Ovation Series

Dispensers
 WARNING

READ THIS MANUAL BEFORE YOU BEGIN

Dispensers have both electricity and a hazardous, flammable and potentially explosive liquid. Failure to
follow the below precautions and the Danger, Warning and Caution instructions in this manual may result
in serious injury. Follow all rules, codes and laws that apply to your area and installation.

SAFETY PRECAUTIONS - MAINTENANCE

Always make sure ALL power to the dispenser is turned OFF before you open the dispenser cabinet for
maintenance. Physically lock, restrict access to, or tag the circuit breakers you turn off when servicing the
dispenser. Be sure to trip (close) the emergency valve(s) under the dispenser BEFORE beginning
maintenance.

Make sure that you know how to turn OFF power to the dispenser and submersible pumps in an emer-
gency. Have all leaks or defects repaired immediately.

EQUIPMENT PRECAUTIONS

Be sure to bleed all air from product lines of remote dispensers and prime suction pumps before dispensing
product, otherwise, damage to the equipment may occur. Always use the approved method for lifting the
dispenser. Never lift by the nozzle boot, sheet metal, valance, etc., otherwise equipment damage or per-
sonal injury may occur.

HOW TO CONTACT WAYNE

Trouble with the installation and operation of the dispenser should be referred to your authorized Wayne
service personnel or Wayne Technical Support (1-800-926-3737).

INDICATORS AND NOTATIONS

Danger indicates a hazard or unsafe practice which, if not avoided, will result in severe injury
DANGER or possibly death.

Warning indicates a hazard or unsafe practice which, if not avoided, may result in severe
WARNING injury or possibly death.

CAUTION Caution indicates a hazard or unsafe practice which, if not avoided, may result in minor injury.

Important information to consider, otherwise, improper installation and/or damage to compo-

NOTE:
nents may occur.
 Ovation Series
Dispensers

Service

November 2002 Part No. 920525-002 Rev A

Part No. 920525-002 Rev A November 2002
 Table of Contents
Title Page
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Components and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Ovation with Standard Display - QVGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Ovation with VGA Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Regional Service Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Ovation Model Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 ELECTRONIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Service Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Location of Components - Standard Ovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Location of Components - Ovation with VGA Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 BOARD LAYOUTS AND CONNECTOR DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 QCAT Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Sales Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Unit Price Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 ADS Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 BCB Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Nozzle Boot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Nozzle Boot Flipper/Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 QVGA Component Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.1 Keypad and Display Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.2 QVGA Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.4.3 QCAT Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5 Sales Display Board and Backlite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Unit Price Display Board and Backlite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.7 PTS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.8 EM Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9 Card Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10 Clamshell Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.11 VGA Component Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11.1 VGA Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11.2 BCB Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.3 Softkey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.4 ADS Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.5 ADS Board Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11.6 VGA Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

iii

November 2002 Part No. 920525-002 Rev A

 Table of Contents (continued)
Title Page

APPENDIX A CAT SELF-TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

APPENDIX B LOCAL AUTHORIZE/STAND-ALONE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 43

APPENDIX C WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

iv

Part No. 920525-002 Rev A November 2002

 1. INTRODUCTION

This manual contains service instructions for Wayne Ovation model series dispensers. This manual
is an addendum to, and should be used in conjunction with, the 3/Vista (iGEM) service manual, part
number 920525, which should be used to program dispenser functions and troubleshoot iGEM
related pump problems. Use this addendum to service components unique to Ovation dispensers.

1.1. COMPONENTS AND FEATURES

Ovation dispensers incorporate the use of some familiar components: the iGEM computer
board and its associated AC and DC power boards are mounted in the electronic head, and the
iMeter, Intelligent Pulser and proportional flow control valves in the hydraulics cabinet.

A new feature with Ovation dispensers is the side-hinged service door that allows for easy
access to the electronic components inside. Most of the new electronic components are
serviced from the back side or the front side of the service door. These components are the
new PTS, unit price and sales display boards.

One of the main features of the Ovation dispenser is the customer display screen. On the
standard Ovation dispenser, the display panel on the front bezel will have the QVGA display
screen with a keypad underneath and an associated QCAT board located on the inside of the
service door. The standard Ovation is shown on the cover of this manual.

As a dispenser option, the display panel on the front bezel may be equipped with the larger
VGA display screen assembly as shown on the following page. With this option, an associated
ADS board will be located inside the head above the dispenser computer and a larger version
of the BCB board will be located on the inside of the service door.

1.2. RELATED DOCUMENTS

3/Vista Dispenser Service manual, part number 920525

Service Terminal Instruction manual, part number 920547

Ovation Dispenser Installation manual, part number 920559

Ovation Dispenser Service manual, part number 920525-002

1
November 2002 Part No. 920525-002 Rev A
1.3. OVATION WITH STANDARD DISPLAY - QVGA

The standard Ovation dispenser is equipped with the 5.7" QVGA display screen and keypad
as shown in Figure 1-1 below; the barcode scanner shown is optional. Resolution wise, the
QVGA screen is one-quarter (Q) the size of the VGA - Video Graphics Array screen shown
in Figure 1-2 on the following page.

QVGA SCREEN

CAT KEYPAD

FIGURE 1-1 STANDARD OVATION MODEL.

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Part No. 920525-002 Rev A November 2002
1.4. OVATION WITH VGA DISPLAY

Ovation dispensers may be equipped with the optional VGA (Video Graphics Array) display
screen as shown in Figure 1-2 below. With this option, the display screen is 10.4" and the
CAT keypad is located under the card reader.

VGA SCREEN

CAT KEYPAD

FIGURE 1-2 OVATION WITH THE VGA DISPLAY OPTION.

3
November 2002 Part No. 920525-002 Rev A
1.5. REGIONAL SERVICE OFFICES

Any service problems that cannot be solved should be referred to Wayne Technical Support or to the
appropriate regional service office below.

Wayne Technical Support 1-800-926-3737

Austin, TX 24 hours/7 days
Northeast Regional 410-546-2321
Service Office 8:30AM-5:00 PM Eastern
Salisbury, MD
Southeast Regional 770-926-5595
Service Office 8:30AM-5:00PM Eastern
Atlanta, GA
Central Regional 847-719-2301
Service Office 8:30AM-5:00PM Central
Chicago, IL
Southwest Regional 714-429-1029
Service Office 8:30AM-5:00PM Pacific
Costa Mesa, CA
Northwest Regional 916-691-5227
Service Office 8:30AM-5:00PM Pacific
Elk Grove, CA

INTERNATIONAL OFFICES

Caribbean and Latin America (Voice) 512-388-8624

Service Office (FAX) 512-388-8643
Austin, TX USA
Mid-East and Africa (Voice) 44-1635-874881
Service Office (FAX) 44-1635-876633
United Kingdom
Far East (Voice) 65-422-2397
Service Office (FAX) 65-225-6604
Singapore

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Part No. 920525-002 Rev A November 2002
1.6. OVATION MODEL DESIGNATIONS

Ovation dispenser model numbers begin with the letter B or R as defined by the model designation chart
below, where B = Blender and R = Regular piped/standard or non-blender. Blending dispensers have two
base products, LO and HI, that are combined to provide a blended grade or grades. Non-blending dispensers
do not combine base products and are referred to as single grade or multi-grade dispensers.

FIGURE 1-3 OVATION MODEL DESIGNATION CHART. Drawing number 888779-001.

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November 2002 Part No. 920525-002 Rev A
6
Part No. 920525-002 Rev A November 2002
 2. ELECTRONIC COMPONENTS

2.1. SERVICE DOOR ACCESS

Door Locks

FIGURE 2-1 SERVICE DOOR LOCK LOCATIONS. Use Door Key part number 1-202022.

2.2. LOCATION OF COMPONENTS - STANDARD OVATION

24V P/S
on Side 2
not shown Sales
Display Board

Heater/
Fan Ass’y

QCAT Board
iGEM
Computer

Unit Price
Display Board

PTS Switches

E-M Totalizers

ISB AC AC DC Printer Card

Ass’y Relay Terminal Distr Reader
Board Block Board

FIGURE 2-2 INSIDE THE SERVICE DOOR - SIDE 1. Standard Ovation shown.

7
November 2002 Part No. 920525-002 Rev A
2.3. LOCATION OF COMPONENTS - OVATION WITH VGA DISPLAY OPTION

Additional components required to support the VGA display option are shown in Figure 2-3 and
Figure 2-4 below. The BCB board replaces the QCAT board on the service door and the ADS
board is added inside the head above the iGEM computer. A 12V Power Supply is mounted
underneath the 24V supply on side 2 as shown in Figure 2-5.

ADS Board

iGEM Computer

Card Keypad
FIGURE 2-3 INSIDE THE ELECTRONIC HEAD - SIDE 1. Ovation with VGA option.

BCB Board

FIGURE 2-4 BACK SIDE OF SERVICE DOOR. Ovation with VGA Option.
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Part No. 920525-002 Rev A November 2002
 .

24V DC Supply
iGEM Standard

12V DC Supply
for VGA Display
Option

Optional
Wayne VAC Board
not shown

Optional
Wayne TRAC Board
not shown

FIGURE 2-5 INSIDE THE ELECTRONIC HEAD - SIDE 2.

9
November 2002 Part No. 920525-002 Rev A
 3. BOARD LAYOUTS AND CONNECTOR DESCRIPTIONS

In general, the TX LEDs are red and the RX LEDs are green. The heartbeat and power LEDs are red.
3.1. QCAT BOARD LAYOUT

Keypad CAT DL LEDs

Keypad Functions TX RX TX RX
J10 J12 J13 J37 J6 JP1

TX RX
Printer
LEDs
J2
J3 Printer CAT DL
J25 Spare
JP7
TX RX
Debug JP6
LEDs

J19
24V In

J14
J20 QVGA
Display

J4 J21
J27 Card Reader
5 Volt Scanner
Power TX RX Heartbeat
LEDs

FIGURE 3-1 QCAT BOARD LAYOUT.

TABLE 3-1. QCAT BOARD CONNECTOR DESCRIPTIONS

Connector Description CONNECTS TO
J2 CAT DATA LINK RS485 PAIR 2 DATA LINK IN J-BOX
J3 RS232 FOR PRINTER PRINTER
J4 SCANNER FUNCTIONS SCANNER LITE BOARD
J6 KEYPAD, PARRELLS J37 ADA KEYPAD
J10, J12, J13 CASH ACCEPTOR CASH ACCEPTOR
J14 QVGA SCREEN LOGIC/POWER QVGA DISPLAY ASSY
J19 24 VDC POWER IN 24V DC DISTR BOARD
J20 QVGA SCREEN BACKLIGHT QVGA DISPLAY ASSY
J21 CARD READER DATA CARD READER
J25 FOR FUTURE USE - UART N/C
J27 SCANNER FUNCTIONS SCANNER, IF NO LITE BOARD
J37 KEYPAD, PARALLELS J6 TRSM KEYPAD
JP1 OPEN TEST POINTS - KEYPAD CIR N/C
JP6, JP7 PROCESSOR RESETS FOR FACTORY USE ONLY
10
Part No. 920525-002 Rev A November 2002
3.2. SALES DISPLAY BOARD LAYOUT

To
Backlight
on front
of board

J5 J3 J4 J1
FIGURE 3-2 SALES DISPLAY BOARD LAYOUT.

TABLE 3-2. SALES DISPLAY BOARD CONNECTOR DESCRIPTIONS

Connector Description CONNECTS TO
J1 BIT BUS TO COMPUTER BD iGEM BOARD
J3 STOP SWITCH SIGNAL STOP SWITCH (OPTION)
J4 BIT BUS TO UNIT PRICE UNIT PRICE DISPLAY BOARD
J5 24V IN 24V DC DISTR BOARD

3.3. UNIT PRICE DISPLAY BOARD LAYOUT

J6

If no Local
AUTH SW,
J7 Jumper
must be in for
Stand-alone J8
Operation

To Backlight
J7 Local AUTH SWITCH Jumper on front of Board
FIGURE 3-3 UNIT PRICE DISPLAY BOARD LAYOUT.

TABLE 3-3. UNIT PRICE DISPLAY BOARD CONNECTOR DESCRIPTIONS

Connector Description CONNECTS TO
J6 BIT BUS TO SALES DISPL BD SALES DISPLAY BOARD
J7 LOCAL AUTHORIZE SWITCH AUTH SWITCH (OPTION)
J8 FUTURE USE N/C
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November 2002 Part No. 920525-002 Rev A
3.4. ADS BOARD LAYOUT

Ethernet
J8

PMCA
Connector

CAN BUS
J18 Reset Button
LEDs
Normal
Operation
D1 Solid Red
24V In D2 Off
J5 D3 Solid Green

J14 Side 1 VGA J28 Side 2 VGA

FIGURE 3-4 ADS BOARD LAYOUT. Ovation with VGA option.

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Part No. 920525-002 Rev A November 2002
3.5. BCB BOARD LAYOUT

(CAN BUS loop) LEDs

J24 J22 J6 Keypad
to to to TX, RX
LEDs BCB iGEM Keypad red, green
CAN BUS activity side1 board normally strobing
LEDs
Cash Acceptor TX RX
TX, RX

LEDs
normal oper
Watchdog-
red Off
Heartbeat-
green On
solid

J3 Printer
LEDs J21
Printer Card
TX, RX LED Reader

VGA
J19 to Softkeys
24V Distr Bd J8,
J9,

JP8 JP6
JP8 is used with Bar Code Scanner
JP6 must be open (no jumper) on Side 1 BCB board
and closed (jumper in) on Side 2 BCB board

FIGURE 3-5 BCB BOARD LAYOUT. Ovation with VGA Option.

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November 2002 Part No. 920525-002 Rev A
 4. REPLACEMENT PROCEDURES

Reference letters (A) through (D) in the procedures below refer to Figure 4-1 on the following page.

4.1. NOZZLE BOOT SWITCH REPLACEMENT

1. Remove nozzle.
2. Remove the (4) 5/32" Allen head screws in the nozzle hook (A) and remove the nozzle
hook.
3. Remove the (1) 5/32" Allen screw underneath the hook (B) and, using a long T-handle
Allen wrench, remove the (2) 5/32" screws at the top of the boot, underneath the flipper.
4. Remove the boot slowly, disconnect the nozzle switch connector (C) and remove the
boot.
5. Replace the switch on the back side of the boot (C).
6. Reassemble in reverse order.

4.2. NOZZLE BOOT FLIPPER/MAGNET REPLACEMENT

1. Remove nozzle.
2. Remove the (4) 5/32" Allen head screws in the nozzle hook (A) and remove the nozzle
hook.
3. Remove the (1) 5/32" Allen screw underneath the hook (B) and, using a long T-handle
Allen wrench, remove the (2) 5/32 screws at the top of the boot, underneath the flipper.
4. Remove the boot slowly, disconnect the nozzle switch connector (C) and remove the
boot.
5. Remove the (2) hex screws (D) on back of the boot.
6. Remove the flipper retainer at the top front of the boot.
7. Remove the flipper and magnet assembly.
8. Install new flipper in the groove in the boot and position the flipper spring leg under the
top of boot casting.
9. Reassemble in reverse order.

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Part No. 920525-002 Rev A November 2002
.

(2) 5/32" Allen Screws

Nozzle Hook.
Note Position of the
Hook before removing.
Numbers shown
for reference.

(4) 5/32" Allen Screws

(1) 5/32" Allen Screw

A. B.
.

Flipper Retainer
Removes From
Front of Boot

Hex Screw (2)

Nozzle
Switch

Switch
Connector

C. FIGURE 4-1 D.

15
November 2002 Part No. 920525-002 Rev A
4.3. PROPORTIONAL VALVE REPLACEMENT

WARNING
Before removing any components, as discussed in the following sections, in the
hydraulics cabinet or in the hydraulic system of the dispenser, you should trip the
impact valve and remove power to the submersible pump for the product(s) in ques-
tion to prevent fuel spills. Failure to do so could cause a fire hazard that may result in
serious injury or death.

WARNING
Drain the fuel into an appropriate container and pour it into an underground tank to
prevent fuel drainage under and around the dispenser. Failure to do so could cause a
fire hazard that may result in serious injury or death.

Reference letters (A) through (H) in the below procedure refer to Figure 4-2 on the following
pages.

1. Adhere to the above Warnings!

2. Disconnect power to the dispenser at J3 on the AC relay board.

3. Disconnect valve wire connector inside the head.

4. Remove the safety retaining clip from the valve (A).

5. Remove product tube from valve (B); if necessary, loosen tube support bracket (C).

6. Loosen and remove the locknut on the valve conduit inside the head and loosen the
locknut under the head.
7. Remove 9/16" nut and lock washer from the coil (D).

8. Remove coil and conduit assembly (E).

9. Remove and save nut and washer at top of conduit.

10. Rotate valve 90º clockwise so that valve stem faces upward position as shown in (F).

11. Remove (2) Allen head metric screws securing the valve retaining plate (F) and remove
retaining plate (G).

12. Remove the valve from the iMeter (H).

13. On the new replacement part assembly, separate the coil/conduit assembly from the valve.

14. Install new parts in reverse order; exception: insert product tube when rotating valve back
to original position.

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Part No. 920525-002 Rev A November 2002
4.3 PROPORTIONAL VALVE REPLACEMENT, Continued

A.

B.

C.

FIGURE 4-2 PROPORTIONAL VALVE REPLACEMENT.

17
November 2002 Part No. 920525-002 Rev A
4.3 PROPORTIONAL VALVE REPLACEMENT, Continued

D.

E.

F.

FIGURE 4-2. PROPORTIONAL VALVE REPLACEMENT, continued.

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Part No. 920525-002 Rev A November 2002
4.3 PROPORTIONAL VALVE REPLACEMENT, Continued

G.

H.

FIGURE 4-2. PROPORTIONAL VALVE REPLACEMENT, continued.

19
November 2002 Part No. 920525-002 Rev A
4.4. QVGA COMPONENT REPLACEMENTS

The QVGA display screen assembly, the protective glass over the display screen, and the
keypad are removed from the front of the bezel. The QCAT board is removed from the back
side of the bezel (service door). In either case, the service door must be opened to gain
access to these components.
Disconnect power to the dispenser before performing the component replacement proce-
dures in the following sections of this manual. Power to the dispenser can be disconnected
at J3 on the AC Relay board as referenced in the 3/Vista service manual, p/n 920525.
Adhere to the warnings in the component replacement section of that manual when
performing replacement procedures in this addendum.

4.4.1. Keypad and Display Glass Replacement

Reference letters (A) through (E) in the following procedures refer to Figure 4-3 on the
following pages.
1. Remove the (8) Phillips head screws on back of the service door (A).
CAUTION: Remove the top center screw last using left hand while holding front
panel in with right hand to avoid the panel falling out the front of the service door.
Note: The three screws at the bottom and one on each side are not visible in the photo.

2. Lower the panel from the front as shown in (B).

3. Disconnect the keypad cable (C).

4. Lay panel on flat surface (D).

5. Proceed with step 6 to replace the keypad or step 7 to replace the display glass.

6. A. Remove the (4) Phillips screws that secure the keypad (D) and remove the keypad.
B. Replace in reverse order, ensuring that ground strap is secured under corner screw.
C. Proceed to step 8.

7. A. Remove the (4) Phillips screws that secure the bracket and remove the bracket (D).
B. Replace the display glass and reinstall bracket.

8. Reinstall panel in reverse order. Be sure to reconnect keypad cable and grounding strap.

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Part No. 920525-002 Rev A November 2002
.

Remove this screw

last while holding
front of panel

(8) Phillips screws

securing the
QVGA panel.
3 bottom and
2 side screws
not shown.

QCAT Board

FIGURE 4-3 A.

QVGA
Display Screen

Display Glass

Keypad

FIGURE 4-3 B.

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November 2002 Part No. 920525-002 Rev A
.

Keypad Cable
Ground Strap

FIGURE 4-3 C.

KEYPAD
Phillips Screws (4) TYP

Ground Strap secured

under corner screw

BRACKET
screw location
Phillips (4) TYP

FIGURE 4-3 D.

22
Part No. 920525-002 Rev A November 2002
 (2) Wires to J20
on QCAT Board

Ribbon Cable Phillips Screws

to J14 on (4) TYP
QCAT Board
FIGURE 4-3 E. QVGA DISPLAY.

(6) TYP
Phillips
screws

FIGURE 4-4 QCAT BOARD.

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November 2002 Part No. 920525-002 Rev A
4.4.2. QVGA Display Screen Replacement

Reference letters (A) through (E) in the below procedure refer to Figure 4-3 on the previous pages.

1. Remove the (8) Phillips head screws on back of the service door (A).
CAUTION: Remove the top center screw last using left hand while holding front
panel in with right hand to avoid the panel falling out the front of the service door.
Note: The three screws at the bottom and one on each side are not visible in the photo.

2. Lower the panel from the front as shown in (B).

3. Disconnect the keypad cable as shown in (C).
4. Lay panel aside.

5. Disconnect the ribbon cable and the wires from the screen assembly shown in (E).
6. Remove the (4) Phillips screws (E) and remove the screen assembly.
7. Replace in reverse order.

4.4.3. QCAT Board Replacement

The QCAT board is located on the inside of the service door. Refer to Figure 4-4 during the
below procedure.

1. Disconnect all wiring from the QCAT board.

2. Remove (6) Phillips screws from the board and lift the board off the standoffs.
3. Replace in reverse order.
4. Set the CAT address (ID#).

24
Part No. 920525-002 Rev A November 2002
4.5. SALES DISPLAY BOARD AND BACKLITE REPLACEMENT

The Sales Display board is located at the top of the service door; see previous Figure 2-2.

Refer to Figure 4-5 below during this procedure.

1. Disconnect all wiring to the display board.

2. Remove (4) Phillips screws located at the corners of the board and remove the board.
Do not remove the outer bracket screws securing the display glass.
3. To remove the backlite, remove the (2) Backlite Retaining Tabs shown below, discon-
nect and slide lamp assembly and cover out from under the LCD on front of the board.
4. Replace in reverse order.

Phillips Phillips
Screws Screws
(4) Typ

(2) Backlite Outer Bracket Screws

Retaining Tabs Securing Display Glass

FIGURE 4-5 SALES DISPLAY BOARD.

25
November 2002 Part No. 920525-002 Rev A
4.6. UNIT PRICE DISPLAY BOARD AND BACKLITE REPLACEMENT

The Unit Price Display board is mounted on the PTS panel located at the bottom of the
service door, Figure 4-6 below. The entire panel can be removed by removing 3 top and 2
bottom panel screws and pulling bottom of panel out from the front of the dispenser.
However, to replace only the Unit Price Display board or to replace the backlite:
1. Disconnect the cable at the top of the board.
2. Disconnect the PTS switch connectors at the bottom of the board.
3. Remove (4) Phillips screws and top metal bracket that secure the board to the panel.
4. Lift the board up and out from the two board retaining slots located on the panel.
5. To remove the backlite, remove the (2) Backlight Retaining Tabs shown below, discon-
nect and slide lamp assembly and cover out from under the LCDs on front of the board.
6. Replace in reverse order.

(3) Top panel

Screws

(4) Phillips
Screws and
Bracket

(2) Backlite
Retaining Tabs

(2) Bottom
Panel Screws

Board Retaining (2) Screws Securing

Slots (2) TYP PTS Switch Ass’y

FIGURE 4-6 UNIT PRICE DISPLAY PANEL AND PTS SWITCHES. 3 product panel shown.

4.7. PTS SWITCH REPLACEMENT

1. Disconnect the switch assembly from the unit price display board; see Figure 4-6.
2. Remove the (2) screws securing the switch assembly.
3. Replace the switch, and the o-ring, and re-secure assembly with the two screws.
4. Reconnect the switch to the unit price display board.

26
Part No. 920525-002 Rev A November 2002
4.8. E-M TOTALIZER REPLACEMENT

1. Remove (4) screws securing the totalizer bracket at the bottom of side 1 service door,
as shown in Figure 4-7.
2. Lay bracket down on the inside edge of the service door and disconnect the totalizer
cable.
3. Remove (2) screws and nuts securing the totalizer to the bracket and remove totalizer.

(4) Screws
Typ

(2) Screws
Typ

FIGURE 4-7 E-M TOTALIZERS.

4.9. CARD READER REPLACEMENT

1. Disconnect the cable at the top of the card reader; see Figure 4-8.
2. Remove (4) screws securing the card reader base to the bezel.
3. Gently pull back on the card reader base to remove from bezel and gasket.

(4) Screws
Typ

FIGURE 4-8 CARD READER.

27
November 2002 Part No. 920525-002 Rev A
4.10. CLAMSHELL PRINTER REPLACEMENT

Reference letters (A) through (H) in the below procedure refer to Figure 4-9.

1. Disconnect the power and data cables from the rear of the printer (A).

2. Remove the (2) Phillips head screws securing the bracket (A).

3. Slide the printer and bracket out from the enclosure (B).

4. Turn printer over and remove the (2) bottom screws (A) securing printer to the bracket.

5. Slide the printer off the bracket.

6. Replace with new printer in reverse order.

7. Open the bezel printer door and pull down the inside printer door (C) to load paper.

8. Important: While holding the paper roll, pull the roll tight (D) and ensure there are no
loops underneath the roll.

9. Place paper roll inside the printer and feed paper from top of roll through chute (E), (F).

10. .While pulling slightly on the paper, push printer door up to the closed position.

11. Wait for printer to print test receipt.

12. Cut receipt, close and lock printer door.

(2) Phillips
Screws
Securing
Bracket

Power
Connector

Data
Connector

Slide Printer and Bracket

(2) Bottom Screws Securing Out from Enclosure
Printer to Bracket
A. B.

FIGURE 4-9 PRINTER REPLACEMENT.

28
Part No. 920525-002 Rev A November 2002
 4.3 PRINTER REPLACEMENT, Continued

Pull Out
From Top

Pull Printer Door Out

Important: Pull Paper Roll Tight
and Down from Top
C. D.

E.
F.

FIGURE 4-9. PRINTER REPLACEMENT, continued.

29
November 2002 Part No. 920525-002 Rev A
4.11. VGA COMPONENT REPLACEMENTS

The VGA display is replaced in the same manner as the QVGA display. Refer to photos
shown previously in Figure 4-3. The BCB board is replaced in the same manner as the
QCAT board shown in previously Figure 4-4. The VGA display is replaced from the front
of the bezel, after removing the screws on back of the service door that secure the VGA
panel. The BCB board is replaced from the back of the service door.

Disconnect power to the dispenser before performing the component replacement proce-
dures in the following sections of this manual. Power to the dispenser can be disconnected
at J3 on the AC Relay board as referenced in the 3/Vista service manual, p/n 920525.
Adhere to the warnings in the component replacement section of that manual when
performing replacement procedures in this addendum.

4.11.1. VGA Display Screen Replacement

1. Disconnect the (2) softkey connectors at the VGA display panel.

2. Remove the (8) Phillips head screws (as shown in Figure 4-3 A or Figure 4-10) on back
of the service door that secure the VGA panel.
CAUTION: Remove top center screw last using left hand while holding front panel in
with right hand to avoid the panel falling out the front.
Note: The three screws at the bottom and one on each side are not visible in the photo.
3. Lower the panel from the front as shown previously in Figure 4-3 B.
4. Lay panel aside.
5. Disconnect the ADS cable from the VGA display screen.
6. From the front side of the VGA screen (similar to Figure 4-3 E) remove the (4) Phillips
screws securing the corners of the screen to the inside metal panel and remove the
screen assembly.
7. Replace in reverse order.
Remove this screw
VGA Display Screen last while holding
front of panel.

(8) Phillips screws

securing the
VGA panel.
3 bottom and
2 side screws
not shown

BCB Board

Softkey cables
to VGA display
panel

FIGURE 4-10 VGA DISPLAY MOUNTED TO PANEL BEHIND THE BCB BOARD.
30
Part No. 920525-002 Rev A November 2002
4.11.2. BCB Board Replacement

The BCB board is located on the inside of the service door.

1. Disconnect all wiring from the BCB board. Refer to Figure 4-11.
2. Remove (6) Phillips screws from the board and lift the board off the standoffs.
3. Replace in reverse order.
(6) TYP
Phillips
screws

FIGURE 4-11 BCB BOARD.

4.11.3. Softkey Replacement

1. Disconnect the softkey cable behind the display panel.

2. Using a thin blade screwdriver as shown in Figure 4-12, gently peel back and remove
the softkey adhesive strip from the panel.
3. Peel paper from adhesive on new softkey strip, install the new strip and reconnect cable.

FIGURE 4-12 SOFTKEYS.

31
November 2002 Part No. 920525-002 Rev A
4.11.4. ADS Board Replacement

The ADS board is located above the iGEM pump computer inside the electronic head.
Refer to Figure 4-13 during the following procedure.

1. Disconnect power to the dispenser at J3 on the AC Relay board.

2. Disconnect cables from the ADS board.
3. Remove (4) Phillips screws (one in each corner of the board).
4. Hold board and remove (1) Phillips screw in the center of the board and lift board off
the standoffs.
5. Install new board using reverse procedure and reconnect cables to the board.
6. Reconnect J3 power to the AC relay board.
7. Re-address the board using the procedure on the following page.

Phillips Screw (1)

ADS Board
Reset Button

Phillips Screw
(4) TYP

iGEM
Board

FIGURE 4-13 ADS BOARD.

32
Part No. 920525-002 Rev A November 2002
4.11.5. ADS Board Addressing

The ADS board performs functions of the CAT control board. The ADS board should be
addressed to the same fueling point ID numbers as the pump computer.

Side 1 (A) of the dispenser is the junction box side and side 2 (B) is the opposite side. Both
sides are addressed using the numeric keypad on side A.

Procedure:

1. Press the Reset button SW1 on the ADS board (Figure 4-13).
2. When the VGA display on side A shows a “Please Wait…” message, begin pressing
any button on the numeric keypad every few seconds. After a short time, the display
will change to “Please Enter Fueling Point ID for Side A".
3. Key in the address of side A, then press the Enter key. The display will change to
“Please Enter Service Mode for Side A (0 = Full, 1 = Self)”. Use the Clear key to back-
space and correct errors.
4. Key in the selection (0 or 1), then press the Enter key. The display will change to
“Please Enter Fueling Point ID number for Side B”.
5. Key in the address of side B, then press the Enter key. The display will change to
“Please Enter Service Mode for Side B (0 = Full, 1 = Self)”.
6. Key in the selection (0 or 1), then press the Enter key. The display will change to
“Please Enter the 12-digit IP of FC”.
7. Key in the 12-digit IP address of the Forecourt Controller PC and then press the Enter
key. The display automatically inserts a period between each group of three numbers.
Note: The IP address will vary per customer specific application.
8. Select: 1. for XML Mode (if the system is connected to an MPOS Server)
2. for Non-XML Mode
9. The display will change to “Press any key on Side A in 10 seconds to reconfigure
fueling points”. If the addresses were entered correctly, allow the ADS board to
continue initializing.
10. The ADS board will connect to the forecourt controller, download HTML pages, and
enter a normal idle state, such as "Insert Card".

33
November 2002 Part No. 920525-002 Rev A
4.11.6. VGA Power Supply Replacement

The 12 VDC power supply assembly for the VGA display is located inside the head on side-
2 just below the iGEM 24 VDC supply. Refer to Figure 4-14.

1. Disconnect wiring to the 12V supply assembly.

2. Remove (4) Phillips screws located at the corners of the board.
3. Replace in reverse order and reconnect wiring.
4. Cycle power to the dispenser or reset the ADS board as necessary.

24V Power Supply

iGEM Standard

Phillips Screws
(4) TYP
12V Power Supply
VGA Option

FIGURE 4-14 12V POWER SUPPLY.

34
Part No. 920525-002 Rev A November 2002
 APPENDIX A

CAT SELF-TEST PROCEDURE

The following are instructions for testing the CAT (Customer Activated Terminal) on the dispenser.

1. CAT SYSTEM SELF-TEST

The following paragraphs provide instructions for testing and setting the address of the CAT. During the
self-test, the system is designed to pause 25 seconds for a response to self-test prompts. When the 25 second
time limit expires, the system automatically advances to either the next self-test or returns to the on-line
mode.
1.1. ENTERING SELF-TEST MODE

Step 1 Power down the CAT.

Step 2 Power up the CAT while holding down any key on the keypad until the alternating message below
appears on the display.

Step 3 Press the indicated key or press ENTER to continue to the next screen prompt.

CONTRAST ADJUST YES = DARKER

PRESS NEXT TO EXIT NO = LIGHTER

1.2. SOFTWARE REVISION LEVEL AND DATA LINK ADDRESS

Step 1 Continue holding the key down until the “REV” message below appears on the display, then
release. Once the system displays the “REV” message, the module has successfully entered the
self-test mode.

REV XXX MM/DD/YY

ADDRESS = YY

The top row of information in the “REV” message display represents the module software revision.
The bottom row is the current terminal address for the data link. Data link addresses are assigned to
the module using the same number as the fueling point.

Step 2 If the CAT’s data link address is correct, press the ENTER key. To change the address, enter the
correct address number on the keypad and press ENTER (if the CAT is equipped with a DES
keypad, the keypad revision will be displayed).

35
November 2002 Part No. 920525-002 Rev A
1.2 CAT SELF TEST, continued

Step 3 Verify that the Keypad revision and BCB revision levels are displayed on the screen. The
BCB revision displayed will be the software revision of the BCB board or the QCAT board
whichever applies.

Step 4 Press ENTER to continue.

KEYPAD REV __

BCB REV __

1.3. CONFIGURE CARD READER

When the system displays the prompt below, proceed as follows:

*CONFIGURE CARD READER

(Y/N)

Answering YES to the prompt causes the screen to display the prompt below

or

press NO on the keypad and the system automatically proceeds to the "Offline msg" prompt.

TRACK 1 OR 3
(1/3)

To answer the “Track 1 or 3" prompt, perform the following steps:

Step 1 Press 1 on the keypad.

Step 2 Press the ENTER key and the following prompt will be displayed.

36
Part No. 920525-002 Rev A November 2002
1.3 Configure Card Reader, continued

Offline msg: Out

of Service (Y/N)

Step 3 Answer NO to the above prompt.

Step 4 Answer the following prompts as they appear:

Long Receipts?
(Y/N)

Fixed Length Scanner?

(Y/N)

Self Test?
(Y/N)

Answering YES to the above prompt will begin the display, printer and card reader self test as discussed on
the following pages.
Answering NO to the above prompt will display the Exit Prompt shown below.

Exit Test Mode?

(Y/N)

Answer YES to the above prompt to exit and return the CAT to normal operation.
Answer NO to the above prompt to return to the beginning of the Self Test mode.

37
November 2002 Part No. 920525-002 Rev A
1.4. DISPLAY SELF-TEST

A series of actions appear on the screen for the display self-test. Two rows of black squares followed
by numbers and letters scroll from right to left across the screen during the display self-test.

1.5. PRINTER SELF-TEST

The message shown below appears continuously on the display screen during the printer self-test.

PRINTING TEST

The printer self-test performs the following actions in sequence:

1. Advance the paper one half inch.

2. Print CAT information (ROM version, processor type, etc.)
3. Print five rows of characters followed by five more rows of slashes (\ and /).
4. Advance the paper one inch and cut the paper.

Once the paper is cut, the system automatically activates the card reader self-test.

1.6. CARD READER SELF-TEST

Any type of valid credit card can be used for the card reader test. The card reader self-test begins
with the screen prompt shown below.

INSERT CARD

Step 1 Insert the card.

Once the credit card is inserted into the card reader, the CAT computer reads data from the
card.

PULL IT OUT

Step 2 Remove the credit card in one smooth continuous motion when the above prompt appears
on the display screen.

38
Part No. 920525-002 Rev A November 2002
1.6. CARD READER SELF-TEST, continued

A series of digits appear on lines 1 and 2 of the display screen. This information is the card data.

Step 3 Press the NEXT key and continue to the keypad self-test.

If either of the following prompts appear on the display screen, “TRACK READ ERROR” or
“CARD READ ERROR”, the credit card is invalid. Depending on the type of invalid credit card, one
or two rows of digits may appear on the display screen. To complete the card reader self-test, select a
different credit card and repeat procedure. If the error message continues to be displayed, the card
reader may need replacing.

TRACK READ ERROR

CARD READ ERROR

1.7. KEYPAD SELF-TEST

Testing the CAT keypad requires the operator to select keys on the keypad and verify the information
on the display screen. Refer to the Keypad Test table on the following page.

Complete the following steps to test the keypad.

Step 1 Press a key listed under the column heading Native Mode Key.

Step 2 Verify the two digit number on the display screen with the number listed under the column
heading Keypad Coordinate.

The screen does not display a two digit number when the NEXT key is pressed. This key
remains functional during the keypad self-test.

Step 3 Repeat Steps 1 and 2 until all of the keys are tested.

Step 4 Press the NEXT key to proceed to the memory self-test.

39
November 2002 Part No. 920525-002 Rev A
1.7 KEYPAD SELF-TEST, continued
KEYPAD TEST

Native Mode Key Keypad Coordinate

CLEAR 00

7 01

4 02

1 03

0 10

8 11

5 12

2 13

ENTER 20

9 21

6 22

3 23

CANCEL 30

NO 32

YES 33

NEXT Proceed to memory test.

1.8. SYSTEM MEMORY SELF-TEST

A successful memory self-test will display the message below.

MEMORY OK

An unsuccessful memory self-test will display one of the following: “BIT 0" through “BIT 7".
A BIT error message is an indication of a defective board in the CAT system. An example of a
BIT error message that may appear on the display screen is shown below.

BIT 4

40
Part No. 920525-002 Rev A November 2002
1.9. EXIT SELF-TEST MODE

Once the system successfully completes the memory self-test, the exit prompt shown below appears
on the screen.

Complete one of the following steps:

Press the YES key to exit the self-test mode,

or

Press the NO key to begin the self-test mode again.

EXIT TEST MODE

(Y/N)

41
November 2002 Part No. 920525-002 Rev A
42
Part No. 920525-002 Rev A November 2002
 APPENDIX B

LOCAL AUTHORIZE / STAND-ALONE OPERATION

When the dispenser is not equipped with a Local Authorize Switch, the jumper (J7) shown below must be in
place to enable Stand-alone operation.

At new dispenser Startups, after product lines have been purged and dispenser operations checked, once the dis-
penser is switched over to control system operation, the jumper should be removed as an extra security measure.
If stand-alone operation is required in the future, the jumper will have to be re-installed.

Service Door

Local
AUTH
Jumper
J7

Unit Price Display Board

43
November 2002 Part No. 920525-002 Rev A
44
Part No. 920525-002 Rev A November 2002
 APPENDIX C

WIRING DIAGRAMS

45
November 2002 Part No. 920525-002 Rev A
 46
November 2002 Part No. 920525-002 Rev A
47
Part No. 920525-002 Rev A November 2002
48
Part No. 920525-002 Rev A November 2002
 SERVICE

Ovation Series
Dispensers

Written by S. G. Martin
This manual was produced using Adobe® FrameMaker® and Adobe® PhotoShop®
Page design uses Times New Roman and Arial Fonts
Manuals were electronically produced on a Xerox Docutech Publishing System at 600 dpi

© Copyright 2002 Dresser, Inc.

All rights reserved.
Printed in the United States of America.

Adobe® FrameMaker®and Adobe® PhotoShop® are trademarks of Adobe Systems, Inc.

This manual and the software described within are furnished under license and may be used or copied only in accordance
with the terms of such license.

No part of this publication may be electronically or mechanically reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, except as permitted by such license. Translation of this material to another language without
express written permission of Dresser, Inc. is prohibited.

The information in this publication is for informational use only and is subject to change without notice. The contents
should not be construed as a commitment by Dresser, Inc. who assumes no responsibility or liability for inaccuracies that
may appear in this publication.

Dresser Wayne, Dresser, Inc., is located at 3814 Jarrett Way, Austin TX 78728.
Wayne’s general telephone number is (512)-388-8311.
 NOTE: “This equipment has been tested and found to comply
with the limits for a Class A digital device, pursuant to Part 15 of
the FCC Rules. These limits are designed to provide reason-
able protection against harmful interference when the equip-
ment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manu-
al, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to
cause harmful interference in which case the user will be re-
quired to correct the interference at his own expense.”

Dresser Wayne, Dresser, Inc. 3814 Jarrett Way, Austin, TX 78728 (512) 388-8311
Part No. 920525-002 Rev A ©2002 Dresser, Inc. 11/02