Printer Module G2 Unit
Printer Module G2 Unit
Printer Module G2 Unit
817419900
SAFETY CONSIDERATIONS
Read all warning notes and instructions carefully. They are included to help you installing the TRP equipment 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
Components substitutions could impair intrinsic safety. Attaching unauthorized components or equipment will void your warranties.
CAUTION
Do not attempt to make any repair on the printed circuit boards residing in the TRP equipment, as this will void all warranties related to this equipment.
PROPRIETY NOTICE
This document contains propriety and confidential information. It is the property of TRP SYSTEMS Ltd. It may not be disclosed or reproduced in whole or in part without written consent of TRP 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, TRP SYSTEMS does not guarantee that there are no errors or omissions in this document.
TABLE OF CONTENTS
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SECTION 2 DESCRIPTION...................................................................................................................1
2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. GENERAL ..............................................................................................................................1 MAIN COMPONENTS .........................................................................................................3 PRINTER CONNECTOR PIN-OUT .....................................................................................6 HOUSING ..............................................................................................................................6 INDICATORS ........................................................................................................................7 PROTECTION .......................................................................................................................7 SPECIFICATIONS .................................................................................................................8
TABLE OF CONTENTS
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LIST OF ILLUSTRATIONS
Figure Page
FIGURE 1-1. PRINTER MODULE G2 UNIT .............................................................................V FIGURE 2-2. PRINTER MODULE G2 UNIT GENERAL VIEW............................................2 FIGURE 2-3. PRINTER MODULE G2 UNIT REAR VIEW....................................................2 FIGURE 2-4. PRINTER MODULE G2 UNIT MAIN COMPONENTS...................................3 FIGURE 2-5. PRINTER MODULE G2 UNIT INTERNAL COMPONENTS .........................4 FIGURE 2-6. PRINTER MODULE G2 UNIT INTERNAL VIEW...........................................5 FIGURE 2-7. PRINTER MODULE G2 CONNECTOR PIN-OUT DESCRIPTION ...............6 FIGURE 3-8. PRINTER MODULE G2 JUMPERS DEFAULT CONFIGURATION ...............1 FIGURE 3-9. PRINTER MODULE G2 JUMPERS CONFIGURATION EXAMPLES............2 FIGURE 4-10. INSTALLATION CLAMP ...................................................................................4 FIGURE 4-11. LOCKING HANDLE............................................................................................5 FIGURE 4-12. RELEASED PRINTER ........................................................................................6 FIGURE 4-13. PAPER ROLL PIVOT HANDLE .........................................................................7 FIGURE 4-14. PROTRUDING PAPER FROM SLICE IN DOOR .............................................9 FIGURE 5-15. LOCKING HANDLE............................................................................................4 FIGURE 5-16. PRINTER INTERNAL VIEW .............................................................................4 FIGURE 5-17. PRINTER AND CUTTER SEPARATED ............................................................5 FIGURE 5-18. PROTRUDING PAPER FROM SLICE IN DOOR .............................................6
LIST OF TABLES
Table TABLE 2-1. TABLE 2-2. TABLE 2-3. TABLE 4-4. TABLE 5-5. Page PRINTER MODULE G2 MAIN COMPONENTS...................................................3 PRINTER MODULE G2 INTERNAL COMPONENTS..........................................4 RS-485 CONNECTOR PIN-OUT DESCRIPTION...............................................6 PRINTER MODULE G2 INSTALLATION MODULE KIT................................3 PRINTER MODULE G2TROUBLESHOOTING....................................................3
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SECTION 1 OVERVIEW
1.1.
GENERAL
This manual describes the Printer Module G2, its technical characteristics and its operation. This manual provides as well as instructions regarding the installation of the Printer Module G2 at the fuel pump. It includes instructions on replacing the printer paper roll. In addition, this manual includes several recommended steps for checking the printer operability. This section provides a general overview of the Printer Module G2. It includes general information regarding the Printer Module G2, its components and functionality.
1.2.
OVERVIEW
The Printer Module G2, P/N 800919900, is installed in the non-hazardous part of the fuel dispenser, or in the Station Controller. It provides the customer a receipt once a refueling action is completed and the transaction is recorded in the fuel station controller. The printer can be also utilized to print various kinds of reports i.e. daily summary reports, fuel station attendant report, shift report and more, in accordance with the station controller requests. Within the station system, the Printer Module G2 is a standalone module connected to the systems RS-485 link. The Printer Module G2 provides visual and audio indications of its activities by means of two green LEDs and a buzzer. The LED functionality is set by the Station Controller that controls the printer. As an example of a implementation, the visual and audio indications are used to indicate whether the printer runs out of paper or when there is approximately 25% of the paper roll left or when the receipt is ready.
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SECTION 2 DESCRIPTION
2.1.
GENERAL
The Printer Module G2 is a compact, ruggedized thermal printer suitable for the harsh environment of the gas station. It uses thermal printer paper only (55 gr., 40m x 57 mm). The Printer Module G2 is connected to the Station Controller via an RS-485 link. Usually, one printer module is provided for each pump in the gas station. The Printer Module G2 requires a 24 26 VDC power supply input. The Printer Module G2 is packed in a compact aluminum enclosure. The Printer Module G2 enclosure is designed to survive the harsh forecourt environment. It uses Spark Gaps protection for the links and 1.5 KV isolation between the forecourt devices. The printer includes two sensors for paper usage alerts: Low paper sensor - activated when there is approximately 25% of the paper roll left End paper sensor - activated when printer paper runs out completely
The paper usage and receipt indications include a buzzer sound, LED indicators or the combination of both, dependent on the station controller. Figure 2 -2 and Figure 2 -3 show a front and rear view of the Printer Module G2, respectively.
2.2.
MAIN COMPONENTS
The Printer Module G2 consists of the following main items (see Table 2 -1, Table 2-2, Figure 2 -4 and Figure 2 -5). Table 2- 1. Printer Module G2 Main Components Item
Advance Paper Push Button Printer Cutter Lock Printer Cutter Thermal Printer Paper Lock Lever Paper Roll Pivot Pawl Front Panel Lock Lever Electronic Board
Functionality
Push to advance the paper into the printer Shifts away from the printer and unlocks the cutter lock Cuts the paper Prints the text on the thermal paper by means of the thermal head Push down to unlock the paper lock Press to release the paper pivot and insert a new paper roll For technician use only. Bypasses the solenoid lock Printer controller
Functionality
Enable to determine the RS485 address and number of copies Stores the printer software Enables to download/upload printer software/data NOTE
Figure 2 -6 shows an internal diagram of the Printer Module G2, indicating the sensors, the paper path within the printer and the internal electronic components.
2.3.
The printer connector is located on the printer rear panel. It provides the printer both the communication link and the power supply input (24 26 VDC). The power is supplied via an external power supply. Figure 2 -7 and Table 2 -3 show the G2 Printer connector pin-out description.
Figure 2-7. Printer Module G2 Connector Pin-out Description Table 2- 3. RS-485 Connector Pin-out Description Pin Number
1 2 3 4 5 6
Functionality
VIN VIN + SLN GND 485 485 + DC Power Supply GND DC Plus Voltage
Description
For technician use, when connected to ground, opens the front panel optional external key for maintenance RS-485 GND RS-485 Communication Line RS-485 Communication Line
2.4.
HOUSING
The Printer module enclosure is made of aluminum. The front panel includes two green LED indicators and the receipt aperture, protected behind a metal lid. See Figure 2 -2. The rear panel includes the printer connector and the front panel lock, see Figure 2 -3. The printer lock is an electro-mechanic lock (Solenoid type) controlled by the Station Controller.
2.5.
INDICATORS
The printer module includes two green LED indicators located on its front panel, and a buzzer. The printer indicators provide visual and audio display on the following events: Printing is in progress Paper alerts paper run out or approximately 25% left (see paragraph 4.7.1) Receipt ready NOTE The indicators activation is controlled by the Station Controller. The printer also includes LEDs under its front door for communication monitoring. At turn on, the LEDs and the buzzer are activated for a short period of time. 2.6. PROTECTION
Two types of protections are included in the printer module: Isolation of 1.5 KVDC to protect against galvanic connection between the host side and the printer side. the printer side is protected against high voltage transient and lightning by using Spark Gaps and Transorbs for RS-485 communication,. This allows the use of long communication cables.
2.7.
SPECIFICATIONS
This section lists the physical, electrical and environmental specifications of the printer, as follows: Supply Voltage: Power Consumption: Dimensions (HxWxD): Operating Temperature: Storage Temperature: Communication Interface: Paper Type: Paper Maximum Printing Area Width: Maximum Printing Speed: Autocutter: 24 - 26 VDC Standby 15 W Typical 60 W 110.2 x 178.4 x 100 mm -5 C to +50 C -20 C to +70 C RS-485 9600 bps Half-Duplex 40m x 57 mm (L x W) 55 gr. thermal 54 mm 120 mm/sec. Integrated
3.1.
JUMPERS CONFIGURATION
The Printer Module G2 includes jumpers that enable setting the RS-485 address and selecting the number of copies automatically produced during each printout (see Figure 2 -5 for the location of the jumpers). The jumpers are set in a matrix of 8 jumpers, where the five first jumpers determine the RS485 address. The last three jumpers determine the number of copies. Figure 3 -8 shows the jumpers default configuration, where the RS485 Address = 70 Hex. Figure 3 -9 provides examples of jumpers configuration and the corresponding RS485 address. CAUTION On a single RS485 bus, each device must be assigned a different address.
3.2.
The Printer Module G2 features two printing modes: 3.3. Print only when the door is lifted Paper save mode Print always CUTTER
The paper cutter may be set to one of three modes: 3.4. No Cut Full Cut Partial Cut PRINTING THE STATUS REPORT
The G2 Printer enables producing a printer status report. Proceed as follows: 1. 2. 3. 4. Turn off the printer Open the printers service door Turn on power to the printer The G2 Printer prints a status report.
SECTION 4 INSTALLATION
4.1.
GENERAL
The Printer Module G2 can be mounted in various locations at the fuel station forecourt at the fuel pump or in a designated enclosure, complying it is located in a non-hazardous area. The printer is usually inserted in a protected enclosure. Installation procedures and requirements depend, to some extent, on the current specific fuel dispenser models and on the station layout. Therefore, use the information in this section to develop installation plans for each specific installation. Since installation requirements vary widely from case to case, no installation hardware is supplied by equipment manufacturer, and installation planners must develop their own requirements. 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. NOTE Before determining the location for the Printer G2 installation, check there is a protective shade above it.
4.2.
Prior to actual installation activities, carefully observe the precautions and safety notes below. WARNING 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 breaker. No other equipment should be powered from this breaker. System power may come from more than one source. Disconnect all power sources before attempting to work on the system. Install the G2 Printer only in non-hazardous locations. Site preparation is in the customers responsibility. Do not connect power to the G2 Printer until complete station installation is inspected and certified. Do not perform any metal work in the hazardous area. Sparks generated by drilling, tapping and 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. 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. INSTALLATION REQUIREMENTS
4.3.
Follow these guidelines for the G2 Printer installation: Install the G2 Printer in a non-hazardous area. Installation must be conducted by a technician authorized to work in a flammable gas station environment in accordance with the local requirements and regulations. All wiring to the dispensing unit must be installed in threaded, rigid metal conduits. AC power wires must be installed in separate conduit from the low voltage wires. The AC power wires must not be run in any sort of common conduit, trough or distribution box. Conduits runs must conform to local codes.
Certify that the required installation preparations have been made: Power supply to the G2 Printer Installation location Layout of the necessary cables to the G2 Printer: RS-485 link.
4.4.
INSTALLATION KIT
Table 4 -4 lists the items required for the printer installation (See Figure 4 -10). Table 4-4. Printer Module G2 Installation Module Kit No.
1 2 3
Description
Connector Screw MC1.5/6-STF-3.81mm Clamp Housing, Printer Module Wing Screw M6x12
Part Number
813326106 814935500 815200100 1 1 2
Quantity
4.5.
INSTALLATION PROCEDURES
Perform the following procedures to install the printer at any non-hazardous area of the fuel station forecourt: 1. 2. Shut down any power source at the installation and working area Prepare an aperture with the following dimensions: Width 110.4 0.2 mm Height 178.6 0.2 mm 3. 4. 5. Insert the printer into the designated aperture. Secure the printer using the clamp housing, two flat washers, two spring washers and two wing screws as listed in. Prepare the power and communication cables to be connected as described in the following paragraph.
4.6.
CABLE CONNECTIONS NOTE Use Shielded Twisted Pair cable, designated for RS-485 communication, such as BELDEN 9729/8723.
Perform the following procedures to connect the power and communication cables to the printer: 1. 2. Connect the power and communication cables to the connector in accordance with the pin-out description in Table 2 -3 and Figure 2 -7. Connect the connector to the printer connector located on the printer rear panel, see Figure 2 -3. PAPER ROLL REPLACEMENT General
4.7. 4.7.1.
The Printer Module G2 is a thermal printer and uses thermal printer paper only. The Printer Module G2 is equipped with two sensors for paper usage alerts as follows: Low paper sensor - warns when there is approximately 25% of the paper roll left
4.7.2.
End paper sensor - warns when printer paper runs out completely Paper Roll Replacement
This procedure applies when the printer is on-line and connected to a power source. In that state the printer pulls the paper automatically and cuts it when paper feeding is completed. Perform the following procedures to replace the printer paper roll: 1. 2. 3. Open the printer front panel. The front panel lock is an electro mechanic lock (Solenoid type) that can be opened from the Station Controller Release the green locking handle (1 in Figure 4 -11) and release the printer (1 in Figure 4 -12) Lift the printer and release the attached paper (see Figure 4 -12)
4. 5. 6.
Press the paper roll pivot handle (2 in Figure 4 -12) and release handle Lift the paper roll pivot (1 in ) Press the paper roll pivot pawl (2 in ) and remove the paper roll
7. 8.
Prepare a new paper roll facing down Press the paper roll pivot pawl (2 in ) and slide back the new paper roll when it is facing down
NOTE Insert the paper as shown in Figure 4 -12, with the thermal (shining) side facing out.
9.
10.
i.
Automatic insertion:
NOTE Verify that the green locking handle is closed Slide the paper gently along the grooves until the printer motor starts pulling the paper. At the end of the process the paper will exit from the cutter.
NOTE Do not pull the paper. The printer pulls the paper automatically and cuts it. Slide the paper from the printer door slice (Figure 4-5).
ii.
Manual insertion:
Release the green locking handle (1 in Figure 4-2). Slide the paper gently along the grooves until the paper exits from the cutter. Lock back the green locking handle and let the printer fall back in its place. Slide the paper from the printer door slice and close the door. (Figure 4-5).
4.8. 4.8.1.
After completing the installation procedure, inspect carefully the connection between the G2 Printer module and Station Controller panel system.
In particular, pay attention to the following issues: Correct wiring Correct routing of wires Clean dirt and wire remnants
NOTE Clean the printer front panel with a damp cloth only. DO NOT use any solvents such as thinner or benzene to clean the printer front panel.
SECTION 5 MAINTENANCE
5.1.
CLEANING
5.1.1. General The G2 Printer itself as a standalone unit, and the OPoS box should be cleaned periodically at short intervals, due to the harsh environment of the forecourt where they operate. 5.1.2. Cleaning The following instructions are valid for the G2 Printer and the OPoS box. Clean the G2 Printer front panel and other devices with a damp cloth only. WARNING DO NOT use any solvents such as thinner or benzene to clean the G2 Printer front panel.
5.2.
The Printer Module G2 includes in its inside rear panel a Flash Memory device for software storage and an AVR access port for data insertion from a Memory Burner/Writer (see Figure 2 -5). These components enable to upgrade the software version. NOTE These components are for maintenance technician use only.
5.3.
TROUBLESHOOTING
In case problems are detected after installation or during operation, repeat the installation procedures listed in Section 4. CAUTION If the problem persists, contact TRP Systems. Under no circumstances, attempt to dismantle the printer. The Printer Module G2 Unit repair should be performed at TRP laboratories only. The G2 Printer module indicates a faulty operation by means of its Leds on the front panel. Perform the recommended corrective actions to troubleshooting the failure and to repair the unit
Table 5- 5. Printer Module G2Troubleshooting No. 1 Failure Indication Left-hand green Led flickers constantly Right-hand green Led flickers constantly Probable Cause of Failure The Printer Module G2 Unit is stuck The Printer Module G2 Unit is stuck 1. 2. Recommended Corrective Action Check paper roll Replace unit
5.3.1.
This procedure applies when a paper is crumpled or jammed inside the printer. In this case the printer is disabled and all actions should be performed manually. Use the following procedure to release the paper.
NOTE Do not attempt to release the paper using sharp objects such as a knife or a screwdriver. Doing so will damage the printer paper cutter and void your warranty. Do not attempt to pull the paper from the printer. Doing so will damage the printer. Perform the following procedures to release the paper when a paper jam occurs.
1.
Open the printer front panel. The front panel lock is an electro mechanic lock (Solenoid type) that can be opened from the Station Controller. Pull out the printer and release the green locking handle (1 in Figure 5 -15).
2.
Figure 5- 17. Printer and Cutter Separated 3. 4. 5. Pull out any crumpled paper Clean the printer area from any paper remnants Push the paper lock lever to its original state (1 in Figure 5-1). NOTE Do not attempt to release the paper using sharp objects such as a knife or a screwdriver. Doing so will damage the printer paper cutter and void your warranty.
Do not attempt to pull the paper from the printer. Doing so will damage the printer.
6. 7.
Slide the new paper roll into the Pivot Handle (2 in Figure 5-2). Make sure the paper roll you insert is not crumpled. The paper can be inserted into the printer Automatically or Manually. iii. Automatic insertion: NOTE Verify that the green locking handle is closed Slide the paper gently along the grooves until the printer motor starts pulling the paper. At the end of the process the paper will exit from the cutter. NOTE Do not pull the paper. The printer pulls the paper automatically and cuts it. iv. Slide the paper from the printer door slice (Figure 5 -18).
Manual insertion: Release the green locking handle (1 in Figure 5 -15) Slide the paper gently along the grooves until the paper exits from the cutter. Lock back the green locking handle and let the printer fall back in its place. Slide the paper from the printer door slice and close the door. (Figure 5 -18).
5.4.
The thermal paper is sensitive to the environmental conditions where it is stored. Just as well, the Printer Module G2 operation is sensitive to the type of paper inserted. Proceed as follows: Use the right paper as specified. Insert the paper edge to the printer. Insert the paper in the correct side. Store the paper in a dry, shaded area, at 18 to 20 C. During paper replacement, avoid dust, moisture and rain. NOTE Dispose of wet or moisten paper. It may cause jamming in the printer