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NCR OPTIC 5 Installation Instructions Manual

For encore 500s non ecim 6001-0011-8801
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Installation Instructions
NCR OPTIC 5 for Encore 500s Non ECIM (6001-0011-
8801)
NCR Eng Kit Part Number: 497-0518324

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  • Page 1 Installation Instructions NCR OPTIC 5 for Encore 500s Non ECIM (6001-0011- 8801) NCR Eng Kit Part Number: 497-0518324...
  • Page 2 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 3 Revision Record Issue Date Remarks Jan 2017 First Issue April 2018 Update to revised part numbers...
  • Page 5 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 6 Safety and Compliance Information This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing the Encore 500s Non-ECIM. 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 7 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 8 Safety Symbols and Terminology Signal Words Warning: Alerts you to a hazard or unsafe practice that could result in death or serious injury. Caution: Designates a hazard or unsafe practice which may result in minor injury, property or equipment damage. Note: To emphasize points or remind installer of something, or to indicate the possibility of minor problems in the outcome of what installer is doing.
  • Page 9 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 10 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 11 • 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 12 viii...

  • Page 13: Table Of Contents

    Table of Contents Installation Components Additional Required Kits Encore Upgrade Kit Contents Tools Required Recommended Materials Deinstallation Instructions For Encore Before Uninstalling Begins Remove Reused Exterior Door Components Open the dispenser Uninstall the printer Uninstall the PPU Remove the Magnetic Boot Switch Uninstall the Comm Speaker (if present).
  • Page 14 Install the Grade Selection Assembly Power Supply Assembly (497-0513438) Installation Prepare the power supply brackets Installing the power supply Install the Comm Cable to the Dispenser Cub Wiring in the Power Supply to the Pump Power Distributor for the First (Side A) PSU Wiring in the Power Supply to the Pump Power Distributor for Second Installed (B Side) PSU Install the power and data connections to the Optic 12...

  • Page 15: Installation Components

    Installation Components Installation Components Additional Required Kits Additional Required Ret- UL Listing Information Amount required rofit Kit Dispenser Cub UL Listed by Report Retrofit Kit Part Number One per dispenser. to be 6009-0008-8801 (InvencoLink Converter) Installed on Side A PSU Bracket.
  • Page 16 Installation Components Part Number Description 497-0513238 Replacement Modular Door 497-0513278 Top Hinge Pin 006-8625157 1/4" Hex Screw Bolt (4 spares) 497-0513806 Nozzle Boot Bracket 006-8625160 Thread Forming Screw 497-0512953 Lower Blanking Plug 497-0512580 Aluminum Blank 006-8625190 Phillips Screw 006-8625159 Machine Screw 497-0512920 Top Boot Aluminum Blank 497-0512581...

  • Page 17: Tools Required

    Tools Required Tools Required The following tools are required to mount the OPTIC 5 Door Upgrade onto a GVR Encore fuel dispenser: • Safety Glasses • GCBO Key • GVR 751 Key • Medium Flathead Screwdriver • #6 (or small) and medium Phillips Screwdriver •...

  • Page 19: 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 21: Deinstallation Instructions For Encore

    Deinstallation Instructions For Encore Deinstallation Instructions For Encore Before Uninstalling Begins 1. Disconnect the main power from the dispenser. 2. Side A is the side with the Junction box located directly under the electronic cabinet. If no junction box is present open the electronic cabinet and locate the customer node.
  • Page 22 Deinstallation Instructions For Encore 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 23 Deinstallation Instructions For Encore 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 24: Open The Dispenser

    Deinstallation Instructions For Encore Open the dispenser 1. Remove the lower door using the GCBO Lower Door Key. (Fig 1.01) Set aside. Fig 1.01 – Lower Doors Removed 2. Using a ‘751’ key, unlock the main door on the dispenser. 3.
  • Page 25 Deinstallation Instructions For Encore Fig 1.1b- Door Latch 4. Open the door until it fully locks into place. (Fig 1.5) Fig 1.5 – Door in its fully open and locked position...

  • Page 26: Uninstall The Printer

    Deinstallation Instructions For Encore Uninstall the printer 1. Unplug the power and communication cables from the printer and discard. 2. Remove the two screws holding the printer assembly to the door. Set the assembly and the screw aside to be discarded. They will not be re-installed. (Fig 1.13) Fig 1.13 –...
  • Page 27 Deinstallation Instructions For Encore Fig 1.14c –Interior Printer Shield 5. Set the interior printer shield aside to be discarded. 6. Reinstall the bolts to cover the bolt holes.

  • Page 28: Uninstall The Ppu

    Deinstallation Instructions For Encore Uninstall the PPU 1. Remove the power, communication, and nozzle boot switch or switches. Retain the cables and switches. Make note of the PPU and Nozzle Boot Switch connections so they are reinstalled in the same locations. Mark the Power and Comm cable and their connections to the Customer Node for installation in the new Modular Door.

  • Page 29: Remove The Magnetic Boot Switch

    Deinstallation Instructions For Encore Remove the Magnetic Boot Switch 1. Record the switch connections to the PPU so the grade selection paddles will match the correct nozzle boot location during the installation process. 2. Locate the Magnetic Boot Switches behind the boot cavities on the non modular door.

  • Page 30: Uninstall The Comm Speaker (If Present)

    Deinstallation Instructions For Encore 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 31 Deinstallation Instructions For Encore Note: Not all speakers will have a bracket. 3. Place the speaker inside the cabinet.

  • Page 32: Uninstall The Totalizers (If Present)

    Deinstallation Instructions For Encore Uninstall the Totalizers (If present) 1. Mark all the connections of the totalizers to the customer node. Unplug the totalizers from the customer node. Marking the Totalizers Customer Node 2. Remove the totalizer bracket with totalizers still installed from the non modular door.
  • Page 33 Deinstallation Instructions For Encore...

  • Page 34: Remove All Cable Harnesses From The Non Modular Door

    Deinstallation Instructions For Encore Remove all cable harnesses from the non modular door 1. Identify the connections on the Customer Node to any other components on the door. Remove and discard. 2. Identify the remaining connections to the Customer Node and note the connections for re-installation.

  • Page 35: Uninstall The Weather Shield

    Deinstallation Instructions For Encore Uninstall the Weather Shield 1. Remove five 1/4 inch screw bolts from the splash shield. Remove the shield and set aside to be reinstalled on new door. Retain the screw bolts for reinstallation. Repeat all previous steps on the other side of the dispenser prior to continuing.

  • Page 36: Uninstall The Non Modular Door

    Deinstallation Instructions For Encore 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 37 Deinstallation Instructions For Encore 4. With the other side's door open, push the Electrical Top cover out of the way until the hinge pin is accessible. 5. With the door fully open and supported at the bottom, use a pair of needle nosed pliers to firmly grasp the hinge pin and pull upwards to remove it.
  • Page 38 Deinstallation Instructions For Encore Repeat the door removal on the other side of the dispenser.

  • Page 39: Installation Instructions For Encore

    Installation Instructions for Encore Installation Instructions for Encore 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. 1.
  • Page 40 Installation Instructions for Encore 2. Mount the new Modular Door (497-0513238). a. Place onto bottom pin bracket.
  • Page 41 Installation Instructions for Encore b. Rotate up and into place on the Pin Bracket. c. Install the top pin (497-0513278) into the Modular Door and Pin Bracket. 3. Install the weather shield (previously retained) to the modular door with five screw bolts (previously retained) with the prop bar storage hooks facing towards you.
  • Page 42 Installation Instructions for Encore 4. Install the prop stick assembly (previously retained) with two screws (previously retained). Insert the prop rod into the cabinet bracket.
  • Page 43 Installation Instructions for Encore...

  • Page 44: Prepare The Modular Door

    Installation Instructions for Encore Prepare the Modular Door Prepare the Nozzle Boot 1. Install the nozzle boot bracket(497-0513806) as shown in the picture. with two thread forming screws (006-8625160). Repeat on each nozzle boot recess.

  • Page 45: Install The Nozzle Blanks And Decals

    Installation Instructions for Encore Install the nozzle blanks and decals. 1. Install the lower blanking plugs (497-0512953) in all positions. 2. 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).
  • Page 46 Installation Instructions for Encore...
  • Page 47 Installation Instructions for Encore 3. 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). 4. 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 48 Installation Instructions for Encore Note: After installing the decal remove the protective film on the front of the decal.

  • Page 49: Install The Nozzle Boot

    Installation Instructions for Encore Install the Nozzle Boot 1. Install the previously retained nozzle boot to the modular door and install with two Phillips machine screws (006-8625159).

  • Page 50: Install The Ppu Bracket

    Installation Instructions for Encore Install the PPU Bracket 1. Slide the PPU plate into place in the new modular door. Note: Verify the correct orientation and locations of the PPU screens when installing the PPU Bracket.

  • Page 51: Transfer The Magnetic Boot Switch Or Switches

    Installation Instructions for Encore Transfer the Magnetic Boot Switch or Switches 1. Install the previously retained Nozzle Boot Switch to the modular door for each nozzle boot present with the provided screw (006-8625344) behind each installed nozzle boot. 2. Plug in the Magnetic Boot Switches into the corresponding PPU according to the previous location on the non modular door.

  • Page 52: Install The Optic 5 Modular Plate (497-0514266)

    Installation Instructions for Encore Install the OPTIC 5 Modular Plate (497-0514266) Caution: Use care to not catch any loose wires on the Optic 5 Modular Plate. Note: Tilt the PPU bracket back and away from the Modular Plate opening to install the Optic 5 Plate.
  • Page 53 Installation Instructions for Encore 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.

  • Page 54: Transfer Components

    Installation Instructions for Encore Transfer Components 1. Transfer and install the customer display Node. 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).
  • Page 55 Installation Instructions for Encore 2. Transfer the Totalizers (if present) and plug in the marked cables. a. Install the Totalizers and Bracket with two provided screw bolts (006-8625157). plug in the Totalizers to the Customer Node according to the previously made marks during deinstallation.
  • Page 56 Installation Instructions for Encore b. Reconnect the marked PPU power and comm cables back to the PPU plate and Customer Node connections previously retained. 3. Install the Comm Speaker (if present). Note: If no speaker is present the speaker plate must still be installed for water sealing.

  • Page 57: Install The Grade Selection Assembly

    Installation Instructions for Encore c. 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 to match with the previously installed PPU's locations.
  • Page 58 Installation Instructions for Encore...
  • Page 59 Installation Instructions for Encore 1. Install using the retained 1/4" screw bolts.
  • Page 60 Installation Instructions for Encore 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 61: Power Supply Assembly (497-0513438) Installation

    Installation Instructions for Encore Power Supply Assembly (497-0513438) Installation Prepare the power supply brackets 1. Install the Cub on one universal Power Supply Bracket. This bracket will now become the Side A PSU bracket. Follow the Cub Installation Instructions (497- 0514466).
  • Page 62 Installation Instructions for Encore 2. Place the studs into holes on the Encore electronic rail. install on the side closest to the Comm connection. 3. When looking from Side A, the power supply for Side A will be mounted in the third set of holes from the left.
  • Page 63 Installation Instructions for Encore 4. Secure in place with the two supplied nuts (006-8617730) per Universal Power Supply Bracket (four nuts total).

  • Page 64: Install The Comm Cable To The Dispenser Cub

    Installation Instructions for Encore 5. Install the single connector end of the Encore adapter cable(497-0513385) to the PSU universal plug connector. Install the Comm Cable to the Dispenser Cub Note: This section is only needed during Side A Install.

  • Page 65: Wiring In The Power Supply To The Pump Power Distributor For The First (Side A) Psu

    Installation Instructions for Encore 1. Plug in the green connector of the Encore Comm adapter cable (497-0513679) to the Dispenser Cub. 2. Disconnect the Comm Two Wire from the CRIND control node board. 3. Plug in the Encore Comm adapter cable to the Comm Two Wire. Wiring in the Power Supply to the Pump Power Distributor for the First (Side A) PSU 1.
  • Page 66 Installation Instructions for Encore b. AC Terminal Board c. AC Bus Line (single cable bus connections)
  • Page 67 Installation Instructions for Encore 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 that was previously installed. a. Cut off the far female end of the Y cable as close to the connector as possible.
  • Page 68 Installation Instructions for Encore b. Strip the wires and crimp on a UL Listed crimp on fork connector/terminal to the green ground wire. 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.
  • Page 69 Installation Instructions for Encore e. Unscrew a bolt with attached ground. Add the new ground wire to floor of electric cabinet and re-tighten bolt. B. AC Terminal Board 1. Plug in the Y cable (497-0514570) to the Encore adapter cable previously installed. 2.
  • Page 70 Installation Instructions for Encore 4. Attach the main AC power line previously unplugged from the AC board to the Y cable's far end pigtail. C. AC Bus Line 1. plug in the previously installed Encore adapter cable's bus connector to the AC Bus Line.

  • Page 71: Wiring In The Power Supply To The Pump Power Distributor For Second Installed (B Side) Psu

    Installation Instructions for Encore Wiring in the Power Supply to the Pump Power Distributor for Second Installed (B Side) PSU Plug directly into the first PSU Adapter cable's AC Bus Connector.

  • Page 72: Install The Power And Data Connections To The Optic 12

    Installation Instructions for Encore Install the power and data connections to the Optic 12 1. Install the red CAT network cable (497-0513383) into the Cub RS232 1 terminal (for Side A). Note: Use the RS232 2 terminal for Side B installation. 2.
  • Page 73 Installation Instructions for Encore 3. Connect all cables to the OPTIC 5 unit. a. Remove the security cover from the OPTIC 5. Remove the two 3mm Hex Screws and retain. Retain the cover.
  • Page 74 Installation Instructions for Encore b. Feed through the pre-installed OPTIC 5 DC Wiring Cable from the PSU assembly into the indicated opening on the Tamper Prevention Plate. Plug in the power cable and reinstall the security cover with the two 3mm Hex Screws previously retained.
  • Page 75 Installation Instructions for Encore d. Plug the open end of the Yellow Cat5e Network Cable (the one that was plugged into terminal LAN1 for Side A; LAN2 for Side B) into the OPT Input/Output terminal labeled as e. Attach the grounding cable pre-installed on the PSU assembly to the OPTIC 5 near the printer spool.
  • Page 76 Installation Instructions for Encore 4. Using a zip-tie, gather all cable assemblies attached to the OPT unit, including the ground cable, and secure them to the Cable Restraint Anchor Point located to the left of the tamper prevention shield. Location of Cable Restraint Anchor Point...
  • Page 77 Installation Instructions for Encore All cable assemblies connected to OPT Unit after being fastened to Anchor Point 5. Install the OPTIC 5 Hatch Cover (497-0517179). a. Place OPTIC 5 Hatch Cover in place over the OPTIC 5 and avoid pinching any cables connected to the OPTIC 5 or Dispenser door. Note: The grounding cable connector for the hatch cover should be on the side closest to the dispenser door hinge as indicated.
  • Page 78 Installation Instructions for Encore c. Connect the grounding cable (497-0513215) to the hatch cover. Attaching grounding cable to shield d. Connect the cover grounding cable to the PSU grounding stud and secure using the preinstalled nut.

  • Page 79: Closing The Dispenser

    Installation Instructions for Encore Attaching grounding cable to PSU stud Closing the Dispenser 1. Route cables and wires away from sharp edges or pinching in the modular door gasket. 2. Disengage the prop rod and close the door. 3. Push the door slightly up and in to engage the bottom latch.
  • Page 80 Installation Instructions for Encore 4. Secure and lock the top of the door. 5. Replace Lower door using GCBO Lower Door Key. 6. Repeat closing steps for Side B. 7. Return Main Power after all installs are complete.

This manual is also suitable for:

497-0518324Optic 12

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