and tested
has been used inand
accordance
found to with the instruction
comply manual,
with the limits for a may
Classcause
A
harmful
digital interference
device to radio
as set forth communications.
in Part Operation
15 of the FCC Rules. Those oflimits
this equipment in ato
are designed residential
provide
area is likely
reasonable to causeagainst
protection harmfulharmful
interference in whichwhen
interference case the
the equipment
user will be is
required to correct
operated in a
the interference at his own expense.
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy, and if it is not installed and used in accordance with the instruction manual, it may
cause harmful interference to radio communications. Operation of this equipment in a res-
idential area is likely to cause harmful interference, in which case you will be required to cor-
rect the interference at your own expense.
Modifications: Any modifications made to this product that are not approved by Wayne Fu-
eling Systems could void your authority to operate this equipment.
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Systems LLC
Systems LLC Hangatan 10AB
tems Sweden Equipment
Equipment Comercio Ltda.
Comercio Ltda
3814
3814 Jarrett
Jarrett Way
Way Box 50559 10
Hangatan (Shanghai)Co.,
(Shanghai) Co.,Ltd
Ltd Estrada
Estrada dodo Timbo
Timb
Austin, TX 78728
Austin, TX 78728 SE-202
Box 5055915 Malm 1221 Dong Lu Road
1221 Dong Lu Road 126-Bonsucesso
126-Higienpolis
USA
USA Sweden15 Malm
SE-202 Pudong,Shanghai
Pudong, Shanghai RioRio
dede Janiero,
Janeiro, Brasil
Brasil
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China
2014 Wayne Fueling Systems P/N 000-940002- Rev 0G 08/2014

000-940002 - Fusion 500 Installation - Nucleus Rev 0G

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000-940002 - Fusion 500 Installation - Nucleus Rev 0G

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Installation/Operation

Wayne Fusion 500 Forecourt System for the

READ THIS MANUAL BEFORE YOU BEGIN

SAFETY PRECAUTIONS - INSTALLATION AND MAINTENANCE

HOW TO CONTACT WAYNE

INDICATORS AND NOTATIONS

Important information to consider, otherwise, improper installation and/or damage to

P/N 000-940002- Rev 0G August 2014 3

3 DEFINITIONS AND ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 HOW TO USE THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 RETURNING DAMAGED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

14 UPDATING FUSION FORECOURT SYSTEM SOFTWARE . . . . . . . . . . . . . . . . . . . . 36

P/N 000-940002- Rev 0G August 2014 v

14.1 Copy CD for Later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

vi P/N 000-940002- Rev 0G August 2014

Product Wayne Fusion 500 Forecourt System

3 DEFINITIONS AND ACRONYMS

P/N 000-940002- Rev 0G June 2014 7

5 UNPACKING AND INSPECTION

6 RETURNING DAMAGED COMPONENTS

8 P/N 000-940002- Rev 0G June 2014

Table 8-1 Mounting Location

Component Preferred Location Notes

Table 8-2 Space Requirements (in inches)

Component Width Height Depth

Dispenser conduit and Wiring requirements

P/N 000-940002- Rev 0G June 2014 9

9 CONFORMITY WITH STANDARDS

10 P/N 000-940002- Rev 0G June 2014

Table 10-1 Required Tools

1 Phillips Screwdriver Set (standard sizes)

1 Slotted Screwdriver Set (standard sizes)

1 Anti-static Wrist Strap

1 Needle Nose Pliers

1 Standard Drill Bit Set

1 PC Feature Card Slot Blank

A C P ow er w iring for F usion

Figure 11-1 Backroom Installation - New Site

P/N 000-940002- Rev 0G June 2014 11

A C P ow er w iring for F usion

Figure 11-2 Backroom Installation - Existing Site

12.1 Shutdown the Site

Figure 12-1 Nucleus POS System Programming Screen - Site

12 P/N 000-940002- Rev 0G June 2014

6. Exit the Programming screen.

9. Open the server and remove the SCC board.

Figure 12-2 IBM 743 Riser Card

12.1.1 Sites with Wayne Dispensers

P/N 000-940002- Rev 0G June 2014 13

12.1.2 Sites with Gilbarco Dispensers

3. Remove the Gilbarco Competitive Primary Distribution Box.

14 P/N 000-940002- Rev 0G June 2014

Figure 12-3 Gilbarco Distribution Box

a. Go to Command Code 48: Zero Previous Transaction

P/N 000-940002- Rev 0G June 2014 15

12.2 Wayne Isolation Box

12.3 Fusion V2 Forecourt System Installation

Figure 12-4 Fusion Forecourt System Mounting Bracket

16 P/N 000-940002- Rev 0G June 2014

P/N 000-940002- Rev 0G June 2014 17

a. Connect the WU002344-0001 cable to the two-pin connector of WU002290-001.