Fuel Kiosk · Two-Pump Build
Wayne A = Premium on channel 1, Wayne B = Diesel on channel 2. This uses the control box you already have. Channels 3 and 4 stay in the box as spares.
Wayne A — Premium
Pulser TB3-1 / TB3-2 → PLC X1 · Enable Y1 → RLY1
MCB1 → CON1 → motor TB5-1/2/3 · Coil fuse FU2 · Pulser fuse FU10
Kiosk command 1
Wayne B — Diesel
Pulser TB3-3 / TB3-4 → PLC X2 · Enable Y2 → RLY2
MCB2 → CON2 → motor TB5-4/5/6 · Coil fuse FU3 · Pulser fuse FU11
Kiosk command 2
Lock out and verify dead
Turn off the dispenser breaker and both field disconnects. Lock and tag them. Use your meter to check for zero volts at TB1 and at each Wayne junction box.
Make channels 3 and 4 safe
Take any wires off MCB3/MCB4, CON3/CON4, RLY3/RLY4 and TB3-5…8 / TB5-7…12. Leave the parts in place and label them SPARE. Turn MCB3/MCB4 OFF.
Run conduit to each Wayne
One conduit per dispenser for power (12AWG black/white/green), and a separate one for the pulser shielded pair. Put an EYS seal at the dispenser entry, plus another within 18" of the island if your inspector requires it.
Wire the motors through the handle switch
CON1 T1 → TB5-1 → Wayne A handle (hook) switch → motor HOT. Neutral TB5-2 → motor, ground TB5-3 → dispenser frame. Do the same for Side B on TB5-4/5/6. The motor only runs when the PLC has armed it AND the nozzle is lifted.
Mount the pulsers
Bolt one pulser to each Wayne mechanical register drive. Land the signal on TB3-1 (A) / TB3-3 (B) and the return on 0V. Ground the shield at the panel end only, and keep the pulser cable away from motor wires.
Set the motor breakers
Read the FLA off each Wayne motor nameplate. Set MCB1/MCB2 to that FLA (no higher than 1.15× FLA). If either motor runs on 240V, call before you wire it: CON L2/T2 would be needed.
Check the 24V side
With 120V still off, power the 24V supply only. Press the E-stop → TB7-4 should drop to 0V. Lift each float → it should also drop. Confirm X7 is ON with both contactors open.
Dry test (no fuel)
Run a demo session on the kiosk. Y1 should pull in RLY1 and CON1 for Premium, and Y2 → CON2 for Diesel. Hit stop and confirm both contactors drop out.
Calibrate with the proving can
Pump 5 gallons from each side into the certified can and read the pulse count off the PLC. Pulses ÷ 5 = pulses per gallon. Send me both numbers so I can put them in the system.
Label and close up
Label every wire at both ends with its tag from the table. Put red tape on each black DC conductor. Close the box and test live once with a small paid sale.