NCR Optic 5 Tokheim Premier B Retrofit Installation Manual
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NCR Optic 5 Tokheim Premier B Retrofit Installation Manual

NCR Optic 5 Tokheim Premier B Retrofit Installation Manual

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RETROFIT INSTALLATION GUIDE
Optic 5 (6001) Tokheim Premier B
6001-0008-8801
497-0513401
Issue B

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  • Page 1 RETROFIT INSTALLATION GUIDE Optic 5 (6001) Tokheim Premier B 6001-0008-8801 497-0513401 Issue B...
  • 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 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 4 Safety and Compliance Information This section introduces the hazards and safety precautions associated with installing, inspecting, maintaining or servicing the Optic 5 OPT. 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. All work must be carried out in accordance with NFPA (National Fire Protection Association) 30, 30A, and 70, and any local authority.
  • Page 5 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 6 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 7 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 8 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 9 • 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 10 viii...

  • Page 11: Table Of Contents

    Table of Contents Chapter 1: Introduction Installation Components Additional Kits Needed Tokheim Premier B OPTIC 5 Upgrade Kit Contents Tools Required Recommended Materials Chapter 2: Disassembly Procedure Wide Frame Disassembly Narrow Frame Disassembly Removing the Lock Assembly Chapter 3: Installation Procedure Wide Frame Installation Narrow Frame Installation Chapter 4: Paper Loading Procedure Loading the Paper...
  • Page 12 Revision Record Issue Date Remarks Oct 2016 First Issue...

  • Page 13: Chapter 1: Introduction

    DO NOT discard removed components into a landfill. Certain components may contain heavy metals and need proper recycling. Contact your NCR representative for possible purchasing of removed components. The Tokheim Premier B has a wide frame version as well as a narrow frame version. The Disassembly Procedure is different between these two.

  • Page 14: Installation Components

    Introduction Installation Components Before starting the installation, inspect the installation kit and confirm that all parts are accounted for as below: Additional Kits Needed Additional Required Retrofit UL Listing Information Amount required Dispenser Cub UL Listed by Report Retrofit Kit Part Number 6009- One per dispenser.
  • Page 15 Introduction Part Number QTY Description Photo Reference 497-0514382 Tokheim Communications Wiring Assembly (One per dispenser) 497-0513525 Tokheim A/C Wiring Assembly 497-0514448 Power Supply Assembly 497-0514863 Cushion Gasket set 497-0514641 Factory Lock Gasket...

  • Page 16: Tools Required

    Introduction Tools Required The following tools are required to mount the OPT into a Tokheim Premier B fuel dispenser: • Safety Glasses • TPX88 Tokheim Key • Medium Flathead Screwdriver • Medium Phillips Screwdriver • Socket Wrench • 7/16", 7/8", and 3/8" Hex Socket or Nut Drivers •...

  • Page 17: Recommended Materials

    Introduction 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 19: Chapter 2: Disassembly Procedure

    Disassembly Procedure Chapter 2: This section provides information on the disassembly of the Optic 5 (6001) Tokheim Premier B Outdoor Payment Terminal (OPT). The following topics are discussed: • Wide Frame Disassembly • Narrow Frame Disassembly • Removing the Lock Assembly...

  • Page 20: Wide Frame Disassembly

    Disassembly Procedure Wide Frame Disassembly 1. Please ensure all safety procedures are followed per requirement by the customer before installing the retrofit kit. 2. At the main disconnect panel, disconnect all power to the dispenser and the pump servicing the dispenser. Tag all disconnected breakers to prevent others from reconnecting power.
  • Page 21 Disassembly Procedure 4. Using a TPX88 Tokheim key, unlock and open the “Blank” Options Door. Identification of Premier B Modules 5. Pull the “Blank” Options Door forward, lift it up and off the track, and set it aside. DO NOT discard the options door. It will be re-installed later during the Installation Procedure Note: Do not discard the Options Door.
  • Page 22 2-10 Disassembly Procedure Latch in lock position Latch in Unlock Position 7. Lower the Money/Volume Display Dial forward, lift it up and off the track, and set it aside. DO NOT discard the Dial. It will be reused during the installation process. Main Display Dial...
  • Page 23 Disassembly Procedure 2-11 Dial after removal 8. Loosen both lock screws (some setups of dispensers use half-turn screws, others use full thread screws) on the Money/Volume Display Assembly, then lower it by laying it forward. Location of lock screws...
  • Page 24 2-12 Disassembly Procedure Main Display Assembly Lowered 9. Unlock and lower the Printer Module Door. Printer Assembly Door lowered...
  • Page 25 Disassembly Procedure 2-13 10. “Unlock” the DPT Module by shifting the lock latches located behind the upper and lower right-hand side of the module. Push the top latch to the left (towards left side of the dispenser) completely. Pull the lower latch to right (towards the right side of the dispenser) completely.
  • Page 26 2-14 Disassembly Procedure Upper Latch viewed from behind in locked position Upper Latch viewed from behind in unlocked position...
  • Page 27 Disassembly Procedure 2-15 Lower Latch viewed from behind in locked position Lower Latch viewed from behind in unlocked position...
  • Page 28 2-16 Disassembly Procedure 11. Pull DPT Module forward to remove it partially; enough to allow access to the terminals and cable assemblies on the DPT Board. Pull out the DPT Module 12. On the DPT board, mark the Dispenser Communications wire assembly (terminal J4) in order to easily identify it later during the Installation Procedure.
  • Page 29 Disassembly Procedure 2-17 13. Including the marked Dispenser Communications wire assembly, unplug every cable assembly attached to the DPT Board as well as any other peripherals, such as a keypad, on the DPT Module.
  • Page 30 2-18 Disassembly Procedure 14. Completely remove the DPT Module by pulling it out and away from the dispenser. The DPT Module can be discarded. It will not be re-installed. Dispenser after DPT has been removed DPT Assembly after removal...
  • Page 31 Disassembly Procedure 2-19 15. Lay the Printer Assembly forward to allow access to the Printer Assembly Cable. Unplug the Printer Assembly cable. Location of Printer Cable 16. Remove the Printer Assembly by pulling it away from the dispenser. Printer Assembly after removal...
  • Page 32 2-20 Disassembly Procedure 17. Remove the Lock Assembly from the Printer Door Assembly. Note: For instructions, refer to Removing the Lock Assembly on page 45 18. The Printer Assembly and Printer Module Door can be discarded. It will not be re- installed.
  • Page 33 Disassembly Procedure 2-21 Location of the four mounting bolts...
  • Page 34 2-22 Disassembly Procedure b. Angle and tilt the DPT Slide Support Bracket and pull it out of the dispenser cabinet. Removing the DPT Slide Support Bracket c. The DPT Slide Support Bracket can be discarded. It will not be re-installed.
  • Page 35 Disassembly Procedure 2-23 21. Pull out and discard both printer cables. Printer Cable after removal 22. Remove the Slide Latch Retainer Assembly. a. Identify the Slide Latch Retainer Assembly and Spacer Assembly located on the upper Enclosure Support Frame. Location of Slide Latch Retainer Assembly...
  • Page 36 2-24 Disassembly Procedure b. Using a small flathead screwdriver, pry both “E-style” retaining rings off of the Pivot Pins. Location of retaining rings Detailed image of removing retaining rings...
  • Page 37 Disassembly Procedure 2-25 c. Push both Pivot Pins through the back of the Enclosure Support Frame. Once the Pivot Pins are removed, both Slide Retainers will fall. Repeat the Slide Latch Retainer Assembly removal process until all Slide Latches are uninstalled. The Pivot Pins and Slide Retainers can be discarded.
  • Page 38 2-26 Disassembly Procedure 23. Remove the old cushion gasket material using a flat head screw driver or similar tool to scrape away the old gasket material and remaining adhesive. a clean flat surface is necessary to install the new gasket. Note: All gasket and left over adhesive material must be fully removed to ensure a clean installation surface for new gaskets during the installation procedure.
  • Page 39 Disassembly Procedure 2-27 24. Repeat steps 20 and 23 for the opposite side of the dispenser. Then proceed to step Note: Throughout this disassembly procedure there are many cable assemblies that have been unplugged and will not be reused. It is up to the discretion of the installer whether to remove these cables or position them inside of the dispenser cavity in as to not cause obstruction.

  • Page 40: Narrow Frame Disassembly

    2-28 Disassembly Procedure Narrow Frame Disassembly 1. Please ensure all safety procedures are followed per requirement by the customer before installing the retrofit kit. 2. At the main disconnect panel, disconnect all power to the dispenser and the pump servicing the dispenser. Tag all disconnected breakers to prevent others from reconnecting power.
  • Page 41 Disassembly Procedure 2-29 4. Identify the dispenser Modules/Doors. Identification of Premier B Modules 5. Unlock and open the Printer Module Door. Printer Access Door opened...
  • Page 42 2-30 Disassembly Procedure 6. Unplug Printer Assembly Cable. Printer Cable Assembly 7. Remove the Printer Module Assembly by lifting it off the tracks away from the dispenser. Printer Assembly after removal 8. Remove the Lock Assembly from the Printer Door Assembly. Note: For instructions, refer to Removing the Lock Assembly...
  • Page 43 Disassembly Procedure 2-31 9. The Printer Assembly and Printer Module Door can be discarded. It will not be re- installed. 10. “Unlock” the Dispenser Payment Terminal (DPT) by shifting the lock latch located behind the upper left-hand side of the module. Pull the latch to left (towards the left side of the dispenser) completely.
  • Page 44 2-32 Disassembly Procedure Close up of latch in unlocked position 11. Lean the DPT Module forward. DPT Module opened and leaning forward...
  • Page 45 Disassembly Procedure 2-33 12. Unscrew the DPT Assembly connector (37-pin barrel) located on the rear of the DPT Module as well as any other cable assemblies that may be present on the module. Location of 37-pin barrel connector 13. Remove the DPT Module by pulling it away from the dispenser. The DPT Module can be discarded.
  • Page 46 2-34 Disassembly Procedure DPT after removal 14. “Unlock” the Money/Volume Display Dial by pulling the lock latch to the left (towards the left-side of the dispenser) completely. The lock latch is located behind the upper left-hand side of the Money/Volume Display Dial. Use the following pictures as a visual aid to help locate and unlock the latch.
  • Page 47 Disassembly Procedure 2-35 Location of Money/Volume latch in unlocked position 15. Lower the Money/Volume Dial forward, lift it off of the track, and set it aside. Do not discard the Money/Volume Dial. It will be reused during the installation process. Money/Volume Dial opened...
  • Page 48 2-36 Disassembly Procedure Money/Volume Dial after removal 16. Loosen the two lock screws (some setups of dispensers use half-turn screws, others use full thread screws) that secure the Money/Volume Assembly to the dispenser face. Location of Sales Volume Display screws...
  • Page 49 Disassembly Procedure 2-37 17. Lower the Money/Volume Assembly by laying it forward completely. Money/Volume Display Assembly in fully forward position 18. Uninstall all the door slide latch retainer assemblies or Spacer Assemblies from the top of the dispenser frame. a. Remove the "E" clips from the Pivot Pins and retain. Push the Pivot Pins through and retain.
  • Page 50 2-38 Disassembly Procedure c. Repeat steps a and b until all door slide latch retainer assembly and Spacer Assembly brackets are removed. the brackets and hardware that were installed where the Optic Panel will be installed can be discarded. The Latch Bracket and hardware for the Money Volume Display should be retained.
  • Page 51 Disassembly Procedure 2-39 19. Remove the old cushion gasket material using a flat head screw driver or similar tool to scrape away the old gasket material and remaining adhesive. a clean flat surface is necessary to install the new gasket. Note: All gasket and left over adhesive material must be fully removed to ensure a clean installation surface for new gaskets during the installation procedure.
  • Page 52 2-40 Disassembly Procedure 20. Using a pair of tin snips or sheet metal shears, cut away the left most cross brace on the Dispenser Electronics Cavity frame. The removed cross brace can be discarded. Warning: Working with sheet metal, especially after it's been cut, can be dangerous.
  • Page 53 Disassembly Procedure 2-41 Example of an ACCEPTABLE CUT 21. Repeat steps 4–20 for Side B of the dispenser Note: Perform this step if Side B is present. Otherwise, proceed to step 22. 22. Locate the DPT Boards. Both are located behind the Printer Module Door and DPT Module (on Side-A of the dispenser) and behind the Money/Volume Display Module (on Side-B of the Dispenser).
  • Page 54 2-42 Disassembly Procedure 23. On one of the DPT boards, mark the Dispenser Communications wire assembly (terminal J4) in order to easily identify it later during the Installation Procedure. The Dispenser Communications wiring assemblies are color coded Yellow, Red, and Blue for Side-A and Orange, Brown, and Green for Side-B.
  • Page 55 Disassembly Procedure 2-43 25. Remove the four 3/8" bolts that are securing the bracket to the frame. Set aside for later in the installation. Location of 3/8" bolts on DPT Bracket 26. Remove the DPT Bracket with the DPT Boards attached to it. Bracket and board can be discarded.
  • Page 56 2-44 Disassembly Procedure DPT Bracket mounting rails after bracket has been removed 27. The Disassembly Procedure is complete. The dispenser is now ready for the installation of the Retrofit Kit. Note: For installation instructions, refer to Narrow Frame Installation on page 75.

  • Page 57: Removing The Lock Assembly

    Disassembly Procedure 2-45 Removing the Lock Assembly During the Disassembly process, the Lock Assembly and its individual pieces will be removed from the Printer Module Door and set aside. Then, it will be re-installed in the new OPT Dial Assembly. Follow the subsequent sub-steps to properly remove the Lock Assembly: Note: Remove the key and make sure the lock cam is in the locked position prior to...
  • Page 58 2-46 Disassembly Procedure 3. Remove the 7/16" cam nut. Location of Cam Nut 4. Remove the Lock Cam.
  • Page 59 Disassembly Procedure 2-47 Location of Lock Cam 5. Remove the Stop Plate. Note: If the Stop Plate is seized to the Lock Cam Shaft and cannot be easily removed, then it can be left in place to prevent damaging the shaft threads. If the Stop Plate is left in place, take care that it does not fall off or become lost.
  • Page 60 2-48 Disassembly Procedure 7. Pull the Lock Cylinder through the front of the door. The old seal can be discarded. Lock assembly components after removal...
  • Page 61 Disassembly Procedure 2-49 8. Keep all of the Lock Assembly Components in a secure place until they are needed for re-installation during the Installation Procedure. 9. The removal of the Lock Assembly is complete. Return to and continue the Disassembly Procedure (step 18 for Wide Frame or step 9 for Narrow Frame). Note: For Wide Frame disassembly instructions, refer to Wide Frame Disassembly...
  • Page 62 2-50...

  • Page 63: Chapter 3: Installation Procedure

    Installation  Procedure Chapter 3: This section provides information on the installation of the Optic 5 (6001) Tokheim Premier B Outdoor Payment Terminal (OPT). The following topics are discussed: • Wide Frame Installation • Narrow Frame Installation...

  • Page 64: Wide Frame Installation

    3-52 Installation Procedure Wide Frame Installation This section follows from the "Wide Frame Disassembly" procedure in Chapter 2, and assumes the pump is still open and that Disassembly is complete. Note: For more information, refer to Wide Frame Disassembly on page 8. 1.
  • Page 65 Installation Procedure 3-53 3. Identify the mounting locations “Premier B” on the Power Supply Assembly bracket. Identifying Premier B Mounting plate 4. Identify the DPT Mount Rails on the right-hand side of Electronics Enclosure (where the DPT Slide Support bracket was removed in step 20 of the Disassembly Procedure).
  • Page 66 3-54 Installation Procedure 5. Insert the Power Supply Bracket vertically onto the left most DPT Mount Rail as shown. Identifying the DPT Mount Rail and mounting holes Power Supply Assembly after installation on the Electronics Mount Rail 6. Using a 3/8" socket, install the PSU bracket using the retained screw bolts to secure the Power Supply Assembly to the Electronics Mount Rail.
  • Page 67 Installation Procedure 3-55 7. Acquire the Tokheim A/C Wire Assembly (497-0513525) from the kit. Tokheim A/C Wire Assembly 8. Insert the Large 3-Position Harness (female socket) of the A/C Wiring Assembly into the Large 3-Position Harness (male socket) pigtail that is present on the Power Supply Assembly.
  • Page 68 3-56 Installation Procedure 9. Locate the A/C Distribution Board (located on the B-Side of the Dispenser) and plug one end the Tokheim A/C Wire Assembly into an open terminal (J10, J11, J12, or J13). A/C Distribution Board and terminal locations A/C Wiring assembly after plugging into distribution board...
  • Page 69 Installation Procedure 3-57 Note: If all four of the terminals are currently being used, unplug one and plug it into the female pigtail harness on the A/C Wire Assembly, then plug the remaining male end of the A/C Wire Assembly into the open terminal on the A/C Distribution Board.
  • Page 70 3-58 Installation Procedure 10. Acquire the Yellow Cat5e Network Cable (497-0513384) and insert one end into the Optic Dispenser Cub Kit port labeled “LAN1” (“LAN2” for Side B). Lay the excess cable inside of the Electronics Cavity. Installing the network cable into the LAN port on Optic Dispenser Cub Kit...
  • Page 71 Installation Procedure 3-59 11. Acquire the Red Cat5e Data Cable (497-0513383) and insert one end into the Optic Dispenser Cub Kit port labeled “RS232-1” (“RS232-2” for Side B). Lay the excess cable inside of the Electronics Cavity. Note: Due to the variety of dispenser setups, it is up to the discretion of the installer how best to position installed cabling inside of the dispenser cavity so as to not cause obstruction.
  • Page 72 3-60 Installation Procedure 12. Acquire the Tokheim Communications Wiring Assembly (497-0514382). Install the Tokheim Communications Wiring Assembly to the green connector on the Dispenser Cub. Note: This procedure is only needed for Side A. Tokheim Communications Wire Assembly Tokheim Communications Wire Assembly plugged into Dispenser Cub 13.
  • Page 73 Installation Procedure 3-61...
  • Page 74 3-62 Installation Procedure 14. Acquire the Cushion Gasket Strip Set (497-0514863) and install the Cushion Gasket to the pump body. Compare the thinnest 13 inch gaskets and install them accordingly. Note: The thinnest 13 inch gasket and shorter top gasket will not be used. a.
  • Page 75 Installation Procedure 3-63 Components of Slide Latch Retainer Assembly c. Align the brackets on the dispenser and push through the retained pivot pins from the inside. Verify the latch is installed with the tab facing to the right. d. Reinstall the "E style" retaining rings to the pivot pins.
  • Page 76 3-64 Installation Procedure e. Verify the latch slides correctly and works properly. 16. Acquire the OPT Premier B Dial Assembly (497-0512466) and lay it face-down on a soft flat surface. Caution: It is recommended that the OPT Assembly is laid on top of a cloth rag to prevent any surface damage to the face of the OPT unit.
  • Page 77 Installation Procedure 3-65 17. Re-install the Lock Assembly (removed in the Dissasembly Procedure) using the new Factory Lock Gasket (497-0514641) in place of the removed and discarded old gasket. a. Make sure that the lock is in the locked position. Insert Lock Cylinder into the front of Lock Cavity keeping in mind the mark made when the lock was removed in the Disassembly Procedure.
  • Page 78 3-66 Installation Procedure c. Insert the stop plate as shown if not still in place. Stop Plate after re-installation d. Insert the Lock Cam and hold it in place. Secure the Lock Cam to the Lock Cylinder by re-installing the 7/16" Cam Nut. Lock Cam and Cam Nut after re-installation e.
  • Page 79 Installation Procedure 3-67 18. With the Lock Assembly in the unlocked position, insert the bottom lip of the OPT Dial Assembly into the right hand side of the Electronics Enclosure Support. Push the top of the dial assembly forward until it stops. Lock the dial to keep it in its closed position.
  • Page 80 3-68 Installation Procedure 19. Using the supplied sub-door key, unlock and open the OPT sub-door. 20. Use a 3mm hex driver or Allen key to remove and retain the tamper prevention plate on the back of the OPT. Location of Tamper Prevention Plate 21.
  • Page 81 Installation Procedure 3-69 23. Plug the open end of the Red Cat5e Data Cable (the one that was plugged into terminal RS232-1 for Side A; RS232-2 for Side B) into the OPT Ethernet terminal labeled as “IOIOI.” Location of Red Cat5e Data Cable 24.
  • Page 82 3-70 Installation Procedure 25. Locate one of the Earth Ground Cables that arrive pre-wired to the Power Supply Assembly and attach the female spade terminal to the male spade stud on the OPT unit’s paper spool. Earth Ground attached to spade terminal on Paper Spool...
  • Page 83 Installation Procedure 3-71 26. Using a zip-tie, gather all cable assemblies attached to the OPT unit, including the Earth Ground, 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 84 3-72 Installation Procedure All cable assemblies connected to OPT Unit after being fastened to Anchor Point 27. Feed excess cabling into the electronics cavity so that the majority of the cables' slack will be placed inside of the Dispenser Head. Re-use any existing cable restraints that may be present.
  • Page 85 Installation Procedure 3-73 29. Re-insert the bottom lip of the Money/Volume Dial into the Electronics Enclosure Support. Push the top of the dial forward until it stops. Reach inside the OPT sub- door opening and pull the Lock Latch (the one that was pushed to unlock in the Disassembly Procedure) towards the right completely until the Money/Volume Dial is secured.
  • Page 86 3-74 Installation Procedure 33. The Installation Procedure is now complete. Caution: Double-check all wire connections to ensure proper placement and good connection before re-applying power. Local regulations may require that the installation is electrically tested and certified BEFORE switch-on. Make sure all local regulations are followed properly.

  • Page 87: Narrow Frame Installation

    Installation Procedure 3-75 Narrow Frame Installation This section follows from the "Narrow Frame Disassembly" procedure in Chapter 2, and assumes the pump is still open and that Disassembly is complete. Note: For more information, refer to Narrow Frame Disassembly on page 28. 1.
  • Page 88 3-76 Installation Procedure 3. Identify the mounting locations “Premier B” on the Power Supply Assembly bracket. Identifying Premier B Mounting plate 4. Facing Side-A, identify the outside DPT Mounting Rail (where the DPT Support bracket was removed). Using a 3/8” socket, insert the retained mounting bolts about halfway into the designated holes as shown.
  • Page 89 Installation Procedure 3-77 5. Insert the first PSU (without CUB unit) Premier B mounting slot as shown (facing towards the outside of the dispenser) and swing it into position. Use the vertical slot, not the side slot.
  • Page 90 3-78 Installation Procedure Note: First PSU in final position facing towards outside of dispenser...
  • Page 91 Installation Procedure 3-79 6. Fasten the retained mounting screws to secure the PSU to the Electronics Mount Rail. 7. Identify the inside DPT Mounting Rail. Using a 3/8” socket, insert the retained #14-10 x ½” (2) self-tapping mounting screws about halfway into the designated holes as shown.
  • Page 92 3-80 Installation Procedure 8. Insert the second PSU (with dispenser Cub) in the same manner as the first PSU except facing towards the inside of the dispenser. Use the vertical slot, not the side slot. Note: Second PSU in final position facing towards inside of the dispenser...
  • Page 93 Installation Procedure 3-81 9. Fasten the retained mounting screws to secure the PSU to the Electronics Mount Rail.
  • Page 94 3-82 Installation Procedure 10. Acquire the Tokheim A/C Wire Assembly (497-0513525) from the kit. Tokheim A/C Wire Assembly 11. Insert the Large 3-Position Harness (female socket) of the A/C Wiring Assembly into the Large 3-Position Harness (male socket) pigtail that is present on the Power Supply Assembly.
  • Page 95 Installation Procedure 3-83 12. Locate the A/C Distribution Board (located on the B-Side of the Dispenser) and plug one end the Tokheim A/C Wire Assembly into an open terminal (J10, J11, J12, or J13). Identifying accessible terminals on A/C Distribution Board A/C Distribution Board after Tokheim Wiring Assembly is installed...
  • Page 96 3-84 Installation Procedure Note: If all four of the terminals are currently being used, unplug one and plug it into the female pigtail harness on the A/C Wire Assembly, then plug the remaining male end of the A/C Wire Assembly into the open terminal on the A/C Distribution Board.
  • Page 97 Installation Procedure 3-85 13. Acquire the Yellow Cat5e Network Cable (497-0513384) and insert one end into the Optic Dispenser Cub Kit port labeled “LAN1” (“LAN2” for Side B). Installing the network cable into the LAN port on Optic Dispenser Cub Kit...
  • Page 98 3-86 Installation Procedure 14. Acquire the Red Cat5e Data Cable (497-0513383) and insert one end into the Optic Dispenser Cub Kit port labeled “RS232-1” (“RS232-2” for Side B). Lay the excess cable inside of the Electronics Cavity. Note: Due to the variety of dispenser setups, it is up to the discretion of the installer how best to position installed cabling inside of the dispenser cavity so as to not cause obstruction.
  • Page 99 Installation Procedure 3-87 15. Acquire the Tokheim Communications Wiring Assembly (497-0514382). Install the Tokheim Communications Wiring Assembly to the green connector on the Dispenser Cub. Note: This procedure is only needed for Side A. Tokheim Communications Wire Assembly Tokheim Communications Wire Assembly plugged into Dispenser Cub 16.
  • Page 100 3-88 Installation Procedure...
  • Page 101 Installation Procedure 3-89 17. Acquire the Cushion Gasket Strip Set (497-0514863) and install the Cushion Gasket to the pump body. Compare the thin 13 inch gaskets and install them accordingly. Note: 2 of the Widest 13 inch gaskets and longer top gasket will not be used. a.
  • Page 102 3-90 Installation Procedure 18. Reinstall the Slide Latch Retainer Assembly for the Money/Volume Display. a. Identify the correct installation location. This should be where the Money/Volume Display is being reinsalled. The latch or spacers are not needed in the OPT location. b. Acquire the retained latch assembly.
  • Page 103 Installation Procedure 3-91 Components of Slide Latch Retainer Assembly c. Align the brackets on the dispenser and push through the retained pivot pins from the inside. Verify the latch is installed with the tab facing to the left. d. Reinstall the "E style" retaining rings.
  • Page 104 3-92 Installation Procedure e. Verify the latch slides correctly and works properly. 19. Acquire the OPT Premier B Dial Assembly (497-0512466) and lay it face-down on a soft flat surface. Caution: It is recommended that the OPT Assembly is laid on top of a cloth rag to prevent any surface damage to the face of the OPT unit.
  • Page 105 Installation Procedure 3-93 20. Re-install the Lock Assembly (removed in the Dissasembly Procedure) using the new Factory Lock Gasket (497-0514641) in place of the removed and discarded old gasket. a. Make sure that the lock is in the locked position. Insert Lock Cylinder into the front of Lock Cavity keeping in mind the mark made when the lock was removed in step 8 of the Disassembly Procedure.
  • Page 106 3-94 Installation Procedure c. Insert the stop plate as shown (if removed). Stop Plate after re-installation d. Insert the Lock Cam and hold it in place. Secure the Lock Cam to the Lock Cylinder by re-installing the 7/16" Cam Nut. Lock Cam and Cam Nut after re-installation e.
  • Page 107 Installation Procedure 3-95 21. With the Lock Assembly in the unlocked position, insert the bottom lip of the OPT Dial Assembly into the left hand side of the Electronics Enclosure Support. Push the top of the dial assembly forward until it stops. Lock the dial assembly to keep it in its closed position.
  • Page 108 3-96 Installation Procedure Location of Tamper Prevention Plate 24. Locate one of the D/C Wiring Assemblies that arrive pre-wired to the Power Supply Assembly. Feed the open end of the cable through the opening on the tamper prevention shield and plug it into the OPT Terminal labeled “VDC.” DC Wiring plugged into OPT Unit 25.
  • Page 109 Installation Procedure 3-97 27. 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 Location of Yellow Cat5e Network Cable 28.
  • Page 110 3-98 Installation Procedure Money/Volume Display assembly re-fastened to Dispenser Frame 30. Re-insert the bottom lip of the Money/Volume Dial into the Electronics Enclosure Support. Push the top of the dial forward until it stops. Reach inside the OPT sub- door opening and pull the Lock Latch (the one that was pushed to unlock the dial in the Disassembly Procedure) towards the left completely until the Money/Volume Dial is secured.
  • Page 111 Installation Procedure 3-99 33. The Installation Procedure is now complete. Caution: Double-check all wire connections to ensure proper placement and good connection before re-applying power. Local regulations may require that the installation is electrically tested and certified BEFORE switch-on. Make sure all local regulations are followed properly.
  • Page 112 3-100...

  • Page 113: Chapter 4: Paper Loading Procedure

    Paper Loading Procedure Chapter 4: This section provides information on how to load the paper to the Optic 5 OPT printer. The image below shows the rear panel of the Optic 5 OPT where the paper is loaded.

  • Page 114: Loading The Paper

    4-102 Paper Loading Procedure Loading the Paper To load the paper, follow these steps: 1. Ensure the paper roll has a neat cut edge. 2. Remove spindle from the paper holder position. Insert roll in place. The paper tension flap is spring-loaded, therefore you will need to apply some pressure. Insert the spindle through the middle of the roll to hold in place.
  • Page 115 Paper Loading Procedure 4-103 4. The photo shows the paper loaded correctly. 5. Feed the paper to the printer. To do this, press either the forward or backward paper feed buttons to move the paper forwrad or back. Press the buttons together to cut the paper.
  • Page 116 4-104 Paper Loading Procedure 6. Feed the paper through the terminal until it appears at the paper exit chute. Cut the paper using both feed buttons, and remove the cut length from the chute.

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