Badger Meter 2012WCE ORION CE Water Meter Endpoint Radio, ORION CE Gas Remote Radio User Manual Exhibit D Users Manual per 2 1033 b3

Badger Meter Inc ORION CE Water Meter Endpoint Radio, ORION CE Gas Remote Radio Exhibit D Users Manual per 2 1033 b3

Exhibit D Users Manual per 2 1033 b3

UNRELEASED DRAFT COPY ONLYORION® Water Endpoint Installation DataORI-I-79 (May 11, 2011 9:01)62014-xxx Rev. 1IMPORTANT: This manual contains important information.READ AND KEEP FOR REFERENCE.
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYPage ii 5-11
Installation DataUNRELEASED DRAFT COPY ONLYContentsOverview ....................................................................................................................................................5Product Unpacking and Inspection .........................................................................................................5License Requirements ...............................................................................................................................5Identication .............................................................................................................................................6Network Endpoint Installation .................................................................................................................7Splicing Considerations ........................................................................................................................................................... 7ORION Installation Kit Part Numbers ....................................................................................................... 7Pit Installation ............................................................................................................................................8Through the Lid Installation Kit (SE, ME and CE Endpoints).................................................................................................. 8Below Lid with Knuckles Installation Kit (ME and CE Endpoints) ......................................................................................... 9Integrated Pit Lid Hanger Installation Kit (ME and CE Endpoints)...................................................................................... 10Vault Installation Kit (ME and CE Endpoints) ........................................................................................................................ 10Remote Installation .................................................................................................................................11Remote Wall Mount Box Enclosure Kit (SE, ME and CE Endpoints) ..................................................................................... 11Remote Installation Bracket Kit (SE, ME and CE Endpoints) ................................................................................................ 14Wiring a Universal Endpoint ...................................................................................................................17Universal Endpoint Identication ......................................................................................................................................... 17Required Splice Tools .............................................................................................................................................................. 17Wiring the ORION Universal Endpoint to an Encoder ..........................................................................................................17Encoder Register Installation .................................................................................................................19Page iii 4-11
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYPage iv 5-11
Installation DataUNRELEASED DRAFT COPY ONLYOverviewThis manual contains installation and programming instructions for the ORION® water endpoint.Proper performance and reliability of ORION endpoints depend upon installation in accordance with these instructions.Product Unpacking and InspectionUpon receipt of the product, perform the following unpacking and inspection procedures.NOTE: If damage to the shipping container is evident upon receipt, request the carrier to be present when the product is unpacked.Carefully open the shipping package, follow any instructions that may be marked on the exterior. Remove all cushioning material surrounding the product and carefully lift the product from the package.Retain the package and all packing material for possible use in reshipment or storage.Visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts or any other sign of damage that may have occurred during shipment.NOTE: If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and le a claim with the carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.Carefully remove the pre-wired ORION endpoint and encoder assembly or ORION endpoint from the shipping carton and inspect for damage. Retain the contents of the installation kit for use in mounting the endpoint in the eld. License RequirementsThis device complies with Part 15 of FCC Rules. Operation of this device is subject to the following 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. This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement.No FCC license is required by a utility to operate an ORION meter reading system.Any changes made, but not approved by Badger Meter, can void the user’s authority to operate the equipment.In accordance with FCC Regulations, “Code of Federal Regulations” Title 47, Part 2, Subpart J, Section 1091, endpoints pass the requirements pertaining to RF radiation exposure. However, to avoid public exposure in excess of limits for general population (uncontrolled exposure), a 20 cm distance between the endpoint and the body of the user must be maintained during testing.IMPORTANTTransportation: The Federal Aviation Administration prohibits operating endpoints and receivers on all commercial aircraft. The ORION endpoint is considered an operating transmitter and cannot be shipped by air. 5-11) Page 5
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYIdenticationEach ORION endpoint can be identied using the unique numeric serial number located on a tag attached to the wire harness and etched on the top (CE) or side (SE, ME) of the endpoint housing. Each Badger Meter encoder is clearly identied on the face of the register with an assembly number, unit of measure and meter model. SE/ME Endpoint (Medium Gray) CE RTR® Endpoint (Black) CE ADE® Endpoint (Light Gray)Recordall® TransmitterRegister (RTR®) Absolute DigitalEncoder (ADE®)Figure 1: Endpoints and EncodersPage 6 5-11
Installation DataUNRELEASED DRAFT COPY ONLYNetwork Endpoint InstallationWhen installing an SE or ME (used with a network gateway transceiver) or CE (used with an ORION 4.0 or 2.0 gateway receiver) endpoint in a pit, the endpoint must be mounted through the lid of a non-metal pit lid for maximum propagation of the radio signal. If the endpoint is being installed indoors, a wired radio endpoint should be mounted on the outside of the building or in the oor joist near the outside wall of the building, and away from large metal objects for maximum propagation of the radio signal. Splicing ConsiderationsFor non-submerged indoor and outdoor applications where splicing is necessary, splice connections together and wrap any cables inside the base of the housing. Splice connections made in pit environments require a pit eld splice kit (62084-001), which can be ordered separately. Please refer to RTR-I-15 for eld splice kit installation instructions.ORION endpoints shipped factory pre-wired to a Badger Meter encoder require no splicing. Only the mounting of the encoder to the meter and tightening the TORX® seal screw is necessary. For all installations, excess wire should be coiled and cable tied to avoid any damage.ORION Installation Kit Part Numbers*TYPE DESCRIPTION ORION SE ORION ME ORION CEPITThrough the Lid Installation Kit 64394-024 64394-024 64394-001Below Lid with Knuckles Installation Kit 64394-025 64394-003Integrated Pit Lid Hanger Installation Kit 64394-026 64394-009VAULT Vault Installation Kit/Non-Standard Permalog+® Installation Kit 64394-027 64394-008REMOTE Remote Wall Mount Box Enclosure Kit 64394-028 64394-028 64394-021Remote Installation Bracket Kit 64394-029 64394-029 64394-019* Refer to ORI-P-09 for individual endpoint installation kit components. 5-11) Page 7
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYPit InstallationThrough the Lid Installation Kit (SE, ME and CE Endpoints)The Through the Lid Installation Kit is designed for use with a lid with maximum thickness of 1 inch, and a standard hole diameter of 1 7/8 inch.Figure 2: ORION Pit EndpointTo install the endpoint through the lid, follow these steps per Figure 2.1. Screw the nut onto the tube threads as shown.2. Insert the tube through the bottom of the lid.3. Screw the top cap onto the tube threads as shown and tighten.4. Tighten the nut against the bottom of the lid until secure.If installing an ORION endpoint through a thick lid, you may use a Pit Tube Extender (67025-001) which requires a 2 inch diameter hole. With line of sight, you will have reduced RF performance when using this extension.Pit LidTop CapNutTube1" Maximum Pit Lid ThicknessPage 8 5-11
Installation DataUNRELEASED DRAFT COPY ONLYBelow Lid with Knuckles Installation Kit (ME and CE Endpoints)For below the lid installations, a special mounting bracket (Figure 3) is available. This mounting support bracket is designed for use with 3/8”, 1/2” and 5/8” rebar or 1/2” schedule 40 PVC pipe. Figure 3: Pit Support Bracket (Knuckles) - Top ViewTo install an ORION endpoint below a meter pit lid, follow these steps.1. Drive rebar or stake into the ground. Drive rebar or stake into the ground prior to attaching the endpoint to avoid damage.2. Once in the ground, secure the mounting bracket on the appropriate rebar or pipe using the enclosed washer, wing nut and hex head bolt provided with the bracket. 3. Insert the endpoint through the bottom of the bracket and thread the lock nut onto the top of the endpoint. For best results, mount the endpoint a maximum of 1 to 2 inches below the underside of the lid.SFigure 4: Pit ORION Beneath Lid Installation 5-11) Page 9
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYIntegrated Pit Lid Hanger Installation Kit (ME and CE Endpoints)ORION endpoints can also be installed in composite and plastic lids with an integrated hanger for AMR/AMI endpoints. An installation kit for installing an ORION pit endpoint to the lid is available. To install an ORION endpoint to a composite or plastic lid, follow these steps.1. Thread the lock nut onto the top of the ORION endpoint as shown. 2. Slide the endpoint into the lid bracket. 3. Tighten the lock nut so that the endpoint is held rmly in place.Figure 5: Integrated Pit Lid Hanger InstallationVault Installation Kit (ME and CE Endpoints)When installation of the ORION endpoint occurs in a deep vault, Badger Meter oers a kit that can be used to mount the endpoint to the side of the vault. To install an ORION endpoint in a deep vault, follow these steps.1. Mount the C-clamp on the side of the vault. Select a location close to the top of the vault that will not be damaged when access to the meter is required. 2. Place the neoprene spacer supplied in the installation kit around the endpoint, approximately ½ inch from the top of the endpoint. 3. Thread the locking ring on the endpoint until it makes contact with the neoprene spacer as shown in Figure 6. 4. Insert the endpoint into the C-clamp as shown. 5. Close the C-clamp and lock it in place so that it closes over the neoprene spacer and securely holds the endpoint.NOTE: ORION radio endpoints perform best with a clear line of sight. Performance varies by installation and lid construction. C-Clamp C-Clamp Around EndpointFigure 6: C-Clamp and PlacementPage 10 5-11
Installation DataUNRELEASED DRAFT COPY ONLYRemote InstallationRemote Wall Mount Box Enclosure Kit (SE, ME and CE Endpoints)The ORION Remote Wall Mount Box Enclosure Kit is for use with either the Recordall Transmitter Register (RTR) or Absolute Digital Encoder (ADE) stepped tube and threaded tube ORION endpoint for remote mounting applications. The Remote Box Enclosure is designed for mounting ORION endpoints in indoor or outdoor environments and also provides an environmentally protected area for gel splice connections (if needed) to be maintained inside the enclosure.The ORION Remote Wall Mount Box Enclosure Kit is recommended for proper mounting of the ORION endpoint for remote applications.Remote Box Enclosure ORION CE RTR EndpointFigure 7: Enclosure and EndpointTo install an ORION endpoint using the Remote Box Enclosure, follow these steps. 1. Flip the Remote Box Enclosure over and look inside to verify the proper orientation. Locate the three security ribs inside the Remote Box Enclosure to determine the top of the enclosure. The bottom of the Remote Box Enclosure is identied by the two strain relief tabs located on both sides of the enclosure housing and the hole in the bottom of the enclosure that allows access to the endpoint IR communication port without having to disassemble the unit (Figure 8). 5-11) Page 11
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYFigure 8: Remote Box Enclosure Mounting2. Place the endpoint into the ORION Remote Box Enclosure as shown in Figure 9. To ensure maximum endpoint performance, it is important to mount the ORION endpoint in the proper orientation, with the endpoint antenna up and ORION endpoint IR communication port and wire down. 3. Make certain the at side of the endpoint is facing the back of the enclosure, or toward the installer, when inserting the ORION endpoint into the Remote Box Enclosure (Figure 9). When installing, mount the endpoint antenna toward the top of the enclosure, between the security ribs. NOTE: The arrow on the back of the Remote Box Enclosure points up, toward the top of the assembly. When installing the Remote Box Enclosure to a wall, mount it with the arrow pointed up (toward the sky).Figure 9: Endpoint OrientationTopHole in Bottom2 Strain Relief Tabs3 Security RibsEndpoint Antenna Security RibsFlat SideArrow/" Wide SlotPage 12 5-11
Installation DataUNRELEASED DRAFT COPY ONLY4. After the endpoint is mounted in the Remote Box Enclosure, loop the endpoint wire through the strain relief tab and through the cut out on the bottom of the enclosure. If needed, gel splice connections can be made and kept inside the Enclosure prior to mounting. Figure 10: Endpoint Wire Positioning5. Verify that the Remote Box Enclosure is properly positioned with the endpoint antenna up and the endpoint IR port facing down. Secure the enclosure to the wall using appropriate customer-supplied screws. Figure 11: Enclosure PositioningRight Side Strain Relief TabCable out of Bottom 5-11) Page 13
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLYRemote Installation Bracket Kit (SE, ME and CE Endpoints)The following instructions are provided to properly install an ORION endpoint in any indoor, outdoor or pit application. Prior to beginning the installation procedure, ensure that the following items are available.• RemoteInstallationBracketKit• Twocustomer-suppliedscrews• ScrewdriveranddrillThe Remote Installation Bracket securely mounts an ORION endpoint. For non-submerged indoor and outdoor applications, the installation bracket can also be used to enclose gel-cap, wire-splice connections to protect them from the environment and to prevent tampering in any indoor or outdoor non-metallic joist, wall or pit application.To install the bracket to the housing, follow these steps.1. Place the encoder cable harness through the slit in the bracket with the screw holes at the bottom.NOTE: Carefully slide the cable harness through the slit in the bracket. Figure 12: Cable Harness ThreadingSlitScrew Holes .18" diameterPage 14 5-11
Installation DataUNRELEASED DRAFT COPY ONLY2. Locate the small triangle aligned with the small hole on the bottom of the installation bracket. This triangle is used to properly align the endpoint to the installation bracket.Figure 13: Aligning TriangleOn the ORION endpoint, there is a small triangle printed on the lower side of the housing.Figure 14: Housing Triangle3. Align the two triangles and push the bracket and endpoint together.Figure 15: Align Both TrianglesTriangleTriangleTriangle 5-11) Page 15
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLY4. With the installation bracket in one hand and the housing in your other hand, hold the bracket still and twist the housing approximately 1/4 turn clockwise until it clicks and locks into place. Figure 16: Bracket and Housing ConnectionTo install the endpoint assembly, follow these steps.1. Align the ORION endpoint and the installation bracket with the antenna facing upwards (Figure 17).2. Using two customer-supplied screws, secure the endpoint and installation bracket assembly to a non-metallic joist or wall.Figure 17: Endpoint PositioningPage 16 5-11
Installation DataUNRELEASED DRAFT COPY ONLYWiring a Universal EndpointUniversal Endpoint IdenticationThe ORION Universal endpoint is available in a three-wire pit or remote endpoint conguration for connection to Sensus® ICETM and ECR II, Neptune® ProRead and E-Coder™, Elster AMCo® ScanCoder ®, Hersey® and Metron Translator encoder registers. All ORION Universal endpoints are shipped from the factory pre-programmed and can be connected to any compatible encoder. Electronic readings broadcast from the ORION Universal endpoint contain the active number wheels programmed into the encoder, with a maximum of six digits. The ORION system oers connectivity to any of the mechanical/absolute encoder registers listed above, with a manufacture date between 2000 to the present, as long as the encoder is programmed into the three-wire output mode for AMR and has three wires connected to it. Encoder registers that are currently in two-wire mode of operation will require programming by the Utility, including registers that support auto two- or three-wire detection systems that do not automatically switch to three-wire mode of operation once a compatible endpoint is connected for ORION connectivity.To identify an ORION pit or remote Universal 1 endpoint, ‘Univ’ has been added to the end of the ORION serial number. In addition, all Universal endpoints are shipped factory programmed in a sleep mode with a standard cable (10 feet for remotes and 3 feet for pit applications) for connection to a compatible Sensus, Neptune, Hersey or Elster AMCo encoder. ORION Universal endpoints begin broadcasting their readings as soon as they are awakened – either by running consumption through the encoder it is connected to or by using the infrared communication program on the ORION reading equipment. If the endpoint is awakened by running consumption, note that it may take several hours for the ORION Universal endpoint to begin broadcasting. This is due to the ORION Universal endpoint update schedule, which has the endpoint updating its reading from the encoder once an hour.Required Splice ToolsWire CutterGel Splice Crimping Tool 59983-001Coax Wire Stripper 59989-001Wiring the ORION Universal Endpoint to an EncoderThe ORION Universal endpoint is a three-wire metering endpoint device that requires connection to an encoder to complete the assembly. All three wires must be connected to complete an installation. The ORION Universal endpoint connection can be made to either existing wires from the encoder or directly to the terminal screws of the encoder, depending on the application and manufacturer. If making a connection to existing wires use the installation kit provided and follow these steps.1. To connect an encoder with existing wires to a ORION Universal endpoint, strip approximately 1 ½ inches of outer insulation sheath from the encoder and endpoint cables using the stripping tool. We recommend using part number 59989-001 Coax Stripper. Use caution when removing the outer sheath so that the inner signal wire insulation is not nicked or damaged.2. Unwind the outer foil shield from the endpoint cable and cut it o evenly with the outer sheath using a cutting device. 5-11) Page 17
ORION® Water Endpoint UNRELEASED DRAFT COPY ONLY3. Using the charts below, connect the ORION Universal 1 endpoint to an approved encoder according to the following guidelines. Verify the endpoint serial number prior to completing the wiring set up.Due to the customized, factory wire congurations of the Hersey Translator, please contact Hersey to determine the terminal post wiring schematic for your encoders. Once the terminal post information is determined, use the Sensus ECR 11, OCE wiring directions below. NOTE: The terminal posts and wire colors may not match.ORION CE Endpoints (Serial Number > 80,000,000) or ORION SE and ME Endpoints Universal 1 Endpoint WireSensus ECR II, ICENeptune ProReadElster AMCo ScanCoderAMCO InvisionARB-V* Metron HawkeyeRed R B G G B BBlack B G B B G BGreen G R R R R G ORION CE Endpoints (Serial Number < 79,999,999)Universal 1 Endpoint WireSensus ECR II, ICENeptune ProReadElster AMCo ScanCoderARB-V* Metron HawkeyeRed R B G R BBlack B G B B BGreen G R R G G R = Red B = Black G = Green *A separate ORION CE endpoint is available for connectivity to the Neptune ARB-V encoder.4. Connect the encoder cable wires to the ORION Universal endpoint wires using the insulation gel connectors provided in the installation kit. Refer to the chart to determine which wires need to be connected to complete an installation. The ORION system was designed as a three-wire AMR system only. Do not strip any insulation from the ends of the wires before you push them into the connector.5. Push the wires that are to be connected together as far as possible into the connector.Figure 18: Wires In ConnectorPage 18 5-11
Installation DataUNRELEASED DRAFT COPY ONLY6. Using the required Gel Splice Crimping Tool (59983-001), place the connector with the wires into the jaws of the crimping tool.Figure 19: Connector in Crimping ToolCrimp the connector by squeezing the handles until the connector is completely compressed. The crimp tool is designed to prevent applying too much pressure to the gel cap. Continue to apply pressure for three seconds.Figure 20: Compress Connector7. Place the two plastic cable ties and tighten securely for strain relief. Remove excess cable tie with the cutting device. For remote installations, the connection is complete.NOTE: For pit installations, it is advisable to test the connections before completing step 8.8. For pit installations, place all three connected wires with gel caps into the eld splice tube provided in the installation kit. Make sure the wires with gel caps are inserted as far as possible into the eld splice tube. Close the eld splice tube. The connection is now complete.Testing the Wire ConnectionsThe connection of the encoder and ORION Universal endpoint can be tested using an ORION data collector. It is recommended that all wiring connections be tested while on site. To test, set the data collector into the Quick Read function. Encoder Register InstallationInstall an RTR or ADE on the water meter and secure it using either the TORX screw or standard seal screw provided.RTR EndpointOnce the Pit ORION endpoint is securely installed and the RTR is mounted on the water meter, the ORION system is ready for operation. Run water through the meter to increment the RTR 1/10th of the test circle. Upon receiving the rst digital signal from the RTR, the endpoint counts the signal and begins its radio frequency transmissions. No specic testing of the wiring or programming of the endpoint is required. Reading each pit endpoint immediately after installation veries proper operation and reading performance. ORION reading equipment only can be used to read installed ORION endpoints.ADE EndpointOnce the ADE is assembled to the meter and the ORION endpoint is installed, the endpoint is ready for operation. The user can either let the endpoint automatically turn itself on by rolling the ADE number wheels to all zeros, or by turning on the endpoint with the handheld or mobile reading equipment. Since the ADE endpoint updates its reading from the ADE once an hour, it may take up to one hour after the ADE number wheel stack rolls to all zeros for the endpoint to begin broadcasting. In either case, no specic testing or programming of the endpoint is required. Reading each pit endpoint after it has been installed veries proper installation and reading performance. 5-11) Page 19
ADE, ORION and RTR are registered trademarks of Badger Meter, Inc.Other trademarks appearing in this document are the property of their respective entities.Copyright 2011 Badger Meter, Inc. All rights reserved. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists.Badger Meter | P.O. Box 245036, Milwaukee, Wisconsin 53224-9536 800-876-3837 | infocentral@badgermeter.com | www.badgermeter.com

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