Badger ORION Automated Meter Reading System ORION Transmitter for American Commercial Meters Installation &
Operation Manual Before Installation with Wire Seal Security Screw After Installation of ORION Transmitter Before Installation with Red Security Seals IMPORTANT: This manual contains important warnings and information. READ AND KEEP FOR REFERENCE. After Installation of ORION Transmitter BadgerMeter,Inc. ORI-IOM-47 P/N 62014 Rev. 1 6-07 Disclaimer The user/purchaser is expected to read and understand the information provided in this manual, follow any listed Safety Precautions and Instructions and keep this manual with the equipment for future reference. Misuse, mishandling and/or inadequate maintenance may impair performance and/or compromise safety. Questions or Service Assistance If you have questions regarding the product or this document contact:
Badger Meter, Inc. P.O. Box 245036 Milwaukee, WI 53224-9536 Telephone:
(414) 355-0400, (800) 876-3837 Fax:
(888) 371-5982 On the Web: www.badgermeter.com or call your local Badger Meter representative. Product Identification Information Record the product identification numbers from the nameplate. Transmitter Model Number _ ______ Serial Number _____________ Tag Number _______________ 2 Table of Contents Disclaimer ................................................................................................................................. 2 Questions or Service Assistance ................................................................................................ 2 Product Identification Information ............................................................................................... 2 Note Explanations ...................................................................................................................... 5 Scope of Manual ........................................................................................................................ 5 Product Unpacking and Inspection............................................................................................. 5 License Requirements ............................................................................................................... 5 Badger ORION Integral Transmitter/Hardcase Gas Meter Identification .................................. 6 Installation Tools and Materials .................................................................................................. 6 Label Information ........................................................................................................................ 6 Installation of Badger ORION Integral Transmitter...................................................................... 6 American Commercial Diaphragm with Wire Seal Security Screw and Dial Index.............. 7 Badger ORION Model 64989-002 ............................................................................................ 7 Index and Index Cover Plate Removal from American Meter ..................................................... 7 Badger ORION Transmitter Label .............................................................................................. 8 Install Badger ORION Transmitter and American Cover Plate ................................................... 8 Program the Badger ORION Transmitter .................................................................................... 9 Complete the Installation ..........................................................................................................10 AMERICAN Commercial Diaphragm with Red Security Seals and Dial Index .................. 11 Badger ORION Model 64989-002 ........................................................................................... 11 Index and Index Cover Plate Removal From American Meter ..................................................11 Badger ORION Transmitter Label ............................................................................................ 12 Install the Badger ORION Transmitter and American Cover Plate ........................................... 12 Program the Badger ORION Transmitter ..................................................................................13 Complete the Installation ..........................................................................................................14 3
(This page intentionally left blank) 4 License Requirements This device complies with Part 15 of FCC Rules. Operation of this device is subject to the following conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. No FCC license is required by a utility to operate a Badger ORION meter reading system. Any changes made, but not approved by Badger Meter, can void the users authority to operate the equipment. Note Explanations NOTE: Communicates installation, operation, or maintenance information that is safety related but not hazard related. Scope of Manual This manual contains installation instructions for mounting the Badger ORION Integral Transmitter for Gas Meters on two American Gas Meters. Proper performance and reliability of the Badger ORION system depends upon installation in accordance with these instructions. Product Unpacking and Inspection Upon receipt of the product, perform the following unpacking and inspection procedures:
NOTE: If damage to the shipping container is evident upon receipt, request the carrier to be present when the product is unpacked. Carefully open the shipping package, follow any instructions that may be marked on the exterior. Remove all cushioning material surrounding the product and carefully lift the product from the package. Retain the package and all packing material for possible use in reshipment or storage. Visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts, or any other sign of damage that may have occurred during shipment. NOTE: If damage is found, request an inspection by the carriers agent within 48 hours of delivery and file a claim with the carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser. 5 Badger ORION Integral Transmitter/Hardcase Gas Meter Identification Badger ORION integral transmitters for gas meters are designed for use with only two major brands of hardcase gas meters. Please refer to and use the following identification table. Identification Table Gas Meter Manufacturer American Meter American Gas Meter Models AL-800, AL-1000, AL-1400, AL-2300, AL-5000 and GTS/GTX Turbine Meters Badger ORION Transmitter Number 64989-002 Installation Tools and Materials Use magnetized screwdrivers. 1/4" flat screwdriver 3/16" flat screwdriver Radix Handheld Label Information Certification markings are noted on the product label. Installation of Badger ORION Integral Transmitter This manual describes two types of installation of the Badger ORION transmitter and American index on an American gas meter. The first section of this manual describes the installation on an American Commercial Diaphragm and Turbine Meter with Wire Seal Security Screws. The second section of this manual describes the installation on an American Commercial Diaphragm and Turbine Meter with Red Security Seals. 6 AMERICAN Commercial Diaphragm and Turbine Meters with Wire Seal Security Screw Index and Index Cover Plate Removal from American Meter with Seal Security Screw Step 1: Remove the wire security seal from the index cover mounting screw. Step 2: Use a large screwdriver to remove the four (4) 18-8 index cover mounting plate screws and American Index. Discard the four screws. Step 3: Remove the American index and mounting plate. American Commercial Diaphragm and Turbine Meter with Wire Seal Security Screw ORION Transmitter 2 Washers 4 Screws 2 Seal Caps 2 Large Tamper Plugs 2 Small Tamper Plugs ORION Model 64989-002 Transmitter Kit for American Commercial Diaphragm and Turbine Meter with Wire Seal Security Screw NOTE: The screws provided in this installation kit are not drilled for wire seals. Therefore, the wire seal is replaced with plastic seal cups provided in the kit. 7 Badger ORION Transmitter Label If the utility chooses to add an additional label, follow steps A, B, and C below. If not, go to Install in the next column. Serial Number Label Step A: With a needle nose pliers pull the plastic cover plate down and off. Install the Badger ORION Transmitter and American Cover Plate Use care when handling the Badger ORION transmitter to insure the drive pawl is not subjected to any physical abuse. Abuse may cause this spindle to become bent, misaligned, or otherwise inoperative. When attaching an Badger ORION transmitter to a gas meter make sure it mounts securely to the meter. Step 1: Place the Badger ORION transmitter on top of the gas meter, where the index and index cover plate were previously removed. Place the transmitter drive pawl so it is perpendicular to the meter drive pawl. Drive Pawl Spindle Step B: Place a new serial number tag above the one that is on the transmitter. Step C: Place the cover plate back on the transmitter. Step 2: When mounting a Badger ORION transmitter to a gas meter, make sure the transmitter drive pawl engages the gas meter drive pawl. These two drive pawls must mate without causing any binding or potential for disengagement. Transmitter Drive Pawl Meter Drive Pawl placing transmitter on meter incorrectly may damage the output seal of the gas meter. Test to ensure the pawls are engaged and moving freely. 8 Step 3: Be sure the gas INLET markings are on the same side of the meter and the lens faces forward. Gas INLET markings Lens facing forward Step 4: Place the American Index and cover plate (removed earlier) back on the Badger ORION transmitter. Place it so the text; TURBINE FRONT FLOW AL-600, AL-1000, AL-1400, AL-2300, and AL-5000 (or other such text); faces the front and the index hole is centered around the transmitter drive pawl. Place the index drive pawl perpendicular to the transmitter drive pawl. Step 5: Place two screws, with a washer on each, into two corners of the cover mounting plate. Use four (4) 18-18x3-1/2 supplied mounting screws to attach the index, cover plate, and Badger ORION transmitter to the gas meter. Step 6: Index and cover has two platic seal caps that are difficult to maneuver around with the long bolts. Place two of the screws, without washers, through the white seal caps. Place them in the other opposite corners of the cover mounting plate. Step 7: Tighten all screws evenly with a large screwdriver to approximately 70 inch lbs. Program the Badger ORION Transmitter Badger uses the Radix system to display and process screens. Place the Radix so the optic read head aligns with the LED output port. The angle of approach should be about 30 degrees. Washer Radix Rotate Radix unit to about 30 degrees
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9 Complete the Installation After programming, add seal caps to the front and rear screws of the index cover plate. Only the front screw is shown below. If the index mounting seal caps were removed, replace them with the extra caps provided in the installation kit. This completes the installation of a Badger ORION transmitter on an American Commercial Diaphragm and Turbine Meter with Wire Seal Security Screw converted to seal caps. 10 AMERICAN Commercial Diaphragm and Turbine Meters with Red Security Seals Index and Index Cover Plate Removal from American Meter with Red Security Seals Step 1: Use a large screwdriver to remove the four (4) 18-8 index cover mounting plate screws and American Index. Discard the four screws. Step 2: Remove the American index and mounting plate. American Commercial Diaphragm and Turbine Meter with Red Security Seals ORION Transmitter 4 Washers 4 Screws 6 Small Tamper Plugs ORION Model 64989-002 Transmitter Kit for American Commercial Diaphragm and Turbine Meter with Red Security Seals 11 Badger ORION Transmitter Label If the utility chooses to add an additional label, follow steps A, B, and C below. If not, go to Install in the next column. Serial Number Label Step A: With a needle nose pliers pull the plastic cover plate down and off. Install the Badger ORION Transmitter and American Cover Plate Use care when handling the Badger ORION transmitter to insure the drive pawl is not subjected to any physical abuse. Abuse may cause this spindle to become bent, misaligned or otherwise inoperative. When attaching a Badger ORION transmitter to a gas meter make sure it mounts securely to the meter. Step 1: Place the Badger ORION transmitter on top of the gas meter, where the index and index cover plate were previously removed. Place the transmitter drive pawl so it is perpendicular to the meter drive pawl. Step B: Place a new serial number tag above the one that is on the transmitter. Drive Pawl Spindle Step 2: When mounting a Badger ORION transmitter to a gas meter, make sure the transmitter drive pawl engages the gas meter drive pawl. These two drive pawls must mate without causing any binding or potential for disengagement. Step C: Place the cover plate back on the transmitter. Transmitter Drive Pawl Meter Drive Pawl placing transmitter on meter incorrectly may damage the output seal of the gas meter. Test to ensure the pawls are engaged and moving freely. 12 Step 3: Be sure the gas INLET markings are on the same side of the meter and the lens faces forward. Step 6: Tighten all screws evenly with a large screwdriver to approximately 70 inch-lbs. Gas INLET markings Lens facing forward Step 4: Place the American Index and cover plate (removed earlier) back on the Badger ORION transmitter. Place it so the text; TURBINE FRONT FLOW AL-600, AL-1000, AL-1400, AL-2300, and AL-5000 (or other such text); faces the front and the top hole is centered around the upper drive pawl. Place the index drive pawl perpendicular to the transmitter drive pawl. Program the Badger ORION Transmitter Badger uses the Radix system to display and process screens. Place the Radix so the optic read head aligns with the LED output port. The angle of approach should be about 30 degrees. Step 5: Use four (4) 18-18x3-1/2 supplied mounting screws and a washer on each to attach the index, cover plate, and Badger ORION transmitter to the gas meter. Radix Rotate Radix unit to about a 30 degree angle
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Washer 13 Complete the Installation After programming, add seal caps to the front and rear index cover screws . Only the front screws are shown below. If the index mounting screw seal caps were removed, replace them with the extra caps provided in the installation kit. This completes the installation of a Badger ORION transmitter on an American Commercial Diaphragm and Turbine Meter with Red Security Seals. 14
(This page is intentionally left blank) 15 Badger is a registered trademark of Badger Meter, Inc. Please see our website at www.badgermeter.com for specific contacts. Copyright Badger Meter, Inc. 2007. All rights reserved. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specifications without notice, except to the extent an outstanding contractual obligation exists. BadgerMeter,Inc. P.O. Box 245036, Milwaukee, WI 53224-9536 Telephone: (414) 355-0400 / (877) 243-1010 Fax: (414) 355-7499 / (866) 613-9305 www.badgermeter.com