NCR OPTIC 12 User manual

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

INSTALLATION INSTRUCTIONS
NCR OPTIC 12 for Enocre 300
Release 1.0
Issue A

The product described in this document is a licensed product of NCR Corporation.
NCR is a registered trademark of NCR Corporation. NCR RealPOS is a trademark of NCR Corporation in the United States
and/or other countries. Other product names mentioned in this publication may be trademarks or registered trademarks of their
respective companies and are hereby acknowledged.
The terms HDMI and HDMI High-Definition Multimedia Interface, and the HDMI Logo are trademarks or registered trademarks
of HDMI Licensing LLC in the United States and other countries.
Where creation of derivative works, modifications or copies of this NCR copyrighted documentation is permitted under the terms
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 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.
To maintain the quality of our publications, we need your comments on the accuracy, clarity, organization, and value of this book.
Please use the link below to send your comments.
EMail: [e-mail]
Copyright © 2016
By NCR Corporation
Duluth, GA U.S.A.
All Rights Reserved

iii
Revision Record
Issue Date Remarks
ADec 2016 First Issue

iv

i
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.

ii
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.
All work must be carried out in accordance with NFPA (National Fire Protection
Association) 30, 30A, and 70, and any local authority.
Preliminary Precautions
You are working in a potentially dangerous environment of flammable fuels, vapor, and
high voltage. Only trained or authorized individuals knowledgeable in the related
procedures should install, inspect, maintain or service this equipment.
Emergency Total Electrical Shut-Off
Locate the forecourt emergency fuel shut-off valves and electrical isolation breakers.
Understand how to use 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 before inspecting, installing, maintaining,
or servicing the [[[Undefined variable Master.Product Short Name]]].
Evacuation, Barricading, and Shut-Off
Any procedures requiring accessing a pump/dispenser head requires the following three
actions:
• An evacuation of all unauthorized persons and vehicles
• Using safety tape or cones as barricades to the effected units
• A total electrical shut-off of the affected unit(s)
Safety Equipment
Throughout the Disassembly and Installation procedures of the OPT Retrofit Kit
involves working with and around hazardous materials and apparatuses. Use of proper
safety equipment such as ANSI (American National Safety Institute) Personal Protective
Equipment such as safety glasses, insulated gloves, and protective footwear.

iii
Read the Manual
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.
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 safe use and
operation of the equipment.

iv
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
serious injury.
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.

v
Out of Box Failure (OBF)
If you experience an out of box failure (OBF) during installation or staging related to a
missing, wrong or defective unit or item, simply provide NCR with a detailed
description of the issue and the item will be replaced free of charge. For assistance with
this process send an email to [e-mail] with the following details:
• NCR Sales Order # (Sales Order # are located on the box)
• Date of Product Installation
• Product Model #
• Unit Serial #
• NCR part # 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 (International) [phone]. When leaving a message, please provide a
phone number and/or an email address so NCR can contact you if additional details are
needed.
Note: Used equipment that experiences a failure does not qualify as an OBF and
should go through the NCR warranty process.

vi
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.
• 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.

vii
Returning Defective Hardware for Service
Use the following procedure to report/return defective hardware.
Call the NCR Customer Care Center at 1-800-262-7782 and have the following information
available when you place the call.
• Class/Model number of 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 be opened for each device that is shipped for repair.
Shipping Address:
NCR Corporation-DCA Depot
200 Hwy 74 South
Peachtree City, GA 30276
Attn: Dock Door 8

viii

ix
Table of Contents
Installation Components 1
Encore Upgrade Kit Contents 1
Tools Required 3
Recommended Materials 5
Deinstallation Instructions For Encore 300
Before Uninstalling Begins 6
Remove Reused Exterior Door Components 6
Open the dispenser 9
Uninstall the wire assembly 10
Uninstall the printer 14
Uninstall the PPUs 15
LON Terminators (if present) 17
Remove the Magnetic Boot Switch 18
Uninstall the Comm Speaker (if present). 19
Uninstall the Totalizers (If present) 22
Remove all cable harnesses from the non modular door 24
Uninstall the Non Modular Door 25
Installation Instructions for Encore 300
Mount the Modular Door 27
Prepare the Modular Door 34
Prepare the Nozzle Boot 34
Install the nozzle blanks and decals. 35
Install the Nozzle Boot 39
Prepare the PPU Bracket 40
Install the PPU Bracket. 43
Install the Optic 12 Modular Plate 45
Transfer Components 47
Install the Grade Selection Assembly 52
Power Supply Assembly (497-0513436) Installation 56
Prepare the power supply brackets 56
Installing the power supply 56

x
Install the Comm Cable to the Dispenser Cub 58
Wiring in the Power Supply to the Pump Power Distributor for the
First (Side A)PSU 58
Install the power and data connections to the Optic 12 64
Install the Printer 65
Closing the Dispenser 65

Installation Components 1
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 QTY Description Photo Reference
497-0512481 1 Replacement Modular Door
497-0513278 1 Top Hinge Pin
497-0514038 1 Lock Bracket
497-0512905 1 Lower Latch Bracket
006-8625195 1 Lower Latch Bracket Nut
497-0512968 1 Electrical Top Plate
497-0513804 1 Weather Shield
006-8625157 1/4" Hex Screw Bolt
497-0513805 4 Nozzle Boot Bracket
497-0513806 4 Nozzle Boot Bracket
006-8625160 8 Thread Forming Screw
497-0512953 4 Lower Blanking Plug
497-0512580 3 Aluminum Blank
006-8625190 8 Phillips Screw
006-8625159 8 Machine Screw
497-0512920 4 Top Boot Aluminum Blank
497-0512581 1 Full Blanking Label
497-0512882 2 Single Blanking Label
497-0514158 1 PPU Stabilizing Bar

2 Installation Components
Part Number QTY Description Photo Reference
006-8611097 5 PPU Bracket Screw
497-0514262 1 PPU Plate Bracket
006-8611952 2 PPU Bracket Nut
497-0513269 1 Encore 300 PPUData Ribbon Cable
497-0513268 1 Encore 300 PPU LEDRibbon Cable
497-0512995 1 Encore 500 Non LED PPU Ribbon Cable
497-0512996 1 Encore 500 LED PPU Ribbon Cable
497-0514480 4 Reed Switch Extension Cable
006-8625344 4 Nozzle Boot Switch Screw
006-8625156 8 Attaching Washer
006-8625189 5 Modular Panel Screw
497-0512903 1 Totalizer Bracket
497-0513436 1 PSU Assembly
006-8617730 2 PSU Nuts
497-0513214 1 Encore ACPower Adapter Cable
497-0513685 1 Encore 300 Comm Adapter Cable
497-0513679 1 Encore 500/500s Comm Adapter Cable
497-0514570 1 Encore AC Adapter Y Cable
497-0513383 1 Cat-5e Data Cable(6ft, red)
497-0513384 1 Cat-5e Network Cable (6ft, yellow)

Tools Required 3
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
• Socket Wrench and Assorted Hex Sockets or Nut Drivers
• 1/4" and 7/16" (Could vary by pump)s
• Security Torex Set
• Wire Stripper and Cutter
• Needle-Nosed Pliers
• Small Wire/Zip-tie Clippers
Warning: Do NOT use power tools if working on a fuel station forecourt. Any spark
could cause an explosion.

4