Natural Gas Solutions 100G Series Gas ERT Module Installation Guide, Remote Mount TDC-0824-014
Identification 100G Series Gas ERT Module Installation Guide, Remote Mount 24 June 2016 TDC-0824-014 100G, 100G DL, 100G DLN, 100G DLS, 100G DLT remote mount gas ERT modules ERT module part numbers: 100G remote mount ERT module: ERG-5000-501, ERG-5000-502, ERG-5000-503 100G Datalogging remote mount ERT module: ERG-5002-501, ERG-5002-502, ERG-5002-503, ERG-5002-505 100G Datalogging FN remote mount ERT module: ERG-5003-501, ERG-5003-502, ERG-5003-503, ERG-5003-505 100G DLS Datalogging remote mount ERT module:
Warning ERT modules contain sensitive electronic components which can be damaged if the module is dropped from heights greater than 36 inches. Product warranty coverage is contingent on not exceeding this drop height limitation. 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.
TDC-0824-014 100G Series Gas ERT Module Installation Guide, Remote Mount Proprietary and Confidential iv
Contents Before You Begin ........................................................................................................ vii Document Conventions ..................................................................................................................... vii Document Purpose ............................................................................................................................ vii About the 100G Series Gas ERT Module .................................................
Contents Wiring the Remote ERT Module to the Honeywell TCI...........................................................47 Honeywell Software Settings ..................................................................................................50 Connecting the Remote Mount ERT to the IMC/W2 or MC2 Cable .......................................52 Installing the ERT Module to the GE Dresser Micro Corrector (IMC/W2 or MC2) .................53 Galvanic Gas Micro Installation .................................
Before You Begin Document Conventions The following documentation conventions are used in this installation guide. Caution A Caution warns the installer that failure to follow the information in the note could result in loss of data. Be sure to carefully read a caution note and follow the advice or instructions. Warning A Warning alerts the installer about potential physical harm to the installer or hardware.
Before You Begin TDC-0824-014 100G Series Gas ERT Module Installation Guide, Remote Mount Proprietary and Confidential viii
CHAPTER 1 About the 100G Series Gas ERT Module Itron 100G series remote ERT modules are radio-frequency (RF) devices designed to transmit meter data to an RF meter reading device within transmission distance of the remote ERT module. The 100G remote gas ERT module was designed with a higher output power than earlier Itron remote gas ERT modules to achieve an increased RF transmission distance.
About the 100G Series Gas ERT Module • • (Optional) Hard to Read Mobile and Handheld Mode. The 100G series remote gas module transmits a high-powered RF message every 30 seconds. Output power in this mode is 250 milliwatts or +24dBm; expected battery life decreases to 15 years in this mode. The hard to read mobile and handheld mode should only be used for exceptionally hard-to-read applications (such as meters installed on roof tops or in sub-basements). Itron Cellular Solutions (ICS) Mode.
About the 100G Series Gas ERT Module 100G Series Gas ERT Module Specifications Functional Specifications Description Power Source 100G Two "A" cell lithium batteries 100G Datalogging 100G Datalogging FN 100G DLS Datalogging 100G DLT Datalogging One "A" cell lithium battery Tamper Detection Tilt and cut cable FCC Compliance Part 15 certified Innovation, Science and Economic Development Canada (ISED) RSS-210 certified Intrinsically Safe per UL Class I, Division 1, Groups C and D Product Identif
About the 100G Series Gas ERT Module 100G Series Remote ERT Module Meter Compatibility List The following table lists meter types compatible with the 100G series remote gas module. Due to continuous research, product improvements and enhancements, Itron reserves the right to change product or system specifications without notice. Eagle Research Meter Model Meter Notes 100G Module Type Itron Part Number Gas Module Notes MPplus Volume Corrector Pulses with 70mS on and 500mS off timing.
About the 100G Series Gas ERT Module GE Oil & Gas/Dresser Meters Meter Model Integral Micro Corrector IMC/W2 Meter Notes Electronic volume corrector for Series A (LMMA) and Series B rotary meters. Must be meter firmware version 1.94 or earlier. Pulse width must be set for 125ms. Pulse output must be at 100CF (CM) or higher.
About the 100G Series Gas ERT Module Honeywell Mercury Instruments Meter Model Meter Notes 100G Module Type Itron Part Number Electronic TC index: TCI Temperature Compensating Index. TCI 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, or 4 blanks). Item # 1014 set to the preset "Itron 100G" selection in the drop-down menu. Compatible TCI firmware versions are 1.06, 1.07, and 1.10.
About the 100G Series Gas ERT Module Romet Meter Model RM Series STD CTR 600—56000 TC 2000—23000 Meter Notes Meter must have factory-installed pulser with connector output. Purchase cable interface from manufacturer.
About the 100G Series Gas ERT Module • Itron programming device: FC200SR handheld computer with Field Deployment Manager (FDM) software or FC300 with SRead with Field Deployment Manager (FDM) software or 900 MHz Belt Clip Radio with Field Deployment Manager (FDM) and a customer-supplied laptop Note The FDM version required is dependent upon the 100G ERT module model in use.
CHAPTER 2 Mounting the 100G Series Gas ERT Module This chapter provides the instructions to mount the 100G series remote gas module on a pipe or other flat vertical surface (wall). Installation Options Mount the remote ERT module using the pipe mount or wall mount (flat vertical surface) procedure. • • Pipe Mount. Pipe mounting is used in conjunction with the Pipe Installation Kit (Itron part number CFG0005-003).
Mounting the 100G Series Gas ERT Module Mounting Installation Considerations Select a proper mounting location. Itron recommends mounting the 100G series remote gas module in close proximity to the meter or instrument. Some applications may require an extended cable-length. The 100G series remote gas module supports cable lengths up to 300 feet with a recommended one-splice limitation. Mount the 100G series remote gas module in a vertical position with the ERT label directional arrow pointed upward.
Mounting the 100G Series Gas ERT Module To mount the pipe bracket on a vertical pipe Caution A vertical mounting position is important to maximize RF performance. Mount the ERT module with the module's label arrow pointing up. The module's arrow must never point to either side or upside down. The module's tilt tamper functionality is designed to operate with the module installed vertically. 1. Remove the pipe bracket and band clamp from the Pipe Mount Installation Kit (Itron part number CFG0005-003). 2.
Mounting the 100G Series Gas ERT Module If the pipe is a 45 degree angle up to the right, install the adapter plate as shown below. Typical module mounting Mounted adapter plate If the pipe is a 45 degree angle up to the left, install the adapter plate as shown below. Typical module mounting Mounted adapter plate If the pipe is horizontal, install the adapter plate as shown below.
Mounting the 100G Series Gas ERT Module 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 installation kit. Place the mounting screws (2) in the holes shown below. 3.
Mounting the 100G Series Gas ERT Module 2. Push up on the module until the adapter plate mounting lug (1) is as far as possible inside the module mounting lug recess (2). 3. Align the ERT module backplate mounting holes with the pipe mount adapter plate holes. Install the two one-inch ERT module mounting screws from the installation kit. 4. Tighten the module mounting screws evenly in an alternating fashion. Tighten to 9 - 12 inch-pounds of pressure. To install tamper seals and cable ties 1.
Mounting the 100G Series Gas ERT Module 3. Gather any excess ERT module cable. Loop a cable tie around the pipe and excess module cable. 4. 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. 100G series remote gas module pipe mount installation is complete.
Mounting the 100G Series Gas ERT Module Mounting the Remote Gas Module on a Wall or Other Flat Vertical 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 module mounting screws so nothing is damaged by the drill or mounting screws.
Mounting the 100G Series Gas ERT Module 4. Install the bottom two mounting screws. Fasten the screws in an alternating pattern until fully tightened to secure the module firmly in position. To install tamper seals and cable ties 1. Place a new tamper seal (from the Pipe Installation Kit) over each ERT module mounting screw. 2. Firmly push both tamper seals into place with a 1/4-inch nut driver or similar blunt tool.
CHAPTER 3 Rotary Meter Installation This chapter provides the instructions to install the 100G series remote gas module on rotary gas meters. Reference the 100G Series Remote ERT Module Meter Compatibility List on page 4 for rotary meters compatible with the 100G series remote gas module.
Rotary Meter Installation Required Installation Materials Available from Itron The materials in the following table are required to install the remote ERT module. Itron Part Number ERG-500X-503 ERG-500X-503 Note this remote ERT module comes standard with 12-inch lead wires and may be shipped directly to the meter manufacturer for a factory-installed cable (interface). The interface cable must be purchased directly from the meter manufacturer.
Rotary Meter Installation 2. Insert the lead wires from the 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. Rotary Meter to Remote ERT Module Wire Table Rotary meter wire Remote ERT module wire Red Red White White Blue Blue Important Use a crimping tool compatible with gel-connectors. Do not use a standard pliers for crimping gel connectors.
Rotary Meter Installation 4. Tuck the three gel connectors and cable tie inside the module housing, as shown in the following placement schematic illustration. 5. Install the 100G series remote gas module backplate using the four screws previously removed from the module and a Torx T-10 screwdriver. Important Verify the cable tie and gel connectors are inside the module housing and the cable extends out of the slot in the backplate. Torque the backplate mounting screws to 9 to 12 inch-pounds. 6.
Rotary Meter Installation To prepare the GE Dresser D800/D1000 meter for the ERT module installation 1. Loosen and remove the two screws holding the mounting brackets to the meter. After the brackets are removed, the pulse output cable is visible. 2. Loosen the cable gland and pull the cable out until it extends 7.5 to 8" out of the cable gland. 3. Tighten the cable gland. Do not use a plier or wrench to tighten the cable gland.
Rotary Meter Installation 4. Rotate one bracket. Route the meter cable through the holes located at the bend of the mounting brackets. 5. Attach the brackets to the meter using the previously removed screws. To connect the 100G ERT module to the meter 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.
Rotary Meter Installation 1. Splice the meter pulse output wires to the ERT module wires using gel cap connectors. Follow the wire connections in the D800/D1000 to 100G ERT module wire connections table.
Rotary Meter Installation 5. Install the ERT module back plate using the T-15 Torx screws supplied with the ERT module. To mount the ERT module on the D800 or D1000 meter 1. Route the cable through the channel in the backplate standoffs. 2. Insert the 8-32 x 1/2" screw into the top hole in the meter mounting bracket and thread one of the Kep nuts loosely onto the end of the screw. 3.
Rotary Meter Installation 4. Install the bottom two mounting screws and Kep nuts. Tighten the three mounting screws in an alternating pattern. 5. Install the supplied red tamper seals over the bottom mounting screws on the ERT module. Connecting and Installing the 100G Series Module to the GE Dresser ES3 or ETC Meter manufacturers may provide ERT mounting kits and installation procedures.
Rotary Meter Installation To connect the ES3 or ETC and 100G ERT module wires 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 (3). If the silicone gel flows out of the crimped connector, avoid touching the gel.
Rotary Meter Installation 4. Align the ERT module mounting holes with the ES3 or ETC bracket mounting holes. Use a T15 Torx screwdriver to insert and tighten the mounting screws. Tighten the screws in an alternating pattern. To confirm the correct ERT module mounting Important Regardless of the meter orientation (side or top inlet), the 100G ERT module must always be mounted in a vertical position with the arrow on the front label and the meter mounting bracket arrow pointing up.
Rotary Meter Installation To change ERT module index settings 1. 2. 3. 4. Open the GE Dresser MeterWare software. Select the LiveData tab. Confirm the firmware version and current index settings. If you change a variable, click Update Values to complete the change. To view the volume configuration 1. Select the Configuration tab. 2. Confirm the volume configuration and pulse width settings. 3. Use the drop down lists to change a variable. 4. Click OK to complete the change.
Rotary Meter Installation Programming the Remote ERT Module for GE Dresser Rotary Meters To program 100G series remote gas modules for use with GE Dresser rotary meters, use the meter drive rates from the drive rate table in this section. B3, LMMA & S3A CTR/TC Meter Drive Rates for Remote ERT Module Programming Caution Do not use these meter drive rates to program residential direct-drive or commercial directdrive modules.
Rotary Meter Installation 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 568CM 100 102M 100 S3A CTR Meter Size S3A CTR Meter Pulse Rate S3A TC Meter Size S3A TC Meter Pulse Rate 1.5M 10 1.
Rotary Meter Installation Wiring the 100G Series Gas ERT Module to the Romet ECM2® Meter Connect the correct interface wirings and set the output pulse spacing to complete 100G series remote 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.
Rotary Meter Installation Romet ECM2/100G Series Gas ERT Module Mounting Option This mounting procedure requires the Romet ECM2/ERT Mounting Kit (Romet part number 34-444-1-KIT). To mount the 100G series remote 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.
Rotary Meter Installation 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. 4. Mount the 100G series remote gas module using the pre-drilled holes on the mounting plate and the module mounting screws. 5. Place new tamper seals over the two screws. Press tamper seals into place using an 11/32-inch nut driver or similar blunt tool. 6.
Rotary Meter Installation To install the 100G series remote gas module on an Elster American RPM series meter 1. Remove the meter's top plate by removing the two 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.
Rotary Meter Installation 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 two 5 mm screws.
Rotary Meter Installation 4. Connect the meter cable to the 100G series remote 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.
Rotary Meter Installation To install the 100G series remote gas module cable 1. Insert the plug on the cable connected to the ERT 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. Programming the Remote ERT Module Caution You must program the 100G series remote gas module before use.
Rotary Meter Installation To enable enhanced security and for more complete programming information, see the Field Deployment Manager Endpoint Tools Mobile Application Guide (TDC-0934). FC200SR FC300 with SRead 900MHz Belt Clip Radio To program the remote ERT module • • • Program the meter drive rate into the 100G series remote gas module using a handheld computer or Belt Clip Radio and laptop computer.
Rotary Meter Installation TDC-0824-014 100G Series Gas ERT Module Installation Guide, Remote Mount Proprietary and Confidential 40
CHAPTER 4 Electronic Instrument Installation This section provides the instructions to install the 100G series remote gas module on: • • • • • • Honeywell Instruments Mini-P, Mini-AT, Mini-Max, and EC-AT volume correctors Honeywell Instruments Temperature Compensated Indexes (TCI) GE Dresser IMC/W2 and MC2 Micro Correctors Galvanic Gas Micro volume Corrector Eagle Research MP plus volume corrector Romet AdEM® volume corrector Mini-AT IMC/W2 XARTU-1 Mini-Max MC2 EC-AT TCI Gas Micro MPplus AdEM T
Electronic Instrument Installation Installation Prerequisites 100G series remote gas module installation to a volume corrector or instrument requires: • • • 100G series remote gas module ERT module compatible to a volume corrector or instrument (see the 100G Series Remote ERT Module Meter Compatibility List on page 4). Volume corrector or instrument compatible with the remote ERT module. Proper tools and devices for installation and programming (see Installation Prerequisites on page 7).
Electronic Instrument Installation Programming the Honeywell Instrument Parameters Item Code Settings Channel A Corrected Volume Channel B Uncorrected Volume Channel C Pulse Output Spacing #58 Instrument Pulse Output Options #56 #93 #57 #94 #95 #115 ECAT Pulse Board Ver-2(3) Form-A 2 Cor Vol 2 Unc Vol 2 Cor Vol 2 Cor Vol 1 = 1.0 sec 2 = 2.0 sec or 4 = 0.
