Users Manual
Natural Gas Solutions
2.4GZ OpenWay Gas Module Installation
Guide
Identification
2.4GZ OpenWay Gas Module Installation Guide
DRAFT PUB-nnnn-nnn
Copyright
© 2007 Itron, Inc. All rights reserved.
Your company has the right to reproduce this contract document, provided that such reproduction shall be subject to the same use and disclosure restrictions contained in the
Confidentiality and Non-Disclosure paragraphs in the Sales Contract.
Applicable Patents
U.S. Patent Numbers: TBD
Canadian Patent Numbers: TBD
Transportation Classification
Itron classifies and ships model 2.4GZ OpenWay Gas Modules as a non-hazardous material. The proper shipping name is Lithium Batteries contain in Equipment, Class 9, UN3091,
Packing Group II.
The Federal Aviation Administration prohibits operating transmitters and receivers on all commercial aircraft. When powered, the 2.4GZ OpenWay Gas Module is considered an
operating transmitter and receiver and cannot be shipped by air.
Compliance Statement
This device complies with Part 15 of the FCC Rules. Operation of this device is subject to the following two conditions:
• This device may not cause harmful interference.
• This device must accept any interference that may cause undesirable operation.
This device must be permanently mounted such that it retains a distance of 20 centimeters (7.9 inches) from all persons in order to comply with FCC and Industry Canada RF exposure
levels.
Modification and Repairs
To ensure FCC and Industry Canada compliance and system performance, this device and antenna shall not be changed or modified in any way without the express written approval of
Itron, Inc. Any unauthorized modification will void the user’s authority to operate the equipment.
Meter Installation/Removal
In the event of malfunction, all repairs should be performed by Itron. It is the responsibility of users requiring service to report the need for service to Itron.
Related Documents
Endpoint-Link Programming Guide (TDC-XXXX)
Trademark Notice
OpenWay and Itron are both registered trademarks of Itron, Inc. All other product names and logos in this documentation are used for identification purposes only and may be
trademarks or registered trademarks of their respective companies.
Suggestions
If you have comments or suggestions on how we may improve this documentation, send them to TechnicalCommunicationsManager@itron.com.
Support
If you have questions or comments about this application, contact Itron Technical Support:
• Mail: Itron, Inc. Attention: Customer Care, 2111 N Molter Road, Liberty Lake, WA 99019
• E-mail: support@itron.com
• Phone: 1 800 635 8725
•
Web Support
http://eKnowledge.itron.com
Itron Website
http://www.itron.com
Document Revision
The content of this publication was last edited on 8/17/2007.
2.4GZ OpenWay Gas Module Installation Guide iii
Chapter 1 Getting Started...........................................................................................1
Specifications ......................................................................................................................................1
Meter Compatibility List.......................................................................................................................2
Chapter 2 American Meter Installation .......................................................................5
Installation Prerequisites .....................................................................................................................5
Materials Supplied by Itron .......................................................................................................5
Materials Supplied By You........................................................................................................5
Replacement Screws......................................................................................................6
Preinstallation Preparations......................................................................................................6
Installing the 2.4GZ OpenWay Gas Module on an American Meter...................................................6
Remove the Existing Index .......................................................................................................6
Assemble the OpenWay Gas Module.......................................................................................9
Program the OpenWay Gas Module.......................................................................................14
Attach the OpenWay Gas Module to the Meter......................................................................16
Chapter 3 Sensus Meter Installation.........................................................................21
Installation Prerequisites ...................................................................................................................21
Materials Supplied by Itron .....................................................................................................21
Materials Supplied By You......................................................................................................21
Replacement Screws....................................................................................................21
Preinstallation Preparations....................................................................................................22
Installing the 2.4 GHz OpenWay Gas Module on a Sensus Meter...................................................22
Remove the Existing Index .....................................................................................................22
Assemble the OpenWay Gas Module.....................................................................................24
Program the OpenWay Gas Module.......................................................................................26
Attach the OpenWay Gas Module to the Meter......................................................................27
Contents
Contents
iv 2.4GZ OpenWay Gas Module Installation Guide
2.4GZ OpenWay Gas Module Installation Guide 1
The 2.4GZ OpenWay Gas Module is Itron's latest module. OpenWay Gas Modules are
radio-frequency (RF) devices that transmit meter data. The 2.4GZ can be read by OpenWay
CENTRON electric meters and is part of Itron's OpenWay solution for combo gas and
electric utilities.
This installation guide shows you how to install the 2.4GZ OpenWay Gas Module on
meters from a variety of manufacturers. To ensure you have a meter that is compatible with
the 2.4GZ OpenWay Gas Module, refer to the Meter Compatibility List on page 2.
An FCC or IC license is not required to read 2.4GZ OpenWay Gas Modules.
Specifications
The functional and operational specifications for the 2.4GZ OpenWay Gas Module are
listed below.
Functional Specifications Description
Power Source Two "A" cell lithium batteries
Tamper Detection Tilt tamper and magnetic tamper
FCC Compliance Part 15 certified
Industry Canada Compliance RSS-210 certified
Measurement Canada Approval Pending
Intrinsic Safety UL Class I, Division 1, Groups C and D pending
Product Identification Numeric and barcoded and serial number
Construction Materials Gray polycarbonate back plate with Santoprene®
gasket; clear polycarbonate front cover; encapsulated
electronics
Operational Specifications Description
Operating Temperatures -40° to 158° F (-40° to +70° C)
Operating Humidity 5 to 95percent relative humidity
Frequency Band 2.4 to 2.4835 GHz ISM band
Modulation Direct Sequence Spread Spectrum
Data Integrity Verified in every data message
CHAPTER 1
Getting Started
Chapter 1 Getting Started
2 2.4GZ OpenWay Gas Module Installation Guide
Meter Compatibility List
The following meters are compatible with the 2.4GZ OpenWay Gas Module. Due to
continuous research, product improvements, and enhancements, Itron reserves the right to
change this list at any time.
To ensure you have the latest Meter Compatibility list available, contact your Itron
representative.
Mfgr. Model Desc. Class Comments OpenWay
Gas
Module
Part No.
American/ Canadian W75AL Residential Aluminum case
Meters Only 2.4GZ OWG-5000-001
American/ Canadian AL-175 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AC-175 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AT-175 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian ALC-175 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AT-210 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AL-225 Canada
only Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AL-250 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AR-250 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AC-250 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AT-250 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AM-250 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AL-310 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AL-350 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AT-350 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian AL-425 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
Meter Compatibility List
2.4GZ OpenWay Gas Module Installation Guide 3
American/ Canadian AC-630 Residential Aluminum case
meters only 2.4GZ OWG-5000-001
American/ Canadian 5B 225 Residential Aluminum case 2.4GZ OWG-5000-001
Sensus/Invensys/
Equimeter/ Rockwell R-175 11 Tooth Residential Compatible with 2
foot drive index; 1
foot drive has 24
teeth
2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell R-200 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell RT-200 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell RT-230 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell R-275 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell RT-275 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell R-315 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell 250 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
310 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
S-110 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
S-200 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
175-S 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
RT-100 18 Tooth Residential 2.4GZ OWG-5000-004
Sensus/Invensys/
Equimeter/ Rockwell
S-190 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/
Invensys/ Equimeter/
Rockwell
S-120 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
T-120 11 Tooth Residential 2.4GZ OWG-5000-002
Sensus/Invensys/
Equimeter/ Rockwell
T-110 11 Tooth Residential 2.4GZ OWG-5000-002
Chapter 1 Getting Started
4 2.4GZ OpenWay Gas Module Installation Guide
Sensus/Invensys/
Equimeter/ Rockwell
R-415 18 Tooth Residential 2.4GZ OWG-5000-004
Sensus/Invensys/
Equimeter/ Rockwell
RT-360 18 Tooth Residential 2.4GZ OWG-5000-004
Sensus/Invensys/
Equimeter/ Rockwell
MR8
(R-275
Metric)
16 Tooth Residential 2.4GZ OWG-5000-003
Sensus/Invensys/
Equimeter/ Rockwell
MR12
(R-415
Metric)
16 Tooth Residential 2.4GZ OWG-5000-003
2.4GZ OpenWay Gas Module Installation Guide 5
This chapter shows you how to install a 2.4GZ OpenWay Gas Module on an American
meter.
Before installing the 2.4GZ OpenWay Gas Module, verify that you have:
• A compatible meter shown in the Meter Compatibility List on page 2.
• A compatible index. Itron 2.4GZ OpenWay Gas Modules can be used with standard
dial and direct read (odometer) indexes on American Meters.
• The list of materials defined under "Installation Prerequisites" in this chapter
Installation Prerequisites
This section describes the items that are required to install Itron's 2.4GZ OpenWay Gas
Module.
Materials Supplied by Itron
The following items are supplied by Itron.
• 2.4GZ OpenWay Gas Modules
• Tamper plugs
Materials Supplied By You
You must supply the following items to successfully install the 2.4GZ OpenWay Gas
Module on the meters listed in the Meter Compatibility List.
• Small and medium flat-blade screwdrivers Used to remove and tighten index and
index-cover screws.
• Side-cutting plier/wire snips Used for cutting wire seals, if necessary.
• Small putty knife Used to remove all traces of old gaskets from the meter.
• Meter seals, wire seals, and seal press Used to secure the meter from tampering, if
necessary.
• 11/32-inch nut driver or other blunt tool Used to securely seat new tamper plugs
over screw holes.
• Replacement screws Used to mount OpenWay Gas Module assembly to meter and
index to module assembly backplates; see "Replacement Screws" below for more
information).
CHAPTER 2
American Meter Installation
Chapter 2 American Meter Installation
6 2.4GZ OpenWay Gas Module Installation Guide
Replacement Screws
Replacement screws used in this procedure must be slotted, zinc-plated, steel machine
screws. Sizing options are shown below.
For mounting 2.4GZ OpenWay Gas Module assemblies on meters:
• Use 1/4 - 20 x 5/8-inch slotted, Fillister head screws.
For mounting indexes on 2.4GZ OpenWay Gas Module backplates:
• Use 8 - 32 x 3/16-inch slotted, round head screws.
Preinstallation Preparations
Before installing the 2.4GZ OpenWay Gas Module on a meter, verify that:
• All OpenWay Gas Modules are type 2.4GZ modules for your brand of gas meters.
• The model numbers of all meters on which the OpenWay Gas Modules will be
installed are included in the Meter Compatibility List on page 2.
Installing the 2.4GZ OpenWay Gas Module on an American
Meter
There are four major steps to installing the 2.4GZ OpenWay Gas Module on a meter:
• Remove the Existing Index
• Assemble the OpenWay Gas Module
• Program the OpenWay Gas Module
• Attach the OpenWay Gas Module to the meter
These procedures are described in the following sections.
NOTE Be sure to properly dispose of all unused screws, old index covers,
gaskets, and other left-over materials. Do not leave any materials on customer
premises.
Remove the Existing Index
The first major step when installing a 2.4GZ OpenWay Gas Module on an American meter
is to remove the existing index from the meter.
To Remove the Existing Index
1. Remove any tamper seals from the meter.
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 7
2. Detach the index cover from the meter by removing the four screws holding it in
place.
3. Examine the index cover screws you just removed. Verify that they are 5/8-inch long
and are not corroded.
• If the screws are 5/8-inch long, and are not corroded, keep them for later use.
• If the screws are an incorrect length or are corroded, dispose of them properly.
Use 1/4 - 20 x 5/8-inch screws as described in Replacement Screws on page 6
instead.
TIP You can use the index cover you just removed as a temporary storage
location for screws.
4. Unscrew one index mounting screw completely.
Hold one hand beneath the index to catch the screw when it falls out of the index
assembly. If it does not fall out by itself, be sure to remove it.
5. Unscrew the other index mounting screw.
Chapter 2 American Meter Installation
8 2.4GZ OpenWay Gas Module Installation Guide
While removing this screw, pull the index away from the meter to keep its backplate
(1) against the back of the screwhead (2). This prevents the screw from falling out
prematurely.
1
2
6. Remove the screw from the index once it is completely free of its hole.
7. Set the index aside for the moment. Place it where it will not be damaged; get filled
with dirt, rain, or snow; or fall to the ground or floor. The index will be used later in
this procedure.
8. Examine the index screws you just removed. Verify that they are 3/16-inch long and
are not corroded.
• If the screws are 3/16-inch long and are not corroded, keep them for later use.
• If the screws are an incorrect length or are corroded, dispose of them properly.
Use 8 - 32 x 3/16-inch screws as described in Replacement Screws instead.
9. Use a putty knife or similar object to completely remove the old index gasket from the
meter (if applicable). All traces of the gasket must be removed before the OpenWay
Gas Module can be installed.
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 9
Assemble the OpenWay Gas Module
When installing a 2.4GZ OpenWay Gas Module, the next major step is to create the
OpenWay Gas Module assembly by combining the module backplate and cover with the
meter index. Follow the procedure below to do so.
To Assemble the OpenWay Gas Module
1. Obtain a new 2.4GZ OpenWay Gas Module.
2. Separate the module backplate (1) from the cover (2).
3. Set the new OpenWay Gas Module index cover aside for the moment. Place it where
it will not be damaged; get filled with dirt, rain, or snow; or fall to the ground or floor.
The index cover will be used later in this procedure.
IMPORTANT Before continuing with the installation, note the following
information about American Meter indexes:
• Index wrigglers on one-foot meters have drive slots.
Chapter 2 American Meter Installation
10 2.4GZ OpenWay Gas Module Installation Guide
• Index wrigglers on two-foot meters have drive posts.
• An index may have mounting screw holes.
• An index may have mounting screw slots.
If the index has mounting screw slots, skip steps 4 and 5 below. Continue with step 6.
If the index has mounting screw holes, perform steps 4 and 5 below, and then skip
steps 6 and 7.
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 11
4. If the index has mounting screw holes, place an index mounting screw (1) in the right-
hand mounting screw hole (2). Use one 8 - 32 3/16-inch screw for this step (you can
use an original mounting screw if it was the correct size and not corroded; otherwise,
use the correct size replacement screw).
1
2
5. Attach the screw to the OpenWay Gas Module backplate's right-hand index mounting
post just far enough to hold the screw and end of the index in place.
6. If the index has mounting screw slots, screw an index mounting screw (1) one to two
turns into the OpenWay Gas Module backplate's right-hand index mounting post (2).
Use one 8 - 32 x 3/16-inch screw for this step (you can use an original mounting
screw if it was the correct size and not corroded; otherwise, use the correct size
replacement screw).
Chapter 2 American Meter Installation
12 2.4GZ OpenWay Gas Module Installation Guide
2
1
7. Place the index mounting screw slot under the screw head. Do not tighten the screw
yet.
2
1
8. Attach the wriggler to the index and backplate.
• If the index wriggler has a drive slot (1), place the backplate wriggler's drive
post (2) in the index wriggler's drive slot.
2
1
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 13
• If the index wriggler has a drive post (1), place the index wriggler's drive post
in the backplate wriggler's drive slot (2).
2
1
9. Install and tighten the left-hand index mounting screw (for indexes with either
mounting screw slots or holes). Use one 8 - 32 x 3/16-inch screw for this step (you
can use an original mounting screw if it was the correct size and not corroded;
otherwise, use the correct size replacement screw).
10. Tighten the right-hand index mounting screw.
11. Slide the OpenWay Gas Module cover (1) over the index and backplate (2).
Next, program the OpenWay Gas Module.
Chapter 2 American Meter Installation
14 2.4GZ OpenWay Gas Module Installation Guide
Program the OpenWay Gas Module
Once the OpenWay Gas Module has been assembled, the module must be programmed
using FieldPro on a laptop with a ZigBee dongle. Refer to FieldPro documentation for
programming information.
IMPORTANT You must perform the following programming procedure for
the OpenWay Gas Module to function properly.
When programming the OpenWay Gas Module, you must take note of the drive rate shown
on the index of American meters.
Examples of 1-foot (1) and 2-foot (2) drive rates are shown below (a 0.05 cubic metre drive
rate is not shown). Be sure to program the OpenWay Gas Module based on the drive rate
indicated on the index.
1
2
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 15
To Program the OpenWay Gas Module
1. Using the FC200SR, program the reading of the index that was on the meter into the
OpenWay Gas Module assembly.
• For initial programming, hold the FC200SR approximately 1 foot away from
the OpenWay Gas Module.
• For reprogramming (30 days or more past initial programming), hold the
FC200SR approximately 4 to 5 feet away from the OpenWay Gas Module.
Be sure to program the OpenWay Gas Module to the correct mode for the reading
technology what will be used (for example, Fixed Network Mode, Mobile/Handheld
Mode, or Hard to Read Mobile/Handheld Mode). In Endpoint-Link Pro v5.0, you will
have access to the one mode that was defined by your system administrator.
During programming, the OpenWay Gas Module is programmed to the nearest 100
cubic feet; the last two digits (the tens and units) are programmed as zeros (0). Once
programming is complete, however, the OpenWay Gas Module assembly can be read
to the nearest cubic foot.
2. Slowly turn the OpenWay Gas Module drive wriggler two turns in the direction
indicated on the index drive rate. This lets you verify the module is counting properly
after assembly.
IMPORTANT Do not turn the drive wriggler faster than one turn per second.
3. Read the OpenWay Gas Module assembly using the FC200SR. Consult the EndPoint-
Link ERT Programming Guide (TDC-0411) or other applicable instructions for details
on how to read an OpenWay Gas Module.
• If this reading is higher than the one you programmed in step 1 above, the
module assembly is counting correctly.
• If the OpenWay Gas Module assembly reading is not higher than what was
programmed in step 1, replace the module with a new one.
Chapter 2 American Meter Installation
16 2.4GZ OpenWay Gas Module Installation Guide
Attach the OpenWay Gas Module to the Meter
After the OpenWay Gas Module has been programmed and is reading correctly, follow the
steps below to attach the module to the meter.
To Attach the OpenWay Gas Module to the Meter
1. For 5B 225 Meters Only: If you are installing the OpenWay Gas Module on a 5B
225 aluminum meter, cut 1/16-inch off each post of the module wriggler to prevent it
from rubbing on the face of the nut that holds the wriggler in place. If you are not
installing on a 5B 225 meter, continue to step 2 below.
2. Set the wriggler to the desired position for mounting the OpenWay Gas Module
assembly to the meter.
• For One-Foot Meters: Align the OpenWay Gas Module assembly wriggler
with the meter drive post (as shown below). Make sure the wriggler is
perpendicular to the meter drive post.
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 17
• For Two-Foot Meters: Align the OpenWay Gas Module assembly wriggler
with the meter drive slot (as shown below). It is acceptable for the pin on the
module wriggler to be installed inside or outside of the meter drive slot. For
ease of assembly, Itron recommends that the pin on the OpenWay Gas Module
wriggler be installed outside of the meter drive slot.
3. Gently place the OpenWay Gas Module assembly on the meter. Align the four screw
holes on the module assembly with the holes on the meter.
Chapter 2 American Meter Installation
18 2.4GZ OpenWay Gas Module Installation Guide
4. Install and tighten all OpenWay Gas Module assembly mounting screws, working in a
diagonal pattern as shown below. Tighten the mounting screws to 15 to 20 inch-
pounds of torque. Use the 1/4 - 20 x 5/8-inch screws for this step (you can use the
original mounting screws if they were the correct size and not corroded; otherwise,
use the correct size Replacement Screws on page 6).
3
41
2
5. Place a new tamper seal over two of the mounting screws as shown below.
1
2
6. Press the new tamper seals into place using the 11/32-inch nut driver (or another
similar blunt tool).
7. Complete any necessary paperwork. Make sure no excess material is left on the
customer premises; dispose of it properly.
Installing the 2.4GZ OpenWay Gas Module on an American Mete
r
2.4GZ OpenWay Gas Module Installation Guide 19
The OpenWay Gas Module is now installed on the meter.
Chapter 2 American Meter Installation
20 2.4GZ OpenWay Gas Module Installation Guide
2.4GZ OpenWay Gas Module Installation Guide 21
This chapter shows you how to install a 2.4GZ OpenWay Gas Module on a compatible
Sensus meter.
Sensus meters are also known by the following names: Invensys,
Equimeter, and Rockwell. For consistency, all of these meter types will
be referred to as Sensus meters for this installation procedure.
Installation Prerequisites
This section describes the items that are required to install Itron's 2.4GZ OpenWay Gas
Module.
Materials Supplied by Itron
The following items are supplied by Itron.
• 2.4GZ OpenWay Gas Modules
• Tamper plugs
Materials Supplied By You
You must supply the following items to successfully install the 2.4GZ OpenWay Gas
Module on the meters listed in the Meter Compatibility List.
• Small and medium flat-blade screwdrivers Used to remove and tighten index and
index-cover screws.
• Side-cutting plier/wire snips Used for cutting wire seals, if necessary.
• Small putty knife Used to remove all traces of old gaskets from the meter.
• Meter seals, wire seals, and seal press Used to secure the meter from tampering, if
necessary.
• 11/32-inch nut driver or other blunt tool Used to securely seat new tamper plugs
over screw holes.
• Replacement screws Used to mount OpenWay Gas Module assembly to meter and
index to module assembly backplates; see "Replacement Screws" below for more
information).
Replacement Screws
Replacement screws used in this procedure must be slotted, zinc-plated, steel machine
screws. Sizing options are shown below.
CHAPTER 3
Sensus Meter Installation
Chapter 3 Sensus Meter Installation
22 2.4GZ OpenWay Gas Module Installation Guide
For mounting 2.4GZ OpenWay Gas Module assemblies on meters:
• Use 10 - 24 x5/8-inch slotted, Fillister head screws.
For mounting indexes on 2.4GZ OpenWay Gas Module backplates:
• Use 6 - 32 x 5/8-inch slotted, round head screws.
Preinstallation Preparations
Before installing the 2.4GZ OpenWay Gas Module on a meter, verify that:
• All OpenWay Gas Modules are type 2.4GZ modules for your brand of gas meters.
• The model numbers of all meters on which the OpenWay Gas Modules will be
installed are included in the Meter Compatibility List on page 2.
Installing the 2.4 GHz OpenWay Gas Module on a Sensus
Meter
There are four major steps to installing the 2.4GZ OpenWay Gas Module on a meter:
• Remove the Existing Index
• Assemble the OpenWay Gas Module
• Program the OpenWay Gas Module
• Attach the OpenWay Gas Module to the meter
These procedures are described in the following sections.
NOTE Be sure to properly dispose of all unused screws, old index covers,
gaskets, and other left-over materials. Do not leave any materials on customer
premises.
Remove the Existing Index
The first major step when installing a 2.4GZ OpenWay Gas Module on a Sensus meter is to
remove the existing index from the meter.
To Remove the Existing Index
1. Remove any tamper seals from the meter.
Installing the 2.4 GHz OpenWay Gas Module on a Sensus Mete
r
2.4GZ OpenWay Gas Module Installation Guide 23
2. Detach the index cover from the meter by removing the four screws holding it in
place.
3
4
1
2
3. Examine the index cover screws you just removed. Verify that they are 5/8-inch long
and are not corroded.
• If the screws are 5/8-inch long and are not corroded, keep them for later use.
• If they are an incorrect length or are corroded, dispose of them properly. Use 10
- 24 x 5/8-inch screws as described in Replacement Screws on page 21 instead.
TIP You can use the index cover you just removed as a temporary storage
location for screws.
4. Unscrew one index mounting screw completely.
5. Remove the other index mounting screw.
6. Set the index aside for the moment. Place it where it will not be damaged; get filled
with dirt, rain or snow; or fall to the ground or floor. The index will be used later in
this procedure.
7. Examine the index screws you just removed. Verify that they are 5/8-inch long and
are not corroded.
Chapter 3 Sensus Meter Installation
24 2.4GZ OpenWay Gas Module Installation Guide
• If the screws are 5/8-inch long and are not corroded, keep them for later use.
• If the screws are an incorrect length or are corroded, dispose of them properly.
Use 6 -32 x 5/8-inch screws as described in Replacement Screws on page 21
instead.
8. Use a putty knife or similar object to completely remove the old index gasket from the
meter (if applicable). All traces of the gasket must be removed before the OpenWay
Gas Module can be installed.
Assemble the OpenWay Gas Module
When installing a 2.4GZ OpenWay Gas Module, the next major step is to create the
OpenWay Gas Module assembly by combining the module backplate and cover with the
meter index. Follow the procedure below to do so.
To Assemble the OpenWay Gas Module
1. Obtain a new 2.4GZ OpenWay Gas Module.
2. Separate the OpenWay Gas Module backplate from the cover.
3. Place the index drive gear (1) in the backplate wriggler gear cup (2) of the OpenWay
Gas Module (please note that the following example uses an 11-tooth drive gear; your
index may have a 16- or 18-tooth drive gear, and you must use the appropriate 2.4GZ
OpenWay Gas Module for your specific meter. See the Meter Compatibility list on
page 2 for more information).
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2.4GZ OpenWay Gas Module Installation Guide 25
Once properly in place, the index drive gear and backplate wriggler cup should look
similar to the following example.
4. Attach the right-hand mounting screw to the index and meter, just far enough to hold
the index in place. Use one 6 - 32 x 5/8-inch screw for this step (you can use an
original mounting screw if it was the correct size and not corroded; otherwise, use the
correct size Replacement Screw see "Replacement Screws" on page 21).
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5. Install and tighten the left-hand index mounting screw.
6. Tighten the right-hand index mounting screw completely.
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26 2.4GZ OpenWay Gas Module Installation Guide
7. Slide the OpenWay Gas Module cover over the index and backplate.
8. Verify that the cover is installed correctly.
Once combined, the OpenWay Gas Module backplate, meter index, and OpenWay
Gas Module cover create an OpenWay Gas Module Assembly.
Next, program the OpenWay Gas Module.
Program the OpenWay Gas Module
Once the OpenWay Gas Module has been assembled, the module must be programmed
using FieldPro on a laptop with a ZigBee dongle. Refer to FieldPro documentation for
programming information.
IMPORTANT You must perform the following programming procedure for
the OpenWay Gas Module to function properly.
When programming the OpenWay Gas Module, you must take note of the drive rate shown
on the index of Sensus meters. Sensus meters have a 2-foot drive rate, as indicated in the
example below (1), or a 0.05 cubic metre drive (not shown).
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2.4GZ OpenWay Gas Module Installation Guide 27
To Program the OpenWay Gas Module
1. Using the FC200SR, program the reading of the index that was on the meter into the
OpenWay Gas Module assembly.
• For initial programming, hold the FC200SR approximately 1 foot away from
the 2.4 GHz OpenWay Gas Module.
• For reprogramming (30 days or more past initial programming), hold the
FC200SR approximately 4 to 5 feet away from the OpenWay Gas Module.
Be sure to program the OpenWay Gas Module to the correct mode for the reading
technology what will be used (for example, Fixed Network Mode, Mobile/Handheld
Mode, or Hard to Read Mobile/Handheld Mode). In Endpoint-Link Pro v5.0, you will
have access to the one mode that was defined by your system administrator.
During programming, the OpenWay Gas Module is programmed to the nearest 100
cubic feet; the last two digits (the tens and units) are programmed as zeros (0). Once
programming is complete, however, the module assembly can be read to the nearest
cubic foot.
2. Slowly turn the OpenWay Gas Module drive wriggler two turns in the direction
indicated on the index drive rate. This lets you verify the module is counting properly
after assembly.
IMPORTANT Do not turn the drive wriggler faster than one turn per second.
3. Read the OpenWay Gas Module assembly using the FC200SR. Consult the EndPoint-
Link ERT Programming Guide (TDC-0411) or other applicable instructions for details
on how to read an OpenWay Gas Module.
• If this reading is higher than the one you programmed in step 1 above, the ERT
module assembly is counting correctly.
• If the OpenWay Gas Module assembly reading is not higher than what was
programmed in step 1, replace the module with a new one.
Attach the OpenWay Gas Module to the Meter
After the OpenWay Gas Module has been programmed and is reading correctly, follow the
steps below to attach the module to the meter.
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28 2.4GZ OpenWay Gas Module Installation Guide
To Attach the OpenWay Gas Module to the Meter
1. Gently place the OpenWay Gas Module assembly against the front of the meter as
shown. Make sure all four mounting screw holes in the 2.4GZ line up with the
corresponding holes on the meter.
2. Insert the top-right cover mounting screw. Tighten the screw just enough to hold the
2.4GZ in place. Use the 10 - 24 x 5/8-inch screws for this and the following step (you
can use the original mounting screws if they were the correct size and not corroded;
otherwise, use the correct size as described in Replacement Screws on page 21).
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2.4GZ OpenWay Gas Module Installation Guide 29
3. Install and tighten the remaining three mounting screws. Tighten the mounting screws
to 15 to 20 inch-pounds of torque.
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4. Tighten the top-right mounting screw.
5. Place a new tamper seal over two of the mounting screws as shown below.
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30 2.4GZ OpenWay Gas Module Installation Guide
6. Press the new tamper seals into place using the 11/32-inch nut driver (or another
similar blunt tool).
7. Complete any necessary paperwork. Make sure no excess material is left on the
customer premises.
The OpenWay Gas Module is now installed on the meter.