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NCR OPTIC 12 Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
OPTIC 12 Door Upgrade Kit
Encore 300 and 500 Series Dispensers
497-0515059
Issue A

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Summary of Contents for NCR OPTIC 12

  • Page 1 INSTALLATION INSTRUCTIONS OPTIC 12 Door Upgrade Kit Encore 300 and 500 Series Dispensers 497-0515059 Issue A...
  • Page 3 INSTALLATION INSTRUCTIONS NCR OPTIC 12 for Enocre 300 Release 1.0 Issue A...
  • Page 4 NCR, therefore, reserves the right to change specifications without prior notice. All features, functions, and operations described herein may not be marketed by NCR in all parts of the world. In some instances, photographs are of equipment prototypes. Therefore, before using this document, consult with your NCR representative or NCR office for information that is applicable and current.
  • Page 5 Revision Record Issue Date Remarks Dec 2016 First Issue...
  • Page 7 Preface Audience This book is written for end users (System Administrator and Maintenance Technician), NCR Field Engineering, and VAR/OEM Hardware and System Integrators Notice: This document is NCR proprietary information and is not to be disclosed or reproduced without consent.
  • Page 8 Safety and Compliance Information This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing the [[[Undefined variable Master.Product Short Name]]]. Before proceeding, check the relevant hazard and safety information. Fire, explosion or electrical shock could occur and cause death or serious injury if these safe service procedures are not followed.
  • Page 9 Read, understand and follow this manual and any other labels or related materials supplied with the equipment. If you do not understand a procedure, call NCR. It is imperative to your safety and the safety of others to understand the procedures before beginning work.
  • Page 10 Safety Symbols and Terminology Caution: This safety alert symbol is used in this manual and on warning labels to alert you to a precaution which must be followed to prevent potential personal safety hazard. Obey safety directives that follow this symbol to avoid possible injury or death. Signal Words Warning: Alerts you to a hazard or unsafe practice which will result in death or...
  • Page 11 If you do not have access to a computer, you may leave a voice message at: 1-800-528- 8658 (USA), or (International) +1-770-623-7400. When leaving a message, please provide a phone number and/or an email address so NCR can contact you if additional details are needed.
  • Page 12 Warranty Warranty terms vary by region and country. All parts of this product that are subject to normal wear and tear are not included in the warranty. In general, damages due to the following are not covered by the warranty. •...
  • Page 13 • Description of the problem, including any system error codes, error condition, or guidance to the area of failure. The NCR Agent will provide you with a work order number, which serves as your Return Material Authorization (RMA). Please provide the RMA on the outside of the shipping box.
  • Page 14 viii...

  • Page 15: Table Of Contents

    Install the nozzle blanks and decals. Install the Nozzle Boot Prepare the PPU Bracket Install the PPU Bracket. Install the Optic 12 Modular Plate Transfer Components Install the Grade Selection Assembly Power Supply Assembly (497-0513436) Installation Prepare the power supply brackets...
  • Page 16 Install the Comm Cable to the Dispenser Cub Wiring in the Power Supply to the Pump Power Distributor for the First (Side A) PSU Install the power and data connections to the Optic 12 Install the Printer Closing the Dispenser...

  • Page 17: Installation Components

    Installation Components Installation Components Before starting the installation, inspect the installation kit and confirm that all parts are accounted for as below (In order of use): Encore Upgrade Kit Contents Part Number Description Photo Reference 497-0512481 Replacement Modular Door 497-0513278 Top Hinge Pin 497-0514038 Lock Bracket...
  • Page 18 Installation Components Part Number Description Photo Reference 006-8611097 PPU Bracket Screw 497-0514262 PPU Plate Bracket 006-8611952 PPU Bracket Nut 497-0513269 Encore 300 PPU Data Ribbon Cable 497-0513268 Encore 300 PPU LED Ribbon Cable 497-0512995 Encore 500 Non LED PPU Ribbon Cable 497-0512996 Encore 500 LED PPU Ribbon Cable 497-0514480 Reed Switch Extension Cable...

  • Page 19: Tools Required

    Tools Required Tools Required The following tools are required to mount the OPTIC 12 Door Upgrade onto a GVR Encore fuel dispenser: • Safety Glasses • GVR 751 Key • Medium Flathead Screwdriver • #6 (or small) and medium Phillips Screwdriver •...

  • Page 21: Recommended Materials

    Recommended Materials Recommended Materials The following tools are not provided in the kit: • Cable Restraints or Zip Ties • Cloth Rags • All-Purpose Lubricant • Adhesive Remover • Rust Penetrator Oil...

  • Page 22: Deinstallation Instructions For Encore 300

    Recommended Materials Deinstallation Instructions For Encore 300 Before Uninstalling Begins 1. Disconnect the main power from the dispenser. 2. Open the small electronic door to access the Customer Node. Identify Side A by locating the jumper. The jumper is on the Side A Customer Node installed on the JP1 jumper terminal.
  • Page 23 Recommended Materials 2. Remove the Grade Select buttons. Note: Keep track of the order to correctly reinstall the Grade Select Switches. a. Use a medium flathead screwdriver to firmly push in the lock tab located on the bottom side of the grade select buttons. (Fig 1.3a,b) Fig 1.3a –...
  • Page 24 Recommended Materials c. Set the buttons aside and note their positions on the door. They will be re- installed later in the process. d. Remove the Grade Select switches. e. Use a ¼” socket to remove both screws holding down the grade select switch. Retain screws for reinstallation.(Fig 1.4) Fig 1.4 –...

  • Page 25: Open The Dispenser

    Recommended Materials Open the dispenser 1. Using a ‘751’ key, unlock the inner electronic cavity door on the dispenser. 2. Disengage the side paddles on the outer main door and open the main door on the dispenser. 3. Place in prop bar to brace door while continuing the deinstallation.

  • Page 26: Uninstall The Wire Assembly

    Recommended Materials Uninstall the wire assembly 1. Remove all unused cables. Determine where the ribbon cables are routed. a. On the Customer Node, the P801, P2115 are the only re-used cables. b. Using a felt tipped marker to label the cables with the connection terminal. c.
  • Page 27 Recommended Materials b. Remove and discard the PPU comm ribbon cable. c. Identify, mark, and unplug the LED Power Cable (P2115) connected to the PPU LED ribbon cable. Note: The P2115 cable has three power connectors with two being used. Verify the correct connection is marked according to it's current location for proper installation.
  • Page 28 Recommended Materials d. Remove the PPU LED ribbon cable from the PPUs. 4. Mark the totalizer connection number P1507 and unplug from the totalizer board. This cable will be reused.
  • Page 29 Recommended Materials...

  • Page 30: Uninstall The Printer

    Recommended Materials Uninstall the printer 5. Unplug the LON cable and power cable connected to the printer.

  • Page 31: Uninstall The Ppus

    Recommended Materials Uninstall the PPUs 1. Unplug the Nozzle Boot Switch and Ribbon Cable from the PPUs. Retain the ribbon cable. 2. Record the PPU Positioning and addressing to ensure they are installed on the modular PPU bracket in the correct order. Note: Addressing refers to the jumper location that specifies the correct gas grade per PPU.
  • Page 32 Recommended Materials 3. Remove the PPUs from the non modular door and set aside. The one screw can be discarded. Note: Some cases a shim will be present. This can be discarded.

  • Page 33: Lon Terminators (If Present)

    Recommended Materials LON Terminators (if present) Remove one of the LON Terminators. The LON Terminator is used to close the LON Loop and may be connected at any LON terminal present on any component that utilizes the loop. Typically the terminators are located on the Printer assemblies. Do not discard the LON Terminator.

  • Page 34: Remove The Magnetic Boot Switch

    Recommended Materials Remove the Magnetic Boot Switch 1. Using a small Philips screwdriver or 1/4" nut driver, remove the screw holding the magnetic boot switch in place. (Fig 1.15) Fig 1.15 – Location of magnetic handle switch 2. Set the switch aside. Screw can be discarded. Repeat steps until all boot switches are removed.

  • Page 35: Uninstall The Comm Speaker (If Present)

    Recommended Materials Uninstall the Comm Speaker (if present). 1. Unscrew the three screws from speaker assembly and remove from the non modular door. The screws can be discarded. 2. Remove from any speaker bracket present. The comm speaker bracket and hardware can be discarded.
  • Page 36 Recommended Materials Note: Not all speakers will have a bracket. 3. Unscrew the top and bottom left side of the electronic cavity bracket. 4. Pull the speaker through the opening by pulling back on the electronic cavity bracket.
  • Page 37 Recommended Materials 5. Place the speaker inside the cabinet.

  • Page 38: Uninstall The Totalizers (If Present)

    Recommended Materials Uninstall the Totalizers (If present) 1. Locate the Totalizers on the inside of the A-Side Main Door 2. Use a felt tipped marker to mark the totalizers and board plugins. Mark to specify where the totalizers are connected to the board to reconnect during reinstallation. 3.
  • Page 39 Recommended Materials 4. Remove the totalizer board from the non modular door and set aside. Do not remove the CPU LON cable. Remove and Discard the Printer LON cable that was previously disconnected from the printer. Place the totalizer board inside the electronics cavity. 5.

  • Page 40: Remove All Cable Harnesses From The Non Modular Door

    Recommended Materials Remove all cable harnesses from the non modular door 1. Pull all the detached cables through the opening on the left side of the electronics cavity and place inside the cabinet. 2. Detach the ground wire connecting the door to the cabinet. Discard the connecting screw.

  • Page 41: Uninstall The Non Modular Door

    Recommended Materials Uninstall the Non Modular Door 1. Remove the non modular door. Caution: Read ALL of the following steps (Uninstall the Non Modular door) before executing. Caution: To prevent injury or damage to any equipment or components, it is recommended a second individual assist with removing the original non-modular door.
  • Page 42 Recommended Materials Removal of hinge pin 5. Lift the door upwards to remove it from the dispenser. Set aside to transfer door components. Repeat the door removal on the other side of the dispenser.

  • Page 43: Installation Instructions For Encore 300

    Recommended Materials Installation Instructions for Encore 300 Mount the Modular Door Caution: Read ALL of the following steps (Uninstall the Non Modular door) before executing. Caution: To prevent injury or damage to any equipment or components, it is recommended a second individual assist with mounting the modular. Reinstall the Pin bracket from the Encore 300 door removal step.
  • Page 44 Recommended Materials 1. Mount the new Modular Door (497-0512481). a. Place onto bottom pin bracket.
  • Page 45 Recommended Materials b. Rotate up and into place on the Pin Bracket. c. Install the top pin (497-0513278) into the Modular Door and Pin Bracket.
  • Page 46 Recommended Materials 2. Install the new modular door latch. d. Remove the hardware (nut or nut and washer) located on the upper left side of the electronics cavity. Do not discard. e. Install the new upper door latch bracket (497-0514038) using the removed hardware in the previous step.
  • Page 47 Recommended Materials g. Install the lower door latch bracket (497-0512905) using the supplied nut(006- 8625195) into the indicated position on the dispenser. h. Reinstall the outer side skirts using retained hardware.
  • Page 48 Recommended Materials Install the Encore Electrical Top Plate (497-0512968). Reinstall the inner side skirts with retained inner side skirt screws.
  • Page 49 Recommended Materials 3. Install the weather shield (497-0513804) to the modular door with five screw bolts (006-8625157) 4. Place in prop bar to brace door while continuing the installation.

  • Page 50: Prepare The Modular Door

    Recommended Materials Prepare the Modular Door Prepare the Nozzle Boot 1. Install the nozzle boot bracket(497-0513805) as shown in the picture. with two thread forming screws (006-8625160). Repeat on each nozzle boot recess.

  • Page 51: Install The Nozzle Blanks And Decals

    Recommended Materials Install the nozzle blanks and decals. 2. Install the lower blanking plugs (497-0512953) . Install the blanking plugs where a nozzle boot will not be installed. 1. Remove the adhesive liner on the Aluminum Blank (497-0512580) and place into the boot recess adhesive side towards the door.
  • Page 52 Recommended Materials...
  • Page 53 Recommended Materials 2. Install the top boot bracket aluminum blank (497-0512920) to fill any gaps in the boot recess where the boot will be installed. Attach with two Phillips screws (006-8625190). 3. Carefully install the boot blank decal covers. Note: Depending on the nozzle configuration there may be a verity of decal configurations using the full blanking label (497-0512581) and single blanking label (497-0512882).
  • Page 54 Recommended Materials k. Trim the lower leg of the single decal as shown. Note: After installing the decal remove the protective film on the front of the decal.

  • Page 55: Install The Nozzle Boot

    Recommended Materials Install the Nozzle Boot 1. Install the previously retained nozzle boot to the modular door and install with two Phillips machine screws (006-8625159). Note: Insert the bottom boot clip first and rotate the boot into place.

  • Page 56: Prepare The Ppu Bracket

    Recommended Materials Prepare the PPU Bracket 1. Prepare PPU modules. 2. Install the PPUs to the bracket bar. Note: Before installing the PPUs to the PPU Bracket, compare to the decal configuration for the pump to determine the correct location of the PPUs to the bracket.
  • Page 57 Recommended Materials 3. Install PPU Plate (497-0514262) to PPU Stabilizing Bar with PPUs attached. a. install the stabilizing bar into the left side (when looking at the back of all components) mounting post first. b. Rotate the bar into place and install in the right side post.
  • Page 58 Recommended Materials c. attach the stabilizing bar to the PPU Plate bracket with the two provided nuts (006-8611952).

  • Page 59: Install The Ppu Bracket

    Recommended Materials Install the PPU Bracket. 1. With the PPU connections facing up, install the corresponding ribbon cable (497- 0513269) into the PPUs attached to the modular door PPU bracket. Begin installing with the farthest of the five connector cable configuration on the right most PPU. Continue installing the ribbon cable connectors.
  • Page 60 Recommended Materials...

  • Page 61: Install The Optic 12 Modular Plate

    Recommended Materials Install the Optic 12 Modular Plate Caution: Use care to not catch any loose wires on the Optic 12 Modular Plate. Note: Tilt the PPU bracket back and away from the Modular Plate opening to install the Optic 12 Plate.
  • Page 62 Recommended Materials c. Install 10 screw bolts to the Modular Plate.

  • Page 63: Transfer Components

    Recommended Materials d. Install the five front screws (006-8625189) to the Modular Plate. e. Attach the PPU bracket to the Modular Plate with three screw bolt (006-8625157) and washer (006-8625156) assembly. Transfer Components 1. Transfer and install the customer display Node.
  • Page 64 Recommended Materials a. Remove the Node from the old door. If present discard hardware. b. Attach the Customer Node to the modular door with the four provided screw bolts (006-8625157). Verify the upright orientation of the board before installing. c. Install the PPU Ribbon Cable (497-0513269)to P804a on customer node. d.
  • Page 65 Recommended Materials e. Reinstall the P2115 ribbon cable marked in deinstallation. Note: The P2115 cable has three power connectors with two being used. Verify the correct connection is used according to it's deinstallation connection. 2. Transfer the Totalizers (if present). a.
  • Page 66 Recommended Materials c. Install the Totalizers and bracket onto the Modular Door in the location shown below with the two provided screw bolts (006-8625157).
  • Page 67 Recommended Materials d. Plug in the Totalizers into the correct board ports. Verify correct connections with markings made during the deinstallation steps. e. Reinstall the P1507 ribbon cable to the connection on the Totalizer board. 3. Install the Comm Speaker (if present). Note: If no speaker is present the speaker plate must still be installed for water sealing.

  • Page 68: Install The Grade Selection Assembly

    Recommended Materials h. Install the speaker plate and speaker onto the modular door with retained hardware. Install the Grade Selection Assembly Install the Grade Selection Assembly onto the Modular Door.
  • Page 69 Recommended Materials...
  • Page 70 Recommended Materials 1. Install using the retained 1/4" screw bolts.
  • Page 71 Recommended Materials 2. Repeat step a until all pump paddle assemblies from the deinstalled door have been transferred to the Modular Door. 3. Install the decal and retained Grade Select Paddles in the correct positions noted during deinstallation.

  • Page 72: Power Supply Assembly (497-0513436) Installation

    Recommended Materials Power Supply Assembly (497-0513436) Installation Prepare the power supply brackets Install the Cub on one of the power supply brackets. Follow the Cub Installation Instructions (497-0514466). Installing the power supply Install the Power Supply Bracket with Power Supply (PSU) attached. a.
  • Page 73 Recommended Materials b. Place the studs into holes on the Encore electronic rail. install on the side closest to the Comm connection. Note: When Installing the PSU with Cub attached, install with Cub and PSU facing the rest of the cabinet. When installing the PSU without the Cub attached, install with the PSU facing the cabinet wall.
  • Page 74 Recommended Materials d. Install the Encore adapter cable(497-0513214) to the PSU with the single connector end. Install the Comm Cable to the Dispenser Cub 1. Plug in the Encore 300 Comm adapter cable (497-0513685) to the Dispenser Cub. 2. Disconnect the dispenser Comm cable from the CRIND control node. 3.
  • Page 75 Recommended Materials b. AC Terminal Board c. AC Bus Line (single cable bus connections)
  • Page 76 Recommended Materials 2. follow the correct wiring steps for the corresponding power distributor assembly. A. Power Control Module 1. Install the Y cable (497-0514570) to the Encore adapter cable. a. Cut off the far female end of the Y cable as close to the connector as possible. b.
  • Page 77 Recommended Materials c. Identify the P1 terminal on the Power Control Module. d. Attach the corresponding leads on the adapter cable to the P1 two prong connector. Note: Do not unplug the connector until the line and neutral terminals are identified.
  • Page 78 Recommended Materials B. AC Terminal Board 1. Plug in the Y cable (497-0514570) to the Encore adapter cable. 2. Unplug the main AC power cable from the AC Terminal Board. 3. Plug in the middle connector of the Y cable to the AC Terminal Board.
  • Page 79 Recommended Materials 4. Attach the main AC power line to the Y cable's far end pigtail. C. AC Bus Line 1. plug in the Encore adapter cable's bus connector to the AC Bus Line.
  • Page 80 D. Second Installed (B Side) PSU Plug directly into the first PSU Adapter cable's AC Bus Connector. Install the power and data connections to the Optic 12 Install the red CAT network cable (497-0513383) into the Cub RS232 1 terminal (for Side Install the yellow CAT network cable (497-0513384) into the Cub LAN 1 terminal (for Side...
  • Page 81 Recommended Materials Install the power and network cables into the Optic 12. Install the Printer Install the receipt printer kit (6003-0100-8801) following the Printer Kit Instructions (497- 0514855). Repeat installation procedure for Side B. Closing the Dispenser 1. Disengage the prop bar and close the door.
  • Page 82 Recommended Materials 3. Secure the door and lock the top. 4. Return Main Power after all installs are complete.
  • Page 83 INSTALLATION INSTRUCTIONS NCR OPTIC 12 for Enocre 500 Release 1.0 Issue A...
  • Page 85 Revision Record Issue Date Remarks Dec 2016 First Issue...
  • Page 87 Install the nozzle blanks and decals. Install the Nozzle Boot Prepare the PPU Bracket Install the PPU Bracket. Install the Optic 12 Modular Plate Transfer Components Install the Grade Selection Assembly Power Supply Assembly (497-0513436) Installation Prepare the power supply brackets...
  • Page 88 Install the Comm Cable to the Dispenser Cub Wiring in the Power Supply to the Pump Power Distributor for the First (Side A) PSU Install the power and data connections to the Optic 12 Install the Printer Closing the Dispenser...

  • Page 89: Installation Components

    Installation Components Installation Components Before starting the installation, inspect the installation kit and confirm that all parts are accounted for as below (In order of use): Encore Upgrade Kit Contents Part Number Description Photo Reference 497-0512481 Replacement Modular Door 497-0513278 Top Hinge Pin 497-0514038 Lock Bracket...
  • Page 90 Installation Components Part Number Description Photo Reference 006-8611097 PPU Bracket Screw 497-0514262 PPU Plate Bracket 006-8611952 PPU Bracket Nut 497-0513269 Encore 300 PPU Data Ribbon Cable 497-0513268 Encore 300 PPU LED Ribbon Cable 497-0512995 Encore 500 Non LED PPU Ribbon Cable 497-0512996 Encore 500 LED PPU Ribbon Cable 497-0514480 Reed Switch Extension Cable...

  • Page 91: Tools Required

    Tools Required Tools Required The following tools are required to mount the OPTIC 12 Door Upgrade onto a GVR Encore fuel dispenser: • Safety Glasses • GVR 751 Key • Medium Flathead Screwdriver • #6 (or small) and medium Phillips Screwdriver •...

  • Page 93: Recommended Materials

    Recommended Materials Recommended Materials The following tools are not provided in the kit: • Cable Restraints or Zip Ties • Cloth Rags • All-Purpose Lubricant • Adhesive Remover • Rust Penetrator Oil...

  • Page 94: Deinstallation Instructions For Encore 500

    Recommended Materials Deinstallation Instructions For Encore 500 Before Uninstalling Begins 1. Disconnect the main power from the dispenser. 2. Open the small electronic door to access the Customer Node. Identify Side A by locating the jumper. The jumper is on the Side B Customer Node installed on the J5 jumper terminal.
  • Page 95 Recommended Materials 2. Remove the Grade Select buttons. Note: Keep track of the order to correctly reinstall the Grade Select Switches. a. Use a medium flathead screwdriver to firmly push in the lock tab located on the bottom side of the grade select buttons. (Fig 1.3a,b) Fig 1.3a –...
  • Page 96 Recommended Materials c. Set the buttons aside and note their positions on the door. They will be re- installed later in the process. d. Remove the Grade Select switches. e. Use a ¼” socket to remove both screws holding down the grade select switch. Retain screws for reinstallation.(Fig 1.4) Fig 1.4 –...

  • Page 97: Open The Dispenser

    Recommended Materials Open the dispenser 1. Using a ‘751’ key, unlock the inner electronic cavity door on the dispenser. 2. Disengage the side paddles on the outer main door and open the main door on the dispenser. 3. Place in prop bar to brace door while continuing the deinstallation.

  • Page 98: Uninstall The Wire Assembly

    Recommended Materials Uninstall the wire assembly 1. At the Door Node, mark the cable assemblies that are plugged into the following terminal positions (they will be disconnected for the Disassembly Procedure and then re-connected during the Installation Procedure): LON Header 1 (P2109), LON Header 2 (if present) (P2112), PPU (P2101), +9.4VAC (P2115), and Manager Keypad (A-Side Only) (P2108).

  • Page 99: Uninstall The Printer

    Recommended Materials Uninstall the printer 8. Unplug the LON cable and power cable connected to the printer.

  • Page 100: Uninstall The Ppus

    Recommended Materials Uninstall the PPUs 9. Record the PPU Positioning and addressing to ensure they are installed on the modular PPU bracket in the correct order. Note: Addressing refers to the jumper location that specifies the correct gas grade per PPU.
  • Page 101 Recommended Materials 10. Remove the PPUs from the non modular door and set aside. The one screw can be discarded. Note: Some cases a shim will be present. This can be discarded.

  • Page 102: Lon Terminators (If Present)

    Recommended Materials LON Terminators (if present) Remove one of the LON Terminators. The LON Terminator is used to close the LON Loop and may be connected at any LON terminal present on any component that utilizes the loop. Typically the terminators are located on the Printer assemblies. Do not discard the LON Terminator.

  • Page 103: Remove The Magnetic Boot Switch

    Recommended Materials Remove the Magnetic Boot Switch 1. Using a small Philips screwdriver or 1/4" nut driver, remove the screw holding the magnetic boot switch in place. (Fig 1.15) Fig 1.15 – Location of magnetic handle switch 2. Set the switch aside. Screw can be discarded. Repeat steps until all boot switches are removed.

  • Page 104: Uninstall The Comm Speaker (If Present)

    Recommended Materials Uninstall the Comm Speaker (if present). 1. Unscrew the three screws from speaker assembly and remove from the non modular door. The screws can be discarded. 2. Remove from any speaker bracket present. The comm speaker bracket and hardware can be discarded.
  • Page 105 Recommended Materials Note: Not all speakers will have a bracket. 3. Unscrew the top and bottom left side of the electronic cavity bracket. 4. Pull the speaker through the opening by pulling back on the electronic cavity bracket.
  • Page 106 Recommended Materials 5. Place the speaker inside the cabinet.

  • Page 107: Uninstall The Totalizers (If Present)

    Recommended Materials Uninstall the Totalizers (If present) 1. Locate the Totalizers on the inside of the A-Side Main Door 2. Use a felt tipped marker to mark the totalizers and board plugins. Mark to specify where the totalizers are connected to the board to reconnect during reinstallation. 3.
  • Page 108 Recommended Materials 4. Remove the totalizer board from the non modular door and set aside. Do not remove the CPU LON cable. Remove and Discard the Printer LON cable that was previously disconnected from the printer. Place the totalizer board inside the electronics cavity. 5.

  • Page 109: Remove All Cable Harnesses From The Non Modular Door

    Recommended Materials Remove all cable harnesses from the non modular door 1. Pull all the detached cables through the opening on the left side of the electronics cavity and place inside the cabinet. 2. Detach the ground wire connecting the door to the cabinet. Discard the connecting screw.

  • Page 110: Uninstall The Non Modular Door

    Recommended Materials Uninstall the Non Modular Door 1. Remove the non modular door. Caution: Read ALL of the following steps (Uninstall the Non Modular door) before executing. Caution: To prevent injury or damage to any equipment or components, it is recommended a second individual assist with removing the original non-modular door.
  • Page 111 Recommended Materials Removal of hinge pin 5. Lift the door upwards to remove it from the dispenser. Set aside to transfer door components. Repeat the door removal on the other side of the dispenser.

  • Page 112: Installation Instructions For Encore 500

    Recommended Materials Installation Instructions for Encore 500 Mount the Modular Door Caution: Read ALL of the following steps (Uninstall the Non Modular door) before executing. Caution: To prevent injury or damage to any equipment or components, it is recommended a second individual assist with mounting the modular.
  • Page 113 Recommended Materials 1. Mount the new Modular Door (497-0512481). a. Place onto bottom pin bracket.
  • Page 114 Recommended Materials b. Rotate up and into place on the Pin Bracket. c. Install the top pin (497-0513278) into the Modular Door and Pin Bracket.
  • Page 115 Recommended Materials 2. Install the new modular door latch. d. Remove the hardware (nut or nut and washer) located on the upper left side of the electronics cavity. Do not discard. e. Install the new upper door latch bracket (497-0514038) using the removed hardware in the previous step.
  • Page 116 Recommended Materials g. Install the lower door latch bracket (497-0512905) using the supplied nut(006- 8625195) into the indicated position on the dispenser. h. Reinstall the outer side skirts using retained hardware.
  • Page 117 Recommended Materials Install the Encore Electrical Top Plate (497-0512968). Reinstall the inner side skirts with retained inner side skirt screws.
  • Page 118 Recommended Materials 3. Install the weather shield (497-0513804) to the modular door with five screw bolts (006-8625157) 4. Place in prop bar to brace door while continuing the installation.

  • Page 119: Prepare The Modular Door

    Recommended Materials Prepare the Modular Door Prepare the Nozzle Boot 1. Install the nozzle boot bracket(497-0513805) as shown in the picture. with two thread forming screws (006-8625160). Repeat on each nozzle boot recess.

  • Page 120: Install The Nozzle Blanks And Decals

    Recommended Materials Install the nozzle blanks and decals. 2. Install the lower blanking plugs (497-0512953) . Install the blanking plugs where a nozzle boot will not be installed.
  • Page 121 Recommended Materials 1. Remove the adhesive liner on the Aluminum Blank (497-0512580) and place into the boot recess adhesive side towards the door. Attach with two Phillips screws (006- 8625190) at the top and two machine screws in the middle (006-8625159). Install the blanks where a nozzle boot will not be installed.
  • Page 122 Recommended Materials 2. Install the top boot bracket aluminum blank (497-0512920) to fill any gaps in the boot recess where the boot will be installed. Attach with two Phillips screws (006-8625190). 3. Carefully install the boot blank decal covers. Note: Depending on the nozzle configuration there may be a verity of decal configurations using the full blanking label (497-0512581) and single blanking label (497-0512882).
  • Page 123 Recommended Materials k. Trim the lower leg of the single decal as shown. Note: After installing the decal remove the protective film on the front of the decal.

  • Page 124: Install The Nozzle Boot

    Recommended Materials Install the Nozzle Boot 1. Install the previously retained nozzle boot to the modular door and install with two Phillips machine screws (006-8625159). Note: Insert the bottom boot clip first and rotate the boot into place.

  • Page 125: Prepare The Ppu Bracket

    Recommended Materials Prepare the PPU Bracket 1. Prepare PPU modules. a. Determine if the PPU needs to be adjusted by looking at the metal bracket tabs. If tabs are not present move to step 2. b. Remove the PPU board from the PPU bracket by pinching the plastic posts holding the board to the bracket.
  • Page 126 Recommended Materials c. Bend the bracket prongs down to allow clearance in the PPU door cavity. d. Replace the board onto the bracket. repeat the process with the remaining PPUs.
  • Page 127 Recommended Materials 2. Install the PPUs to the bracket bar. Note: Before installing the PPUs to the PPU Bracket, compare to the decal configuration for the pump to determine the correct location of the PPUs to the bracket. a. Slide the PPUs onto the stabilizing bar (497-0514158) in the correct addressing order determined in the "Uninstall the PPUs"...
  • Page 128 Recommended Materials b. Repeat step a until all PPUs are transferred.
  • Page 129 Recommended Materials 3. Install PPU Plate (497-0514262) to PPU Stabilizing Bar with PPUs attached. a. install the stabilizing bar into the left side (when looking at the back of all components) mounting post first. b. Rotate the bar into place and install in the right side post.
  • Page 130 Recommended Materials c. attach the stabilizing bar to the PPU Plate bracket with the two provided nuts (006-8611952).

  • Page 131: Install The Ppu Bracket

    Recommended Materials Install the PPU Bracket. 1. With the PPU connections facing up, install the corresponding ribbon cable (497- 0512995, non LED configuration cable)(497-0512996, LED configuration cable) into the PPUs attached to the modular door PPU bracket. Begin installing with the farthest of the five connector cable configuration on the right most PPU.
  • Page 132 Recommended Materials Note: Verify the correct orientation and locations of the PPU screens when installing the PPU Bracket. 3. Install the Nozzle Boot Reed Switch to the modular door for each nozzle boot present with the provided screw (006-8625344).

  • Page 133: Install The Optic 12 Modular Plate

    Recommended Materials Install the Optic 12 Modular Plate Caution: Use care to not catch any loose wires on the Optic 12 Modular Plate. Note: Tilt the PPU bracket back and away from the Modular Plate opening to install the Optic 12 Plate.
  • Page 134 Recommended Materials c. Install 10 screw bolts to the Modular Plate.

  • Page 135: Transfer Components

    Recommended Materials d. Install the five front screws (006-8625189) to the Modular Plate. e. Attach the PPU bracket to the Modular Plate with three screw bolt (006-8625157) and washer (006-8625156) assembly. Transfer Components 1. Transfer and install the customer display Node.
  • Page 136 Recommended Materials a. Remove the Node from the old door. If present discard hardware. b. Attach the Customer Node to the modular door with the four provided screw bolts (006-8625157). Verify the upright orientation of the board before installing. c. Install the PPU Ribbon Cable (497-0512995, 497-0512996)to P804a on customer node.
  • Page 137 Recommended Materials d. Reinstall all previously marked cables during the deinstallation section back to the Customer Node. 2. Transfer the Totalizers (if present). a. Install the Totalizer board with four screw bolts (006-8625157). b. Transfer the Totalizers into the Modular Door Totalizer assembly bracket (497- 0512903) as shown below.
  • Page 138 Recommended Materials c. Install the Totalizers and bracket onto the Modular Door in the location shown below with the two provided screw bolts (006-8625157).
  • Page 139 Recommended Materials d. Plug in the Totalizers into the correct board ports. Verify correct connections with markings made during the deinstallation steps. 3. Install the Comm Speaker (if present). Note: If no speaker is present the speaker plate must still be installed for water sealing.

  • Page 140: Install The Grade Selection Assembly

    Recommended Materials g. Install the speaker plate and speaker onto the modular door with retained hardware. Install the Grade Selection Assembly Install the Grade Selection Assembly onto the Modular Door.
  • Page 141 Recommended Materials...
  • Page 142 Recommended Materials 1. Install using the retained 1/4" screw bolts.
  • Page 143 Recommended Materials 2. Repeat step a until all pump paddle assemblies from the deinstalled door have been transferred to the Modular Door. 3. Install the decal and retained Grade Select Paddles in the correct positions noted during deinstallation.

  • Page 144: Power Supply Assembly (497-0513436) Installation

    Recommended Materials Power Supply Assembly (497-0513436) Installation Prepare the power supply brackets Install the Cub on one of the power supply brackets. Follow the Cub Installation Instructions (497-0514466). Installing the power supply Install the Power Supply Bracket with Power Supply (PSU) attached. a.
  • Page 145 Recommended Materials b. Place the studs into holes on the Encore electronic rail. install on the side closest to the Comm connection. Note: When Installing the PSU with Cub attached, install with Cub and PSU facing the rest of the cabinet. When installing the PSU without the Cub attached, install with the PSU facing the cabinet wall.
  • Page 146 Recommended Materials d. Install the Encore adapter cable(497-0513214) to the PSU with the single connector end. Install the Comm Cable to the Dispenser Cub 1. Plug in the Encore Comm adapter cable (497-0513679) to the Dispenser Cub. 2. Disconnect the Comm Two Wire (J3105) from the CRIND control node board. 3.
  • Page 147 Recommended Materials b. AC Terminal Board c. AC Bus Line (single cable bus connections)
  • Page 148 Recommended Materials 2. follow the correct wiring steps for the corresponding power distributor assembly. A. Power Control Module 1. Install the Y cable (497-0514570) to the Encore adapter cable. a. Cut off the far female end of the Y cable as close to the connector as possible. b.
  • Page 149 Recommended Materials c. Identify the P1 terminal on the Power Control Module. d. Attach the corresponding leads on the adapter cable to the P1 two prong connector. Note: Do not unplug the connector until the line and neutral terminals are identified.
  • Page 150 Recommended Materials B. AC Terminal Board 1. Plug in the Y cable (497-0514570) to the Encore adapter cable. 2. Unplug the main AC power cable from the AC Terminal Board. 3. Plug in the middle connector of the Y cable to the AC Terminal Board.
  • Page 151 Recommended Materials 4. Attach the main AC power line to the Y cable's far end pigtail. C. AC Bus Line 1. plug in the Encore adapter cable's bus connector to the AC Bus Line.
  • Page 152 D. Second Installed (B Side) PSU Plug directly into the first PSU Adapter cable's AC Bus Connector. Install the power and data connections to the Optic 12 Install the red CAT network cable (497-0513383) into the Cub RS232 1 terminal (for Side Install the yellow CAT network cable (497-0513384) into the Cub LAN 1 terminal (for Side...
  • Page 153 Recommended Materials Install the power and network cables into the Optic 12. Install the Printer Install the receipt printer kit (6003-0100-8801) following the Printer Kit Instructions (497- 0514855). Repeat installation procedure for Side B. Closing the Dispenser 1. Disengage the prop bar and close the door.
  • Page 154 Recommended Materials 3. Secure the door and lock the top. 4. Return Main Power after all installs are complete.

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