Dover Wayne Helix WM048523 User Manual (English)

Questions and Answers:

M
Michael ShawAug 6, 2025
What to do if the Dover Dispenser pump motor is running but no fuel is delivered?
- C
  Crystal SmithAug 6, 2025
  If the pump motor is running but no fuel is being delivered from your Dover Dispenser, several factors could be at play. First, ensure the tank has fuel by sticking it. If the tank has fuel, vapor lock could be the issue; ensure the correct fuel type is used for the season and that the underground piping was installed correctly, without excessive elbows or runs. A defective hose or nozzle could also be the culprit; try dispensing without the nozzle, and if necessary, replace the hose or nozzle. Alternatively, the by-pass valve might be held open, in which case it should be repaired or replaced. Finally, a check valve stuck in the closed position would need replacing.
M
Michael MoonAug 13, 2025
Why is my Dover Wayne Helix WM048523 Dispenser pump delivering fuel slowly?
- R
  Rebecca ToddAug 13, 2025
  If your Dover Dispenser pump delivers fuel slowly, start by checking for a dirty strainer or filter and clean or replace it. A defective nozzle or hose can also cause slow delivery; remove the nozzle to test, and replace the hose or nozzle if needed. Ensure the pump isn't drawing air by checking the fuel tank level. Also, a by-pass valve held in the open position can cause this issue, so repair or replace the by-pass valve assembly. Lastly, internal wear in the compact pumping unit could be the problem; inspect the parts in the CPU.
O
oclarkAug 21, 2025
What to do if the Dover Wayne Helix WM048523 pumping unit will not prime?
- Z
  zstevensonAug 21, 2025
  If the pumping unit of your Dover Dispenser will not prime, the first step is to check the fuel tank level to ensure there is fuel and that the pump isn't drawing air. If the fuel level is adequate, a defective nozzle or hose could be the cause; remove the nozzle and attempt to dispense product, replacing the hose or nozzle if necessary. Additionally, a by-pass valve held in the open position can prevent priming, requiring repair or replacement of the by-pass valve assembly. Finally, internal wear in the compact pumping unit might be the issue, necessitating an inspection of the CPU parts.
M
Ms. Taylor King PhDAug 28, 2025
How to fix a Dover Wayne Helix WM048523 motor that is running too slow?
- K
  Kari RobinsonAug 28, 2025
  If the motor of your Dover Dispenser is running too slow, first verify that the operating voltage matches the limits specified on the motor's serial plate. If the voltage is correct, internal wear in the compact pumping unit could be the cause, requiring an inspection of the CPU parts. Another potential issue is a by-pass valve stuck in a partially closed position, which would need repair or replacement. Lastly, the motor itself could be defective and require replacement.

Dover Wayne Helix WM048523 Specifications

General

Brand	Dover
Model	Wayne Helix WM048523
Category	Dispenser
Language	English

Summary

Introduction

Features

Details the key features and capabilities of the Helix fuel dispensers.

Unlocking the Bezel

Step-by-step guide on how to open the dispenser bezel and payment terminal for service.

Payment Terminal

Details the payment terminal drawer lock location and its function.

Bezel Latches

Instructions on locating and operating the bezel latches to open the dispenser.

Service Position

Illustrates the Helix dispenser in its service view position.

Non-Payment Bezel

Describes the non-payment bezel and how to access components for servicing.

Hydraulics

Triple Bump Product Tubes

Explains the triple bump product tubing and its connection to the hose outlet casting.

Filter and Strainer Remotes

Procedure for changing the filter and cleaning the strainer on remote dispensers.

Strainer and Filter Suction Pumps

Details on strainer and filter components for suction pump models.

Proportional Flow Control Valve

Description of the pilot-operated solenoid valve controlling fuel flow and blending.

Vapour Recovery - IEC

References manuals for service procedures related to Vapour Recovery in IEC countries.

Additive - IEC

Information on additive systems integrated into IEC dispensers, including safety warnings.

Startup, priming and purging of the additive system

Steps for starting, priming, and purging the additive system on IEC dispensers.

Electronics

Dispenser Connection Board

Details the dispenser connection board's function and components.

Dispenser Power On/Off Switch

Location and function of the dispenser's AC power switch.

Heater/Fan

Information on the heater and fan assembly, including settings and operation.

Sales Volume and Unit Price Displays

Description of the LCD digits and backlighting used in sales and unit price displays.

Nozzle Switch Interface Board

Details the nozzle switch interface board and its function in the serial communications channel.

Nozzle Switch Converter Board

Explains the function of the nozzle switch converter board in converting nozzle serial communications.

ISB Module

Description of the Intrinsic Safe Barrier (ISB) module and its interfaces.

Temp Comp Module and TTL/CAN Converter

Details optional equipment for temperature compensation and data conversion.

WIP

Information on the Wayne Intelligent Pulser (WIP) and its components.

Board Layout and Connector Descriptions

iGEM Computer Board

Details the iGEM computer board, including jumpers, LEDs, and communication indicators.

iGEM Board NA

Layout and connector information for the iGEM Board, North American version.

iGEM Board IEC

Layout and connector information for the iGEM Board, IEC version.

iX R2 Board

Details the iX R2 board, including its connectors and functionality.

Unit Price Display Controller Board

Description of the Unit Price Display Controller Board and its connectors.

Secure Payment Module (SPM) - Low Profile

Details the Secure Payment Module (SPM) and its associated connectors.

24V Power Supply

Description of the 24V power supply unit and its connectors.

Heater/Fan

Details the Heater/Fan assembly, its connectors, and thermostat setting.

WIP Pulser

Information on the WIP pulser, including its components and connections.

VGA Backlight Driver Board

Details the VGA Backlight Driver Board and its connections.

EM Totalizers

Information on Electro Mechanical Totalizers (EMT) and their installation.

Wayne Connect IP-485

Optional equipment for network solutions using existing wiring pairs.

Vapour (Vapor) Recovery

References manuals for service procedures related to Vapour Recovery.

Door Security Switch Board - Metal Head Models IEC

Details the Door Security Switch Board for Metal Head Models in IEC.

VGA Softkeys - Metal Head Models - IEC

Description of VGA Softkeys for Metal Head Models in IEC.

Preset Keypad 15-button - Metal Head Models IEC

Details the Preset Keypad for Metal Head Models in IEC, including CAN bus connections.

Sales Volume Display

Procedure for replacing the Sales Volume Display board.

R2 Board

Procedure for replacing the R2 board, including cable management.

Secure Door Board

Procedure for removing and replacing the Secure Door Board.

VGA Backlight Driver Board

Procedure for removing and replacing the VGA Backlight Driver Board.

Fan

Procedure for replacing the fan assembly.

EMT Totalizers

Procedure for replacing Electro Mechanical Totalizers (EMT).

Removing the Lower Covers and Vapor Vents

Instructions for removing lower covers, vapor vents, and upper vent/cable trough.

Parts and Tools Reference

New and Existing Parts

Lists new and existing service parts for Helix dispensers, categorized by electronics and hydraulics.

Replacement Procedures

iGEM Computer Board Replacement

Step-by-step guide for replacing the iGEM computer board.

Nozzle Switch Converter Board

Procedure for replacing the Nozzle Switch Converter Board.

Nozzle Switch Interface Board

Procedure for replacing the Nozzle Switch Interface Board.

ISB Assembly Replacement

Procedure for replacing the Intrinsic Safe Barrier (ISB) assembly.

Nozzle Boot, Switch, or Flipper Replacement

Procedure for replacing the nozzle boot, switch, or flipper components.

WIP Replacement

Procedure for replacing the Wayne Intelligent Pulser (WIP).

IEC Proportional Valve and Coil Replacement

Procedure for replacing the proportional valve and coil in IEC regions.

NA Proportional Valve Replacement

Procedure for replacing the proportional valve and conduit assembly in NA dispensers.

Meter Replacement - Removing Meter from Base

Procedure for removing the iMeter from the base casting.

Check valve replacement

Procedure for replacing the check and pressure relief valves in the iMeter module.

Product Tube Replacement - Using the Tube Removal Tool

Procedure for replacing product tubes using the specialized tube removal tool.

Product Tube Replacement - Not Using the Tube Removal Tool

Procedure for replacing product tubes when the removal tool is unavailable.

Outlet Casting Replacement

Procedure for replacing the outlet casting on Helix dispensers.

Unit Price, Control Board, and Glass Replacement

Procedures for replacing unit price, control board, and glass components.

UPD, Controller Board or Totalizer Replacement

Steps for replacing the UPD, controller board, or totalizer components.

Unit Price Display Glass Panel

Procedure for replacing the unit price display glass panel.

Sales Display and Glass Replacement

Procedures for replacing the sales display and its glass panel.

Sales Display Assembly

Procedure for replacing the sales display assembly.

Sales Display Glass Replacement

Procedure for replacing the sales display glass panel.

QVGA Display, Softkeys, and Glass Replacement

Procedures for replacing the QVGA display, softkeys, and glass.

QVGA Display

Procedure for replacing the QVGA display unit.

Softkeys and Glass Replacement

Procedure for replacing the softkeys and glass assembly.

VGA and Backlight Replacement

Procedures for replacing the VGA display and backlight components.

VGA Replacement

Procedure for replacing the VGA display unit.

Backlight Replacement

Procedure for replacing the display backlight.

Dispenser Connection Board Replacement

Procedure for replacing the dispenser connection board.

24V Power Supply Replacement

Procedure for replacing the 24V power supply unit.

Heater / Fan Replacement

Procedure for replacing the heater and fan module.

Low Profile USB Printer Replacement

Procedure for replacing the low profile USB printer.

iX R2 Board Replacement

Procedure for replacing the iX R2 board.

SPM and Battery Replacement

Procedures for replacing the SPM keypad and battery.

Battery Replacement

Procedure for replacing the SPM battery.

SPM Replacement

Procedure for replacing the Secure Payment Module (SPM).

Card Reader Replacement

Procedure for replacing the card reader assembly.

Wayne Connect Module Replacement

Procedure for replacing the Wayne Connect module.

Hose Handling

Covers nozzle boot, hose, and hose retractor service for Helix 6000 C style models.

6000 C style models - IEC

Service procedures for nozzle boot, hose, and hose retractors in IEC regions.

iGEM Software Downloads - IEC version

Bootstrap Procedure

Procedure for bootstrapping the iGEM computer when software is interrupted or missing.

iGEM Software Downloads - NA version

Bootstrap Procedure

Procedure for bootstrapping the iGEM computer for NA versions.

Error Codes, Problem Symptoms and Solutions - NA

Error Codes and Solutions - NA

Descriptions of error codes, probable causes, and corrective actions for NA systems.

Error Codes and Descriptions - IEC

Error/Event Classification

Classification of errors and events based on their severity and impact.

Error/Event Types

Table specifying error/event types and their classification.

Suction Pumps

Compact Pumping Unit

Description of the CPU, including its components like pump, air separator, and bypass valve.

By-pass (Relief) Valve Assembly

Details the spring-loaded bypass valve and its function in the pumping unit.

Float and Valve Seat Assembly

Explains the float and valve seat assembly within the air separator chamber.

Air Separation

Describes the process of air separation within the pumping unit.

Testing the Suction Pumping System

Guides on using vacuum and pressure gauges for testing suction pump systems.

Vacuum Test

Procedure for performing a vacuum test on the suction pump system.

Pressure Test

Procedure for performing a pressure test on the suction pump system.

Adjusting the By-pass Pressure

Instructions for adjusting the by-pass pressure on the suction pump.

Suction Pump Motors

Information on motors used for suction pump CPU and their associated relays.

Troubleshooting

Table of common symptoms, probable causes, and corrective actions for suction pumps.

Repair

General repair procedures for suction pump components.

Lapping the Pressure Relief Valve

Procedure for lapping the pressure relief valve to correct slow pump delivery.

Lapping the Pressure Relief Poppet Stem

Procedure for checking and correcting the fit of the pressure relief poppet stem.

Strainer

Procedure for cleaning the strainer to resolve slow delivery issues.

Rebuilding the Pumping Unit

Detailed procedure for checking and correcting tolerances when rebuilding the pumping unit.

Replacing the Lip Seal

Procedure for replacing the lip seal to prevent product leakage around the rotor shaft.

Small Pump 2000 Model Series

Sales/Vol and Unit Price Displays

Details display board cable connections for sales and unit price displays.

Lower Electronics Enclosure (LEE)

Procedure to access power supply, connection board, or ISB within the LEE.

Meter Calibration Procedure

NA Procedures

Calibration procedure for iMeters in North America, including sealing bracket details.

IEC Procedures

References manuals for calibration procedures used in IEC countries.

Models with Metal Electronic Head - IEC

Bezel Components

Identifies components inside the VGA media bezel and required tools.

Removing the Bezel

Procedure for removing the bezel frame and associated components.

Replacement Procedures

General procedures for replacing components mounted on the backside of the bezel.

Display Glass and Speakers

Procedure for replacing the display glass and speakers.

VGA Display or Backlight

Procedure for disconnecting cables and removing VGA display or backlight.

VGA Softkeys and Preset Keypad

Procedures for replacing VGA Softkeys and the Preset Keypad.

Sales Volume Display

Procedure for disconnecting cables and removing the Sales Volume Display board.

R2 Board

Procedure for disconnecting cables and removing the R2 board.

Secure Door Board

Procedure for disconnecting and removing the Secure Door Board.

VGA Backlight Driver Board

Procedure for disconnecting cables and removing the VGA Backlight Driver Board.

Fan

Procedure for disconnecting the fan power cable and removing the fan bracket.

EMT Totalizers

Procedure for disconnecting the EMT cable and removing the EMT.

Removing the Lower Covers and Vapor Vents

Instructions for removing lower covers, vapor vents, and upper vent/cable trough.

Helix 6000 DEF, Extra Narrow Model Dispensers - IEC

Heater and Tank Replacement

Procedure for replacing the heater and tank assembly for DEF dispensers.

Pump Replacement

Procedure for replacing the pump in the dispenser.

Motor Replacement

Procedure for replacing the motor for the pump.

iMeter Replacement

Procedure for replacing the iMeter component.

Hose Replacement

Procedure for replacing the hose on Helix 6000 C style models.

Helix LPG - IEC

Degassing Unit Replacement

Procedure for replacing the degassing unit in Helix LPG dispensers.

Differential Valve Replacement

Procedure for replacing the differential valve in Helix LPG dispensers.

Solenoid Valve Replacement

Procedure for replacing the solenoid valve in Helix LPG dispensers.

Meter Replacement

Procedure for replacing the meter in Helix LPG dispensers.

Degassing Unit Filter Replacement

Procedure for replacing the degassing unit filter.

Printer Maintenance

Printer Paper Specification

Specifications for the thermal printer paper used in the dispenser.

Thermal Characteristics

Paper requirements regarding visual change under temperature and humidity.

Thermal Response Range

Specifies the temperature ranges for print initiation, functional printing, and image development.

Residual Particles

Guidelines for testing paper for residual particles.

Loading Printer Paper

Step-by-step instructions for loading paper into the printer.

Clearing Paper Jams

Procedure for clearing paper jams and printing a test receipt.

iMeter2 Components Replacement Procedures

Proportional Valve

Procedure for replacing the proportional valve on the iMeter2.

Check Valve Replacement

Procedure for replacing the check valve in the iMeter2 meter outlet.

iMeter 2 Replacement

Procedure for replacing the iMeter 2 component.

iMeter 2 Cylinder Cover O-ring Replacement

Procedure for replacing the O-ring on the iMeter 2 cylinder cover.

iMeter 2 WIP Replacement

Procedure for replacing the iMeter 2 WIP (Wayne Intelligent Pulser).

Appendix A iX Pay Secure Payment Configuration U.S. Version (Optional)

Initial Configuration Procedure

Steps to perform the initial configuration for iX Pay Secure Payment dispensers.

Appendix B Valance Installation

Appendix C Wiring Diagrams NA (North America)

Appendix D Wiring Diagrams IEC

Appendix E Hydraulic Configurations - Helix 2000, 4000 & 5000 Model Dispensers

Appendix F TORX Kit

Appendix G IEC ATEX Information

Appendix H NA UL Sub-pump Relay Information

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Dover Wayne Helix WM048523 User Manual

Table of Contents

Questions and Answers:

Dover Wayne Helix WM048523 Specifications

Summary

Introduction

Features

Unlocking the Bezel

Payment Terminal

Bezel Latches

Service Position

Non-Payment Bezel

Hydraulics

Triple Bump Product Tubes

Filter and Strainer Remotes

Strainer and Filter Suction Pumps

Proportional Flow Control Valve

Vapour Recovery - IEC

Additive - IEC

Startup, priming and purging of the additive system

Electronics

Dispenser Connection Board

Dispenser Power On/Off Switch

Heater/Fan

Sales Volume and Unit Price Displays

Nozzle Switch Interface Board

Nozzle Switch Converter Board

ISB Module

Temp Comp Module and TTL/CAN Converter

WIP

Board Layout and Connector Descriptions

iGEM Computer Board

iGEM Board NA

iGEM Board IEC

iX R2 Board

Unit Price Display Controller Board

Secure Payment Module (SPM) - Low Profile

24V Power Supply

Heater/Fan

WIP Pulser

VGA Backlight Driver Board

EM Totalizers

Wayne Connect IP-485

Vapour (Vapor) Recovery

Door Security Switch Board - Metal Head Models IEC

VGA Softkeys - Metal Head Models - IEC

Preset Keypad 15-button - Metal Head Models IEC

Sales Volume Display

R2 Board

Secure Door Board

VGA Backlight Driver Board

Fan

EMT Totalizers

Removing the Lower Covers and Vapor Vents

Parts and Tools Reference

New and Existing Parts

Replacement Procedures

iGEM Computer Board Replacement

Nozzle Switch Converter Board

Nozzle Switch Interface Board

ISB Assembly Replacement

Nozzle Boot, Switch, or Flipper Replacement

WIP Replacement

IEC Proportional Valve and Coil Replacement

NA Proportional Valve Replacement

Meter Replacement - Removing Meter from Base

Check valve replacement

Product Tube Replacement - Using the Tube Removal Tool

Product Tube Replacement - Not Using the Tube Removal Tool

Outlet Casting Replacement

Unit Price, Control Board, and Glass Replacement

UPD, Controller Board or Totalizer Replacement

Unit Price Display Glass Panel

Sales Display and Glass Replacement

Sales Display Assembly

Sales Display Glass Replacement

QVGA Display, Softkeys, and Glass Replacement

QVGA Display

Softkeys and Glass Replacement

VGA and Backlight Replacement