Itron 24GZRB AMR transceiver device for utility meters. User Manual Part1

Itron, Inc. AMR transceiver device for utility meters. Users Manual Part1

Contents

Users Manual Part1

Natural Gas Solutions 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount TDC-0838-001
Identification 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 09/17/2010 TDC-0838-001 2.4GZ OpenWay Gas Module part numbers: OWG-5001-501, OWG-5001-502, OWG-5001-503, OWG-5001-504 OWG-5002-501, OWG-5002-502, OWG-5002-503, OWG-5002-504 Copyright © 2010 Itron, Inc. All rights reserved. Confidentiality Notice The information contained herein is proprietary and confidential and is provided subject to the condition that (i) it is held in confidence except to the extent required otherwise by law and (ii) it is used only for the purposes described herein. Any third party given access to this information is similarly bound in writing. Trademark Notice Itron is a registered trademark 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. Safety Approvals Intrinsically safe per UL Class I, Division 1, Groups C & D Applicable Patents U.S. Patent Numbers: 4,614,945; 4,753,169; 4,768,903; 4,799,059; 4,867,700 Canadian Patent Numbers: 1,254,949; 1,267,936; 1,282,118 Compliance Statement This device complies with Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. Operation 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 RF exposure levels. Compliance Statement This equipment has been tested and found to comply with the limits, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. Operation is subject to the following conditions: • This device may not cause interference. • This device must accept any interference that may cause undesired operation of the device. Compliance Statement This equipment complies with policies RSS-210 and RSS-GEN of the Industry Canada rules. 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. Transportation Classification The Federal Aviation Administration prohibits operating transmitters and receivers on all commercial aircraft. When powered, the 2.4GZ OpenWay remote mount gas module is considered an operating transmitter and receiver and cannot be shipped by air. All product returns must be shipped by ground transportation. Modifications and Repairs To ensure system performance, this device and antenna shall not be changed or modified without the expressed approval of Itron. 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. Warning To prevent ignition of flammable or combustible atmospheres, read, understand, and follow the manufacturer’s live maintenance procedures. Warning Follow these procedures to avoid injury to yourself or others: The lithium battery may cause a fire or chemical burn if it is not disposed of properly. Do not recharge, disassemble, heat above 100º Celsius (212º Fahrenheit), crush, expose to water, or incinerate the lithium battery. Fire, explosion, and severe burn hazard. Keep the lithium battery away from children. Warning Only authorized Itron personnel should attempt repairs on Itron equipment. Attempts to do so by others might void any maintenance contract with your company. Unauthorized service personnel might also be subject to shock hazard on some Itron equipment if removal of protective covers is attempted. Warning Substitution of components may impair intrinsic safety. Suggestions If you have comments or suggestions on how we may improve this documentation, send them to TechnicalCommunicationsManager@itron.com If you have questions or comments about the software or hardware product, contact Itron Technical Support: Contact Internet: www.itron.com E-mail: support@itron.com Phone: 1 877 487 6602
TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount ii Proprietary and Confidential Before You Begin ......................................................................................................... iv Document Conventions ............................................................................................................ iv Chapter 1 2.4GZ OpenWay Remote Mount Gas Module Installation ........................ 1 Transmission Modes ........................................................................................................................... 1 Programming Modes ........................................................................................................................... 2 Specifications ...................................................................................................................................... 3 Related Documents ............................................................................................................................. 3 2.4GZ OpenWay Remote Mount Gas Module Meter Compatibility List.............................................. 3 Installation Prerequisites ..................................................................................................................... 7 Chapter 2 Mounting the 2.4GZ OpenWay Remote Mount Gas Module .................... 8 Installation Options .............................................................................................................................. 8 Mounting Screw Specifications ............................................................................................................ 8 Mounting Installation Considerations .................................................................................................. 9 Mounting the 2.4GZ OpenWay Remote Mount Gas Module on a Pipe ............................................ 10 Mounting the Endpoint on a Wall or Other Flat Vertical Surface .................................. 16 Chapter 3 Rotary Meter Installation .......................................................................... 19 Required Installation Materials Available from Itron .......................................................................... 20 Connecting the 2.4GZ OpenWay Remote Mount Gas Module to the Rotary Meter Cable ............... 20 Programming 2.4GZ OpenWay Remote Mount Gas Module for Dresser ROOTS® Rotary Meters . 24 B3, LMMA & S3A CTR/TC Meter Pulse Rates for Remote Module Programming ........................... 24 Installing the 2.4GZ OpenWay Remote Mount Gas Module to the Elster American Meter RPM Series Rotary Meter ................................................................................................................ 25 Mounting the 2.4GZ Remote Mount Module ..................................................................................... 30 Installing the 2.4GZ OpenWay Remote Mount Gas Module to the Romet Electronically Compensated Meter (ECM2®) ................................................................................................ 30 Connecting the 2.4GZ OpenWay Remote Mount Gas Module to the Romet ECM2® Meter ............ 31 Romet ECM2 Mounting Requirement ..................................................................................... 31 Programming the 2.4GZ OpenWay Remote Mount Gas Module Assembly ..................................... 34 Contents
Contents TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount iii Proprietary and Confidential Chapter 4 Electronic Instrument Installation ........................................................... 36 Installation Prerequisites ................................................................................................................... 37 Installation Overview ......................................................................................................................... 37 Programming the Mercury Instrument ............................................................................................... 38 Code Settings.......................................................................................................................... 38 Wiring the 2.4GZ OpenWay Remote Mount Gas Module to the Mercury Instrument ....................... 40 Wiring Dual Endpoints to a Mercury Instrument Corrector ............................................................... 42 Required Tools* ....................................................................................................................... 42 Wiring the Remote Module to the Mercury TCI ................................................................................. 44 Connecting the 2.4GZ Remote Gas Module to the Dresser ROOTS® IMC/W2 or MC2 Cable ....... 48 Installing the Endpoint to the Dresser ROOTS® Micro Corrector (IMC/W2 or MC2) ........................ 51 Programming the 2.4GZ OpenWay Remote Mount Gas Module Assembly ..................................... 55 Chapter 5 Diaphragm Meter Installation ................................................................... 57 Tools and Materials Supplied By You ............................................................................................... 57 Materials Available from Itron ............................................................................................................ 58 Replacement Gaskets ............................................................................................................. 58 Installing the 2.4GZ OpenWay Remote Mount Gas Module ............................................................. 59 Installing 2.4GZ OpenWay OpenWay Remote Mount Gas Module Encoders ................................. 60 Programming the OpenWay Remote Mount Gas Module Assembly ................................................ 69 Chapter 6 Curb Diaphragm Meter Installation .......................................................... 71 Materials Available from Itron ............................................................................................................ 71 Tools and Materials Supplied By You ............................................................................................... 72 Installing the 2.4GZ Remote Mount Gas Module on the Curb Meter ................................................ 73 Programming the 2.4GZ OpenWay OpenWay Remote Mount Gas Module Assembly.................... 81 Chapter 7 Dattus Meter Installation .......................................................................... 83 Installation Prerequisites ................................................................................................................... 83 Programming the Dattus Meter ......................................................................................................... 83 Installation Overview .......................................................................................................................... 84 Installing the 2.4GZ Remote Mount Gas Module to Itron Dattus Meters .......................................... 84 Direct Mounting the 2.4GZ OpenWay Remote Mount Gas Module to the Dattus Meter .................. 85 Connecting the 2.4GZ OpenWay Remote Mount Gas Module to a Dattus meter ............................ 86 Mounting the 2.4GZ OpenWay Remote Mount Gas Module ............................................................. 87 Programming the 2.4GZ OpenWay Remote Mount Gas Module Assembly ..................................... 87 Chapter 8 Sensus Sonix Meter Installation .............................................................. 90 Programming the Sensus Sonix Meter ............................................................................................. 90 Adjusting the Pulse Output for Sonix 600 and 880 Meters ................................................................ 90 Installing the 2.4GZ OpenWay Remote Mount Gas Module with Sensus Sonix Meters ................... 91 Sensus Sonix2000 Pulse Output Wiring ............................................................................................ 91 Direct Mounting the 2.4GZ OpenWay Remote Mount Gas Module to the Sonix Meter .................... 92 Connecting the 2.4GZ OpenWay Remote Mount Gas Module to a Sensus Sonix 600 or 880 Meter .............................................................................................. 93 Programming the 2.4GZ OpenWay Remote Mount Gas Module Assembly ..................................... 94 Index ............................................................................................................................. 96
Before You Begin TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount iv Proprietary and Confidential Document Conventions The following documentation conventions are used: Caution A Caution warns the user that failure to heed the information in the note could result in loss of data. Be sure to carefully read a Caution note and follow the advice/instructions. Warning A Warning alerts you of potential physical harm to the user or hardware. It is critical that you pay strict attention to WARNING notes, read the information carefully, and follow the advice/instructions. Before You Begin Tip A Tip provides the user with extra hints/tips to make a task easier to perform or a concept easier to understand. Note A Note supplies generic information to the user. The user can ignore the information and continue the task without suffering any adverse consequences.
TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 1 Proprietary and Confidential 2.4GZ OpenWay remote mount gas modules are radio-frequency (RF) devices operating over the 2.4 GHz frequency. The 2.4GZ OpenWay remote mount gas modules communicate with ZigBee®-compliant electric meters to transmit gas consumption data. Modules can store 40 days of hourly intervals and are programmed to bubble-up every 12 or 24 hours. Alternatively, the 2.4GZ OpenWay remote mount gas module can be awakened with an Itron magnet for programming or for binding to an OpenWay electric meter. When 2.4GZ Openway gas modules are installed alongside Itron OpenWay electric meters, the OpenWay solution for combo gas and electric utilities provides unprecedented management flexibility. This installation guide provides step-by-step instructions to install the 2.4GZ OpenWay remote mount gas module on a wide variety of meters. 2.4GZ OpenWay remote mount gas module compatible meters are listed in the Meter Compatibility List. Transmission Modes The 2.4GZ OpenWay remote mount gas module can be set to transmit to Standard, Daily or Hourly Mode. Standard Mode. The 2.4GZ remote mount gas module transmits the current index read and Daily Freeze Time read; Daily Freeze Time read is programmable for any hour. Daily Mode. In addition to transmitting Standard Mode information, the 2.4GZ remote mount gas module transmits 40 days of daily interval data based on Daily Freeze Time reads. Hourly Mode. In addition to transmitting Standard Mode information, the 2.4GZ remote mount gas module transmits the last 24 hourly intervals. CH A P T E R 1 2.4GZ OpenWay Remote Mount Gas Module Installation
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 2 Proprietary and Confidential Programming Modes The 2.4GZ OpenWay gas module is programmed or reprogrammed to Normal, Sleep, or Doze Mode as defined in the configuration file. The table below describes these modes. Mode Description/Use Case Radio Metering (counting) How to Enter this Mode How to Exit this Mode Normal Normal Operating Mode. Used for Field Programming when electric meters are present or being installed. On On Mag Swipe or Programmer Programmer (can reprogram to any mode specified) Sleep For Shipping or Storage of modules Uses the least amount of battery current since the module does not communicate with the electric meter. Off Off Programmer Mag Swipe (to normal) or Programmer (to specified) Snooze Pre-program modules and deploy so they try to join the network automatically when they are installed in the field. The flow of gas or Mag Swipe triggers the module to change to Normal Mode. Off On Programmer Mag Swipe (to normal) Programmer (to specified) or Count Increment (to normal) Doze Pre-program meters in factory and deploy so they do not try to join the network when installed (for example, install gas before electric OR in factory counts will be added after programming and user does not want the radio turned on). Off On Programmer Mag Swipe (to normal) or Programmer (to specified)
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 3 Proprietary and Confidential Specifications The following tables list the functional and operational specifications for the 2.4GZ OpenWay remote mount gas module. Functional Specifications Description Power Source Two "A" cell lithium batteries Tamper Detection Tilt 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 Product Identification Numeric and bar coded and serial number Construction Materials Gray polycarbonate housing and back plate with encapsulated electronics Operational Specifications Description Operating Temperatures -40° to 158° F (-40° to +70° C) Operating Humidity 5 to 95% relative humidity Frequency Band 2.405 to 2.475 GHz ISM band Modulation Direct Sequence Spread Spectrum Data Integrity Verified in every data message Related Documents Document Title Document Part Number Gas Endpoint Meter Compatibility List PUB-0117-002 Gas Endpoint Ordering Guide PUB-0117-001 2.4GZ OpenWay Gas Module Specification Sheet Publication 100818SP-XX Endpoint Link Programming Guide TDC-0744 2.4GZ OpenWay Gas Module Entity Parameters ENG-2400-500 2.4GZ OpenWay Remote Mount Gas Module Meter Compatibility List Note This table lists meters compatible with the 2.4GZ OpenWay remote mount gas module. Due to continuous research, product improvements, and enhancements Itron reserves the right to change this list without notice. Meter Model Description Class Comments Endpoint Type ERT Part Number Elster/American/ Canadian AC250 AC250 Extended Top Curb meter Aluminum case coated with two-component polyurethane. Must have top-reading odometer-style index Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 4 Proprietary and Confidential Meter Model Description Class Comments Endpoint Type ERT Part Number Elster/American/ Canadian AC425 AC425 Extended Top Curb meter Aluminum case coated with two-component polyurethane. Must have top-reading odometer-style index Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Elster/American/ Canadian AC630 AC630 Extended Top Curb Meter Aluminum case coated with two-component polyurethane. Must have top-reading odometer-style index Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Elster/American/ Canadian 10 Metric (10B) Iron case Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Sensus/Invensys Sonix 12,16,25,57, 600,880,2000 Pulser Metric Cubic foot Commercial IPP* SEP* 2.4GZ OpenWay Remote 12" lead wires 2.4GZ OpenWay Remote 12" lead wires OWG-5001-503 OWG-5002-503 National/ Lancaster All meters Where direct mount is not compatible Residential IPP* SEP* 2.5' foot cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Itron/Actaris Schlumberger/ Sprague 1A Where direct mount is not compatible Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Itron/Actaris/ Schlumberger/ Sprague Metris 250 Straight Face meter Residential IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Schlumberger/ Sprague 400 #3 flat-face meter IPP* SEP* 2.5' cable with encoder 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Itron/Actaris/ Schlumberger/ Sprague 675, 1000 Front mount index Commercial IPP* SEP* 2.5' cable with encoder Also requires thicker gasket for magnet hub to clear index box. 1-hole gasket: FAB-0014-001 2-hole gasket: FAB-0014-002 4-hole gasket: FAB-0014-003 2.4GZ OpenWay Remote 2.4GZ OpenWay Remote OWG-5001-501 OWG-5002-501 Elster/American TC and STD CTR American RPM series rotary meters including TC and non-TC. Commercial IPP* SEP* Meter must have a factory installed pulser with connector output. Purchase endpoint from Itron and correct cable interface from appropriate meter manufacturer. 2.4GZ OpenWay Remote 12" lead wires 2.4GZ OpenWay Remote 12" lead wires OWG-5001-503 OWG-5002-503
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 5 Proprietary and Confidential Meter Model Description Class Comments Endpoint Type ERT Part Number Romet STD CTR 600 through 56000 TC 2000-23000 RM series Commercial IPP* SEP* Meter must have factory-installed pulser with connector output. Purchase endpoint from Itron and correct cable interface from appropriate meter manufacturer. 2.4GZ OpenWay SE1.0 Remote with 12” lead wires 2.4GZ OpenWay SE1.0 Remote with 12” lead wires OWG-5001-503 OWG-5002-503 Romet RM Series 600 through 56000 ECM2 Electronically compensated meter Commercial IPP* SEP* Meter must have connector pin with factory-installed pulse output. Purchase endpoint from Itron and correct cable interface from Romet. ECM2 must be configured for 750ms "off-time" between pulses. The ECM2 must have firmware version J or later. 2.4GZ OpenWay Remote 12" lead wires 2.4GZ OpenWay Remote 12" lead wires OWG-5001-503 OWG-5002-503 Dresser ROOTS® B3/LMMA Dresser ROOTS® rotary meters equipped with WeigandWire solid state pulsers Commercial IPP* SEP* Meter must have factory-installed pulser with connector output. Purchase endpoint from Itron and correct cable interface from Dresser. Dresser pulser must be version 17 or higher to be compatible. 2.4GZ OpenWay Remote 12" lead wires 2.4GZ OpenWay Remote 12" lead wires OWG-5001-503 OWG-5002-503 Dresser ROOTS® Integral Micro Corrector IMC\W2 MC2 Electronic Volume Corrector for Series A (LMMA) and Series B ROOTS® rotary meters Commercial IPP* SEP* Endpoint compatibile with IMC/W2 firmware version 1.91A or earlier. Pulse width must be set for 125ms. Pulse output must be at 100CF(CM) or higher. 2.4GZ OpenWay SE 1.0 Remote with 12" lead wires 2.4GZ OpenWay SE 1.0 Remote with 12" lead wires OWG-5001-503 OWG-5002-503 Itron/Actaris Dattus fM2/fM3 Commercial IPP* SEP* For all meter types, pulse width must be set to .050 seconds. Meter type 11M or smaller must have pulse weight minimum of 10 cubic feet or 1 cubic meter. Meter type 16M or greater must have pulse weight minimum of 100 cubic feet or 1 cubic meter. 2.4GZ OpenWay Remote 5' cable 2.4GZ OpenWay Remote 5' cable OWG-5001-502 OWG-5002-502
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 6 Proprietary and Confidential Meter Model Description Class Comments Endpoint Type ERT Part Number Mercury Correctors EC-AT Mini-P Mini-AT Mini-Max Pressure and temperature electronic volume correctors Commercial IPP* SEP* Correctors must have a Form A board; Form C is NOT supported. Item #056 Pulse Scaling Factor must be set to 2.0. Item #096 Cor Vol Display must be set at 1, 2, 3, or 4 blanks. Endpoint does NOT support 8 digits (0 blanks). Item #1014 set to the preset "Itron" selection in the drop-down menu. Item #115 Output Pulse Code must be set at 1, 2, 3, or 4 (not "0"). 2.4GZ OpenWay Remote 5'cable 2.4GZ OpenWay Remote 5'cable OWG-5001-502 OWG-5002-502 Mercury Correctors TCI Temperature Compensating index Commercial IPP* SEP* Correctors must have a Form A board, Form C is NOT supported. Item #56 Pulse Scaling Factor must be 2.0. Item #96 must be 7, 6, 5, or 4 digits (1, 2, 3, & 4 blanks). Endpoint does NOT support 8 digits (0 blanks). Item # 1014 set to the preset “Itron” selection in the drop down menu. Compatible firmware versions on TCI are 1.06, 1.07, and 1.10. 2.4GZ OpenWay SE 1.0 Remote with 12" lead wires 2.4GZ OpenWay SE 1.0 Remote with 12" lead wires OWG-5001-504 OWG-5002-504 *IPP: Itron Private Profile *SEP: Smart Energy Profile
2.4GZ OpenWay Remote Mount Gas Module Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 7 Proprietary and Confidential Installation Prerequisites The following tools are required to install, program, and check the 2.4GZ OpenWay remote mount gas module. Some specific tools may be required dependent on meter or instrument type. Medium flat-blade screwdriver Small flat-blade screwdriver Medium Phillips-drive screwdriver Hand pliers Side-cutting pliers 1/4-inch nut driver or similar blunt tool One-inch width putty knife Adjustable wrench 3M crimping tool: E-9R, E-9BM, E-9C/CW, E-9E, or E-9Y. Itron recommends the E-9R tool. All-weather electrical tape Size T-10 Torx screwdriver Itron programming device to program and check 2.4GZ OpenWay remote mount gas module installation and operation: FC300 with SRead with Endpoint-Link or Endpoint Link Pro version 5.5 or higher or FC200 (with Bluetooth-enabled) handheld computer loaded with Endpoint-Link or Endpoint-Link Pro software to program and check endpoint. ZigBee Belt-clip Radio with Endpoint-Link or EndPoint-Link Pro software - to program and check 2.4GZ OpenWay remote mount gas module installation and operation. Caution You must program the 2.4GZ OpenWay remote mount gas module with a Bluetooth-enabled FC200 or FC300 with SRead handheld computer and ZigBee Belt Clip Radio loaded with EndPoint-Link Pro software version 5.3.1.26 or version 5.5 for Itron Private Profile (IPP) gas modules (OWG-5001-XXX). Endpoint-Link Pro software version 5.5 must be used for Smart Energy Profile (SEP) gas modules (OWG-5002-XXX).
TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 8 Proprietary and Confidential This chapter provides the instructions to mount the 2.4GZ OpenWay remote mount gas module on a pipe or other flat vertical surface (wall). Installation Options Mount the 2.4GZ OpenWay remote mount gas module using the Pipe Mount or Wall Mount (Flat Surface) procedure. Pipe Mount. Pipe mounting is used in conjunction with the Remote Mount Kit (Itron part number CFG-0005-003). The pipe mount option places the endpoint on a pipe near the meter or instrument (not on a wall surface). This option requires a meter manufacturer's cable to connect the endpoint to the meter or instrument. Flat Vertical (Wall) Mount. Installation using the wall mount option places the endpoint on a wall or other vertical surface. A cable connects the endpoint to the meter or instrument. Mounting Screw Specifications Application Itron Part Number Description To mount adapter plates on pipe brackets 575-9930-016 8-16 x 1/2-inch length, Type 8 slotted pan-head tapping screw - corrosion-resistant steel To mount endpoints on adapter plates 575-9930-032 8-16 x 1-inch Type 8, slotted pan-head tapping screw, corrosion-resistant steel To mount endpoints on sheet metal surfaces (to mount endpoints to wood surfaces, a comparable wood screw is required) SCR-0009-001 10-16 x 1 1/2-inch Type AB thread for sheet metal, Phillips pan-head tapping screw, corrosion-resistant steel CH A P T E R 2 Mounting the 2.4GZ OpenWay Remote Mount Gas Module
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 9 Proprietary and Confidential Mounting Installation Considerations Select a proper mounting location. Itron recommends mounting the 2.4GZ OpenWay remote mount gas module in close proximity to the meter or instrument. Some applications may require an extended cable-length. The 2.4GZ OpenWay remote mount gas module supports cable lengths up to 300 feet. Mount the 2.4GZ OpenWay remote mount gas module in a vertical position with the endpoint label directional arrow pointed upward or downward. Caution Vertical mounting position is important to maximize RF performance. You can mount a 2.4GZ OpenWay remote gas module with the module's label arrow pointing up or down, dependent upon the application as noted in relevant sections of this installation manual. The module's arrow must never point to either side. The module's tilt tamper functionality is designed to operate with the module installed vertically. The 2.4GZ module's tilt tamper will operate with the label arrow pointed up or down. The module's tilt tamper will not operate with the module installed horizontally (the label arrow pointed to either side). Warning Do not mount the 2.4GZ OpenWay remote mount gas module in an orientation other than vertical (endpoint label arrow pointed upward or downward). Violating the mounting orientation requirements will void the product warranty.
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 10 Proprietary and Confidential Mounting the 2.4GZ OpenWay Remote Mount Gas Module on a Pipe The following items are required to mount the 2.4GZ OpenWay remote mount gas module on a pipe or vertical flat surface (wall): Itron Part Number Description OWG-5001/5002-501 OWG-5001/5002-502 OWG-5001/5002-503 OWG-5001/5002-504 2.4GZ OpenWay remote mount gas module OWG-5001-501 shown CFG-0005-003 Remote Mount Installation Kit Kit includes: (2) two band clamps (2) two tamper seals pipe bracket cable ties adapter plate Screws - (2) 1/2" - to attach the adapter plate to pipe bracket (2) 1" - to attach the endpoint to the adapter plate (3) 1 1/2" - to attach the endpoint to a vertical surface (wall)
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 11 Proprietary and Confidential To mount the pipe bracket on a vertical pipe Caution Vertical mounting position is important to maximize RF performance. You can mount a 2.4GZ OpenWay remote gas module with the module's label arrow pointing up or down, dependent upon the application as noted in relevant sections of this installation manual. The module's arrow must never point to either side. The module's tilt tamper functionality is designed to operate with the module installed vertically. The 2.4GZ module's tilt tamper will operate with the label arrow pointed up or down. The module's tilt tamper will not operate with the module installed horizontally (the label arrow pointed to either side). 1. Remove the pipe bracket and band clamp from the Remote Mount Installation Kit (Itron part number CFG-0005-003). 2. Loosen the band clamp screw until the end of the band releases. 3. Push the end of the clamp's band (1) through the holes (2) in the pipe bracket. The pipe bracket must be oriented as shown below. 4. Place the band clamp around the pipe. The band will loosely wrap around the pipe. Push the end of the band through the band clamp screw assembly. Turn the band clamp's screw assembly to fit into the pipe bracket opening. Tighten the clamp screw until the band clamp is secure on the pipe. Caution The pipe bracket must fit firmly against the pipe to prevent slippage.
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 12 Proprietary and Confidential To mount the adapter plate on the pipe bracket Caution Vertical mounting position is important to maximize RF performance. You can mount a 2.4GZ OpenWay remote gas module with the module's label arrow pointing up or down, dependent upon the application as noted in relevant sections of this installation manual. The module's arrow must never point to either side. The module's tilt tamper functionality is designed to operate with the module installed vertically. The 2.4GZ module's tilt tamper will operate with the label arrow pointed up or down. The module's tilt tamper will not operate with the module installed horizontally (the label arrow pointed to either side). 1. Place the adapter plate on the pipe bracket with the mounting lug at the top or bottom. The adapter plate screw bosses fit into the pipe bracket recess. 2. Ensure the adapter plate is positioned as shown below with the mounting lug (1) at the top or bottom. To install the adapter plate on a vertical pipe, use the two shortest (1/2-inch) adapter plate mounting screws from the Remote Mount Installation Kit. Place the mounting screws (2) in the holes shown below. Upright module mounting Inverted module mounting (curb meter) 3. Tighten both screws securely in an alternating fashion. Itron recommends 9 to 12-inch-pounds torque.
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 13 Proprietary and Confidential To mount the 2.4GZ OpenWay remote mount gas module on the adapter plate 1. Take the 2.4GZ OpenWay remote mount gas module and the two 1-inch mounting screws from the Remote Mount Installation kit. Place the back of the remote endpoint against the face of the adapter plate. The adapter plate mounting lug (1) must be positioned just above the endpoint mounting lug recess (2). 2. Push up on the 2.4GZ OpenWay remote mount gas module until the adapter plate mounting lug (1) is as far as possible inside the endpoint mounting lug recess (2). 3. Install the two 1" endpoint-mounting screws from the installation kit. 4. Tighten the endpoint mounting screws evenly in an alternating fashion. Itron recommends 9 to 12 inch-pounds torque. Adapter Plate Mounting Positions The following pictures show adapter plates mounted on horizontal or 45-degree angle pipes. Caution Regardless of the pipe's direction, the adapter plate mounting lug must always be at the top or bottom. (Bottom lug installation for inverted curb meter module mounting).
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 14 Proprietary and Confidential If the pipe is a 45-degree angle up to the right, install the adapter plate as shown below. Typical module mounting Inverted module mounting Mounted adapter plate (curb meter) back view If the pipe is a 45-degree angle up to the left, install the adapter plate as shown below. Typical module mounting Inverted module mounting Mounted adapter plate (curb meter) back view If the pipe is horizontal, install the adapter plate as shown below. Typical module mounting Inverted module mounting Mounted adapter plate (curb meter) back view
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 15 Proprietary and Confidential To install tamper seals and cable ties 1. Ensure the label arrow points up or down (1). Place the new tamper seals from the Remote Mount Installation Kit over the 2.4GZ OpenWay remote mount gas module mounting screws (2, 3). Firmly push both tamper seals all the way into place with a 1/4-inch nut driver or similar blunt tool. Note A tamper seal is fully seated when the top of the tamper seal is approximately 1/16-inch below the top of the screw recess. 2. Gather any excess endpoint cable. Loop a cable tie around the pipe and excess endpoint cable. 3. Insert the chiseled end of the cable tie into the locking end and pull the cable tie tight. Cut off and properly dispose the excess cable tie. 2.4GZ OpenWay remote mount gas module pipe mount installation is complete.
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 16 Proprietary and Confidential Mounting the Endpoint on a Wall or Other Flat Vertical Surface Caution Vertical mounting position is important to maximize RF performance. You can mount a 2.4GZ OpenWay remote gas module with the module's label arrow pointing up or down, dependent upon the application as noted in the relevant section of this installation manual. The module's arrow must never point to either side. The module's tilt tamper functionality is designed to operate with the module installed vertically. The 2.4GZ module's tilt tamper will operate with the label arrow pointed up or down. The module's tilt tamper will not operate with the module installed horizontally (the label arrow pointed to either side). To mount the 2.4GZ OpenWay remote mount gas module on a wall or other flat vertical surface Note For easier installation, you may drill three pilot holes in the mounting surface (use the proper size drill bit to accommodate the endpoint mounting screws, see the Drilling Template below). When drilling pilot holes to mount the 2.4GZ OpenWay remote mount gas module, the holes for the two bottom screws must be on a horizontal line. If the endpoint will be mounted on a sheet metal surface, use the mounting screws included with the 2.4GZ OpenWay remote mount gas module mounting kit. Use a comparable wood screw to mount the endpoint on a vertical wood surface. Carefully select a mounting location free from electrical wires. The mounting location must have the proper clearance to accommodate the 1-1/2-inch endpoint mounting screws so nothing is damaged by the drill or mounting screws. 2.4GZ OpenWay remote mount gas module drilling template A 3 inches B 1-11/16 inches C 3-3/8 inches
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 17 Proprietary and Confidential 1. Using the three 1-1/2-inch mounting screws from the Remote Mount Installation Kit, turn the mounting screw for the mounting lug (top of endpoint) part way into the mounting surface. 2. Place the 2.4GZ OpenWay remote mount gas module mounting lug recess (on the top of the endpoint backplate) just under the screw head. Slide the endpoint upward until the screw head fits completely inside the mounting lug recess. Several adjustments may be necessary to properly position the screw for endpoint mounting. 3. Install the bottom two mounting screws. Fasten screws in an alternating fashion until fully tightened to secure the endpoint firmly in position. To install tamper seals and cable ties 1. Place a new tamper seal (from the Remote Mount Installation Kit) over each endpoint mounting screw. 2. Firmly push both tamper seals into place with a 1/4-inch nut driver or similar blunt tool. Note A tamper seal is fully seated when the top of the tamper seal is approximately 1/16 inch below the top of the screw recess.
Mounting the 2.4GZ OpenWay Remote Mount Gas Module TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 18 Proprietary and Confidential 3. To reduce the risk of cable damage, secure the excess endpoint cable with the cable ties from the Remote Mount Installation Kit. Pull the cable tight. Remove and properly dispose the excess cable tie. 2.4GZ OpenWay remote mount gas module installation on a vertical flat surface or wall is complete.
TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 19 Proprietary and Confidential This chapter provides the instructions to install the 2.4GZ OpenWay remote mount gas module on rotary gas meters. Reference the Gas Endpoint Meter Compatibility List (see Related Documents on page 3) for rotary meters compatible with the 2.4GZ OpenWay remote mount gas module. American rotary meter Dresser ROOTS® Series LMMA rotary meter Dresser ROOTS® series B3 meter Dresser ROOTS® IMC\W2 meter Romet Imperial series RM meter Romet Imperial ECM2 meter CH A P T E R 3 Rotary Meter Installation
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 20 Proprietary and Confidential Required Installation Materials Available from Itron The materials in the following table are required to install a 2.4GZ OpenWay remote mount gas module. Itron Part Number OWG-5001-503 OWG-5002-503 Note: this remote mount endpoint comes standard with 12" lead wires and may be shipped directly to the meter manufacturer for a factory-installed cable (interface). Important The interface cable must be purchased directly from the meter manufacturer. CFG-0005-003 Remote Endpoint Mounting Kit Connecting the 2.4GZ OpenWay Remote Mount Gas Module to the Rotary Meter Cable You may ship the Itron 2.4GZ OpenWay remote mount gas module directly to the meter manufacturer for a factory-installed cable. If you connect the endpoint to the meter using an existing cable purchased from the meter manufacturer, complete the following cable installation procedure. Caution The purchased cable must have a mating connector compatible to the meter receptacle. Dresser ROOTS® cables may be wired in different configurations for specific applications. If necessary, contact Dresser ROOTS® Meters for wiring diagrams for your specific application.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 21 Proprietary and Confidential To connect the 2.4GZ OpenWay remote mount gas module to the rotary meter cable 1. Remove the backplate (4 screws) from the 2.4GZ OpenWay Remote and expose the module's lead wires. The backplate and screws will be re-installed on the gas module later in this procedure so store them (temporarily) in a safe, secure place. 2. Insert the lead wires from the 2.4GZ OpenWay remote mount gas module into new 3M gel connectors (Itron part number CON-0023-001) together with the same colored lead wire from the meter cable (see the wiring table below) and crimp using a 3M hand-held crimping tool. Note Do not strip lead wire prior to inserting the wire in the gel connector. Rotary Meter to Remote Module Wire Table Rotary Meter Wire Remote module wire Red Red White White Blue Blue
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 22 Proprietary and Confidential 3. After completing the wiring connections, install a cable tie to the meter cable just below the exposed colored lead wires on the cable insulation. Remove the excess cable tie using a hand-held sidecutter pliers. The cable tie performs as a cable strain relief to mitigate the risk of destructive tension on the lead wires. 4. Tuck the three gel connectors and cable tie inside the module housing. Position the cable tie as shown in the placement schematic below. 5. Install the 2.4GZ OpenWay remote mount gas module backplate using the four screws previously removed from the module and a Torx T-15 screwdriver. Install the new 2.4GZ OpenWay remote mount gas module on the wall or a pipe using the Remote Endpoint Mount Kit (Itron part number CFG-0005-003). See Mounting the 2.4GZ OpenWay Remote Mount Gas Module on page 8 for mounting instructions.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 23 Proprietary and Confidential To connect the 2.4GZ OpenWay remote mount gas module cable assembly to the rotary meter Caution Verify the cable connector mates with the meter connector. Meter manufacturers use different connector styles (types). 1. Align the large lug on the 2.4GZ OpenWay remote mount gas module connector with the large notch on the meter connector. 2. Align the lock ring notches on the module cable connector with the pins on the meter connector. 3. Hold the lock ring on the module connector back and push the plug into the meter connector until it is securely seated. 4. Turn the lock ring clockwise as far as it will go. You will feel it snap into place when it locks. Warning To remove the module connector plug from the meter connector jack, push in on the lock ring, turn the lock ring counterclockwise as far as possible, and pull out the plug body. Do not pull on the module's connector cable.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 24 Proprietary and Confidential Programming 2.4GZ OpenWay Remote Mount Gas Modules for Dresser ROOTS® Rotary Meters To program 2.4GZ OpenWay remote mount gas modules for use with Dresser ROOTS® rotary meters, use the meter drive rates from the drive rate table in this section. B3, LMMA & S3A CTR/TC Meter Pulse Rates for Remote Module Programming Caution Do not use these meter drive rates to program residential direct-drive or commercial direct-drive modules. Use the information in the following tables to program 2.4GZ OpenWay remote mount gas modules connected to Dresser ROOTS® rotary meters. B3 CTR Meter Size B3 CTR Meter Pulse Rate LMMA CTR Meter Size LMMA CTR Meter Pulse Rate 8C 10 1.5M 10 11C 10 3M 10 15C 10 5M 10 2M 10 7M 10 3M 10 11M 10 5M 10 16M 100 7M 10 23M 100 11M 10 38M 100 16M 100 56M 100 23M 100 102M 100 38M 100 56M 100 LMMA CTR Meter Size LMMA CTR Meter Pulse Rate LMMA TC Meter Size LMMA TC Meter Pulse Rate 1.5M 10 1.5M 10 3M 10 3M 10 5M 10 5M 10 7M 10 7M 10 11M 10 11M 10 16M 100 16M 100 23M 100 38M 100 56M 100 102M 100
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 25 Proprietary and Confidential Meters built 1/99 and beyond Meters built prior to 1/99 B3 TC Meter Size B3 TC Meter Pulse Rate B3 TC Meter Size B3 TC Meter Pulse Rate 8C 10 8C 50 11C 10 11C 50 15C 10 15C 50 2M 10 2M 50 3M 10 3M 50 5M 10 5M 50 7M 10 7M 50 11M 10 11M 50 16M 100 16M 500 S3A CTR Meter Size S3A CTR Meter Pulse Rate S3A TC Meter Size S3A TC Meter Pulse Rate 1.5M 10 1.5M 10 3M 10 3M 10 5M 10 5M 10 7M 10 7M 10 11M 10 11M 10 16M 100 16M 100 Installing the 2.4GZ OpenWay remote mount gas module to the Elster American Meter RPM Series Rotary Meter Some meter manufacturers provide endpoint mounting kits and installation procedures for their meters. If 2.4GZ OpenWay remote mount gas module to Elster American RPM meter installation instructions are not available, follow the installation procedure in this section. Elster American Meter RPM Series Rotary Meter
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 26 Proprietary and Confidential To install the 2.4GZ OpenWay remote mount gas module on an Elster American RPM series meter 1. Remove the meter's top plate by removing the two (2) 5mm screws and carefully prying up on the plate. The plate is secured with an o-ring seal. Remove the o-ring from the plate. Caution If the o-ring is damaged during removal, obtain a replacement from Elster American Meter Co. 2. Look into the meter tower and find the meter switch lead and connector (4-pin). 3. If the lead and connector are not visible or cannot be found, remove the four (4) 5mm mounting screws and the register cover. The meter switch lead and connector will be visible inside the cover. Note Save any meter tags. You will re-install them later in the installation process. 4. Feed the lead and connector into the register cover tower. 5. If you removed the register cover, replace the cover using the four (4) 5mm mounting screws.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 27 Proprietary and Confidential 6. Attach the 4-pin male connector on the Elster American Meter adapter plate to the 4-pin female connector inside the meter's tower. The connectors will slide together and latch. 7. Carefully push the connectors and wires into the meter tower housing. 8. Lubricate the o-ring with o-ring lubricant and install the o-ring on the adapter plate. Insert the adapter plate into the tower and tighten the (2) 5 mm screws. To connect the manufacturer cable to the endpoint Note Connection to an Elster American Meter requires a cable interface compatible to an Elster American Meter RPM rotary meter. 1. Trim the 2.4GZ OpenWay remote mount gas module wires to 3.5-inches. 2. Carefully strip the insulation covering from the meter cable (purchased from the meter manufacturer) approximately 1-1/2-inces from the end. Caution Do not cut through the individual wire insulation.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 28 Proprietary and Confidential 3. Separate the black, white, and blue wires for connection to the 2.4GZ OpenWay remote mount gas module. Cut off the unused wires even with the outer covering (insulation). Caution Do not strip the individual wires. 4. Connect the meter cable to the 2.4GZ OpenWay remote mount gas module using 3M gel-cap connectors. Follow the wire connection table and wiring diagrams below. See Installation Prerequisites on page 7 for appropriate 3M crimping tools. Important Use a crimping tool compatible with gel-connectors. Do not use a standard pliers for crimping gel-connects. The crimping tool provides an even pressured crimp to make a secure connection. Apply pressure for three seconds until the gel cap is fully crimped (collapsed) to allow time for the low viscosity silicone-based gel to flow. If the silicone gel flows out of the crimped connector, avoid touching the gel. Gel flowing from the connector provides environmental protection for the connection. American RPM Meter to 2.4GZ Remote Mount Module Wire Connections American RPM Meter wire 2.4GZ remote mount module wire Red Red White White Black Blue
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 29 Proprietary and Confidential 5. Insert the meter cable through the slot on the module backplate. Install a cable tie to the meter cable wire below the meter cable insulation to provide strain relief. Position the cable tie as shown in the position schematic below. 6. Tuck the connectors and cable tie into the endpoint housing. Place backplate on the assembly and tighten the four backplate screws using a size T-10 Torx screwdriver. Important Verify the cable tie and gel connectors are inside the endpoint housing and the cable extends out of the slot in the backplate. Torque the backplate mounting screws to 9 - 12 inch-pounds. To install the 2.4GZ OpenWay remote mount gas module cable 1. Insert the plug on the cable connected to the module into the receptacle on the meter adapter plate. 2. Tighten the threaded collar on the plug onto the American Meter interface receptacle. Verify the connection is hand-tight.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 30 Proprietary and Confidential Mounting the 2.4GZ OpenWay Remote Mount Module Select an appropriate mounting location on adjacent piping close to the meter. Using the pipe bracket, mounting plate and band clamps from the Remote Mount Kit (Itron part number CFG-0005-003), secure the 2.4GZ OpenWay remote mount gas module. Use the cable ties from the kit to secure any excess wire to the piping (see Mounting the 2.4GZ Remote Mount Module on a Pipe on page 9). Installing the 2.4GZ OpenWay Remote Mount Gas module to the Romet Electronically Compensated Meter (ECM2®) The Romet ECM2® meter has three Form "A" outputs that can be configured at the factory to provide any combination of the following three outputs: Uncorrected volume (UNC VOL) Corrected volume (COR VOL) Alarm The pulse weight for the volumetric outputs is configured in SetUp Mode at Menu items>SET UNC OUT and SET COR OUT. Since Setup Mode is fully configurable, the ECM2® module is universally adaptable to all Romet TC meter bodies. Reference the Romet technical manual for specific details on the ECM2®.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 31 Proprietary and Confidential Connecting the 2.4GZ OpenWay Remote Mount Gas Module to the Romet ECM2® Meter Connect the correct interface wirings and set the output pulse spacing to complete 2.4GZ OpenWay remote mount gas module installation with the Romet ECM2® meter. See the ECM2® Interface Wiring Table below to complete wire connections. Function (+)UC (-)UC (+)CC (-)CC (+)ALM (-)ALM (+)Aux.CC (-)Aux.CC Endpoint Wire White and Blue Red White and Blue Red White and Blue Red White and Blue Red Pin location for Cannon Connector Part Number 34-125-20 C B A B E D 34-125-40 A B C D E F 34-125-41 A B C D E F 34-125-42 E F A B C D 34-125-43 A B E F C D 34-125-44 A B 34-125-45 A B E D C F 34-125-50 3 1 2 5 6 4 34-125-51 3 1 2 5 6 4 Caution Set the ECM2® output pulse spacing to 750ms for operation with the 2.4GZ OpenWay remote mount gas module. Output spacing represents an off-time between pulses. Romet ECM2 Mounting Requirement This mounting procedure requires the Romet ECM2/ERT Mounting Kit (Romet part number 34-444-1-KIT).
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 32 Proprietary and Confidential To mount the 2.4GZ OpenWay remote mount gas module on the Romet ECM2 meter 1. Remove the module screw from the back of the ECM2 meter and discard. 2. Insert the mounting screw fitted with the three lock washers. Two lock washers are used as spacers as shown. 3. Attach the mounting plate to the meter. Insert the mounting screw where the module screw was removed. Torque the mounting screw to 5 - 7 ft.lbs. to secure the plate to the Romet meter.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 33 Proprietary and Confidential 4. Mount the 2.4GZ OpenWay remote mount gas module using the pre-drilled holes on the mounting plate and the module mounting screws. Place new tamper seals over the two screws. Press tamper seals into place using an 11/32" nut driver or similar blunt tool. Connect the module to the meter using the previously installed cable interface.
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 34 Proprietary and Confidential Programming the 2.4GZ OpenWay Remote Mount Gas Module Assembly Caution The 2.4GZ Remote Mount Gas Module must be programmed before use. Program the 2.4GZ OpenWay remote mount gas module with a Bluetooth-enabled FC200 or FC300 with SRead handheld computer and ZigBee Belt Clip Radio loaded with Endpoint-Link or Endpoint-Link Pro software version 5.3.1.26 or version 5.5 for Itron Private Profile (IPP) gas modules (OWG-5001-XXX). Endpoint-Link Pro software version 5.5 must be used for Smart Energy Profile (SEP) gas modules (OWG-5002-XXX). See the Endpoint-Link Endpoint Programming Guide (TDC-0744) for more complete programming information. An Itron magnet is also required for programming. FC200SR FC300 with SRead Zigbee Belt Clip Radio Itron Magnet
Rotary Meter Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 35 Proprietary and Confidential To program the 2.4GZ OpenWay remote mount gas module 1. Program the meter drive rate into the 2.4GZ OpenWay remote mount gas module using the handheld computer and Belt Clip Radio. Programming parameters are based on the configuration file loaded into the handheld computer. 2. Place the magnet over the barcode on the module cover label with the magnet face (inked Itron logo and part number) arrow pointed up toward the top of the module. 3. Hold the magnet in place for 5 seconds and remove it. 4. The LED will blink red three times. This signifies the 2.4GZ OpenWay remote mount gas module is searching for a programming device. Within a few seconds of locating the handheld computer, the red LED will blink five more times. The handheld computer will confirm programming success or failure. 5. Read the 2.4GZ OpenWay remote mount gas module using the handheld computer and Belt Clip Radio. If the read result is higher than the number programmed in Step 1, the 2.4GZ OpenWay remote mount gas module is counting correctly. If the read result is not higher than the number programmed in Step 1, replace the 2.4GZ OpenWay remote mount gas module.
TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 36 Proprietary and Confidential This section provides the instructions to install the 2.4GZ OpenWay remote mount gas module on the Mercury Instruments Mini-P, Mini-AT, Mini-Max, and EC-AT and Dresser ROOTS® Micro Correctors. Mini-AT Mini-Max EC-AT TCI IMC/W2 MC2 CH A P T E R 4 Electronic Instrument Installation
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 37 Proprietary and Confidential Installation Prerequisites 2.4GZ OpenWay remote mount gas module installation to a Mercury Instrument requires: 2.4GZ OpenWay remote mount gas module compatible to a Mercury Instrument (see the 2.4GZ OpenWay Remote Mount Gas Module Meter Compatibility List on page 3). Mercury Instrument compatible with the remote endpoint. Proper tools and devices for installation and programming (see Installation Prerequisites on page 7). Installation Overview Installing the 2.4GZ OpenWay remote mount gas module to a Mercury Instrument involves five tasks: 1. Programming the Mercury Instrument on page 37 (reference the Mercury Instrument Programming Guide for more information). 2. Installing Mercury retrofit parts (if necessary). 3. Attaching the 2.4GZ OpenWay remote mount gas module to a pipe or vertical flat surface (wall) (see Mounting the 2.4GZ OpenWay Remote Mount Gas Module on page 8). 4. Wiring the 2.4GZ OpenWay remote mount gas module to the Mercury Instrument (see Wiring the 2.4GZ OpenWay Remote Mount Gas Module to the Mercury Instrument on page 39). 5. Programming the 2.4GZ OpenWay remote mount gas module (see Programming the 2.4GZ OpenWay Remote Mount Gas Module).
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 38 Proprietary and Confidential Programming the Mercury Instrument Code Settings Volume Corrector Type Item Code Settings and Corresponding Terminal Board Channel Terminal Board Connections* Pulse Output Options Channel A Channel B Channel C Number of Blanked digits on CorVol Display Pulse Output Spacing Ka, Ya = Channel A #056 #93 #057 #094 #058 #095 #96 #115 #1014 #1015 ECAT Pulse Board Ver-1(3) Form-C n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a Module does not support a Form-C pulse output board. Pulse Board Ver-2(3) Form-A 2.0000 0 2.0000 0 2.0000 0 1, 2, 3, or 4 1, 2, 3, or 4 n/a n/a Ka, Kb, Kc (Red Wire) Ya, Yb, Yc (Blue & White Wire) Connection must be on same terminal board channel (for example, Ka/Ya; Kb/Yb; Kc/Yc). Pulse Board Ver-3(2) Form-C1 Form-A n/a n/a n/a n/a 2.0000 0 1, 2, 3, or 4 1, 2, 3, or 4 n/a n/a Kc (Red Wire) Y (Blue & White Wire). For this option, module must be connected to Channel C. Mini with Form A Mainboard Main Board Type-2 2.0000 0 n/a n/a n/a n/a 1, 2, 3, or 4 1, 2, 3, or 4 n/a n/a K (Red Wire) Y (Blue & White Wire). For optional SPA Bd., jumper must be installed on J1-B as indicated in the Mercury Quick Reference Guide (page 148) for Form A. Mini-AT JB29, JB30 & JB31 Jumpered for Form-A 2.0000 0 2.0000 0 n/a n/a 1, 2, 3, or 4 1, 2, 3, or 4 n/a n/a K (Red Wire) Y (Blue & White Wire). For optional SPA Bd., jumper must be installed on J1-B as indicated in the Mercury Quick Reference Guide (page 148) for Form-A. JB29, JB30 & JB31 Jumpered for Form-C n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a Module does not support a Form-C pulse output board. Mini-Max All Main Boards 2 0 2 0 n/a n/a 1, 2, 3, or 4 1, 2, or 4 n/a n/a K (Red Wire) Ya or Yb (Blue & White Wire) Form C Main Board n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a Module does not support a Form-C pulse output board. Form A Main Board 2.0000 0 2.0000 0 n/a n/a 1, 2, 3, or 4 blanks (7, 6, 5, or 4 active) n/a Itron selection in dropdown menu. Itron selection in dropdown menu Connections to channels of output pulses are made through loose unterminated cable wires and gel connect connectors. Notes: Code 0 for items 093, 094 & 095 = Corrected Volume Pulse Data Code 1 for item 115 = 1.000 Sec. Code 2 for item 115 = 2.000 Sec. Code 1 for item 096 = blank 1 digit and display 7 digits Code 2 for item 096 = blank 2 digits and display 6 digits Code 3 for item 096 = blank 3 digits and display 5 digits Code 4 for item 096 = blank 4 digits and display 4 digits *For more information, see pages 11-20 of the "Basic Pulse Information for Mercury Instruments, Inc., Electronic Volume Correctors" manual, or contact Mercury Instruments at 513-272-1111.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 39 Proprietary and Confidential Mercury corrector programming parameters: Caution A Mercury Instrument Volume Correctors must have a Form A board. A Form C board is not compatible with the 2.4GZ OpenWay remote mount gas module. For TCI, when using both outputs, items 1014 and 1015 must be set to Itron. Item #056: Pulse A Scaling. Set at 2.0000 for a form A switch. Item #057: Pulse A Scaling. Set at 2.0000 for a form A switch. Item #058: Pulse A Scaling. Set at 2.0000 for a form A switch. Item #090: Corrected Volume Units: Code (0-20) selects the unit of measure for Corrected Volume (Item000) and other "CorrVol" related items. Item #092: Uncorrected Volume Units: Code (0-20) selects the unit of measure for Uncorrected Volume (Item002) and other "UncVol" related items. Item # 093, 094, 095: Type of gas volume information to be sent. For "CorrVol" selected, must be set at 0. Item # 096: Corrected Volume Display: Must be set at 1, 2, 3 or 4 blanks. Endpoint does not support a setting of 0 blanks. Item # 097: Uncorrected Volume Display: Must be set at 1, 2, 3, or 4 blanks. Endpoint does not support a setting of blanks. Item # 098: Check drive rate of the corrector. Should be the same as the plate above the uncorrected dials and the same as the plate on the index drive of the meter. Item # 115: Output Pulse Code: Must be set at 1 or 2.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 40 Proprietary and Confidential Wiring the 2.4GZ OpenWay Remote Mount Gas Module to the Mercury Instrument Use the Terminal strip connector (Phoenix connector) in the Mercury Instrument to connect the 2.4GZ OpenWay remote mount gas module to the instrument. Note In Mercury Instrument EC-AT correctors, the connector may be soldered to the pulse board. The 2.4GZ OpenWay remote mount gas module has three lead wires (red, white, and blue). The red wire is attached according to Mercury Instrument Code Settings (see Code Settings on page 38). The blue and white wires are twisted together and attached according to Mercury Instrument's Code Settings (see Code Settings on page 38).
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 41 Proprietary and Confidential To wire the 2.4GZ OpenWay remote mount gas module to the Mercury Instrument 1. Insert the module cable into the instrument's compression connector. 2. Strip one inch of the outer insulation from the 2.4GZ OpenWay remote mount gas module. Strip 1/4-inch individual wire insulation from the red, white, and blue lead wires. A White wire B Blue wire C Red wire Caution Keep wires away from the rotating magnetic spindle in the Mercury Instrument. 3. See Mounting the 2.4GZ OpenWay Remote Mount Gas Module on page 8 for module mounting instructions.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 42 Proprietary and Confidential Wiring Dual Modules to a Mercury Instrument This section includes the information to wire dual endpoints to a single Mercury Instrument. Installation requires the correct programming parameters (see Code Settings on page 38). With Itron 2.4GZ OpenWay remote mount gas modules, utilities can receive corrected and uncorrected consumption values by installing two modules. The module for corrected reads is attached to the instrument's pulse output. The module for uncorrected reads is attached to the input switch board. The corrected pulse output is programmable; the uncorrected pulse output is dependent on the connected meter's drive rate. Important Some Mercury Instruments have two pulse outputs so the uncorrected pulse output could be connected to the additional output, but the connection should be to the input switch board in case the instrument battery fails. Counts will be collected if the uncorrected pulse is connected to the switch board since the board is not dependent on battery power. Dual remote modules mounted on a Mercury Instrument To install dual 2.4GZ OpenWay remote mount gas modules to a Mercury Instrument Mini-Max Case Corrector using Mercury Kit 22-1077 Required Tools* Drill with 3/16-inch bit Screw drivers: slotted and Phillips head (medium size) 1-inch open-end wrench or medium-size adjustable wrench 7/16-inch open- or closed-end wrench Clean shop rag Alcohol wipe
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 43 Proprietary and Confidential 1. Place the Mercury Instrument in shutdown condition and disconnect all power from the Mini-Max main board. 2. Remove the battery pack from the corrector and set aside. 3. Remove the four screws from the main board and the board from the enclosure. Set the board aside. 4. Remove the two hex screws from the input switchboard and the switchboard from the enclosure and set aside. Warning The battery pack, main board and switchboard may be damaged if left in the Mercury Instrument while completing this installation. 5. Drill two 3/16-inch holes in the back of the Mini-Max enclosure as specified by the information included in the kit. Remove any metal shavings from the enclosure. 6. Clean the 2.4GZ OpenWay remote mount gas modules with the alcohol wipe where you will place the Corrected and Uncorrected labels (included in the kit). Note Clean the 2.4GZ OpenWay remote mount gas modules with the alcohol wipe to ensure good label adhesion. 7. Mount the module for corrected pulse outputs on the left bracket mounting space. Insert three #8-32 x 1/2-inch screws in a triangular pattern. Install the top screw so the head of the screw is approximately 1/8-inch from the module mounting bracket surface. Slide the module onto the screw so the mounting lug fits securely onto the screw. If necessary, remove the module and make any necessary adjustment to the screw depth to ensure a secure fit. Install the two bottom screws in an alternating fashion. 8. Mount the module for uncorrected pulse outputs on the right bracket mounting space. Insert three #8-32 x 1/2-inch screws in a triangular pattern. Install the top screw so the head of the screw is approximately 1/8-inch from the Module Mounting Bracket surface. Slide the module onto the screw so the mounting lug fits securely onto the screw. If necessary, remove the module and make any necessary adjustment to the screw depth to ensure a secure fit. Install the two bottom screws in an alternating fashion. 9. Route the module cables under the bracket edge and toward the rear of the Mercury Instrument. 10. Mount the Module Mounting Bracket (Mercury Instrument part number 22-1077, included in the kit) onto the Mini-Max enclosure. Place a #8 metal flat washer followed by a rubber sealing washer onto both #8-32 x 3/8-inch screws. Align the lower threaded holes in the mounting bracket with the drilled enclosure holes and insert a screw/washer through the enclosure housing. Screws heads must be inside the enclosure. Tighten both screws using a screwdriver. Note Aligning the second bracket threaded hole and drilled hole may require some manipulation of the mounting bracket. 11. Insert the module cables (both units) through the large cable strain relief on the left rear of the corrector's enclosure. Leave a one-half to one inch drip loop under the cable strain relief. 12. Secure three cable ties on the module cables in three places on the cables as specified by information included in the kit. 13. Re-install the input switchboard, main board, and battery pack removed in Step 2.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 44 Proprietary and Confidential 14. Connect the corrected module wires to TB1 on the Mini-Max board following the table below. Use Mercury upgrade kit 40-2678-1 to provide the second pulse output channel for the uncorrected module. Corrected Module Connections Module Mini-Max TB1 Red wire K terminal Blue wire* Ya terminal White wire* Ya terminal *Twist the blue and white module wires together before connecting to the Mini-Max board. Tighten terminal connections securely. 15. Connect the uncorrected module wires to the Input Switch Board UNC.VOL following the table below. Uncorrected Module Connections Endpoint Mini-Max Input Switch Board UNC. Vol. Red wire COM terminal Blue wire NO terminal White wire NO terminal *Twist the blue and white module wires together before connecting to the Mini-Max board. 16. Tighten terminal connections securely. 17. Tighten the large strain relief securely. Warning Do not crush the module through cables when tightening the strain relief. 18. Re-install or reconnect the power or battery sources. 19. Close the instrument case and tighten the case screw securely. Replace any locks that were removed for installation. Wiring the Remote Module to the Mercury TCI The Mercury Instruments Temperature Compensating Index (TCI) provides two Form-A volume pulse outputs and one Form-B alarm output. These outputs are electronic switches. The first two pulse outputs are configurable for compensated or uncompensated volume. The third output (Form-B) is for alarm output use only.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 45 Proprietary and Confidential Connections to the three output pulse channels are completed using loose unterminated wires (the individual wires from a cable) and gel-connectors. The TCI unit has six unterminated wires and six gel-connectors (Itron part number CON-0023-001) to enable pulse connections to ancillary devices. Loose wires are located inside the gray adapter plate behind the black strain relief fitting. Adapter plate with black strain relief Loose cable wires The three switch contacts on the TCI PC board are MOSFET output type opto-isolators that provide high voltage isolation between the sensitive processor components of the TCI board and the outside world. Wire Color Description Function Orange Volume output channel A Comp/uncomp volume pulse Yellow Volume output channel A (configurable pulse timing) White Volume output channel B Comp/uncomp volume pulse Green Volume Output channel B (configurable pulse timing) Brown Alarm channel Alarm event signal Blue Alarm channel (Pulse timing)
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 46 Proprietary and Confidential To make TCI pulse connections Note Connect one endpoint/channel to the alarm output if the endpoints are used on channels A and B. Configuration for two endpoints connected to one TCI Channel A OWG-500x-504 TCI White Orange and brown Red Yellow Blue Blue (alarm) Channel B OWG-500x-504 TCI White White Red Green Blue White 1. Remove strain relief fitting by unscrewing from the gray adapter plate. Note Do not remove the fitting's hex nut. Un-screw the entire fitting from the gray adapter plate. A tether line is secured to the strain relief fitting. When the strain relief fitting is removed, the tether line pulls the unterminated wires out of the adapter plate for access to the loose wires. 2. Loosen the strain relief fitting hex nut and remove the white plug from the center. 3. Place the strain relief fitting onto the field pulse cable.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 47 Proprietary and Confidential 4. If the field pulse cable is smaller than a 0.2-inch diameter, install the rubber tube supplied with the TCI onto the cable so the strain relief will clamp onto the tube after it is re-installed. 5. Connect the individual external pulse cable conductors to the un-terminated wires following Configuration for two endpoints connected to one TCI at the beginning of these instructions. Insert one un-terminated wire into an opening of a gel-connector (six gel-connectors were included with the TCI). Insert the appropriate field cable wire into the other gel-connector opening. 6. Verify both wires are fully inserted into the gel-connector prior to crimping. Important Use a crimping tool compatible with gel-connectors. Do not use a standard pliers for crimping gel-connects. The crimping tool provides an even pressured crimp to make a secure connection. 7. Insert the gel-connected wires into the threaded gray adapter plate hole. 8. Replace the strain relief and tighten until secure.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 48 Proprietary and Confidential Connecting the OpenWay Remote Mount Gas Module to the Dresser ROOTS® IMC/W2 or MC2 Cable You may ship the Itron 2.4GZ OpenWay remote mount gas module directly to Dresser ROOTS® Meters for a factory-installed cable. If you connect the module to the meter using an existing cable purchased from Dresser ROOTS®, complete the following cable installation procedure. Caution The purchased cable must have a mating connector compatible with the IMC/W2 or MC2 receptacle. Dresser ROOTS® cables may be wired in different configurations for specific applications. If necessary, contact Dresser ROOTS® Meters for wiring diagrams for your specific application. To connect the 2.4GZ OpenWay remote mount gas module to the IMC/W2 or MC2 cable 1. Remove the backplate (4 screws) from the 2.4GZ remote module and expose the endpoint lead wires. The backplate and screws will be re-installed on the endpoint module later in this procedure so store them (temporarily) in a safe, secure place.
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 49 Proprietary and Confidential 2. Insert the lead wires from the 2.4GZ OpenWay remote mount gas module into new 3M gel connectors (Itron part number CON-0023-001) together with the same colored lead wire from the meter cable (see the wiring table below) and crimp using a 3M hand-held crimping tool. Important Use a crimping tool compatible with gel-connectors. Do not use a standard pliers for crimping gel-connects. The crimping tool provides an even pressured crimp to make a secure connection. Apply pressure for three seconds until the gel cap is fully crimped (collapsed) to allow time for the low viscosity silicone-based gel to flow. If the silicone gel flows out of the crimped connector, avoid touching the gel. Gel flowing from the connector provides environmental protection for the connection. Note Do not strip lead wire prior to inserting the wire in the gel connector. IMC/W2 to Remote Endpoint Wire Table IMC/W2 Wire Remote endpoint wire Red Red White White Blue Blue
Electronic Instrument Installation TDC-0838-001 2.4GZ OpenWay Gas Module Installation Guide - Remote Mount 50 Proprietary and Confidential 3. Dresser ROOTS® IMC/W2 and MC2 cables are typically delivered with a cable tie installed. If the meter cable does not include a cable tie, install a tie to the cable just below the exposed colored lead wires on the cable insulation. Remove the excess cable tie using a hand-held sidecutter pliers. The cable tie performs as a cable strain relief to mitigate the risk of destructive tension on the lead wires. 4. Tuck the three gel connectors and cable tie inside the endpoint housing, as shown. Position the cable tie as shown by the arrow in the position schematic below. 5. Install the 2.4GZ OpenWay remote mount gas module backplate using the four screws previously removed from the endpoint and a Torx T-15 screwdriver. Important Verify the cable tie and gel connectors are inside the endpoint housing and the cable extends out of the slot in the backplate. Torque the backplate mounting screws to 9-12 inch-pounds.

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