Orpak Systems Secured OrPT User manual

No. 817426100
Revision A
S
Se ec cu ur re ed d O Or rP PT T S Si in ng gl le e B Bo ox x
INSTALLATION MANUAL

Secured OrPT Single Box Installation Manual
i
SAFETY CONSIDERATIONS
Read all warning notes and instructions carefully. They are included to help you installing the Product safely
in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions
could result in serious injury or property damage. It is the installer responsibility to install, operate and
maintain the equipment according to the instructions given in this manual, and to conform to all applicable
codes, regulations and safety measures. Failure to do so could void all warranties associated with this
equipment.
Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installation is performed by experienced personnel, licensed to perform work in fuel station and at
a flammable environment, according to the local regulations and relevant standards.
WARNING - EXPLOSION HAZARD
Use separate conduit for the intrinsically safe wiring. Do not run any other wires or cables through this
conduit, because this could create an explosion hazard.
Install the Product only in the non-hazardous area of the fuel station.
Use standard test equipment only in the non- hazardous area of the fuel station, and approved test equipment
for the hazardous areas.
In the installation and maintenance of the Product, comply with all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-30A “Automotive
and Marine Service Station Code”, NFPA-70 “National Electric Code”, federal, state and local codes and any
other applicable safety codes and regulations.
Do not perform metal work in a hazardous area. Sparks generated by drilling, tapping and other metal work
operations could ignite fuel vapors and flammable liquids, resulting in death, serious personal injury,
property loss and damage to you and other persons.
CAUTION - SHOCK HAZARD
Dangerous AC voltages that could cause death or serious personal injury are used to power the Product.
Always disconnect power before starting any work. The Product has more than one power supply connection
port. Disconnect all power before servicing.
WARNING – PASSING VEHICLES
When working in any open area of fuel station, beware of passing vehicles that could hit you. Block off the
work area to protect yourself and other persons. Use safety cones or other signaling devices.
CAUTION
Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will void all
warranties related to this equipment.

Secured OrPT Single Box Installation Manual
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PROPRIETY NOTICE
This document contains propriety and confidential information. It is the property of ORPAK SYSTEMS
Ltd. It may not be disclosed or reproduced in whole or in part without written consent of ORPAK
SYSTEMS. The information in this document is current as of the date of its publication, but is subject to
change without notice.
DISCLAIMER
This document is provided for reference only. Although every effort has been made to ensure correctness,
ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this document.
CAUTION
For supply connections, use wires suitable for at least 90°C.
Signal wiring connected in this box must be rated at least 300 V.
FCC COMPLIANCE STATEMENT IN USER'S MANUAL
This device complies with part 15 of the FCC rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference, and
(2) This device must accept any interference received, including interference that may cause
undesired operation.
User information for a Class A digital device:
THE FCC WANTS YOU TO KNOW:
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
reasonable protection against harmful interference when the equipment 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 manual, 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 required to correct the interference at his
own expense.

Secured OrPT Single Box Installation Manual
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User information for a Class B digital device
This document is the property of:
ORPAK SYSTEMS Ltd.
ISRAEL
FCC Warning
Modifications not expressly approved by the manufacturer responsible could void
the user’s authority to operate the equipment under FCC rules.
THE FCC WANTS YOU TO KNOW:
This equipment has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
in a residential area.
This equipment generates, uses, and can radiate radio frequency energy
and, if not installed and used in accordance with the instructions, may
cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this
equipment does not cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on,
the user is encouraged to try to correct the interference by one or more of
the following measures:
Reorient or relocate the receiving antenna
Increase the separation between the equipment and the receiver
Connect the equipment to an outlet on a circuit different from that
to which the receiver is connected
 Consult the dealer or an experienced radio/TV technician
FCC Warning
Modifications not expressly approved by the manufacturer responsible
could void the user’s authority to operate the equipment under FCC rules.

Secured OrPT Single Box Installation Manual
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TABLE OF CONTENTS
Paragraph Page
SECTION 1 GENERAL DESCRIPTION
1-1. GENERAL ……………………….. .................................................................................... 1
1-2. SECURED ORPT SPECIFICATIONS................................................................................ 1
1-2.1. Secured OrPT Housing ………………................................................................................ 2
1-3. PRINTER SPECIFICATIONS ............................................................................................ 3
1-3.1. Printer Housing ……………………. .................................................................................. 3
1-4. VOLTAGE PROTECTION ……………………. ............................................................... 5
SECTION 2 SINGLE BOX INSTALLATION
2-1. GENERAL ………………………. ..................................................................................... 6
2-2. COMPONENTS …………………….................................................................................. 7
2-2.1. Single Box Specifications ………………… ....................................................................... 8
2-3. INSTALLING SECURED OrPT PANEL & PRINTER IN THE SINGLE BOX............... 9
2-3.1. Wiring ………………………….......................................................................................... 9
2-3.2. Secured OrPT & Printer Installation .................................................................................... 10
2-4. INSTALLING SECURED ORPT SINGLE BOX & PRINTER ON THE POLE............... 10
2-4.1. General ……………………………………………. ........................................................... 10
2-4.2. Safety Distances ………………….. .................................................................................... 11
2-4.3. Precautions and Safety Notes ……………………………………………………………...12
2-4.4. Installation Requirements ……………................................................................................ 13
2-4.4.1. Conduits Sealing ……………................................................................................... 13
2-4.5. Preliminary Pole Installation Instructions ............................................................................ 14
2-4.6. Pole Installation Instructions ............................................................................................... 15
2-4.7. Single Box Pole Installation Instructions ............................................................................. 15
2-5. SINGLE BOX WALL INSTALLATION INSTRUCTIONS.............................................. 18

Secured OrPT Single Box Installation Manual
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LIST OF ILLUSTRATIONS
Figure Page
Figure 1-1. Secured OrPT – General View 2
Figure 1-2. Secured OrPT – Enclosure Opening Dimensions 2
Figure 1-3. G2 Printer – General View 4
Figure 1-4. G2 Printer – Enclosure Opening Dimensions 4
Figure 2-1. Secured OrPT Single Box – Pole Installation 6
Figure 2-2. Secured OrPT Single Box – Wall Mounted 7
Figure 2-3. Secured OrPT Single Box Components Location 8
Figure 2-4. Secured OrPT Single Box – Installation Pole P/N 819038022 11
Figure 2-5 Secured OrPT – Installation Control Drawing 12
Figure 2-6 Conduit Fitting 14
Figure 2-7. Single Box – Pole Set, P/N 819038022 16
Figure 2-8. Single Box Wall- Mounted Perforation's Dimensions 18
Figure 2-9. Single Box Wall-Mounting Installation Instructions 19
Figure 2-10. Single Box –Installation Kit (Optional) for Wall Mount Installation, P/N 81902251920
LIST OF TABLES
Table Page
Table 1-1. Secured OrPT Specifications 1
Table 1-2. Printer Specifications 3
Table 2-1. Secured OrPT Single Box Components 7
Table 2-2. Secured OrPT Single Box Specifications 8
Table 2-3. Secured OrPT Internal Wiring 9
Table 2-4. G2 Printer Internal Wiring 9
Table 2-5. Secured OrPT Single Box – Pole, Single Box, Installation Assembly Parts 17
Table 2-6. Single Box –Installation Assembly Part List for Wall Mount Installation 20

Secured OrPT Single Box Installation Manual
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GE EN NE ER RA AL L D DE ES SC CR RI IP PT TI IO ON N
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1- -1 1. . G GE EN NE ER RA AL L
This manual provides installation instructions for the Secured OrPT (Orpak Secured Payment
Terminal, OrSPT) and the G2 Outdoor Printer. The Secured OrPT is an outdoor payment terminal
that can accept a variety of payment types: smart cards, magnetic cards and contactless cards.
The G2 Printer Module is a compact, ruggedized thermal printer suitable for the harsh outdoor
environments. It uses thermal printer paper only (55 gr., 40m x 57 mm).
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1- -2 2. . S SE EC CU UR RE ED D O OR RP PT T S SP PE EC CI IF FI IC CA AT TI IO ON NS S
Table 1-1 displays the physical, electrical and environmental specifications applicable to the
Secured OrPT.
Table 1-1. Secured OrPT Specifications
Supply Voltage: 15 – 24VDC
Power Consumption:
Maximum current without heater
Maximum current with heater
10 W with no heater (21 W with Heater on)
0.7 A
1.4 A
Operating Temperature: -20°C to +70°C (optional -40°C to +70 °C with internal
heater)
Storage Temperature: -20 °C to +70 °C
Humidity: 80% Non-condensing
Communication Interface: RS-485 – 9600 bps Half-Duplex
Ethernet RJ-45 10 Mbps (x2)
RS-232 (x2)
GPIO (DB9)
Dimensions H 197 mm X W 179 mm X D 162 mm ; Weight: 950 gr

Secured OrPT Single Box Installation Manual
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1-2.1. Secured OrPT Housing
Secured OrPT enclosure is made of a plastic-molded front panel, and an aluminum rear casing (see
Figure 1-1). The enclosure is weather-proof in order to sustain the harsh outdoor environments
when installed in an outdoor enclosure. The front panel of the OrPT is made of rugged plastic. The
devices front is sealed.
Figure 1-2 depicts the enclosure dimensions of the opening required for installing the Secured OrPT
into 3
rd
party panels.
Figure 1-1. Secured OrPT – General View
Figure 1-2. Secured OrPT – Enclosure Opening Dimensions

Secured OrPT Single Box Installation Manual
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1- -3 3. . P PR RI IN NT TE ER R S SP PE EC CI IF FI IC CA AT TI IO ON NS S
Table 1-2 displays the physical, electrical and environmental specifications applicable to the
Printer.
Table 1-2. Printer Specifications
Supply Voltage: 24 VDC
Power Consumption:
Maximum standby current
Maximum current
Standby 15 W.
Typical 60 W (without heater).
0.625 A
2.5 A
Dimensions (HxWxD): 110.2 x 178.4 x 100 mm
Operating Temperature: -5 °C to +55°C (-40°C to +55°C with optional heater)
Storage Temperature: -20 °C to +70 °C
Communication Interface: RS-485 – 9600 bps Half-Duplex
Paper Type: 40m x 57 mm (L x W)
55 gr. – thermal
Paper Maximum Printing Area
Width:
54 mm
Maximum Printing Speed: 120 mm/sec.
Paper cutter: Integrated, Full cutter, Automatic
1-3.1. Printer Housing
The Printer module enclosure is made of aluminum (see Figure 1-3.). The front panel includes two
green LED indicators and the receipt aperture, protected behind a metal lid. The printer lock is an
electro-mechanic lock (Solenoid type) controlled by the Station Controller/POS.
Figure 1-4 depicts the enclosure dimensions of the opening required for installing the G2 Printer
into 3
rd
party panels.

Secured OrPT Single Box Installation Manual
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Figure 1-3. G2 Printer – General View
Figure 1-4. G2 Printer – Enclosure Opening Dimensions

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1- -4 4. . V VO OL LT TA AG GE E P PR RO OT TE EC CT TI IO ON N
Secured OrPT and Printer housing requires a grounding attachment, i.e. the devices should be
connected to the dispenser (in case of retrofit in petroleum environments) for protection against
high voltage transient and lightning.
Furthermore, two types of protections are included in the devices:
•Isolation of 1.5 KVDC to protect against galvanic connection between the host side and the
device side.
•In RS-485 communication, the terminal side is protected against high voltage transient and
lightning by using Spark Gaps and transorbs. This allows the use of long communication
cables.

Secured OrPT Single Box Installation Manual
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SE EC CT TI IO ON N 2 2
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SI IN NG GL LE E B BO OX X I IN NS ST TA AL LL LA AT TI IO ON N
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2- -1 1. . G GE EN NE ER RA AL L
The single box configuration takes into consideration the ease of use of the user related equipment.
The front panel of the Secured OrPT faces the attendant and the driver, and the printer is located
below the keyboard.
This section provides instructions for installing the Secured OrPT & Printer Single Box on its pole
(accessory, see Figure 2-1) or on the wall (see Figure 2-2).
Figure 2-1. Secured OrPT Single Box – Pole Installation

Secured OrPT Single Box Installation Manual
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Figure 2-2. Secured OrPT Single Box – Wall Mounted
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2- -2 2. . C CO OM MP PO ON NE EN NT TS S
Table 2-1 defines the Secured OrPT Single Box components (see Figure 2-3 for the location of the
main components within the box). Communication link is obtained either directly from the LAN, or
via the RS-485 link.
The Secured OrPT Single Box components are interconnected within the box by an RS-485 link.
Table 2-1. Secured OrPT Single Box Components
No. Function Module Type Quantity
1. Payment terminal Secured OrPT – P/N 800926100-800926299 1
2. Printer Outdoor printer (G2 model) - P/N 800919900 1 (Optional)
4. Power Supply 100-220 VAC input; 75W, 24 VDC output, power
supply unit - P/N 811308210
1

Secured OrPT Single Box Installation Manual
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Figure 2-3. Secured OrPT Single Box Components Location
2-2.1. Single Box Specifications
Table 2-2 displays the physical, electrical and environmental specifications applicable to the
Secured OrPT Single Box.
Table 2-2. Secured OrPT Single Box Specifications
Supply Voltage: 100-220 VAC
Maximum current (230VAC)
Maximum current (115 VAC)
1.2 A
2 A
Operating Temperature: -5°C to +60°C (optional -40°C to +60 °C with internal
heater)
Storage Temperature: -20 °C to +70 °C
Humidity: 80% Non-condensing
Communication Interface: RS-485 – 9600 bps Half-Duplex
Ethernet RJ-45 10 Mbps (x2)
Dimensions H 505 mm X W 200 mm X D 160 mm

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2- -3 3. . I IN NS ST TA AL LL LI IN NG G S SE EC CU UR RE ED D O Or rP PT T P PA AN NE EL L & & P PR RI IN NT TE ER R I IN N T TH HE E
S
SI IN NG GL LE E B BO OX X
The following instructions provide the procedures for the installation of the Secured OrPT & Printer
modules in the Single Box. The Single Box is delivered fully installed, thus no further installation is
required. Use these instructions only for replacing the unit, due to a malfunction or unit upgrade.
The Secured OrPT installation procedures consist of two main steps:
•Mechanical installation of the Secured OrPT inside the Single Box using the holder
•Connecting the Secured OrPT cables in the Single Box
2-3.1. Wiring
Table 2-3 and Table 2-4 list the different types of Single Box internal cables to be connected to the
Secured OrPT and to the G2 Printer during installation.
Table 2-3. Secured OrPT Internal Wiring
Cable Type Function/
Connection
Termination Note
Communication &
Power
Connects Secured OrPT
to RS-485 &Power
RS-485 comm.
connector
Shielded CAT-5 Connects Secured OrPT
to Ethernet
Hub/Switch inside or
outside the Single Box.
Only in Ethernet
connectivity
Ground single wire
Connection to earth for
surge protection
Ring connector with
Phillips screw
Connected to Secured
OrPT box chassis
(Thread M3)
Table 2-4. G2 Printer Internal Wiring
Cable Type Function/
Connection
Termination Note
Communication &
Power
Connects printer to
RS-485/Power harness
6-pin green connector
(P/N 813326106)
Ground single wire
Connection to earth for
surge protection
Ring connector with
Phillips screw
Connected to printer box
chassis (Thread M3)

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2-3.2. Secured OrPT & Printer Installation
Perform the following procedures for installing the Secured OrPT and the printer in the Secured
OrPT Single Box:
1. Prepare a comfortable place to perform the installation, which will allow easy access to the
Secured OrPT Box
2. Disconnect all power sources to the Single Box and in installation area
3. Insert the Secured OrPT Panel to its designated aperture in the Single Box (see Figure 2-3)
4. Place the spacers on the protruding screws on the rear side of the Secured OrPT
5. Place the Secured OrPT Panel holder on top of the spacers
6. Close the Secured OrPT Panel holder using two wing screws
7. Connect the applicable cables to the Secured OrPT in accordance with the connectors'
description given on paragraph 2-3.1
8. Connect the grounding cord to the designated screw in the Secured OrPT Panel (near the
center of the panel)
9. Insert the printer into the designated aperture in the Single Box (see Figure 2-3)
10. Secure the printer using the clamp housing, two flat washers, two spring washers and two
wing screws
11. Connect the applicable cables to the Secured OrPT in accordance with the connectors'
description given on paragraph 2-3.1
12. Connect the grounding cord to the designated screw in the Printer (on the upper left corner
on the rear panel)
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2- -4 4. . I IN NS ST TA AL LL LI IN NG G S SE EC CU UR RE ED D O OR RP PT T S SI IN NG GL LE E B BO OX X & &
P
PR RI IN NT TE ER R O ON N T TH HE E P PO OL LE E
2-4.1. General
Orpak offers a standard pole, P/N 814921650, or an adjustable pole, P/N 819038025, on which the
Secured OrPT Single Box can be mounted. Installation instructions are provided below. However,
the customer should develop installation plans for each specific installation.
N
NO OT TE E
Perform a site survey of the site prior to installation.
For further information, contact Orpak Technical
Support.

Secured OrPT Single Box Installation Manual
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The customer should provide an installation plan, designed by an authorized engineer, and
applicable to all authorities having jurisdiction. This plan design should reflect the existing electric
infrastructure of the site.
Regardless of the installation plan, the safety precautions and installation requirements, detailed
in the following paragraphs, must be conformed to.
Figure 2-4. Secured OrPT Single Box – Installation Pole P/N 819038022
2-4.2. Safety Distances
The Secured OrPT is suitable for use over Class 1, Division 2. Figure 2-5 shows the safety
distances required for the installation of the Secured OrPT in a non hazardous location adjacent
to the dispensers. When mounting the Secured OrPT, a minimum clearance of 18 inches
between the unit and any of the pumps or the dispensers must be maintained. This clearance
allows room for the wiring and maintenance of the system.

Secured OrPT Single Box Installation Manual
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Figure 2-5 Secured OrPT – Installation Control Drawing
2-4.3. Precautions and Safety Notes
Prior to actual installation activities, carefully observe the precautions and safety notes below.
W
WA AR RN NI IN NG G
Before installing or servicing equipment, carefully
observe the warnings and precautions in the
beginning of this manual.
 Remember that the fuel station environment is highly flammable and combustible. Therefore,
make sure that actual installation is performed by experienced personnel, licensed to perform
work in fuel stations and capable of implementing all applicable requirements of the National
Fire Protection Association NFPA-30 “Flammable and Combustible Liquids Code”, NFPA-
30A “Automotive and Marine Service Station Code”, NFPA-70A “National Electric Code”,
federal, state and local codes and any other applicable safety codes and regulations.
 Remember that high quality installation will ensure correct system operation and user safety:
-All installed wiring must conform with all building/fire codes, all Federal, State and Local
codes and regulations, the National Electrical Code (NFPA 70), NFPA 30, and the
Automotive and Marine Service Station Code (NFPA 30A).
-Use only threaded, rigid, metal conduits.
-Use only UL-approved correctly sized insulated gasoline and oil-resistant copper wiring.
-Unit power should be supplied from a dedicated circuit breaker (6A). No other equipment
should be powered from this breaker.