7872 Scanner Upgrade to Scanner/Scale

7872 Scanner Upgrade toScanner/ScaleFor use with the following:7872-2990-9090 (7872-1000 to 7872-2000)7872-5990-9090 (7872-6000 to 7872-5000)497-0422375Release AAugust 6, 2001Information ProductsRSD-Atlanta

7872 Scanner Upgrade to Scanner/ScaleUpgrade InformationTo upgrade and NCR 7872 Scanner to include a scale requires installing a scale. Thescale is a factory built, tested, and serialized instrument. This includes a new VIDSboard containing the scale circuitry, the Load Cell / H Bar assembly, and theCalibration Switch. Fastened to the H Bar is a Scale Identification Label containing theApproval/Certificate number issued by the government agency where the scaleupgrade is being installed. The label also includes the scale parameters, which identifythe capability of the scale. Other miscellaneous components are also required. Thereare two NCR 7872 Scanner to Scanner/Scale upgrades.• 7872-2990-9090 – converts an NCR 7872-1000 full size scanner to an NCR 7872-2000Scanner/Scale.• 7872-5990-9090 – converts an NCR 7872-6000 compact scanner to an NCR 7872-5000 Scanner/Scale.All components are the same except the H Bar, which is smaller for the compactscanner conversion. Since the installation procedure is the same, this document ispackaged with both upgrades. Although most drawings show the full size scanner, theprocedures apply to both sizes.Note: Before installing this upgrade, verify that the Approval/Certificate numbermatches the country where you are performing the upgrade.2 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleRemove the Top Plate18438The Top Plate sits on top of the NCR 7872 and is not fastened in any way. Most TopPlates do not have any lifting device.1. Remove power from the NCR 7872 by turning off the checkstand circuit breakerthat supplies power to the outlet.2. Carefully extend your index finger under the Top Plate at one of the front corners.3. Raise the Top Plate enough to get your other hand under it. Now grasp both sidesof the Top Plate and lift it off the unit.497-0422375 Release A 08/01 3 of 20

7872 Scanner Upgrade to Scanner/ScaleRemove the NCR 7872 fromCheckstand18401The NCR 7872 must be removed from the checkstand.1. With one hand grasp the back of the Tower Cabinet Assembly. With the otherhand grasp the front of the unit.2. Lift the NCR 7872 up out of the cutout in the checkstand.4 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleRemove the Tower CabinetAssembly17953The Tower Cabinet Assembly covers the rear portion of the unit. It is fastened withtwo screws, one on each side.1. Remove the two mounting screws.2. Carefully tilt the Tower Cabinet Assembly forward a little to release the latches,then lift it up off the unit.3. Disconnect the Operator Control Panel harness from the VIDS Board (J4).497-0422375 Release A 08/01 5 of 20

7872 Scanner Upgrade to Scanner/ScaleRemove the VIDS Board17988The Video Interface Digital Scale (VIDS) Board mounts to the Optics Tower with twoscrews. All cables and internal harnesses connect to this board.1. Disconnect all cables and internal harnesses from the VIDS Board.• J1 – Speaker• J2 – Interface cable• J5 – Power Supply• J6 – Spinner Motor• J7 – Laser Module Assembly• J8 – RS-232 Peripheral (if present)• J10 – RS-232 Peripheral (if present)• J11 – Checkpoint (if present)2. Remove the two mounting screws.3. Carefully lift the VIDS Board from the unit and place it on an anti-static mat.6 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleRemove Top Plate Support PostsFour Top Plate Support Posts (with rubber bumpers) are mounted in the FrontSupport. These must be removed since the Top Plate is supported by the H Bar in ascale unit. Be sure to remove the posts as well as the rubber bumpers.Note: Extra force is required to remove the support posts from the Front Supportbecause they are fastened with Locktight.Top Plate Support Postswith Rubber BumpersFront Support19214497-0422375 Release A 08/01 7 of 20

7872 Scanner Upgrade to Scanner/ScaleInstall the Calibration Switch17962The Calibration Switch is fastened to the mounting bracket with one mounting nut.1. Slide the Calibration Switch toward the front, through the slotted hole in themounting bracket.2. Tighten the Mounting Nut.3. Route the Calibration Switch cable along the side of the front part of the OpticsCasting. There are tabs in the Front Support that hold the cable. The cable goesunder the back part of the Optics Casting and up though a hole in the back of theunit.Calibration Switch CableCable ClampLoad Cell Cable184518 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleInstall the Load Cell / H BarNote: DO NOT disassemble the Load Cell / H Bar assembly. This is a factory set andtested scale assembly.The Load Cell and H Bar come assembled in this kit. To install this assembly, first routthe Load Cell cable, then install the copper tape over the Load Cell cable and theCalibration Switch cable, and then mount the Load Cell assembly.Note: Do not install the Load Cell Set Screw at this time or you may damage the LoadCell.1. Thread the Load Cell cable through the hole in the bottom of the Optics Casting,then route the cable along side the Calibration Switch cable.2. Remove the paper backing from the Cable Clamp and install it on the OpticsCasting to hold the cables in place. Refer to the previous illustration.3. Fasten the white Ferrite Bead around the end of the Load Cell cable, close to whereit connects to the VIDS board.4. Set the Load Cell into the cutout in the front of the Optics Casting. Do not fasten itat this time.5. There are two pieces of copper tape that must be installed over the cables toprevent unacceptable levels of radio frequency interference.Copper Tape17960497-0422375 Release A 08/01 9 of 20

7872 Scanner Upgrade to Scanner/Scale6. With one hand hold the Nut Plate under the Optics Casting while using the otherto install the two mounting screws – hand-tighten the screws.Plastic Plug184397. Align the Load Cell / H Bar assembly so that the H Bar is parallel with the sides ofthe Front Support.8. Using a 3/16-inch hex key wrench and a torque wrench, tighten the two mountingscrews to 17 Nm (150 inch-pounds) of torque.9. Install the two plastic plugs in the holes in the H Bar where the Load Cellmounting screws are located. Once installed, these plastic plugs cannot beremoved.Note: Future access to the Load Cell mounting screws is gained by removing theH Bar from the Load Cell. This is done by removing the two screws on the otherside of the H Bar.10 of 2008/01 497-0422375 Release A

4 1 304 1 304 1 304 1 30U16C15 C16C277872 Scanner Upgrade to Scanner/ScaleInstall IC PacksJ1EEPROMU5 CR8CR6CR7U4 U8U3U2R1W7W6W5W4W3W2W1CR4C1U10U12U9C2C9J4U24 U27R6C3CR10U17 U20C7 U23 U26R5C4U21 U22C5U7 U11 U15 U25R2 R3 R4U14 U19CR3CR2CR1U13U18C6J2 J3 J5Y1C8SpeechJ6C12U30C11U29C10C13Q2 Q4Q1 Q3U32J7U28 U31 U33 U34C14A R7AU37 U60C15AQ8C139 Q6U35 U36 U42 Q5 Q7C14U38U39U40U41U43U46U45U48U49J9U44CR11U47J8U50DS1U55C17R10U52 R8U53U51W8C18CR13CR12U54C19U56J10R9R7L1 L2J11J12C21J14U58R17R15R14 C26C23R12U59 R20 R19R11 R18C20Y2Firmware ChipU39U47Socket19212The Scanner Firmware and EEPROM chips must be transferred from the old VIDSboard to the new board included in this kit.1. Using a Chip Extractor tool (NCR part number 603-9013240, AMP 822154-1)carefully remove the two firmware chips (U39 & U47). Install these chips into thesockets on the new VIDS board, making sure they are properly aligned. Pin 1 onthe chip is identified by a dot.2. Use the Chip Extractor tool and remove the EEPROM (U21). Install this chip intothe socket on the new VIDS board, making sure it is properly aligned.3. If you are adding speech, carefully insert the speech chip into the socket (U22) onthe new VIDS board. Again, make sure it is properly aligned.497-0422375 Release A 08/01 11 of 20

7872 Scanner Upgrade to Scanner/ScaleInstall the VIDS Board17989The VIDS Board is mounted with two screws.1. Carefully position the VIDS Board into the mounting location on the back of theOptics Tower.2. Install the two mounting screws.3. Connect all cables and internal harnesses to the VIDS Board.• J1 – Speaker• J2 – Interface cable• J3 – Display cable (if present)• J5 – Power Supply• J6 – Spinner Motor• J7 – Laser Module Assembly• J8 – RS-232 Peripheral (if present)• J10 – RS-232 Peripheral (if present)• J11 – Checkpoint (if present)• J12 – Calibration Switch (Connect to Scale Upgrade Board)• J14 – Load Cell (Connect to Scale Upgrade Board)12 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleInstall the Front BezelA new Front Bezel and Operator Control Panel Label are supplied. Remove the oldFront Bezel and install the new Operator Control Panel Label and new Front Bezel asfollows.1. Carefully loosen the latch at one of the bottom corners of the Tower CabinetAssembly.2. Loosen the upper latch on the same side of the Tower Cabinet Assembly.3. Separate the Front Bezel from the Tower Cabinet.181674. Remove the paper backing from the adhesive on the back of the Operator ControlPanel Label and attach the label to the Front Bezel.SCALEZERO19213497-0422375 Release A 08/01 13 of 20

7872 Scanner Upgrade to Scanner/Scale5. Position one side of the Front Bezel onto the Tower Cabinet. Be sure the twolatches are fastened.6. Push the other side of the Front Bezel onto the Tower Cabinet until the two latchesare fastened.1816914 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleInstall the Tower CabinetAssembly17954The Tower Cabinet Assembly covers the rear portion of the unit. It is fastened withtwo screws, one on each side.1. Connect the Operator Control Panel harness to the VIDS Board (J4).2. Carefully lower the Tower Cabinet onto the unit.3. Install the two mounding screws.497-0422375 Release A 08/01 15 of 20

7872 Scanner Upgrade to Scanner/ScaleInstall Load Cell Set ScrewA set screw must be installed under the Load Cell to prevent it from being damagedwhen too much weight is set on the Top Plate.1. Set the NCR 7872 Scanner/Scale on the counter top. Do not install it in thecheckstand at this time.Note: To install the Load Cell set screw, the front of the unit must be off the edgeof the counter top just enough to install the screw. Be very careful not to permit thescanner to tip or fall off the counter top.2. Connect the Power cable and Display cable.Note: Some installations do not use the NCR 7825 Compact Display. In theseinstallations the POS Terminal display must be used to verify weight placed on theTop Plate.3. Install the Top Plate. Refer to Install the Top Plate section.4. Supply power to the unit.5. Scan one of the following sequences of programming tags to enable the scalefunction. These must be the first tags scanned after supplying power to the unit.Kilogram Installations• Programming Mode• Hex 3, Hex 0, Hex 1• Save and ResetPound Installations• Programming Mode• Hex 3, Hex 0, Hex 2• Save and Reset6. Depending on the weight feature, place 9.0 kg, 13.5 kg, or 30.0 lb. on the center ofthe Top Plate as shown in the illustration.9.0 kgor13.5 kgor30.0 lb.1922916 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/Scale7. Install the set screw and slowly turn it until it just contacts the Load Cell. Theweight displayed decreases slightly. Now back out the set screw ¼ to ½ turn.Nut PlateLoad CellMounting ScrewsSet Screw192288. Remove the weights.9. Turn off the power to the unit and remove the Top Plate10. Turn the unit over and put Locktight (Thread Locker) on the set screw to prevent itfrom turning.497-0422375 Release A 08/01 17 of 20

7872 Scanner Upgrade to Scanner/ScaleInstall the NCR 7872 inCheckstand175441. Grasp the front and back of the unit.2. Slowly lower it into the checkstand cutout being careful not to pinch any of thecables.3. Calibrate the Scale. Refer to the NCR 7882 Scanner/Scale Repair Guide (CD) or theNCR 7872 Scanner/Scale Installation and Owner Guide.4. Verify that the calibrated weight range and mass values correspond to theinformation on the Scale Identification Label.18 of 2008/01 497-0422375 Release A

7872 Scanner Upgrade to Scanner/ScaleInstall the Top PlateTop PlateWith Weigh Bar17980The Top Plate sits on four posts that are connected to the H-Bar and is installed invarious ways depending on its construction.Top Plate with No Lifting Device1. Using both hands, position the Top Plate over the front of the 7872 and lower theback of the Top Plate until the two back supporting posts are in the notches in theTop Plate.2. While holding the Top Plate with one hand, grasp the front with the other.Carefully lower the Top Plate until it is sitting on the two front supports. You mayneed to drop it when it gets too close to the NCR 7872 for you to keep your handunder it.Top Plate with Weigh Bar1. Using both hands, position the Top Plate over the front of the 7872 and lower theback of the Top Plate until the two back supporting posts are in the notches in theTop Plate.2. While holding the Top Plate with one hand, grasp the Weigh Bar with the other.Let go of the Top Plate, holding it only by the Weigh Bar, and lower the front untilit is sitting on the two front supports.3. Push the Weigh Bar down until it is level with the top surface of the Top Plate.Note: This does not latch the Top Plate down, it just stows the Weigh Bar belowthe surface of the Top Plate.497-0422375 Release A 08/01 19 of 20

7872 Scanner Upgrade to Scanner/ScaleProgram the UnitThe NCR 7872 may need some programming changes to be supported by theapplication. If so, scan the Default programming tag then make all necessary changes.Refer to the NCR 7872 Scanner/Scale User Guide for detailed programming information.20 of 2008/01 497-0422375 Release A