NCR OPTIC 5 Installation Instructions Manual Download Page 1

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Installation Instructions

NCR OPTIC 5 for Encore 500s Non ECIM (6001-0011-
8801)

NCR Eng Kit Part Number: 497-0518324

Summary of Contents for OPTIC 5

Page 1: ...Installation Instructions NCR OPTIC 5 for Encore 500s Non ECIM 6001 0011 8801 NCR Eng Kit Part Number 497 0518324 ...

Page 2: ...erms and conditions of an agreement you have with NCR NCR s copyright notice must be included It is the policy of NCR Corporation NCR to improve products as new technology components software and firmware become available 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 t...

Page 3: ...iii Revision Record Issue Date Remarks A Jan 2017 First Issue B April 2018 Update to revised part numbers ...

Page 4: ...iv ...

Page 5: ...en 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: ...e these should they be required Locate the switch or circuit breakers that shut off all power to all fueling equipment and dispensing devices Total Electrical Shut Off Before Access Any procedure requiring access to electrical components or the electronics of a pump dispenser requires total electrical shut off of that unit Understand the function and location of this switch or circuit breaker befo...

Page 7: ...understand the procedures before beginning work Follow the Regulations Regulations in OSHA Occupational Safety and Health Administration national state and local codes including customer requirements must be followed Failure to install inspect maintain or service this equipment in accordance with these codes regulations and standards may lead to legal citations with penalties and may affect the sa...

Page 8: ...at 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: ...art of defective missing wrong component Description of Failure please be specific For example display will not power on Customer Requestor s contact name phone number and or e mail address Address to ship replacement part s Transport the product n its original packaging to prevent impact damages If you do not have access to a computer you may leave a voice message at 1 800 528 8658 USA or Interna...

Page 10: ...d tear are not included in the warranty In general damages due to the following are not covered by the warranty Improper or insufficient maintenance Improper use or unauthorized modifications of the product Inadequate location or surroundings For detailed warranty arrangements please consult your contract documents ...

Page 11: ... the defective equipment Serial Number of the defective equipment Equipment location in the store 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 Note A work order must...

Page 12: ...viii ...

Page 13: ...t Switch 15 Uninstall the Comm Speaker if present 16 Uninstall the Totalizers If present 18 Remove all cable harnesses from the non modular door 20 Uninstall the Weather Shield 21 Uninstall the Non Modular Door 22 Installation Instructions for Encore Mount the Modular Door 25 Prepare the Modular Door 30 Prepare the Nozzle Boot 30 Install the nozzle blanks and decals 31 Install the Nozzle Boot 35 I...

Page 14: ...talling the power supply 47 Install the Comm Cable to the Dispenser Cub 50 Wiring in the Power Supply to the Pump Power Distributor for the First Side A PSU 51 Wiring in the Power Supply to the Pump Power Distributor for Second Installed B Side PSU 57 Install the power and data connections to the Optic 12 58 Closing the Dispenser 65 ...

Page 15: ...on Amount required Dispenser Cub UL Listed by Report Retrofit Kit Part Number 6009 0008 8801 InvencoLink Converter One per dispenser to be Installed on Side A PSU Bracket Encore Upgrade Kit Contents Before starting the installation inspect the installation kit and confirm that all parts are accounted for as below In order of use ...

Page 16: ...ank 497 0512581 2 Full Blanking Label 497 0512882 4 Single Blanking Label 006 8625344 8 Nozzle Boot Switch Screw 497 0514266 2 Encore OPTIC 5 Retrofit Kit Modular Plate 006 8625156 16 Attaching Washer 006 8625189 10 Modular Panel Screw 497 0513438 2 PSU Assembly 006 8617730 4 PSU Nuts 497 0513385 2 Encore AC Power Adapter Cable 497 0513679 2 Encore 500 500s Comm Adapter Cable 497 0514570 2 Encore ...

Page 17: ... Flathead Screwdriver 6 or small and medium Phillips Screwdriver Socket Wrench and Assorted Hex Sockets or Nut Drivers 1 4 and 7 16 Could vary by pump s Wire Stripper and Cutter Needle Nosed Pliers UL Listed Crimp on Fork Connectors Terminals Small Wire Zip tie Clippers Warning Do NOT use power tools if working on a fuel station forecourt Any spark could cause an explosion ...

Page 18: ...4 ...

Page 19: ...Recommended Materials 5 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 20: ...6 ...

Page 21: ...ion box is present open the electronic cabinet and locate the customer node Follow the indication for side one on the customer node jumper cluster to determine side 1 A Remove Reused Exterior Door Components 1 Remove the Nozzle Boot by removing the two screws on each side Set the boot aside Discard the screws Note the location of the nozzle for installation process Note Screws will be medium Phill...

Page 22: ...witches 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 Button before removal Fig 1 3b Location of lock tab Fig 1 3c Flathead screwdriver pushing in on lock tab b Lift up on the buttons while pushing in the lock tab until the button disengages Fig 1 3c ...

Page 23: ...s on the door They will be re installed later in the process d Remove the Grade Select switches e Use a socket to remove both screws holding down the grade select switch Retain screws for reinstallation Fig 1 4 Fig 1 4 Grade select switch and screws f Set the switches aside Do not discard ...

Page 24: ... 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 Undo door latch located underneath the lower left hand side of the dispenser door Fig 1 1a b Fig 1 1a Far picture of door latch ...

Page 25: ...Deinstallation Instructions For Encore 11 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: ...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 Screws holding down printer bracket 3 Remove the interior Printer Shield 4 Remove the four 5 16th bolts securing the interior printer shield Fig 1 14b c and retain to be reinstalled Fig 1 14b Far picture of printer shield ...

Page 27: ...Deinstallation Instructions For Encore 13 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: ...hes 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 2 Detach the PPU bracket from the non modular door with three screw bolts Discard the screw bolts 3 Remove the PPU bracket and set aside ...

Page 29: ...location during the installation process 2 Locate the Magnetic Boot Switches behind the boot cavities on the non modular door 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 3 Set the switch aside Screw can be discarded Repeat steps until all boot switches are removed ...

Page 30: ...ove 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 place the speaker inside the electronic opening Note To remove from bracket deflect the two tabbed side in and pull up on the bracket Because of the magnet the bracket cover may stick ...

Page 31: ...Deinstallation Instructions For Encore 17 Note Not all speakers will have a bracket 3 Place the speaker inside the cabinet ...

Page 32: ...resent 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 Set aside Discard any screws ...

Page 33: ...Deinstallation Instructions For Encore 19 ...

Page 34: ...ing connections to the Customer Node and note the connections for re installation Unplug the now marked cables from the Customer Node Set inside the cabinet 3 Unplug all remaining cables on the non modular door 4 Detach the ground wires 5 Check for any other cables or wires attached from the cabinet to the Non Modular Door Place into the cabinet Remove and discard any loose cables no longer connec...

Page 35: ...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: ...e to any equipment or components it is recommended a second individual assist with removing the original non modular door 2 Push the prop stick up and pull out of the slot of the dispenser frame Fig 1 18 Fig 1 18 Removing the prop stick from the dispenser frame 3 Remove the prop stick bracket from the non modular door by removing the two screws holding it in place Set the prop stick assembly aside...

Page 37: ... 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 Discard the pin Removal of hinge pin 6 Lift the door upwards to remove it from the dispenser Set aside to transfer door components ...

Page 38: ...24 Deinstallation Instructions For Encore Repeat the door removal on the other side of the dispenser ...

Page 39: ...ad 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 Before mounting the modular door push the Electrical Top cover out of the way of the hinge pin ...

Page 40: ...26 Installation Instructions for Encore 2 Mount the new Modular Door 497 0513238 a Place onto bottom pin bracket ...

Page 41: ...o 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: ...28 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 29 ...

Page 44: ...nstructions 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: ...7 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 Install the blanks where a nozzle boot will not be installed ...

Page 46: ...32 Installation Instructions for Encore ...

Page 47: ...s 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: ...34 Installation Instructions for Encore Note After installing the decal remove the protective film on the front of the decal ...

Page 49: ...Installation Instructions for Encore 35 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: ...ation 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: ...nstall 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: ...ket back and away from the Modular Plate opening to install the Optic 5 Plate 1 Install the Optic 5 Modular Plate 497 0514266 into the Modular Door a Slide the Modular Plate into the opening from the bottom b Attach five washer 006 8625156 and screw bolt 006 8625157 assemblies to the top of the Modular Plate to hold in place c Install 10 screw bolts 006 8625157 to the Modular Plate ...

Page 53: ...ation Instructions for Encore 39 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: ...ransfer 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 Verify the upright orientation of the board before installing ...

Page 55: ...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 reinstall the rest of the cable connections back to the Customer Node Install the marked cables from the deinstallation process back to the Customer Node ...

Page 56: ...tions 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 Verify the speaker plate is properly installed a Remove the speaker plate from the modular door and retain the hardware b Place the speaker plate onto the comm speaker as shown below ...

Page 57: ...43 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: ...44 Installation Instructions for Encore ...

Page 59: ...Installation Instructions for Encore 45 1 Install using the retained 1 4 screw bolts ...

Page 60: ...r 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: ...Installation Instructions 497 0514466 Acquire the Cub Retrofit Kit UL Listed by Report Retrofit kit part number 6009 0008 8801 2 The second power supply bracket with no Cub is now the Side B universal Power Supply Bracket Installing the power supply Install the Power Supply Bracket with Power Supply PSU attached 1 Identify the correct Encore stud set on the universal Power Supply Bracket Note The ...

Page 62: ...re 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 The power supply for side B will be mounted in the next set of holes with the backs facing each other ...

Page 63: ...Installation Instructions for Encore 49 4 Secure in place with the two supplied nuts 006 8617730 per Universal Power Supply Bracket four nuts total ...

Page 64: ...ions 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: ...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 Identify the correct power distributor assembly a Power Control Module upgraded distributor ...

Page 66: ...52 Installation Instructions for Encore b AC Terminal Board c AC Bus Line single cable bus connections ...

Page 67: ...t 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: ...inal 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 Note Do not unplug the connector until the line and neutral terminals are identified White corresponds to neutral and black corresponds to live ...

Page 69: ... 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 Unplug the main AC power cable from the AC Terminal Board and retain for reassembly 3 Plug in the middle connector of the Y cable to the AC Terminal Board ...

Page 70: ...tions 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: ...Installation Instructions for Encore 57 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: ...ic 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 Install the yellow CAT network cable 497 0513384 into the Cub LAN 1 terminal for Side A Note Use the LAN 2 terminal for Side B installation ...

Page 73: ...Installation Instructions for Encore 59 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: ...e 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 c 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 ...

Page 75: ... 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: ...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: ... 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 b Install the cover to the modular door using 8 captive Phillips head screws ...

Page 78: ...nstructions 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: ...hing 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: ...nstallation 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 ...

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